For 1990-2009 cars

### Removal Procedure

Warning: Refer to Approved Equipment for Collision Repair Warning 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. Remove all related panels and components.
4. Repair as much of the damage as possible. Refer to Dimensions - Body.
5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.

Note: Do not damage any inner panels or reinforcements.

6. Cut the panel along the front edge of the die mark.
7. Locate and drill out all factory welds. Note the number and location of the welds for installation of the front lower inner rail section.
8. Remove the damaged front lower inner rail.
9. If the inner rail reinforcement is damaged beyond repair, replace the reinforcement as needed.

### Installation Procedure

1. Install the inner rail reinforcement as needed.
2. Cut the replacement service part along the front edge of the arrow on the die mark.

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

Note: Some panels may have structural weld-thru adhesive. Replace the weld-thru adhesive with an additional spot weld between each factory spot weld.

3. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted on the original panel.
4. Drill 8 mm (5/16 in) plug weld holes along the sectioning cut on the service part. Locate these holes 13 mm (½ in) from the edge and spaced 40 mm (1½ in) apart.
5. Prepare all mating surfaces as necessary.
6. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair.
7. Position the front lower inner rail to the vehicle using 3-dimensional measuring equipment. Clamp the front lower inner rail into place.
8. Plug weld accordingly.
9. To create a solid weld with minimum heat distortion at the sectioning joint, make 25 mm (1 in) gaps between them. Complete the stitch weld.
10. Clean and prepare all of the welded surfaces.
11. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
12. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
13. Install all of the related panels and components.
14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
15. Enable the SIR system. Refer to SIR Disabling and Enabling.