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. Refer to Dimensions - Body .
- Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
- Cut the panel along the front edge of the die mark.
- Locate and drill out all factory welds. Note the number and location of the welds for installation of the front lower inner rail section.
- Remove the damaged front lower inner rail.
- If the inner rail reinforcement is damaged beyond repair, replace the reinforcement as needed.
Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.
Important: Do not damage any inner panels or reinforcements.
Installation Procedure
- Install the inner rail reinforcement as needed.
- Cut the replacement service part along the front edge of the arrow on the die mark.
- Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted on the original panel.
- Drill 8 mm (5/16 in) plug weld holes along the sectioning cut on the service part. Locate these holes 13 mm (½ in) from the edge and spaced 40 mm (1½ in) apart.
- 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 lower inner rail to the vehicle using 3-dimensional measuring equipment. Clamp the front lower inner rail into place.
- Plug weld accordingly.
- To create a solid weld with minimum heat distortion at the sectioning joint, make 25 mm (1 in) gaps between them. Complete the stitch weld.
- Clean and prepare all of the welded surfaces.
- 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 .
- Install all of the related panels and components.
- 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 can not be determined, space the plug weld holes every 40 mm (1½ in) apart.
Important: Some panels may have structural weld-thru adhesive. Replace the weld-thru adhesive with an additional spot weld between each factory spot weld.
