2000 Chevy Suburban Body Repair Manual

(note: all procedures apply to all models,unless otherwise noted)

2000 Chevrolet/GMC

Full-Size Sport Utility Vehicles (SUVs)

Upper Body Cargo Hinge

Replacement 4-20

Lower Body Cargo Hinge

Replacement 4-23

Front Body Side Hinge Replacement 4-12

Front Door Side Hinge Replacement 4-14

Quarter Panel

Replacement 4-30

Center PillarSectioning 4-6

Rail End Front

Crush Cap

Replacement 4-32

Front Lower Hinge Pillar

Sectioning 4-4

Rear Lock Pillar

Sectioning 4-8

Rocker Panel

Sectioning 4-10

Door Frame Sectioning 4-1

Front Bumper Bracket

Replacement 4-28

Windshield Pillar

Sectioning 4-2

Dimensions 4-34

Rear Body Side

Hinge Replacement

4-16

Rear Door SideHinge Replacement

4-18

2000 chevrolet/gmc full-size sport utility vehicles 4-1

Fig. 4-1 — Suburban

Fig. 4-2 — Sport Utility

Door Frame SectioningThe door frame opening is a unique laser-weld design incorporatingmultiple metal thicknesses to ensure the structural integrity of thecab. The door frame can be replaced at factory seams, but requiresthe removal of the roof panel, windshield and quarter panel.Sectioning procedures have been developed as a more cost-effective alternative to complete replacement. The specific area tobe sectioned is determined by the extent of the damage to thevehicle.Refer to Door Frame Sectioning - Windshield; Door FrameSectioning - Front Pillar; Door Frame Sectioning - Center Pillar;Door Frame Sectioning - Rear Lock Pillar; Door Frame Sectioning -Rocker.

IMPORTANT: Section in specified areas only. Sectioning outsideof these areas may compromise the structural integrity of thevehicle (Figs. 4-1, 4-2).

4-2 2000 chevrolet/gmc full-size sport utility vehicles

Windshield Pillar SectioningRemoval Procedure1. Remove all related panels and components.2. Restore as much of the damage as possible to

factory specifications.3. Note the location and remove the following as

necessary:• Sealers• Sound deadeners• Anti-corrosion materialsIMPORTANT: Perform sectioning in thewindshield area 30 ␣ mm (1-3/16␣ in) abovethe third trim mounting hole (Fig. 4-3).

IMPORTANT: Take care not to damage theinner panels or reinforcements.

4. Cut the pillar in the locations where sectioningis to be performed.

5. Locate and drill out all factory welds. note thenumber and location of the welds forinstallation of the service part.

6. Remove the damaged pillar section.

30 MM (1-3/16 IN)

50 MM (2 IN)

Fig. 4-3 — Windshield Pillar


Installation Procedure1. Cut the replacement pillar in corresponding

locations to fit the remaining original panel.The sectioning joint should be trimmed toallow a gap of one and one-half times themetal thickness at the sectioning joint.

2. Create a 50␣ mm (2␣ in) backing plate from theunused portion of the service part. Trim thebacking plate as necessary to fit behind thesectioning joint (Fig. 4-4).

3. Perform additional sectioning procedures asnecessary. Refer to Center Pillar Sectioning;Front Lower Pillar Sectioning; Rear Lock PillarSectioning; and Rocker Sectioning.

4. Drill 8␣ mm (5/16␣ in) holes for plug welding inthe original part. Locate these holesapproximately 13␣ mm (1/2␣ in) from the edgeof the sectioning cuts and spaced 40␣ mm(1-1/2␣ in) apart.

5. Drill 8␣ mm (5/16␣ in) plug weld holes in theservice panel as necessary in the locationsnoted from the original panel and along thesectioning cut.CAUTION: Foam sealers are flammable andshould be removed from all weld locations.

6. Prepare the mating surfaces, as necessary.7. Apply weld-through primer to all bare metal

surfaces.8. Fit the backing plate halfway into the

sectioning joint, clamp and plug weld to thevehicle (Fig. 4-5).

9. Align the windshield pillar to adjacent panelsusing three-dimensional measuringequipment.

10. Plug weld accordingly.11. Make 25␣ mm (1␣ in) stitch welds along the

seam with 25␣ mm (1␣ in) gaps between them,then go back and complete the stitch weld.This will create a solid joint with minimal heatdistortion (Fig. 4-6).

12. Clean and prepare all welded surfaces.IMPORTANT: Prior to refinishing, refer tothe publication GM4901M-D-2000 “GMApproved Refinish Materials” forrecommended products. Do not combinepaint systems. Refer to paint manufacturer’srecommendations.

13. Apply an approved anti-corrosion primer.14. Apply sealers and refinish as necessary.15. Install all related panels and components.

Fig. 4-4 — Create Backing Plate

Fig. 4-5 — Drill and Plug Weld

Fig. 4-6 — Align Windshield Pillar

PLUG WELDS

13 MM(1/2 IN)

ORIGINAL PART

BACKING PLATE

GAP =ONE AND ONE-HALF TIMESMETAL THICKNESS STITCH WELD

50 MM(2 IN)

100 MM(24 IN)

100MM(4 IN)

BACKING PLATE

GAP = ONE AND ONE-HALF TIMESTHE THICKNESS OF THE METAL


Front Lower Hinge PillarSectioningRemoval Procedure1. Visually inspect and restore as much of the

damage as possible to factory specifications.2. Remove all related panels and components.3. Note the location and remove the following as

necessary:• Sealers• Sound deadeners• Anti-corrosion materials

4. Measure 80␣ mm (3-1/8 inches) down fromthe large wiring harness hole in the hinge pillarand mark a horizontal line.

5. Cut the pillar in the locations where sectioningis to be performed.IMPORTANT: Take care not to damage theinner panel (Fig.␣ 3-7).

6. Locate, mark and drill out all necessary factorywelds. Note the number of welds for theinstallation of the service section.

7. Remove the damaged section of the doorframe opening.

8. Cut and remove 30␣ mm (1-3/16 inches) fromthe flanges on either side of the remainingsection of the original hinge pillar to create30␣ mm (1-3/16␣ in) tabs. Cut 5␣ mm (3/16␣ in)wide gaps in the bottom corners(Fig. 4-8).

9. Step the tabs inward to allow the door frameopening service section to fit over the originalhinge pillar. Weld the tabs together along theedges (Fig. 4-9).IMPORTANT: The metal of the hinge pillaris of a heavy gauge. However, the tabs canbe created using the appropriate tools.

80 MM (3-1/8 IN)

ORIGINALPANEL

30 MM (1-3/16 IN)

5 MM (3/16 IN)

WELD TOGETHER

Fig. 4-7 — Cut the Original Panel

Fig. 4-8 — Create Tab

Fig. 4-9 — Weld Corners


Installation Procedure1. On the service part, measure 50␣ mm (2␣ in)

down from the large wiring harness hole inthe hinge pillar and mark a horizontal line. Cutthe hinge pillar along this line (Fig. 4-10).

2. Perform additional sectioning procedures asnecessary to remove the unused areas of theservice part. Refer to Windshield Sectioning;Center Pillar, Rear Lock Pillar, and RockerSectioning.NOTICE: In any area damaged beyondrecognition, space plug weld holes every40␣ mm (1-1/2 in) apart.

3. Drill 8␣ mm (5/16␣ in) plug weld holes asnecessary in the locations noted from theoriginal section. Also drill plug weld holesalong the hinge pillar sectioning cut of theservice part. These should be locatedapproximately 15␣ mm (9/16␣ in) from theedge of the cut.CAUTION: Foam sealers are flammable andshould be removed from all weld locations.

4. Prepare mating surfaces as necessary.5. Apply weld-thru primer to all bare-metal

surfaces.6. Position the service section over the stepped

tab on the original hinge pillar, allowing30␣ mm (1-3/16 inches) of overlap (Fig.␣ 4-11).Check fit using three-dimensional measuring.

7. Plug weld service part in position.8. Make 25␣ mm (1␣ in) welds along the seam

with 25␣ mm (1␣ in) gaps between. Then goback and complete the stitch weld. This willcreate a solid joint with minimal heatdistortion (Fig.␣ 4-12).


10. Apply approved anti-corrosion primer.11. Apply sealers and refinish as necessary.12. Reinstall all related panels and components.

50 MM (2 IN)

SERVICEPANEL

ORIGINALPANEL

NEWSERVICE PANEL

ORIGINALPANEL

30 MM (1-3/16 IN)OF OVERLAP

Fig. 4-12 — Stitch Weld

Fig. 4-11 — Drill Panel

Fig. 4-10 — Cut the Service Panel


Center Pillar SectioningRemoval Procedure1. Remove all related panels and components.2. Restore as much of the damage as possible to


necessary:• Sealers• Sound deadeners• Anti-corrosion materialsIMPORTANT: Take care not to damage theinner panels or reinforcements.

4. Cut the pillar in a location where sectioning isto be performed (Figs. 4-13, 4-14).

5. Locate and drill out all factory welds. Note thenumber and location of the welds forinstallation of the service part.


Fig. 4-13 — Suburban Sectioning Locations

Fig. 4-14 — Sport Utility SectioningLocations


Installation Procedure1. Cut the replacement center pillar in

corresponding locations to fit the remainingoriginal panel. The sectioning joint should betrimmed to allow a gap of one-and-one-halftimes the metal thickness at the sectioningjoint.


3. Perform additional sectioning procedures asnecessary. Refer to Windshield Sectioning;Front Lower Pillar Sectioning; Rear Lock PillarSectioning; and Rocker Sectioning.

4. Drill 8␣ mm (5/16␣ in) plug weld holes along thesectioning cut on the remaining original part.

5. Drill 8␣ mm (5/16␣ in) plug weld holes in theservice panel as necessary in the locationsnoted from the original panel and along thesectioning cut.CAUTION: Foam sealers are fla␣ mmble andshould be removed from all weld locations.




9. Align the center pillar to adjacent panels usingthree-dimensional measuring equipment(Fig. 4-17).


seam with 25␣ mm (1␣ in) gaps between them,then go back and complete the stitch weld.This will create a solid joint with minimal heatdistortion.



Fig. 4-17 — Align Panels

Fig. 4-16 — Install Backing Plate

Fig. 4-15 — Cut Center Pillar

1

50MM(2 IN)

100MM(4 IN)

PLUG WELDS

13 MM(1/2 IN)

ORIGINAL PART

BACKING PLATE



Rear Lock Pillar SectioningRemoval Procedure1. Remove all related panels and components.2. Restore as much of the damage as possible to



4. Cut the pillar in the locations where sectioningis to be performed (Figs. 4-18, 4-19).



Fig. 4-18 — Suburban Sectioning Locations



Installation Procedure1. Cut the replacement rear lock pillar in



3. Perform additional sectioning procedures asnecessary. Refer to Windshield Sectioning;Front Lower Pillar Sectioning; Center Pillar;and Rocker Sectioning.

4. Drill 8 ␣ mm (5/16␣ in) plug weld holes alongthe sectioning cut on the remaining originalpart.





9. Align the rear lock pillar to adjacent panelsusing three-dimensional measuringequipment (Fig. 4-22).





Fig. 4-22 — Align Rear Lock Pillar

Fig. 4-21 — Drill and Plug Weld

Fig. 4-20 — Cut Replacement Pillar

BACKING PLATE

50 MM(2 IN)

100 MM(4 IN)

PLUG WELDS

13 MM(1/2 IN)

ORIGINAL PANEL

BACKING PLATE

GAP =ONE AND ONE-HALF TIMEMETAL THICKNESS

STITCH WELD


Rocker Panel SectioningRemoval Procedure1. Remove all related panels and components.2. Restore as much of the damage as possible to



4. Cut the pillar in the locations where sectioningis to be performed (Figs. 4-23, 4-24).


6. Remove the damaged pillar section.Fig. 4-23 — Suburban Sectioning Locations



Installation Procedure1. Cut the replacement rocker panel in


2. Create a 100␣ mm (4␣ in) backing plate fromthe unused portion of the service part. Trimthe backing plate as necessary to fit behindthe sectioning joint (Fig. 4-25).

3. Perform additional sectioning procedures asnecessary. Refer to Windshield Sectioning;Front Lower Pillar Sectioning; Rear Lock PillarSectioning; and Center Pillar sectioning.

4. Drill 8␣ mm (5/16␣ in) plug weld holes along thesectioning cut on the remaining original part.




sectioning joint, clamp and plug weld to thevehicle.

9. Align the rocker panel to adjacent panelsusing three-dimensional measuringequipment.

10. Plug weld service part in position.11. Make 25␣ mm (1␣ in) stitch welds along the




Fig. 4-25 — Rocker Backing Plate

100 MM(4 IN)

BACKING PLATE



HINGE

PILLAR

13 MM (1/2 IN)ROTABROACH BIT

HINGE REINFORCEMENT

TYPICAL MIG WELDDRILL THROUGH HINGE ONLY

Door Side HingeReplacement

Front Body Side HingeReplacementRemoval Procedure1. Remove related panels and component.2. Remove any excess sealer surrounding the

existing hinge and scribe the location of thehinge on the hinge pillar.

3. Lightly hand-sand the existing hinge with 100grit or finer sandpaper in order to locate the4 welds that attach the hinge to the pillar(Fig. 4-26).IMPORTANT: Punch the center of the weldso that as much of the weld as possible isremoved during the drilling.

4. Center punch each of the four weld marks onthe original hinge.IMPORTANT: Do not drill into the hingepillar.

5. Drill through the hinge only, at each punchlocation. Use a 13 ␣ mm (1/2␣ in) rotabroachhole saw or equivalent (Fig. 4-27).

6. Remove the hinge. If necessary, use a chisel inorder to separate the hinge from the pillar.

7. Remove all of the remaining weld from thepillar surface in order to ensure a flush fit ofthe service hinge.

Fig. 4-26 — Hand Sand Hinge

Fig. 4-27 — Body Side Hinge


Installation Procedure1. Repair any damage done to the pillar during

the drilling or the removal.2. Position the service hinge within the scribe

marks on the pillar.3. Center punch each stud location on the hinge

pillar according to the service hinge.4. Drill a 3 ␣ mm (1/8␣ in) pilot hole at each center

punch location.IMPORTANT: Drill must be exact size.

5. Drill an 11.5 mm (29/64␣ in) hole at the pilotlocations for the studs (Fig. 4-28).IMPORTANT: Prior to refinishing, refer tothe publication GM4901M-D-2000 “GMApproved Refinish Materials” forrecommended products. Do not combinepaint systems. Refer to paint manufacturer’srecommendations.

6. Clean and prepare all of the bare metalsurfaces.

7. Apply approved anti-corrosion primer.8. Feed fish wire, GM P/N 15017229 or the

equivalent, through the hinge, the hinge studhole and out of the conduit hole in the pillar(Fig. 4-29).

9. Install the stud, GM P/N 15017230, suppliedwith the service hinge into the wire end. Pullthe stud into position.

10. Hold the stud in position with the hinge andremove the fish wire.

11. Draw the stud tight through the pillar. Usethe nuts (GM P/N 11516746) supplied.

12. Repeat steps 7-10 on the remaining studlocations.

13. Remove each service nut.14. Apply a full-bodied caulk to the entire hinge

mounting surface in order to ensure a properseal.

15. Install the hinge to the pillar. Use the suppliednuts. Torque the hinge to the pillar nuts to25␣ N·m (20 ft lb.) (Fig. 4-30).

16. Clean and prepare all of the surfaces asnecessary for refinishing.

17. Apply the sealers. Refinish the surfaces asnecessary.

18. Install and align all of the related panels andthe components.

3 MM (1/8 IN)PILOT

11.5 MM (29/64 IN)DRILL

Hinge

Nuts

Pillar

Hinge Reinforcement

Studs

Fig. 4-28 — Drill Hinge Holes

Fig. 4-29 — Feed Fish Wire

Fig. 4-20 — Install Hinge


Front Door Side HingeReplacementRemoval Procedure1. Remove related panels and components.2. Remove any excess sealer surrounding the

hinge and scribe the location of the hinge onthe door.

3. Lightly hand-sand the existing body hingewith 100 grit or finer sandpaper in order tolocate the 4 welds that attach the hinge to thedoor (Fig. 4-31).IMPORTANT: Punch the center of the weldso that as much of the weld is removedduring the drilling as possible.

4. Center punch each of the four weld marks onthe original hinge base.IMPORTANT: Do not drill into the door.

5. Drill through hinge base only at the punchlocation. Use a 13 mm (1/2␣ in) rotabroachhole saw, or the equivalent (Fig. 4-32).

6. Remove hinge. If necessary, use a chisel toseparate the hinge from the door.

7. Remove all of the remaining weld from thedoor surface in order to ensure a flush fit ofthe service hinge.

13mm (1/2 inch)Rotabroach Bit

Hinge

Door

Hinge Reinforcement

Typical Mig WeldDrill through hinge only


Fig. 4-32 — Rotabroach Hinge


Installation Procedure1. Repair any damage done to door during the

drilling or the removal.2. Clean and prepare the backing plate

mounting surfaces in order to ensure a flushfit of the backing plate.

3. Position the service hinge within the scribemarks on the door.

4. Center punch each hole location on the dooraccording to the service hinge.

5. Drill a 3 mm (1/8␣ in) pilot hole at each centerpunch location.

6. Drill a 13 mm (1/2␣ in) hole at the pilotlocations (Fig. 4-33).IMPORTANT: Prior to refinishing, refer tothe publication GM4901M-D-2000 “GMApproved Refinish Materials” forrecommended products. Do not combinepaint systems. Refer to paint manufacturer’srecommendations.


8. Apply approved anti-corrosion primer.9. Apply full-bodied caulk to the entire hinge


10. Align the hinge and the backing plate with theholes in the door (Fig. 4-34).

11. Install the bolts. Tighten the bolts to 25 N·m(20 ft lb).

12. Apply the sealers.13. Refinish the metal surfaces as necessary.14. Install and align all of the related panels and

the components.

3 MM (1/8 IN)PILOT

13 MM (1/2 IN)DRILL

Fig. 4-33 — Drill Door

Fig. 4-34 — Replace Hinge

HINGE DOOR

BOLTS

BACKINGPLATE


Rear Body Side HingeReplacementRemoval Procedure1. Remove related panels and components.2. Remove any excess sealer surrounding the

existing hinge and scribe the location of thehinge on the hinge pillar.

3. Lightly hand-sand the existing hinge with 100grit or finer sandpaper in order to locate the4 welds that attach the hinge to the pillar(Fig. 4-35).IMPORTANT: Punch the center of the weldso that as much of the weld as possible isremoved during the drilling.

4. Center punch each of the 4 weld marks on theoriginal hinge.IMPORTANT: Do not drill into the hingepillar.

5. Drill through the hinge only at each punchlocation. Use a 13␣ mm (1/2␣ in) rotabroachhole saw or the equivalent (Fig. 4-36).

6. Remove the hinge. If necessary, use a chisel inorder to separate the hinge from the pillar.

7. Remove all of the remaining weld from thepillar surface in order to ensure a flush fit ofthe service hinge.

HINGE

PILLAR


HINGE REINFORCEMENT


Fig. 4-35 — Locate Welds

Fig. 4-36 — Rotabroach Weld Locations




marks on the pillar.3. Center punch each stud location on the hinge

pillar according to the service hinge.4. Drill a 3␣ mm (1/8␣ in) pilot hole at each center

punch location (Fig. 4-37).IMPORTANT: Drill must be exact size.

5. Drill an 11.5␣ mm (29/64␣ in) hole at the pilotlocations for the studs.IMPORTANT: Prior to refinishing, refer tothe publication GM4901M-D-2000 “GMApproved Refinish Materials” forrecommended products. Do not combinepaint systems. Refer to paint manufacturer’srecommendations.


7. Apply an approved anti-corrosion primer.8. Feed fish wire, GM P/N 15017229 or the

equivalent, through the hinge, the hinge studhole and out of the conduit hole in the pillar(Fig. 4-38).

9. Install the stud, GM P/N 15017230, suppliedwith the service hinge, into the wire end. Pullthe stud into position (Fig. 4-39).

10. Hold the stud in position with the hinge andremove the fish wire.

11. Draw the stud tight through the pillar. Usethe nuts GM P/N 11516746, supplied.

12. Repeat steps 7 through 10 on the remainingstud locations.

13. Remove each service nut.14. Apply a full-bodied caulk to the entire hinge


15. Install the hinge to the pillar. Use the suppliednuts.

16. Torque the hinge to the pillar nuts to 25N·m(20 ft lb).

17. Clean and prepare all of the surfaces asnecessary for refinishing.

18. Apply the sealers. Refinish the surfaces asnecessary.

19. Install and align all of the related panels andthe components.

Hinge

Nuts

Pillar

Hinge Reinforcement

Studs

Fig. 4-37 — Drill Pilot Holes and StudHoles

Fig. 4-38 — Feed Fish Wire

Fig. 4-39 — Install Hinge (Body Side)

3 MM (1/8 IN)PILOT

11.5 MM (29/64 IN)DRILL

STUD


Rear Door Side HingeReplacementRemoval Procedure1. Remove related panel and components.2. Remove any excess sealer surrounding the

existing hinge and scribe the location of thehinge on the door (Fig. 4-40).

3. Lightly hand-sand the existing body hingewith 100 grit or finer sandpaper in order tolocate the 4 welds that attach the hinge to thedoor.IMPORTANT: Punch the center of the weldso that as much of the weld is removedduring the drilling as possible.

4. Center punch each of the 4 weld marks on theoriginal hinge base.IMPORTANT: Do not drill into the door.

5. Drill through the hinge base only at the punchlocation. Use a 13␣ mm (1/2␣ in) rotabroachhole saw or the equivalent (Fig. 4-41).

6. Remove the hinge. If necessary, use a chisel inorder to separate the hinge from the door.

7. Remove all of the remaining weld from thedoor surface in order to ensure a flush fit ofthe service hinge.

HINGE

PILLAR


HINGE REINFORCEMENT



Fig. 4-41 — Rotabroach Holes


Installation Procedure1. Repair any damage done to the door during

the drilling or the removal.2. Clean and prepare the backing plate

mounting surfaces in order to ensure a flushfit of the backing plate.

3. Position the service hinge within the scribemarks on the door.

4. Center punch each hole location on the dooraccording to the service hinge.

5. Drill a 3␣ mm (1/8␣ in) pilot hole at each centerpunch location (Fig. 4-42).

6. Drill a 13␣ mm (1/2␣ in) hole at the pilotlocations.IMPORTANT: Prior to refinishing, refer tothe publication GM4901M-D-2000 “GMApproved Refinish Materials” forrecommended products. Do not combinepaint systems. Refer to paint manufacturer’srecommendations.


8. Apply an approved anti-corrosion primer.9. Apply a full-bodied caulk to the entire hinge


10. Align the hinge and the backing plate with theholes in the door (Fig. 4-43).NOTICE: Refer to Fastener Notice inCautions and Notices.

11. Install the bolts.12. Torque the bolts to 25N·m (20 ft lb).13. Apply the sealers.14. Refinish the metal surfaces as necessary.15. Install and align all of the related panels and

the components.

HINGE DOOR

BOLTS

BACKINGPLATE

Fig. 4-42 — Drill Holes

Fig. 4-43 — Install Hinge (Door Side)

13 MM (1/2 IN) DRILL

3 MM (1/8 IN) PILOT


Fig.␣ 4-44 — Remove Excess Sealer

Fig.␣ 4-45 — Mark Hinge Location

Fig.␣ 4-46 — Drill Factory Welds

Fig.␣ 4-47 — Pry Access Panel

Cargo Body Side HingeReplacement

Upper Cargo HingeRemoval Procedure1. Visually inspect and restore as much of the

damage as possible to factory specifications.2. Remove all of the related panels and the

components.3. Remove any excess sealer surrounding the

hinge (Fig. 4-44).4. Scribe the location of the hinge on the hinge

pillar (Fig. 4-45).5. Locate and drill out all necessary factory welds

in the hinge access panel. (Fig. 4-46).6. Pry access door out to gain access to the back

side of the hinge (Fig. 4-47).


Fig.␣ 4-49 — Chisel Hinge from Pillar

Fig.␣ 4-48 — Drill Out Hinge Welds

Fig.␣ 4-50 — Remove Hinge

13 MM (1/2 IN) DRILL

7. Locate and drill the center of the hinge weldsusing a 13␣ mm (1/2␣ in) drill bit or theequivalent (Fig. 4-48).

8. If necessary, use a chisel in order to separatethe hinge from the pillar (Fig. 4-49).

9. Remove the hinge (Fig. 4-50).


Fig.␣ 4-52 — Apply Chalk to Hinge

Fig.␣ 4-51 — Prepare Pillar Surface

Fig.␣ 4-53 — Position Hinge to Pillar

Installation Procedure1. Clean and prepare the pillar surface in order to

ensure a flush fit of the service hinge and thefasteners (Fig. 4-51).IMPORTANT: Prior to refinishing, refer tothe publication GM4901M-D-2000 “GMApproved Refinish Materials” forrecommended products. Do not combinepaint systems. Refer to paint manufacturer’srecommendations.


mounting surface (Fig. 4-52).4. Position the service hinge within the scribe

marks on the pillar (Fig. 4-53).NOTICE: Refer to Fastener Notice inCautions and Notices.

5. Install the hinge fasteners. Tighten the bolts to25 N•m (20 lb. Ft.).

6. Refinish the metal surfaces as necessary.7. Align and install all of the related panels and

the components.


Fig.␣ 4-56 — Hand Sand Hinge

Fig.␣ 4-57 — Center Punch Lower HingeBolt Locations

Fig.␣ 4-54 — Remove Sealer

Fig.␣ 4-55 — Mark Hinge Location

Lower Cargo HingeRemoval Procedure1. Visually inspect and restore as much of the

damage as possible to factory specifications.2. Remove all of the related panels and the

components.3. Remove any excess sealer surrounding the

hinge (Fig. 4-54).4. Scribe the location of the hinge on the hinge

pillar (Fig. 4-55).5. Lightly hand-sand the existing hinge with 100

grit or finer sandpaper in order to locate the4 welds that attach the hinge to the pillar (Fig.4-56).

6. Center punch each of the four weld marks onthe original hinge (Fig. 4-57).


Fig.␣ 59 — Chisel Rear Body Opening Filler Panel

Fig.␣ 4-58 — Drill Out Filler Welds

7. Locate and drill out all necessary factory weldsin the rear body opening lower filler, using8mm (5/16␣ in) spot weld remover, to gainaccess to the backside of the lower hinge(Fig. 4-58).IMPORTANT: Take care not to damage thefiller panel when removing it. The fillerpanel must be reinstalled (Fig. 4-59).

8. Remove rear body opening lower filler. Ifnecessary, use a chisel in order to separate thefiller from the opening (Fig. 4-59).IMPORTANT: Do not drill into the hingepillar.


Fig.␣ 4-61 — Separate Hinge from Pillar

Fig.␣ 4-62 — Grind Surface

9. Drill through the hinge only at each punchlocation. Use a 13␣ mm (1/2␣ in) rotabroachhole saw or the equivalent (Fig. 4-60).

10. If necessary, use a chisel in order to separatethe hinge from the pillar (Fig. 4-61).

11. Remove the hinge.12. Remove all of the remaining weld from the

pillar surface in order to ensure a flush fit ofthe service hinge (Fig. 4-62).

Fig.␣ 4-60 — Drill Welds


Fig.␣ 4-63 — Center Punch

Fig.␣ 4-64 — Drill Pilot Holes

Fig.␣ 4-65 — Drill 13␣ mm Holes

Fig.␣ 4-66 — Apply Full-Bodied Caulk



marks on the pillar.3. Center punch each bolt location on the pillar

according to the service hinge (Fig. 4-63).4. Drill a 3␣ mm (1/8␣ in) pilot hole at each punch

location (Fig. 4-64).5. Drill a 13␣ mm (1/2␣ in) hole at the pilot

locations (Fig. 4-65).6. Clean and prepare all bare metal surfaces.

IMPORTANT: Prior to refinishing, refer tothe publication GM4901M-D-2000 “GMApproved Refinish Materials” forrecommended products. Do not combinepaint systems. Refer to paint manufacturer’srecommendations.


mounting surface (Fig. 4-66).


Fig.␣ 4-67 — Align Hinge

Fig.␣ 4-68 — Install Fasteners

Fig.␣ 4-69 — Install Rear Body Opening Filler Panel

9. Align hinge with the holes in the pillar(Fig. 4-67).

10. Install the hinge fasteners (Fig. 4-68).11. Tighten the bolts to 25N·m (20 lb. Ft.).12. Position the rear body opening lower filler and

mig weld in place at factory weld locations(Fig. 4-69).

13. Clean and prepare all weld surfaces.14. Refinish the metal surfaces as necessary.15. Align and install all of the related panels and

the components.


Front Bumper BracketReplacement

1500 Series1. Remove related panels and components.2. Remove damaged bumper bracket (Fig. 4-70).

IMPORTANT: Do not remove any materialfrom end of frame rail.

3. Position the service template on the end of theframe rail; use 3M’s Repositionable Adhesiveor equivalent.

4. Drill three 13␣ mm (1/2␣ in) holes at locationsindicated on template that is supplied withpart.IMPORTANT: Prior to refinishing, refer tothe publication GM4901M-D-2000 “GMApproved Refinish Materials” forrecommended products. Do not combinepaint systems. Refer to paint manufacturer’srecommendations.

5. Apply approved anti-corrosion primer to baremetal surfaces.

6. Position replacement bumper bracket.7. Install bolts, torque to 50 N•m (37 ft.lb.).

Fig. 4-70 — Front bumper bracket



2500 Series1. Remove related panels and components.2. Remove damaged bumper bracket.3. Visually inspect frame and restore all damage

to factory specifications using three-dimensional measuring.IMPORTANT: If vehicle is equipped withtow hooks, discard original fasteners(Fig. 4-71).

4. Align replacement bracket lower bolt holeswith tow hook mounting locations and installbolts supplied.

5. Align front edge of bracket with front edge offrame and mark upper bolt locations on frame(Fig. 4-72).

6. Rotate bracket forward and drill 13␣ mm(1/2␣ in) holes in frame at upper bolt locations(Fig. 4-73).

7. Rotate bracket back into position.8. Install fasteners supplied. Torque bracket

fasteners to 70 N•m (52 ft. lb.) (Fig. 4-74).

Fig. 4-71 — Front Bumper Bracket

Fig. 4-74 — Torque to 70 N•m (52 FT.LB.)

Fig. 4-73 — Drill 13␣ mm (1/2␣ in) holes

Fig. 4-72 —Mark upper bolt locations

DISCARD ORIGINALFASTENERS

MARK BOLTLOCATIONS


Quarter PanelReplacementThe quarter panel may be serviced as a completepanel in the event the roof panel is to be replaced.Sectioning procedures have been developed tosimplify the repair. The service part can bereplaced by making sectioning cuts at the windowpillars (Figs. 4-75, 4-76).

Removal Procedure1. Remove all related panels and components.2. Restore as much of the damage as possible to



4. Cut the pillar in a location where sectioning isto be performed.

5. Locate and drill out all factory welds. note thenumber and location of the welds forinstallation of the service part.


Fig. 4-75 — Suburban

Fig. 4-76 — Utility


Installation Procedure1. Cut the replacement quarter panel in


2. Create a 50␣ mm (2␣ in) backing plate form theunused portion of the service part. Trim thebacking plate as necessary to fit behind thesectioning joint (Fig. 4-77).

3. Drill 8 ␣ mm (5/16␣ in) plug weld holes alongthe sectioning cut on the remaining originalpart.

4. Drill 8␣ mm (5/16␣ in) plug weld holes in theservice panel as necessary in the locationsnoted from the original panel.CAUTION: Foam sealers are flammable andshould be removed from all weld locations.

5. Prepare the mating surfaces.6. Apply weld-through primer to all bare metal



8. Align the rear lock pillar to adjacent panelsusing three-dimensional measuringequipment. Leave a gap of one-and-one-halftimes the metal thickness at the sectioningjoint (Fig. 4-79).





Fig. 4-77 — Quarter Panel Service Part

50 MM(2 IN)BACKING

PLATE

SERVICE PANEL

50 MM(2 IN)


PLUG WELDS

13 MM(1/2 IN)

ORIGINAL PART

BACKING PLATE

Fig. 4-79 — Align Panels

Fig. 4-78 — Install Backing Plate


Rail EndFront Crush CapReplacement

Removal Procedure1. Remove all of the related panels and the

components.IMPORTANT: If the crush cap is bent ordamaged in any way you must replace thecrush cap.

2. Visually inspect the damage. Use three-dimensional measuring in order to restore allof the damage rearward of the crush cap tothe factory specifications.IMPORTANT: Use caution not to damagethe rail.

3. Remove the core support mounting bracket(Fig. 4-80).

4. Locate the brake line attachment hole on thetop of the rail. Measure forward 155 mm(6-1/8␣ in). This is the cut line (Fig. 4-81).

5. Scribe a line 360 degrees around the framerail.IMPORTANT: Use caution to not damagethe cross tube

6. Remove the crush cap at the cut-line and theforward edge of the cross tube.

7. Grind the remaining weld off of the cross tubewhere you removed the damaged crush cap(Fig. 4-82).

155 MM(6 IN)

Fig. 4-80 — Remove Mounting Bracket

Fig. 4-81 — Remove Crush Cap

Fig. 4-82 — Grind Weld Material


13mm

50mm


Fig. 4-83 — Drill Plug Weld Holes

Fig. 4-84 — Position Mounting Bracket

Installation Procedure1. Drill 4 plug weld holes (2 at the top and 2 at

the bottom), 13 mm (1/2␣ in) from the cut lineand 50 mm (2␣ in) apart on the existing framerail (Fig. 4-83).

2. Prepare all of the bare metal surfaces with asuitable weld through primer.IMPORTANT: The replacement bumperbracket is a bolt-on component that must beordered separately.

IMPORTANT: Retain a gap of one andone-half times the metal thickness at thebutt joint when attaching the service part tothe vehicle (Fig. 4-84).

3. Install and position the replacement crush capusing three-dimensional measuring.

4. Tack weld the part into position at the initialplug weld holes.

5. Inspect the service part for properdimensions.

6. Stitch weld along the entire sectioning joint.Make 25 mm (1␣ in) welds along the seamwith 25 mm (1␣ in) gaps between.

7. Complete the stitch weld.8. Position the new core support mounting

bracket and weld the bracket in placeaccording to the specified dimensions.

9. Clean and prepare the welded surfaces.IMPORTANT: Prior to refinishing, refer tothe publication GM4901M-D-2000 “GMApproved Refinish Materials” forrecommended products. Do not combinepaint systems. Refer to paint manufacturer’srecommendations.

10. Apply approved anti-corrosion primer.11. Apply the sealers.12. Refinish the welded surfaces as necessary.13. Replace the related panels and the

components.


Description Location Length Width Height

13 mm hole A 1441 388 56232 mm hole B 1327 411 55217 mm hole zero line C 0 522 38215 mm hole D 1471 601 35119 mm hole E 3214 500 574

All dimensions are measured in millimeters, from a zero line, center line, and a common datum. All dimensions are symmetrical, unless otherwise specified.

CL

Ø

C

Ø

Ø Ø

CL

A

388 411 522 601 500

562

1441

1327

1471

3214

552 382 351 574

B

D

E

1760 1475

2073

1851

1343

1714

1459

1632

2000 Chevrolet/GMC Utilities


2000 Chevrolet Suburban/GMC Yukon XL

CLCL

Ø

C

Ø

ØØ

A

388 411 522 601 500

562

1441

1327

1827

3732

552 382 351 574

B

D

E

1921 1829

2212

2145

1343

1714

1459

1632

Description Location Length Width Height

13 mm hole A 1441 388 56232 mm hole B 1327 411 55222 x 19 mm slot zero line C 0 522 38233 x 17 mm hole D 1827 601 35119 mm hole E 3732 500 574

All dimensions are measured in millimeters, from a zero line, center line, and a common datum. All dimensions are symmetrical, unless otherwise specified.

Documents

2000 Chevy Suburban Body Repair Manual