GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Lumina Ute 🢒 Body Repair 🢒 Collision Repair 🢒 Upper Rail Replacement

Removal Procedure

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

    Caution: Refer to Vehicle Lifting Caution in the Preface section.

    Caution: Refer to Safety Glasses Caution in the Preface section.

    Caution: Refer to Foam Sound Deadeners 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 the engine assembly. Refer to Engine Replacement for the 3.6L engine or Engine Replacement for the 6.0L engine.
  4. Remove the negative cable from the engine bay. Refer to Battery Negative Cable Replacement .
  5. Remove the positive cable from the engine bay. Refer to Battery Positive Cable Replacement .
  6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  7. Remove the front wheels. Refer to Tire and Wheel Removal and Installation .
  8. Remove the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement .
  9. Remove the front wheel hub assembly. Refer to Front Wheel Bearing and Hub Replacement .
  10. Remove the front strut assembly. Refer to Strut Assembly Replacement .
  11. Lower the vehicle.
  12. Remove the brake lines. Refer to Brake Pipe Replacement .
  13. Remove the fender assembly. Refer to Front Fender Replacement .
  14. Remove the front fascia. Refer to Front Bumper Fascia Replacement .
  15. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement .
  16. Remove the front end module. Refer to Front End Panel Module Carrier Assembly Replacement .
  17. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement .
  18. Remove the plenum chamber. Refer to Air Inlet Assembly Replacement .
  19. Remove the relay box. Refer to Underhood Electrical Center or Junction Block Replacement .
  20. Remove the ABS unit. Refer to Brake Pressure Modulator Valve Assembly Replacement .
  21. Remove the brake master cylinder. Refer to Master Cylinder Replacement .
  22. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

    23. Object Number: 1937505 Size: SH
  23. Locate, mark and drill out the factory welds (1) attaching the upper wheelhouse brace to the front wheelhouse assembly.
  24. Remove the upper wheelhouse brace from the front wheelhouse assembly and discard.

    25. Discard the upper wheelhouse brace.

Installation Procedure

    Important: Spot welding is the preferred method for attaching panels and should be used wherever possible. A plug weld should be performed where your spot welder is unable reach.

    Important: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 32 mm (1¼ in).

  1. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original assembly.
  2. Clean and prepare the mating surfaces of the front wheelhouse assembly and the upper wheelhouse brace.

    3. Object Number: 1937413 Size: SH
  3. Apply the primary sealer (1) HN2484 along the rear edge of the upper wheelhouse brace.
  4. Position the upper wheelhouse brace on the vehicle. Verify correct alignment and position using three-dimensional measuring equipment.

    5. Object Number: 1937320 Size: SH
  5. Puddle weld (1) the front wheelhouse assembly to the upper wheelhouse brace.
  6. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
  7. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
  8. Install the brake master cylinder. Refer to Master Cylinder Replacement .
  9. Install the ABS unit. Refer to Brake Pressure Modulator Valve Assembly Replacement .
  10. If re-programming is required. Refer to Control Module References .
  11. Install the relay box. Refer to Underhood Electrical Center or Junction Block Replacement .
  12. Install the plenum chamber. Refer to Air Inlet Assembly Replacement .
  13. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement .
  14. Install the relay box. Refer to Underhood Electrical Center or Junction Block Replacement .
  15. Install the plenum chamber. Refer to Air Inlet Assembly Replacement .
  16. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement .
  17. Install the front end module. Refer to Front End Panel Module Carrier Assembly Replacement .
  18. Install the brake lines. Refer to Brake Pipe Replacement .
  19. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  20. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement
  21. Install the front fascia. Refer to Front Bumper Fascia Replacement .
  22. Install the front strut assembly. Refer to Strut Assembly Replacement .
  23. Install the front wheel hub assembly. Refer to Front Wheel Bearing and Hub Replacement .
  24. Install the front wheel house liner. Refer to Front Wheelhouse Liner Replacement .
  25. Install the front wheels. Refer to Tire and Wheel Removal and Installation .
  26. Lower the vehicle.
  27. Install the fender assembly. Refer to Front Fender Replacement .
  28. Install the engine assembly. Refer to Engine Replacement for the 3.6L engine or Engine Replacement for the 6.0L engine.
  29. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  30. Enable the SIR system. Refer to SIR Disabling and Enabling .
  31. If re-programming is required. Refer to Control Module References .