GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2007 🢒 ION 🢒 Body Repair 🢒 Collision Repair 🢒 Front Compartment Upper Side Rail Sectioning

Removal Procedure

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

    Caution: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle and cause personal injury if the vehicle is in a collision.

  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. Remove all related panels and components.
  4. Repair as much of the damage as possible. Refer to Dimensions - Body .
  5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

    6. Object Number: 874293 Size: SH

    Important: Note the number and location of the factory welds for installation of the front compartment of the side upper rail.

  6. Locate and drill out all the necessary factory welds.

    7. Object Number: 874296 Size: SH
  7. Measure forward 75 mm (3 in) (a) of the center of the third fender bolt hole location. Mark the location.
  8. Using the mark made in the previous step as a starting point, use a sliding square to transfer a line on the top, side, and bottom of the rail.

    9. Object Number: 874298 Size: SH
  9. Cut the side upper rail at the marked location.

    10. Object Number: 874299 Size: SH
  10. Remove the front portion of the side upper rail.
  11. Drill 2 8 mm (5/16 in) plug weld holes 10 mm (1/2 in) rearward from the edge of the top, bottom, and outer side on the front edge of the remaining portion of the side upper rail on the vehicle.

Installation Procedure

    Object Number: 874296 Size: SH
  1. Measure a section on the service part that is 50 mm (2 in) (a) forward of the third fender bolt hole. Mark this section.
  2. Using the mark made in the previous step as a starting point, use a sliding square to transfer a line on the top, side, and bottom of the rail.

    3. Object Number: 874298 Size: SH
  3. Cut the service part at the marked location.

    4. Object Number: 874290 Size: SH

    Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1½ in) apart.

  4. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted on the original panel.
  5. Prepare all mating surfaces as necessary.
  6. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
  7. Measure 25 mm (1 in) forward from the cut area. Mark the location on top of the rail.
  8. Using the mark made in the previous step as a starting point, use a sliding square to transfer a line on the top, side, and bottom of the rail.

    9. Object Number: 875630 Size: SH

    Important: Do not cut past the scribed line.

  9. At the weld flange areas of the rail and at each radius, cut toward the scribed line. This will aid in the flange-forming process.
  10. Bend the cut area of the rail inward to create a 25 mm (1 in) step flange for the weld joint.

    11. Object Number: 874299 Size: SH

    Important: Flanges on the service part will slide inside the rail portion of the vehicle.

  11. Position the side upper rail to the vehicle using 3-dimensional measuring equipment. Clamp the rail in place.

    12. Object Number: 874293 Size: SH
  12. Stitch and plug weld accordingly.
  13. Clean and prepare all of the welded surfaces.
  14. Install all of the related panels and components.
  15. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
  16. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
  17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  18. Enable the SIR system. Refer to SIR Disabling and Enabling .