For 1990-2009 cars only
Removal Procedure
- Remove all related panels and components.
- Restore as much of the damage as possible to factory specifications.
- Note the location and remove the following as necessary:
- Perform the necessary procedures to gain access to repair. Refer to Radiator Upper Support Replacement Upper Rail Replacement , Radiator Lower Support Replacement , or to Front Wheelhouse Sectioning .
- Locate and drill out all factory welds (1). Note the number and location of welds for installation of the service part.
- Cut the inner-upper rail.
- Remove the damaged front inner upper rail.
| • | Sealers |
| • | Sound deadeners |
| • | Anti-corrosion materials |
Body and Accessories-Collision Repair Important: Do not damage any inner panels or reinforcements.
Installation Procedure
- Mark the service part at the inboard contour (1) to create a weld flange.
- Cut the service part.
- Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
- Drill 8 mm (5/16 in) plug weld holes along the sectioning cut on the service part. Locate these holes 40 mm (1 1/2 in) apart.
- Prepare all attachment surfaces as necessary.
- Apply weld-through primer to all bare metal surfaces.
- Align the service part over the stepped tab using dimensional measuring equipment.
- Plug weld accordingly.
- Clean and prepare all welded surfaces.
- Apply an approved anti-corrosion primer.
- Apply sealers and refinish as necessary.
- Complete the necessary procedures. Refer to Radiator Upper Support Replacement Upper Rail Replacement , Radiator Lower Support Replacement , or to Front Wheelhouse Sectioning .
- Install all other related components.
Important: In any area damaged beyond recognition, space plug weld holes every 40 mm (1 1/2 in) apart.
Important: Prior to refinishing, refer to publication GM 4901M-D-01 GM Approved Refinish Materials, for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.
