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Front Rail Replacement

Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure will perform the following tasks:

   • Identify how to disable high voltage.
   • Identify how to test for the presence of high voltage.
   • Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.
Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:
   • Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.
   • Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.
      - Visually and functionally inspect the gloves before use.
      - Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energised or not.
Failure to follow the procedures exactly as written may result in serious injury or death.

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. Inspect the high voltage system. Refer to High Voltage System Inspection .
  3. Remove all related panels and components.
  4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body .
  5. Note the location and remove the sealers and anti-corrosion materials from the repair area. Refer to Anti-Corrosion Treatment and Repair .

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    Note : Do not damage any inner panels or reinforcements.

  6. Locate and drill out all factory welds. Note the number and location of the welds for installation of the front rail (1).

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  7. Remove the damaged front rail (1).

Installation Procedure

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

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

  1. Drill 8 mm (5/16 in) plug weld holes in the service part front rail (1) as necessary in the locations noted from the original panel.
  2. Prepare all mating surfaces as necessary.
  3. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair .

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  4. Position the front rail (1) to the vehicle using 3-dimensional measuring equipment. Clamp the rail in place.

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  5. Plug weld the front rail (1) accordingly.
  6. Clean and prepare all welded surfaces.
  7. Install all related panels and components.
  8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
  9. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems .
  10. If disabled, enable the high voltage system. Refer to High Voltage Enabling .
  11. Enable the SIR system. Refer to SIR Disabling and Enabling .
   


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