For 1990-2009 cars only
Removal Procedure
- Disable the SIR system. Refer to SIR Disabling and Enabling .
- Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
- Remove all related panels and components.
- Repair as much of the damaged area as possible. Refer to Dimensions - Body .
- Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
- Locate and drill out all the necessary factory welds.
- Remove the header panel.
Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.
Important: Note the number and location of the factory welds for installation of the header panel.
Installation Procedure
- Drill 8 mm (5/16 in) plug weld holes in the service part, as necessary in the locations noted from the original panel.
- Prepare all mating surfaces, as necessary.
- Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair .
- Position the header panel to the vehicle using 3-dimensional measuring equipment. Clamp the front header panel in place.
- Plug weld accordingly.
- Clean and prepare all of the welded surfaces.
- Install all of the related panels and components.
- Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
- Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
- Enable the SIR system. Refer to SIR Disabling and Enabling .
Important: If the location of the original plug weld holes cannot be determined, space the plug weld holes every 40 mm (1½ in) apart.
