The lower rail close-out panel (2) is attached to the lower edge of the cowl on the outboard side of the lower rail. The mid-section of the lower rail is sandwiched between the close-out panel and the floor pan for added vehicle strength and ridigity. When performing a full rail replacement, the close-out panel must be removed and installed, or replaced if necessary. The lower rail service part comes as a sub-assembly, which consists of seven brackets and panels. Instruction sheets are also included. The front bumper brackets (3) are available and serviced separately. Diemarks (4) have been added to the rails to indicate sectioning locations. The mid-rail reinforcement (1) panel must be purchased separately for full rail replacement.

Important: the powertrain and engine cradle must be removed from the vehicle to perform the full rail replacement.

1. Remove all related panels and components, including the strut axle assemblies as necessary.
2. Visually inspect and restore as much of the damage as possible to factory specifications.
3. Remove the following as necessary:

•

Sealers.

•	Sound deadeners.

•	Anti-corrosion materials.

4. Remove the close-out panel to access all factory welds attaching the rail to the vehicle
5. Locate, mark, and drill out all factory welds. Note the number and location of welds for installation of the service rail and components.
6. Remove the damaged rail.

1. Prepare the mating surfacres as necessary.
2. Position the service rail sub-assembly on the vehicle.
3. Check fit with three-dimensional measuring equipment.
4. Position the mid-rail reinforcement to the new service rail.
5. Plug weld as necessary as noted from the original rail.
6. Position the front bumper mounting brackets.
7. Plug weld accordingly.

Important: Two of the bumper mounting holes are provided. The third hole is to be located with three-dimensional measuring equipment.

8. Clean and prepare all welded surfaces.
9. Prime with two-part catalyzed primer.
10. Apply the following as necesssary:

•

Sealers.

•	Anti-corrosion materials.

•	Sound deadening materials.

Important: Prior to refinishing, refer to GM P/N 4901MD-99 Refinish Manual for recommended products. Do not combine paint systems. Refer to paint manufacturers recommendations.

11. Install all related panels and components.