Laminated Steels - General Information and Specific Repair Procedures for Wheelhouse Replacement - Front, Extension Replacement Front Compartment Side Rail - Rear and Rail Replacement - Lower

Laminated steel consists of three layers of material: two layers of mild steel with a layer of "visco-elastic" material between them. This "sandwich" of material layers provides better sound absorbing properties than regular, non-laminated materials.

Laminated steel is being used on the above listed vehicles to enhance the acoustic performance of these vehicles. Currently, the front dash panel of these vehicles is made from laminated steel.

This material is very different than standard steel applications. Because of these differences, it requires different repair procedures to be used when replacing components that attach directly to the laminated steel surfaces. Those components are typically structural rails, front wheelhouse/shock towers and front body hinge pillar inner panels. Depending on the design and build of the vehicle, though, some of the components may not attach directly to the laminated steel surface. Components that do not attach directly to the laminated steel surface may be attached in the normal manner.

Refer to GM Service Information for the above-listed vehicles for specific procedures related to the components that attach to laminated steels. The procedure below has recently been added to SI. Additional procedures are currently being developed and Service Manual Update bulletins will be published to inform dealers of this new information.

Important: Model year 2004 and prior vehicles are not manufactured with laminated steel in front of the dashes. Therefore the front wheelhouse assembly can be MIG welded instead of the rivet and bonding process as stated in these instructions.

The front of the dash panel is formed from laminated steel. This steel is constructed by bonding 2 pieces of cold rolled steel (1) with a viscoelastic layer of adhesive (2). Metal inert gas (MIG) welding laminated steel does not meet GM Corporate standards for structural integrity. As an alternative, all factory welds will be replaced by using the rivet and adhesive bond method described in the installation portion of this procedure. The rivet and adhesive bond method must only be used in the areas as described in this procedure.

Important: Failure to follow this procedure will compromise the structural integrity of the vehicle.

Removal Procedure

Caution:  Refer to Approved Equipment for Collision Repair Caution in Cautions and Notices.

Caution: Foam sound deadeners must be removed from areas within 152.4 mm (6 in) of where flame is to be used for body repairs. When reinstalling foam sound deadeners, avoid inhaling fumes as bodily injury may result.

1. Disable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.

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.

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




Important: Note the number and location of the factory welds for installation of the full wheelhouse service part.

6. Remove the radiator support assembly. Refer to Radiator Support Replacement.
7. Remove the upper fender rail. Refer to Rail Replacement - Upper.




Important: Drill through the wheelhouse flange only. Do NOT drill into the dash panel or the inner reinforcements.

8. Using an 8-mm (5/16-in) spot weld remover, locate and drill out the factory welds on the weld flange connecting the wheelhouse to the dash panel.



9. Remove the wheelhouse.

Installation Procedure

1. Position the service wheelhouse to the vehicle using three-dimensional measuring equipment.
2. Clamp the wheelhouse in place.



3. Using a 7-mm (17/64-in) bit, drill the rivet attachment holes through the service wheelhouse and the dash panel in the exact locations as noted from the factory wheelhouse.



4. Remove the service wheelhouse.




Important: If the location of the original plug weld holes cannot be determined, space the plug weld holes every 40 mm (1.5 in) apart.

5. Drill 8-mm (5/16-in) plug weld holes in the service wheelhouse, as necessary, in the remaining locations noted from the original wheelhouse.
6. Prepare the plug weld mating surfaces, as necessary.
7. Apply 3M® Weld-Thru Coating, P/N 05913, or equivalent, to the plug weld mating surfaces.



8. Prepare the bond mating areas by grinding the body mating and the service part flanges to bare steel. Do NOT damage the corners or thin the metal during the grinding process.
9. Clean the mating surfaces.




Important: The adhesive has a 40-50 minute working time. Do NOT allow the adhesive to cure prior to installing the service wheelhouse.

10. Apply a 3-6 mm (1/8 to 1/4 in) bead of metal panel bonding adhesive, GM P/N 12378567 (Canadian P/N 88901675), or equivalent, to both of the mating surfaces.



11. Using a small acid brush, spread a coat of adhesive to both of the mating surfaces. Cover all of the bare metal to ensure corrosion protection.



12. Apply a 3-6 mm (1/8 to 1/4 in) bead of metal panel bonding adhesive, GM P/N 12378567 (Canadian P/N 88901675), or equivalent, to the mating surface of the service wheelhouse.




Important: Do NOT pull the wheelhouse off of the dash after adhesion. To align the parts, slide the wheelhouse against the front of the dash.

13. Position the service wheelhouse to the vehicle using three-dimensional measuring equipment.
14. Clamp the wheelhouse in place.




Important: Verify proper positioning of the service wheelhouse prior to riveting and welding.

15. Install the 9 mm (11/32 in) long rivets so that the rivet head contacts the passenger compartment side of the dash.
16. Remove the excess adhesive from the wheelhouse area.



17. Plug weld the remaining holes accordingly.
18. Clean and prepare all of the welded surfaces.
19. Install the radiator support assembly. Refer to Radiator Support Replacement.
20. Install the upper fender rail. Refer to Rail Replacement - Upper.
21. Apply the sealers and anti-corrosion materials to the repaired area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint/Coatings.
22. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint/Coatings.
23. Install all of the related panels and components.
24. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
25. Enable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR.

Important: Model year 2004 and prior vehicles are not manufactured with laminated steel in front of the dashes. Therefore the front lower rail extension can be MIG welded instead of the rivet and bonding process as stated in these instructions.

The front of the dash panel is formed from laminated steel. This steel is constructed by bonding 2 pieces of cold rolled steel (1) with a viscoelastic layer of adhesive (2). Metal inert gas (MIG) welding laminated steel does not meet GM Corporate standards for structural integrity. As an alternative, all factory welds will be replaced by using the rivet and adhesive bond method described in the installation portion of this procedure. The rivet and adhesive bond method must only be used in the areas as described in this procedure.

Important: Failure to follow this procedure will compromise the structural integrity of the vehicle.

Removal Procedure

Caution: Refer to Approved Equipment for Collision Repair Caution in Cautions and Notices.

Caution: Foam sound deadeners must be removed from areas within 152.4 mm (6 in) of where flame is to be used for body repairs. When reinstalling foam sound deadeners, avoid inhaling fumes as bodily injury may result.

1. Disable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.

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.

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




Important: Note the number and location of the factory welds for installation of the rail side extension service part.

Important: Drill through the rail side extension flange only. Do NOT drill into the dash panel or the inner reinforcements.

6. Using an 8-mm (5/16-in) spot weld remover, locate and drill out the factory welds on the weld flange connecting the lower rail side extension to the vehicle structure.



7. Remove the rail side extension.

Installation Procedure

1. Position the service rail side extension to the vehicle.
2. Clamp the rail in place.



3. Using a 7-mm (17/64-in) bit, drill the rivet attachment holes through the service rail side extension and the dash panel in the exact locations as noted from the factory rail side extension.



4. Remove the service rail side extension.

Important: If the location of the original plug weld holes cannot be determined, space the plug weld holes every 40 mm (1.5 in) apart.

5. Drill 8-mm (5/16-in) plug weld holes in the service rail side extension, as necessary, in the remaining locations noted from the original rail side extension.
6. Prepare the plug weld mating surfaces, as necessary.
7. Apply 3M® Weld-Thru Coating, P/N 05913, or equivalent, to the plug weld mating surfaces.



8. Prepare the bond mating areas by grinding the body mating and the service part flanges to bare steel. Do NOT damage the corners or thin the metal during the grinding process.
9. Clean the mating surfaces.




Important: The adhesive has a 40-50 minute working time. Do NOT allow the adhesive to cure prior to installing the service rail side extension.

10. Apply a 3-6 mm (1/8 to 1/4 in) bead of metal panel bonding adhesive, GM P/N 12378567 (Canadian P/N 88901675), or equivalent, to both of the mating surfaces.



11. Using a small acid brush, spread a coat of adhesive to both of the mating surfaces. Cover all of the bare metal to ensure corrosion protection.



12. Apply a 3-6 mm (1/8 to 1/4 in) bead of metal panel bonding adhesive, GM P/N 12378567 (Canadian P/N 88901675), or equivalent, to the mating surface of the service rail side extension.




Important: Do NOT pull the service rail side extension off of the dash after adhesion. To align the parts, slide the service rail side extension against the front of the dash.

13. Position the service rail side extension to the vehicle using three-dimensional measuring equipment.
14. Clamp the service rail side extension in place.




Important: Verify proper positioning of the service rail side extension prior to riveting and welding.

15. Install the 9 mm (11/32 in) long rivets so that the rivet head contacts the passenger compartment side of the dash.



16. Install the 14 mm (17/32 in) long rivets so that the rivet head contacts the passenger compartment side of the dash.
17. Remove the excess adhesive from the service rail side extension area.



18. Plug weld the remaining holes accordingly.
19. Clean and prepare all of the welded surfaces.
20. Apply the sealers and anti-corrosion materials to the repaired area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint/Coatings.
21. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint/Coatings.
22. Install all of the related panels and components.
23. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
24. Enable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR.

Important: Model year 2004 and prior vehicles are not manufactured with laminated steel in front of the dashes. Therefore the front lower rail can be MIG welded instead of the rivet and bonding process as stated in these instructions.

The front of the dash panel is formed from laminated steel. This steel is constructed by bonding 2 pieces of cold rolled steel (1) with a viscoelastic layer of adhesive (2). Metal inert gas (MIG) welding laminated steel does not meet GM Corporate standards for structural integrity. As an alternative, all factory welds will be replaced by using the rivet and adhesive bond method described in the installation portion of this procedure. The rivet and adhesive bond method must only be used in the areas as described in this procedure.

Important: Failure to follow this procedure will compromise the structural integrity of the vehicle.

Removal Procedure

Caution: Refer to Approved Equipment for Collision Repair Caution in Cautions and Notices.

Caution: Foam sound deadeners must be removed from areas within 152.4 mm (6 in) of where flame is to be used for body repairs. When reinstalling foam sound deadeners, avoid inhaling fumes as bodily injury may result.

1. Disable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.

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.

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




Important: Note the number and location of the factory welds for installation of the full rail service part.

6. Remove the front wheelhouse assembly. Refer to Wheelhouse Replacement - Front.
7. Remove the radiator support assembly. Refer to Rail Replacement - Upper.
8. Remove the front rail side extension. Refer to Extension Replacement Front Compartment Side Rail - Rear.




Important: Drill through the rail flange only. Do NOT drill into the dash panel or the inner reinforcements.

9. Using an 8-mm (5/16-in) spot weld remover, locate and drill out the factory welds on the weld flange connecting the lower rail to the dash panel.



10. From the passenger compartment, locate and drill out the remaining factory weld.



11. Remove the full rail.

Installation Procedure

Important: Failure to install the front compartment lower rail reinforcement to the front compartment lower rail will compromise the structural integrity of the vehicle.

1. Drill 8-mm (5/16-in) plug weld holes in the service front lower rail reinforcement in the location noted from the original rail.
2. Prepare the plug weld mating surfaces, as necessary.
3. Apply 3M® Weld-Thru Coating, P/N 05913, or equivalent, to the plug weld mating surfaces.
4. Position the front lower rail reinforcement.



5. Plug weld the holes accordingly.



6. Position the service rail to the vehicle using three-dimensional measuring equipment.
7. Clamp the rail in place.



8. Using a 7-mm (17/64-in) bit, drill the rivet attachment holes through the service rail and the dash panel in the exact locations as noted from the factory rail.




Important: If the location of the original plug weld holes cannot be determined, space the plug weld holes every 40 mm (1.5 in) apart.

9. Remove the service rail.
10. Prepare the plug weld mating surfaces, as necessary.
11. Apply 3M® Weld-Thru Coating, P/N 05913, or equivalent, to the plug weld mating surfaces.



12. Prepare the bond mating areas by grinding the body mating and the service part flanges to bare steel. Do NOT damage the corners or thin the metal during the grinding process.




Important: Do NOT allow the adhesive to cure prior to installation of the front rail side extension. Refer to Extension Replacement Front Compartment Side Rail - Rear.

Important: Note the necessary location for installation of a 14-mm (17/32-in) long rivet.

13. Clean the mating surfaces.




Important: The adhesive has a 40-50 minute working time. Do NOT allow the adhesive to cure prior to installing the service rail.

14. Apply a 3-6 mm (1/8 to 1/4 in) bead of metal panel bonding adhesive, GM P/N 12378567 (Canadian P/N 88901675), or equivalent, to both of the mating surfaces.



15. Using a small acid brush, spread a coat of adhesive to both of the mating surfaces. Cover all of the bare metal to ensure corrosion protection.



16. Apply a 3-6 mm (1/8 to 1/4 in) bead of metal panel bonding adhesive, GM P/N 12378567 (Canadian P/N 88901675), or equivalent, to the mating surface of the service rail.




Important: Do NOT pull the rail off of the dash after adhesion. To align the parts, slide the rail against the front of the dash.

17. Position the service rail to the vehicle using three-dimensional measuring equipment.
18. Clamp the rail in place.




Important: Verify proper positioning of the service rail prior to riveting and welding.

19. Install the 9 mm (11/32 in) long rivets so that the rivet head contacts the passenger compartment side of the dash.



20. Install the 14-mm (17/32-in) long rivet so that the rivet head contacts the passenger compartment side of the dash, extending through the front rail and through the rail side extension.
21. Remove the excess adhesive from the rail area.



22. Plug weld the remaining holes accordingly.
23. Clean and prepare all of the welded surfaces.
24. Install the front wheelhouse assembly. Refer to Wheelhouse Replacement - Front.
25. Install the front rail side extension. Refer to Extension Replacement Front Compartment Side Rail - Rear.
26. Install the radiator support assembly. Refer to Rail Replacement - Upper.
27. Apply the sealers and anti-corrosion materials to the repaired area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint/Coatings.
28. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint/Coatings.
29. Install all of the related panels and components.
30. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
31. Enable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR.

Important:  These kits contain a panel or rail, an instruction sheet and rivets. The rivets and instruction sheet are common among the kits, but the panel or rail is specific to each kit.

Parts are expected to be available from GMSPO.