For 1990-2009 cars

### Removal Procedure

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

1. Disable the SIR system. Refer to SIR Disabling and Enabling .
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Remove all related panels and components.

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

4. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

Important: Do not damage any inner panels or reinforcements.

5. Locate and drill out all factory welds. Note the number and location of welds for installation of the header panel.
6. Using a grinder or an equivalent tool, remove the silicon bronze welds on each end of the header.
7. Remove the damaged header panel.

### Installation Procedure

1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary at the locations noted from the original header 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 .
4. Position the header panel to the vehicle. Use 3-dimensional measuring equipment to ensure fit. Clamp the panel into place.

Important: Use either metal inert gas (MIG) or silicon bronze for welding the outer ends of the header panel.

5. Using either a MIG or silicon bronze welder, weld the outer ends of the header panel, duplicating the factory welds.
6. Using a MIG welder, plug weld as necessary, duplicating the factory welds.
7. Clean and prepare all welded surfaces.
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 Paint Identification .
10. Install all related panels and components.
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
12. Enable the SIR system. Refer to SIR Disabling and Enabling .