For 1990-2009 cars only
Removal Procedure
- Disable the supplemental inflatable restraint (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 .
- 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 welds for installation of the front lower outer rail section.
- Remove the damaged front lower outer rail.
Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.
Important: Do not damage any inner panels or reinforcements.
Installation Procedure
- Cut the replacement service part along the back edge of the arrow on the die mark.
- Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the locations noted from the original panel, and along the sectioning cut.
- 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 .
- Slide the replacement service part behind the original panel at the sectioning joint.
- Position the front lower outer rail to the vehicle using 3-dimensional measuring equipment. Clamp the front lower outer rail into place.
- Plug weld accordingly.
- To create a solid weld with minimum heat distortion at the sectioning joint, make 25-mm (1-in) welds with 25-mm (1-in) gaps between them. Then go back and complete the stitch weld.
- Clean and prepare all welded surfaces.
- 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 .
- Install all 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 (1 1/2 in) apart.
Some panels may have structural weld-thru adhesive. It is necessary to replace the weld-thru adhesive with an additional spot weld between each factory spot weld.
