Chevrolet Trax: Front compartment upper side rail replacement

Removal Procedure

WARNING: Refer to Approved Equipment for Collision Repair Warning .

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.
4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body (Opel, Encore), Dimensions - Body (Trax).
5. Remove the sealers and anti-corrosion materials from the repair area. Refer to Anti-Corrosion Treatment and Repair (Base) .

NOTE: Do not damage any inner panels or reinforcements.

6. Locate and mark all the necessary factory welds and weld seams of the front compartment upper side rail.

Fig. 20: Drilling All Factory Welds

7. Drill all factory welds (1). Note the number and location of welds for installation of the service assembly

Fig. 21: Factory Weld Seams

8. Grind factory weld seams (1).

Fig. 22: Front Compartment Upper Side Rail

9. Remove the front compartment upper side rail (1).

Installation Procedure

Fig. 23: Drilling Holes For Plug Welding

NOTE: If the location of the original plug weld holes cannot be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 40 mm (1 in) apart.

1. Drill 8 mm (5/16 in) holes for plug weld as necessary on service part, in the locations noted from the original assembly (1).
2. Clean and prepare the mating surfaces for welding, as necessary.

Fig. 24: Front Compartment Upper Side Rail

3. Position the front compartment upper side rail (1) on the vehicle.
4. Verify the fit of the front compartment upper side rail.
5. Clamp the front compartment upper side rail into position.

Fig. 25: Front Hinge Pillar Body

NOTE: Plug weld factory slots in the front hinge pillar body area (1) as noted from the original panel.

6. Plug weld accordingly (1).
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 (Base) .
9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
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 .

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