GM Service Manual Online
For 1990-2009 cars only

Removal Procedure


Object Number: 1526779  Size: SH

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

The front of the dash panel and the plenum lower are formed from laminated steel. This steel is constructed by bonding 2 pieces of cold rolled steel (1) with a viscoelastic layer of adhesive (2). 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.

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


    Object Number: 1526769  Size: SH

    Important: The full rail service part is replaced at factory seams.

  1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  3. Caution: Refer to Collision Sectioning Caution in the Preface section.

  4. Remove all related panels and components.
  5. Repair as much of the damage as possible.
  6. Important: Note the number and location of the factory welds for installation of the full rail service part.

  7. Remove the sealers and the anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint/Coatings.

  8. Object Number: 1526785  Size: SH

    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 inner rail to the dash panel.

  10. Object Number: 1526788  Size: SH
  11. Using an 8-mm (5/16-in) spot weld remover, locate and drill out the factory welds on the weld flange connecting the lower outer rail to the dash panel.

  12. Object Number: 1526794  Size: SH
  13. 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 outer dash panel.

  14. Object Number: 1526832  Size: SH
  15. 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.

  16. Object Number: 1526967  Size: SH
  17. Locate and drill out the remaining factory welds on the rail.

  18. Object Number: 1527803  Size: SH
  19. Remove the section of frame by applying heat. Pry to detach the adhesive along the bonding surface.

  20. Object Number: 1526769  Size: SH
  21. Remove the full damaged rail.

Installation Procedure


    Object Number: 1526769  Size: SH
  1. Position the service rail to the vehicle using 3-dimensional measuring equipment.
  2. Clamp the service rail in place.

  3. Object Number: 1527172  Size: SH
  4. Using a 7-mm (17/64-in) bit, drill the rivet attachment holes through the lower inner rail and the dash panel in the exact locations as noted from the factory rail.

  5. Object Number: 1527173  Size: SH
  6. Using a 7-mm (17/64-in) bit, drill the rivet attachment holes through the lower outer rail and the dash panel in the exact locations as noted from the factory rail.

  7. Object Number: 1527174  Size: SH
  8. Using a 7-mm (17/64-in) bit, drill the rivet attachment holes through the lower rail and the dash panel in the exact locations as noted from the factory rail.
  9. Remove the service rail.
  10. Important: If the location of the original plug weld holes cannot be determined, or if the structural weld-through adhesive is present, space the plug weld holes every 40 mm (1.5 in) apart.

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

  14. Object Number: 1527281  Size: SH
  15. Prepare the bond mating areas by grinding to bare steel the lower inner rail and the dash panel mating surfaces. Do NOT damage the corners or thin the metal during the grinding process.

  16. Object Number: 1527284  Size: SH
  17. Prepare the bond mating areas by grinding to bare steel the lower outer rail and the dash panel mating surfaces. Do NOT damage the corners or thin the metal during the grinding process.

  18. Object Number: 1527282  Size: SH
  19. Prepare the bond mating areas by grinding to bare steel the surface of the lower rail and the dash panel mating surfaces. Do NOT damage the corners or thin the metal during the grinding process.

  20. Object Number: 1527803  Size: SH
  21. Prepare the bond mating areas by grinding to bare steel the lower rail and the floor panel mating surfaces. Do NOT damage the corners or thin the metal during the grinding process.
  22. Clean the mating surfaces.

  23. Object Number: 1527344  Size: SH

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

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

  25. Object Number: 1527345  Size: SH
  26. Apply a 3-6 mm (1/8-1/4 in) bead of metal panel bonding adhesive GM P/N 12378567 (Canadian P/N 88901675) or equivalent to the lower inner rail and the dash panel mating surfaces.

  27. Object Number: 1527341  Size: SH
  28. Apply a 3-6 mm (1/8-1/4 in) bead of metal panel bonding adhesive GM P/N 12378567 (Canadian P/N 88901675) or equivalent to the lower outer rail and the dash panel mating surfaces.

  29. Object Number: 1527753  Size: SH
  30. Apply a 3-6 mm (1/8-1/4 in) bead of metal panel bonding adhesive GM P/N 12378567 (Canadian P/N 88901675) or equivalent to the lower rail and the floor panel mating surfaces.

  31. Object Number: 1527396  Size: SH
  32. Using a small acid brush, spread a coat of adhesive to the lower inner rail and the dash panel mating surfaces. Cover all of the bare metal to ensure corrosion protection.

  33. Object Number: 1527400  Size: SH
  34. Using a small acid brush, spread a coat of adhesive to the lower outer rail and the dash panel mating surfaces. Cover all of the bare metal to ensure corrosion protection.

  35. Object Number: 1527398  Size: SH
  36. Using a small acid brush, spread a coat of adhesive to the lower rail and the dash panel mating surfaces. Cover all of the bare metal to ensure corrosion protection.

  37. Object Number: 1526769  Size: SH

    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.

  38. Position the service rail to the vehicle using 3-dimensional measuring equipment.
  39. Clamp the rail in place.

  40. Object Number: 1527418  Size: SH

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

  41. Install the 9-mm (11/32-in) long rivets (1) and the 14-mm (17/32-in) long rivets (2) to the lower inner and outer rail so that the rivet head contacts the passenger compartment side of the dash panel.

  42. Object Number: 1527417  Size: SH
  43. Install the 9-mm (11/32-in) long rivets (1) and the 14-mm (17/32-in) long rivets (2) to the lower inner and the outer dash panel so that the rivet head contacts the rail side.

  44. Object Number: 1527420  Size: SH
  45. Install the 9-mm (11/32-in) long rivets (1) and the 14-mm (17/32-in) long rivets (2) to the lower rail and the dash panel so that the rivet head contacts the passenger compartment side of the dash panel.
  46. Remove the excess adhesive from the rail area.
  47. Plug weld the remaining holes accordingly.
  48. Clean and prepare all of the welded surfaces.
  49. Apply the sealers and anti-corrosion materials to the repaired area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint/Coatings.
  50. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint/Coatings.
  51. Install all of the related panels and components.
  52. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  53. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.