Front Compartment Front Inner Side Rail Extension Replacement for Buick Regal 2009

1. Remove the front wheelhouse front liner. Refer to Front Wheelhouse Front Liner Replacement.



2. Locate and drill out all of the battery tray support bracket factory welds.




Note: Do not damage any inner panels or reinforcements.

3. Cut out the front compartment front inner side rail extension.

Note: Note the number and location of the welds for installations of the service part.

4. Locate and drill out all of the necessary factory welds.




Note: Do not damage any inner panels or reinforcements.

5. Cut out the front compartment front outer side rail (1) 10 mm (0.4 in) staggered to the front compartment front inner side rail extension.

Note: Note the number and location of the welds for installations of the service part.

6. Locate and drill out all of the necessary factory welds.
7. Remove the damaged front compartment front inner side rail extension and front compartment front outer side rail.

1. Prepare battery tray support bracket in the area (1).

4x slots 6x20 mm (0.2x0.8 in).




2. Apply bodywork repair through structural adhesive to body. Refer to Structural Adhesive Body Repairs.



3. Position the front compartment front inner side rail extension.




Note: Refer to Welded, Brazed, and Riveted Joint Specifications.

4. Spot weld the headlamp mount panel inner accordingly.



5. Apply bodywork repair through structural adhesive to body. Refer to Structural Adhesive Body Repairs.



6. Position the front compartment front outer side rail.

Note: Refer to Welded, Brazed, and Riveted Joint Specifications.

7. Spot weld the front compartment front outer side rail accordingly.
8. MIG-braze the front compartment front outer side rail.




Note: Refer to Welded, Brazed, and Riveted Joint Specifications.

9. Spot weld the drivetrain and front suspension frame front outer support accordingly




Note: Refer to Welded, Brazed, and Riveted Joint Specifications.

10. Spot weld the front end sheet metal cross panel reinforcement accordingly.



11. MIG-braze the battery tray support bracket.
12. Grind all MIG brazed seams.
13. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
14. Install all related panels and components.

Remove the front wheelhouse front liner. Refer to Front Wheelhouse Front Liner Replacement.

15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
16. Enable the SIR system. Refer to SIR Disabling and Enabling.