Service Procedure

1. Turn the key off and remove it from the ignition.





2. From within the driver door opening locate the ">" marking stamped into the B-pillar, ahead of the rear door upper hinge.





3. Measure from the ">" marking upward 177 mm (7 in) and make a mark with a grease pencil. Refer to the illustrations above.

4. Gain access to the pinch-weld flange from the grease pencil mark to below the driver door striker by removing the driver door primary weatherstrip (on body) from the flange.

5. Locate the six pinch-weld locations from the level of the grease pencil mark downward to the level of the driver door striker. The welds in question are evenly spaced and approximately 64 mm (2.5 in) apart.

Notice
The welds above the top-most weld in question are spaced at approximately 25 mm (1 in) apart. Be careful to locate the six welds spaced at approximately 64 mm (2.5 in).





6. Install the rubber drill stop (provided) onto a # 21 or 4 mm (5/32 in) drill bit with the larger end toward the drill chuck.

Caution
Use protective eye glasses at all times.

Notice
The rubber drill stop is provided to help protect the flange from damage as the drill passes through the flange. If a drill motor with a large chuck is being used, ensure that the outer diameter of the chuck does not damage the paint within the door opening.

7. Carefully drill out the six spot welds identified above.

8. Using a shop vacuum remove all metal shavings created from drilling the holes. It may also be necessary to use a magnet to remove some small shavings.





Notice
Before performing step 9, be prepared to perform step 10 in order to install structural fasteners before the applied sealer skins over.

9. Using Kent Industries HIGH TECH Seam sealer (black) P/N 10070 or equivalent, apply sealer to the drilled holes on the outside of the flange.





10. Install six structural fasteners (provided) into drilled holes. Ensure the head of the fastener is flush with the sheet metal and completely seated before compressing.





11. Using 3M(R) WINDO-WELD(TM) Butyl Primer (black) P/N 08643 or equivalent, completely coat the outside of the installed six fasteners. Allow enough time for the primer to skin over.

12. Once primer is skinned over, reinstall the removed portion of the primary weatherstrip (on body). Start at the bottom and install weatherstrip making sure weatherstrip flap is tucked under the "B" pillar trim panel (lower and upper).

13. Remove the grease pencil mark made in step 3 above. Inspect weatherstrip, trim panel, and door opening for proper installation and any traces of excess sealer and remove as necessary.

Important
Do not cover any existing underhood labels when affixing Campaign Completion Label.

14. Affix Campaign Completion Label on a clean and dry surface of radiator core support, in an area clearly visible when hood is raised. For more information, refer to Campaign Completion Label.