PRE-RELEASE

Front Compartment Upper Side Rail Replacement

/ 9-4x / 2011 / 8. Body / Body / Adjustment/replacement / Front Compartment Upper Side Rail Replacement

Removal Procedure

Refer to Approved Equipment for Collision Repair Warning .

Refer to Glass and Sheet Metal Handling Warning .

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.

Note
Do not damage any inner panels or reinforcements. Record the number and location of the original welds for installation of the service part.

Locate and drill out all factory welds (1).

Remove the damaged front upper outer rail (1).

Installation Procedure

Note
If the location of the original plug welds cannot be determined or structural weld- thru adhesive was present, space plug weld holes every 40 mm (1 1/2 in) apart.

Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel (1).

Prepare all mating surfaces as necessary.

Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces.

Place the front upper outer member on the vehicle using the 3-dimensional measuring equipment (1). Clamp the front upper outer member in place.

Plug weld accordingly (1).

Clean and prepare all welded surfaces.

Apply the sealers and anti-corrosion materials to the repair area, as necessary.

Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems .

Install all related panels and components.

10.

Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

11.

Activate the SIR system. Refer to SIR Disabling and Enabling .