For 1990-2009 cars only
Removal Procedure
- Remove all related panels and components.
- Remove sealers and anti-corrosion materials as necessary.
- Locate, mark, and drill out all factory welds attaching the outer rail.
- Remove the damaged outer rail (3).
- Locate, mark, and drill out the welds attaching the inner rail (1).
- Remove the damaged inner rail.
Important: The front upper rail is serviced as two components: inner (1) and outer (3) panels. The outer panel is serviced as a sub-assembly which includes an inner reinforcement (2). After removing the outer rail has been removed, the inner rail is completely accessible and can be serviced at the factory seams.
Sectioning of the front upper rails is not recommended.
Installation Procedure
- Prepare the mating surfaces as necessary.
- Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original panels.
- Temporarily position the inner and outer rails on the vehicle.
- Using three-dimensional measuring equipment, locate and mark front fender mounting bolt holes in the outer rail.
- Drill 5.5 mm (7/32 in) holes for self-tapping bolts as marked.
- When the service panels are correctly positioned, remove the outer panel and plug weld the inner panel as necessary.
- Reposition the outer rail with frequent measurements to ensure proper fit and alignment.
- Plug weld accordingly.
- Clean and prepare all welded surfaces.
- Prime with a two-part catalyzed primer.
- Apply sealers and anti-corrosion materials as necessary.
- Install all related panels and components.
Important: If original locations are damaged beyond recognition, locate holes for plug welding 40 mm (1½ in) apart.
Important: Prior to refinishing, refer to GM 4901MD-99 Refinish Manual for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.
