GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 SL1/SC1 🢒 Body and Accessories 🢒 Collision Repair 🢒 Bar Dash Panel Cross Car

Removal Procedure
Object Number: 862128 Size: MF
  1. Remove the dash insulator.
  2. Remove the front seats.
  3. Remove the carpet and insulation.
  4. Protect the windshield with a welding blanket.
  5. Drill spot welds from the end bracket of the bar assembly at the attachment points to the dash assembly.
  6. Drill spot welds from the pedal brackets.
  7. Remove the bolts.
  8. Remove the bar assembly from the vehicle.

Installation Procedure
  1. Drill holes in the new bar assembly for the plug welds in the same amount and location as in the removed part.
  2. Install the beam into the proper position.

    3. Notice: Refer to Fastener Notice in the Preface section.

  3. Reinstall the bolts to help hold the beam in place.

    4. Tighten
    Tighten the cross car beam-to-body bolts to 25 N·m (18 lbs ft).

  4. Plug the weld bar into position.
  5. Check for water leaks in the cowl plenum after welding.
  6. Install the carpet and insulation.
  7. Install the front seats.
  8. Install the dash insulator.