GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Opel 🢒 2009 🢒 Insignia NB (Global Epsilon) 🢒 Body Repair 🢒 Collision Repair 🢒 Front Compartment Front Inner Side Rail Extension Replacement

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

    2. Object Number: 2020348 Size: SH
  2. Locate and drill out all of the battery tray support bracket factory welds.

    3. Object Number: 2020349 Size: SH

    Note: Do not damage any inner panels or reinforcements.

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

    4. 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.

    5. Object Number: 2020350 Size: SH

    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.

    6. 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.

Installation Procedure

    Object Number: 2020351 Size: SH
  1. Prepare battery tray support bracket in the area (1).

    2. 4x slots 6x20 mm (0.2x0.8 in).


    Object Number: 2020352 Size: SH
  2. Apply bodywork repair through structural adhesive to body. Refer to Structural Adhesive Body Repairs.

    3. Object Number: 2020353 Size: SH
  3. Position the front compartment front inner side rail extension.

    4. Object Number: 2020354 Size: SH

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

  4. Spot weld the headlamp mount panel inner accordingly.

    5. Object Number: 2020355 Size: SH
  5. Apply bodywork repair through structural adhesive to body. Refer to Structural Adhesive Body Repairs.

    6. Object Number: 2020356 Size: SH
  6. Position the front compartment front outer side rail.

    7. 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.

    9. Object Number: 2020357 Size: SH

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

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

    10. Object Number: 2020358 Size: SH

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

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

    11. Object Number: 2020359 Size: SH
  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.

    15. 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.