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 damage as possible to factory specifications. 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 factory welds. Note the number and location of the welds for installation of the front upper rail.
- Remove the damaged front upper rail.
Warning: Refer to Approved Equipment for Collision Repair Warning in the Preface section.
Note: Do not damage any inner panels or reinforcements.
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 front upper rail on the vehicle using 3-dimensional measuring equipment. Clamp the rail in place.
- Plug weld accordingly.
- Clean and prepare all welded surfaces.
- Install all 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 repair 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.
Note: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart.
