Warning: Refer to Approved Equipment for Collision Repair Warning in the Preface section.

Warning: Refer to Foam Sound Deadeners Warning in the Preface section.

Note: 

1. Disable the SIR system. Refer to SIR Disabling and Enabling.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.

Warning: Refer to Collision Sectioning Warning in the Preface section.

3. Remove all related panels and components.
4. Repair as much of the damage as possible.
5. Remove the sealers and the anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.




Note: 

•	Note the number and location of the factory welds, for installation of the rail side extension service part.

•	Drill through the rail side extension flange only. Do NOT drill into the dash panel or the inner reinforcements.

6. Using an 8 mm (5/16 in) spot weld remover, locate and drill out the factory welds on the weld flange connecting the lower rail side extension to the vehicle structure.



7. Remove the rail side extension.

1. Position the service rail side extension to the vehicle.
2. Clamp the rail in place.



3. Using a 7 mm (17/64 in) bit, drill the rivet attachment holes through the service rail side extension and the dash panel, in the exact locations, as noted from the factory rail side extension.



4. Remove the service rail side extension.

Note: If the location of the original plug weld holes cannot be determined, space the plug weld holes every 40 mm (1.5 in) apart.

5. Drill 8 mm (5/16 in) plug weld holes in the service rail side extension as necessary, in the remaining locations noted from the original rail side extension.
6. Prepare the plug weld mating surfaces, as necessary.
7. Apply GM approved Weld-Thru coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair.



8. Prepare the bond mating areas by grinding the body mating and the service part flanges to bare steel. Do NOT damage the corners or thin the metal during the grinding process.
9. Clean the mating surfaces.




Note: The adhesive has a 40-50 minute working time. Do NOT allow the adhesive to cure prior to installing the service rail side extension.

10. Apply a 3-6 mm (1/8 to 1/4 in) bead of metal panel bonding adhesive GM P/N 12378567 (Canadian P/N 88901675) or equivalent to both of the mating surfaces.



11. Using a small acid brush, spread a coat of adhesive to both of the mating surfaces. Cover all of the bare metal to ensure corrosion protection.



12. Apply a 3-6 mm (1/8 to 1/4 in) bead of metal panel bonding adhesive GM P/N 12378567 (Canadian P/N 88901675) or equivalent to the mating surface of the service rail side extension.




Note: Do NOT pull the service rail side extension off of the dash after adhesion. To align the parts, slide the service rail side extension against the front of the dash.

13. Position the service rail side extension to the vehicle using 3-dimensional measuring equipment.
14. Clamp the service rail side extension in place.




Note: Verify proper positioning of the service rail side extension prior to riveting and welding.

15. Install the 9 mm (11/32 in) long rivets so that the rivet head contacts the passenger compartment side of the dash.



16. Install the 14 mm (17/32 in) long rivets so that the rivet head contacts the passenger compartment side of the dash.
17. Remove the excess adhesive from the service rail side extension area.



18. Plug weld the remaining holes accordingly.
19. Clean and prepare all of the welded surfaces.
20. Apply the sealers and anti-corrosion materials to the repaired area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
21. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
22. Install all of the related panels and components.
23. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
24. Enable the SIR system. Refer to SIR Disabling and Enabling.