GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2001 🢒 SL1/SC1/SW1 🢒 Body and Accessories 🢒 Collision Repair 🢒 Engine Compartment Rail Extension Replacement

    Object Number: 860618 Size: MF
  1. Note the amount and location of the spot welds.
  2. Remove the sealer and drill spot welds from:
    3. 2.1. The bar assembly front end crossmember
    2.2. The rail assembly engine compartment side
    2.3. The extension wheelhouse engine compartment front
  3. Clean all of the weld seams with a wire brush, prime, and seal all repair areas.
  4. Apply a permanent underbody sealant.

    5. Important: Ensure that proper corrosion protection processes are used on all repair areas.

  5. Prime with a 2-part catalyzed primer.
  6. Apply sealers and corrosion protection materials according to the information in the Body Paint section of this service manual or the paint manufacturer's recommendations.
  7. Clean the surface for welding and grind the 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.
  8. Measure and align the engine compartment rail extension. Clamp into place.
  9. Use a MIG to plug the weld.