GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

    Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

  1. Disable the SIR system. Refer to SIR Disabling and Enabling .
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

  3. Object Number: 805871  Size: SH

    Important: Sectioning of the front upper rails is not recommended.

  4. Remove all related panels and components.
  5. Restore as much of the damage as possible .
  6. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
  7. Locate, mark, and drill out all factory welds attaching the outer rail.
  8. Remove the damaged outer rail.

Installation Procedure


    Object Number: 805871  Size: SH
  1. Prepare the mating surfaces as necessary.
  2. Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.
  3. Important: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 40 mm (1½ in).

  4. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original panels.
  5. Temporarily position the outer rail on the vehicle.
  6. Verify the location using 3-dimensional measuring equipment.
  7. Plug weld accordingly.
  8. Clean and prepare welded surfaces.
  9. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
  10. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
  11. Install all of the related panels and components.
  12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  13. Enable the SIR system. Refer to SIR Disabling and Enabling .