GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 SL1/SC1 🢒 Body and Accessories 🢒 Collision Repair 🢒 Rail Sectioning - Engine Compartment Replacement

Object Number: 861992 Size: MF

       Important: Only the engine compartment rail may be sectioned in the area specified. Repair and restore as much structure as possible before cutting and preparing the joint for welding. Do not section the reinforcements. The following conditions for repair must be met:

    • No wrinkles or distortions in post repair rail surfaces may exceed 2 mm (5/64 in) up or down in deflection of the rail surface or structure from the original location
    • The joint reinforcement to extend 10 mm (25/64 in) either side of the butt joint. Lap weld is NOT recommended. The joint is located where the front end panel vertical surface meets the engine compartment rail.
    • Reinforcements must be constructed from the old rail piece or an area of the unused portion of the new part. The joint reinforcement backs up the butt weld joint but is not plug welded.
  1. Note the amount and location of the spot welds. The joint is to be located directly under the front end panel attachment point to the engine compartment rail.
  2. Remove the sealer and drill spot welds from:
    3. 2.1. The engine compartment rail extension
    2.2. The front end assembly
    2.3. The engine compartment side outer, if necessary
    2.4. The bar assembly front end lower tie

    Notice: Do not damage the inner reinforcements.

    Important: To ensure a secure weld the sectioning joint should have a gap of approximately 1 1/2 times the thickness of the metal. Trim the parts as necessary to achieve this proper gap.

  3. Perform additional procedures as necessary to remove unused areas of the service part. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original section.
  4. Clean the surface for welding and grind the ELPO® primer off of the new part at the connecting points. Apply 3M® Weld-Thru Coating P/N 05913, or equivalent, to all areas to be welded.
  5. Stitch weld along the entire joint. Make 25 mm (63/64 in) gaps between. Then go back and complete the stitch weld. This will create a solid joint with minimal heat distortion. See Space Frame Sectioning .