Removal Procedure
- Remove all related panels and components.
- Visually inspect and restore as much of the damage as possible to factory specifications.
- Remove sealers and anti-corrosion materials as necessary.
- Locate, mark and drill out all factory welds as necessary. Note the number of welds for installation of the service panels.
- Remove the damaged panels in the upper tie bar assembly and the front end lower brace, as necessary.
Important: The front end structure consists of six resistance-welded components. The upper tie bar and upper reinforcement panel are serviced as individual components. The brace (1), (front-end lower structure), includes rail reinforcement gussets, which provide cross-car vehicle alignment of the service assembly. The left and right impact bar brackets are serviced separately and must be installed using three-dimensional coordinates.
Installation Procedure
- Prepare the mating surfaces and check for proper fit of the service panels.
- Drill 8 mm (5/16 in) plug weld holes in the locations noted from the original assembly on the service panels.
- Position the service panels.
- Check the fit using body dimensions.
- Plug the weld accordingly with frequent measurementsin order to ensure proper fit.
- Clean and prepare welded surfaces.
- Apply an approved anti-corrosion primer.
- Apply sealers and refinish as necessary.
- Install all related panels and components.
Important: If original components are damaged beyond recognition, place plug the weld holes every 40 mm (1 1/2 in) apart.
Important: Prior to refinishing, refer to the publication GM 4901M-2000 "GM Approved Refinish Materials" for recommended products. Do Not combine paint systems. Refer to paint manufacturer's recommendations.
Important: Upper tie-bar service parts do not have a mounting location for the three center latch support holes. Use threaded inserts such as Riv-nuts, available through Kent-Moore™ tools Riv-nut Kit P/N 42151-8 MS or equivalent.
