Caution: Refer to Approved Equipment for Collision Repair 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 .

Important: Sectioning of the front wheelhouse assembly is not recommended. The front wheelhouse service panel is serviced as a complete assembly, which includes the upper front strut mounting surface. The upper strut mounting surface is a dimensionally critical area. Use 3-dimensional measuring equipment to locate the front wheelhouse assembly.




3. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

Important: 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.

4. Repair as much of the damage as possible.



5. Locate, mark, and drill out all factory welds. Note the number and location of welds for installation of the service assembly.



6. Drill from the outside of the wheelhouse to remove the spot welds that attach the wheelhouse to the frame rail.



7. Remove the wheelhouse from the vehicle.

1. Prepare the mating surfaces as necessary.
2. Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.
3. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original assembly.

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 40 mm (1½ in).

4. Position the wheelhouse on the vehicle. Verify proper fit using three-dimensional measuring equipment.



5. When the service assembly is correctly positioned, plug weld accordingly.



6. Measure frequently to ensure proper fit and alignment.
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 .
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 .