Removal Procedure
- Remove all related panels and components, including the upper rail outer and inner panels.
- Visually inspect and restore as much of the damage as possible to factory specifications.
- Remove sealers and anti-corrosion protection materials as necessary.
- Locate, mark, and drill out all factory welds. Note the number and location of welds for installation of the service assembly.
Important: Sectioning of the front wheelhouse assembly is not recommended. The front wheelhouse service panel is serviced as a complete assembly, which included the upper front strut mounting surface (2). The upper strut mounting surface is a dimensionally critical area, and three-dimensional measuring equipment should be used to locate the front wheelhouse assembly. The front apron close-out panel (1) is available and serviced separately.
Important: Some interior components must be removed to access the welds attaching the wheelhouse to the front of the cowl panel. Be sure to inspect the front of the cowl for damage. If the metal surface is damaged, the cowl panel must be repaired to restore the structural integrity of the vehicle.
Installation Procedure
- Prepare the mating surfaces as necessary.
- Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original assembly.
- Position the wheelhouse on the vehicle. Check for proper fit using three-dimensional measuring equipment.
- When the service assembly is correctly positioned, plug weld accordingly.
- Measure frequently to ensure proper fit and alignment.
- Clean and prepare all welded surfaces.
- Prime with two-part catalyzed primer.
- Apply sealers and anti-corrosion protection materials as necessary.
- Install all related panels and components.
Important: If the original locations are damaged beyond recognition, locate holes for plug welding 40 mm (1½ in) apart.
Important: Some of the plug welding may be performed from inside the vehicle. Make sure before welding that there is no change of damage to components or panels from welding sparks and heat. Take necessary fire prevention precautions.
Important: Prior to refinishing, refer to GM 4901MD-99 Refinish Manual for recommended products. Do not combine paint systems. Refer to paint manufacturers recommendations.
