Chevrolet Suburban 2000 User Manual
2000 Chevrolet/GMC
Full-Size Sport Utility Vehicles (SUVs)
Door Frame Sectioning 4-1
Upper Body Cargo Hinge
Replacement 4-20
Lower Body Cargo Hinge
Replacement 4-23
Quarter Panel
Replacement 4-30
Front Body Side Hinge Replacement 4-12
Front Door Side Hinge Replacement 4-14
Rocker Panel
Sectioning 4-10
Windshield Pillar
Sectioning 4-2
Front Bumper Bracket
Replacement 4-28
Center Pillar
Sectioning 4-6
Rear Body Side
Hinge Replacement
4-16
Rear Door Side
Hinge Replacement
4-18
Rail End Front
Crush Cap
Replacement 4-32
Rear Lock Pillar
Sectioning 4-8
Front Lower Hinge Pillar
Sectioning 4-4
Dimensions 4-34
(note: all procedures apply to all models,
unless otherwise noted)
Door Frame Sectioning
The door frame opening is a unique laser-weld design incorporating
multiple metal thicknesses to ensure the structural integrity of the
cab. The door frame can be replaced at factory seams, but requires
the removal of the roof panel, windshield and quarter panel.
Sectioning procedures have been developed as a more costeffective alternative to complete replacement. The specific area to
be sectioned is determined by the extent of the damage to the
vehicle.
Refer to Door Frame Sectioning - Windshield; Door Frame
Sectioning - Front Pillar; Door Frame Sectioning - Center Pillar;
Door Frame Sectioning - Rear Lock Pillar; Door Frame Sectioning Rocker.
IMPORTANT: Section in specified areas only. Sectioning outside
of these areas may compromise the structural integrity of the
vehicle (Figs. 4-1, 4-2).
Fig. 4-1 — Suburban
Fig. 4-2 — Sport Utility
2000 chevrolet/gmc full-size sport utility vehicles 4-1
Windshield Pillar Sectioning
Removal Procedure
1. 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 materials
IMPORTANT: Perform sectioning in the
windshield area 30 ␣ mm (1-3/16␣ in) above
the third trim mounting hole (Fig. 4-3).
IMPORTANT: Take care not to damage the
inner panels or reinforcements.
4. Cut the pillar in the locations where sectioning
is to be performed.
5. Locate and drill out all factory welds. note the
number and location of the welds for
installation 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
4-2 2000 chevrolet/gmc full-size sport utility vehicles
50 MM
(2 IN)
100 MM
(24 IN)
Fig. 4-4 — Create Backing Plate
PLUG WELDS
13 MM
(1/2 IN)
BACKING PLATE
Fig. 4-5 — Drill and Plug Weld
GAP =
ONE AND ONE-HALF TIMES
MET AL THICKNESS
100MM
(4 IN)
BACKING PLATE
GAP = ONE AND ONE-HALF TIMES
THE THICKNESS OF THE METAL
ORIGINAL PART
STITCH WELD
Installation Procedure
1. Cut the replacement pillar in corresponding
locations to fit the remaining original panel.
The sectioning joint should be trimmed to
allow a gap of one and one-half times the
metal thickness at the sectioning joint.
2. Create a 50␣ mm (2␣ in) backing plate from the
unused portion of the service part. Trim the
backing plate as necessary to fit behind the
sectioning joint (Fig. 4-4).
3. Perform additional sectioning procedures as
necessary. Refer to Center Pillar Sectioning;
Front Lower Pillar Sectioning; Rear Lock Pillar
Sectioning; and Rocker Sectioning.
4. Drill 8␣ mm (5/16␣ in) holes for plug welding in
the original part. Locate these holes
approximately 13␣ mm (1/2␣ in) from the edge
of the sectioning cuts and spaced 40␣ mm
(1-1/2␣ in) apart.
5. Drill 8␣ mm (5/16␣ in) plug weld holes in the
service panel as necessary in the locations
noted from the original panel and along the
sectioning cut.
CAUTION: Foam sealers are flammable and
should 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 the
vehicle (Fig. 4-5).
9. Align the windshield pillar to adjacent panels
using three-dimensional measuring
equipment.
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 heat
distortion (Fig. 4-6).
12. Clean and prepare all welded surfaces.
IMPORTANT: Prior to refinishing, refer to
the publication GM4901M-D-2000 “GM
Approved Refinish Materials” for
recommended products. Do not combine
paint systems. Refer to paint manufacturer’s
recommendations.
13. Apply an approved anti-corrosion primer.
14. Apply sealers and refinish as necessary.
15. Install all related panels and components.
Fig. 4-6 — Align Windshield Pillar
2000 chevrolet/gmc full-size sport utility vehicles 4-3
Front Lower Hinge Pillar
30 MM (1-3/16 IN)
5 MM (3/16 IN)
WELD TOGETHER
Sectioning
Removal Procedure
1. 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 from
the large wiring harness hole in the hinge pillar
and mark a horizontal line.
5. Cut the pillar in the locations where sectioning
is to be performed.
IMPORTANT: Take care not to damage the
inner panel (Fig.␣ 3-7).
6. Locate, mark and drill out all necessary factory
welds. Note the number of welds for the
installation of the service section.
7. Remove the damaged section of the door
frame opening.
8. Cut and remove 30␣ mm (1-3/16 inches) from
the flanges on either side of the remaining
section of the original hinge pillar to create
30␣ 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 frame
opening service section to fit over the original
hinge pillar. Weld the tabs together along the
edges (Fig. 4-9).
IMPORTANT: The metal of the hinge pillar
is of a heavy gauge. However, the tabs can
be created using the appropriate tools.
ORIGINAL
PANEL
80 MM (3-1/8 IN)
Fig. 4-7 — Cut the Original Panel
Fig. 4-8 — Create Tab
4-4 2000 chevrolet/gmc full-size sport utility vehicles
Fig. 4-9 — Weld Corners
Fig. 4-10 — Cut the Service Panel
Fig. 4-11 — Drill Panel
30 MM (1-3/16 IN)
OF OVERLAP
SERVICE
PANEL
50 MM (2 IN)
ORIGINAL
PANEL
NEW
SERVICE PANEL
ORIGINAL
PANEL
Installation Procedure
1. On the service part, measure 50␣ mm (2␣ in)
down from the large wiring harness hole in
the hinge pillar and mark a horizontal line. Cut
the hinge pillar along this line (Fig. 4-10).
2. Perform additional sectioning procedures as
necessary to remove the unused areas of the
service part. Refer to Windshield Sectioning;
Center Pillar, Rear Lock Pillar, and Rocker
Sectioning.
NOTICE: In any area damaged beyond
recognition, space plug weld holes every
40␣ mm (1-1/2 in) apart.
3. Drill 8␣ mm (5/16␣ in) plug weld holes as
necessary in the locations noted from the
original section. Also drill plug weld holes
along the hinge pillar sectioning cut of the
service part. These should be located
approximately 15␣ mm (9/16␣ in) from the
edge of the cut.
CAUTION: Foam sealers are flammable and
should 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, allowing
30␣ 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 go
back and complete the stitch weld. This will
create a solid joint with minimal heat
distortion (Fig.␣ 4-12).
9. Clean and prepare all welded surfaces.
IMPORTANT: Prior to refinishing, refer to
the publication GM4901M-D-2000 “GM
Approved Refinish Materials” for
recommended products. Do not combine
paint systems. Refer to paint manufacturer’s
recommendations.
10. Apply approved anti-corrosion primer.
11. Apply sealers and refinish as necessary.
12. Reinstall all related panels and components.
Fig. 4-12 — Stitch Weld
2000 chevrolet/gmc full-size sport utility vehicles 4-5
Center Pillar Sectioning
Removal Procedure
1. 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 materials
IMPORTANT: Take care not to damage the
inner panels or reinforcements.
4. Cut the pillar in a location where sectioning is
to be performed (Figs. 4-13, 4-14).
5. Locate and drill out all factory welds. Note the
number and location of the welds for
installation of the service part.
6. Remove the damaged pillar section.
Fig. 4-13 — Suburban Sectioning Locations
4-6 2000 chevrolet/gmc full-size sport utility vehicles
Fig. 4-14 — Sport Utility Sectioning
Locations
Fig. 4-15 — Cut Center Pillar
PLUG WELDS
13 MM
(1/2 IN)
BACKING PLATE
Fig. 4-16 — Install Backing Plate
GAP =
ONE AND ONE-HALF TIMES
MET AL THICKNESS
50MM
(2 IN)
1
100MM
(4 IN)
ORIGINAL PART
STITCH WELD
Installation Procedure
1. Cut the replacement center pillar in
corresponding locations to fit the remaining
original panel. The sectioning joint should be
trimmed to allow a gap of one-and-one-half
times the metal thickness at the sectioning
joint.
2. Create a 50␣ mm (2␣ in) backing plate from the
unused portion of the service part. Trim the
backing plate as necessary to fit behind the
sectioning joint (Fig. 4-15).
3. Perform additional sectioning procedures as
necessary. Refer to Windshield Sectioning;
Front Lower Pillar Sectioning; Rear Lock Pillar
Sectioning; and Rocker Sectioning.
4. Drill 8␣ mm (5/16␣ in) plug weld holes along the
sectioning cut on the remaining original part.
5. Drill 8␣ mm (5/16␣ in) plug weld holes in the
service panel as necessary in the locations
noted from the original panel and along the
sectioning cut.
CAUTION: Foam sealers are fla␣ mmble and
should 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 the
vehicle (Fig. 4-16).
9. Align the center pillar to adjacent panels using
three-dimensional measuring equipment
(Fig. 4-17).
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 heat
distortion.
12. Clean and prepare all welded surfaces.
IMPORTANT: Prior to refinishing, refer to
the publication GM4901M-D-2000 “GM
Approved Refinish Materials” for
recommended products. Do not combine
paint systems. Refer to paint manufacturer’s
recommendations.
13. Apply an approved anti-corrosion primer.
14. Apply sealers and refinish as necessary.
15. Install all related panels and components.
Fig. 4-17 — Align Panels
2000 chevrolet/gmc full-size sport utility vehicles 4-7
Rear Lock Pillar Sectioning
Removal Procedure
1. 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 materials
IMPORTANT: Take care not to damage the
inner panels or reinforcements.
4. Cut the pillar in the locations where sectioning
is to be performed (Figs. 4-18, 4-19).
5. Locate and drill out all factory welds. Note the
number and location of the welds for
installation of the service part.
6. Remove the damaged pillar section.
Fig. 4-18 — Suburban Sectioning Locations
4-8 2000 chevrolet/gmc full-size sport utility vehicles
Fig. 4-19 — Sport Utility Sectioning
Locations
BACKING PLATE
50 MM
(2 IN)
100 MM
Fig. 4-20 — Cut Replacement Pillar
PLUG WELDS
13 MM
(1/2 IN)
BACKING PLATE
Fig. 4-21 — Drill and Plug Weld
GAP =
ONE AND ONE-HALF TIME
METAL THICKNESS
(4 IN)
ORIGINAL PANEL
STITCH WELD
Installation Procedure
1. Cut the replacement rear lock pillar in
corresponding locations to fit the remaining
original panel. The sectioning joint should be
trimmed to allow a gap of one-and-one-half
times the metal thickness at the sectioning
joint.
2. Create a 50␣ mm (2␣ in) backing plate from the
unused portion of the service part. Trim the
backing plate as necessary to fit behind the
sectioning joint (Fig. 4-20).
3. Perform additional sectioning procedures as
necessary. Refer to Windshield Sectioning;
Front Lower Pillar Sectioning; Center Pillar;
and Rocker Sectioning.
4. Drill 8 ␣ mm (5/16␣ in) plug weld holes along
the sectioning cut on the remaining original
part.
5. Drill 8␣ mm (5/16␣ in) plug weld holes in the
service panel as necessary in the locations
noted from the original panel and along the
sectioning cut.
CAUTION: Foam sealers are flammable and
should 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 the
vehicle (Fig. 4-21).
9. Align the rear lock pillar to adjacent panels
using three-dimensional measuring
equipment (Fig. 4-22).
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 heat
distortion.
12. Clean and prepare all welded surfaces.
IMPORTANT: Prior to refinishing, refer to
the publication GM4901M-D-2000 “GM
Approved Refinish Materials” for
recommended products. Do not combine
paint systems. Refer to paint manufacturer’s
recommendations.
13. Apply an approved anti-corrosion primer.
14. Apply sealers and refinish as necessary.
15. Install all related panels and components.
Fig. 4-22 — Align Rear Lock Pillar
2000 chevrolet/gmc full-size sport utility vehicles 4-9
Rocker Panel Sectioning
Removal Procedure
1. 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 materials
IMPORTANT: Take care not to damage the
inner panels or reinforcements.
4. Cut the pillar in the locations where sectioning
is to be performed (Figs. 4-23, 4-24).
5. Locate and drill out all factory welds. Note the
number and location of the welds for
installation of the service part.
6. Remove the damaged pillar section.
Fig. 4-23 — Suburban Sectioning Locations
4-10 2000 chevrolet/gmc full-size sport utility vehicles
Fig. 4-24 — Sport Utility Sectioning
Locations
100 MM
(4 IN)
BACKING PLATE
GAP = ONE AND ONE-HALF TIMES
THE THICKNESS OF THE METAL
Fig. 4-25 — Rocker Backing Plate
Installation Procedure
1. Cut the replacement rocker panel in
corresponding locations to fit the remaining
original panel. The sectioning joint should be
trimmed to allow a gap of one-and-one-half
times the metal thickness at the sectioning
joint.
2. Create a 100␣ mm (4␣ in) backing plate from
the unused portion of the service part. Trim
the backing plate as necessary to fit behind
the sectioning joint (Fig. 4-25).
3. Perform additional sectioning procedures as
necessary. Refer to Windshield Sectioning;
Front Lower Pillar Sectioning; Rear Lock Pillar
Sectioning; and Center Pillar sectioning.
4. Drill 8␣ mm (5/16␣ in) plug weld holes along the
sectioning cut on the remaining original part.
5. Drill 8␣ mm (5/16␣ in) plug weld holes in the
service panel as necessary in the locations
noted from the original panel and along the
sectioning cut.
CAUTION: Foam sealers are flammable and
should 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 the
vehicle.
9. Align the rocker panel to adjacent panels
using three-dimensional measuring
equipment.
10. Plug weld service part in position.
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 heat
distortion.
12. Clean and prepare all welded surfaces.
IMPORTANT: Prior to refinishing, refer to
the publication GM4901M-D-2000 “GM
Approved Refinish Materials” for
recommended products. Do not combine
paint systems. Refer to paint manufacturer’s
recommendations.
13. Apply an approved anti-corrosion primer.
14. Apply sealers and refinish as necessary.
15. Install all related panels and components.
2000 chevrolet/gmc full-size sport utility vehicles 4-11
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