GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Chevy C Cab/Chassis HD (GMT 400) 🢒 Engine 🢒 Engine Electrical 🢒 Front Fender Replacement - Left Side

Removal Procedure
  1. Disconnect the battery negative cable, if equipped. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the link assembly from the fender. Refer to Hood Link Replacement .
  3. Remove the outboard cowl grille section.
  4. Remove the hood. Refer to Hood Replacement .
  5. Remove the battery and the battery tray, if equipped. Refer to Battery Tray Replacement in Engine Electrical.
  6. Remove the windshield washer reservoir. Refer to Windshield Washer Solvent Container Replacement in Wipers/Washer Systems.
  7. Remove the electrical connector.

    8. Object Number: 277524 Size: SH
  8. Remove the hood release cable from the clip on the fender.
  9. Remove the wiring harness from the clips.
  10. Remove the auxiliary battery relay, if equipped.
  11. Remove the bolts (5) holding the fender (4) to the wheelhouse (3).

    12. Object Number: 277528 Size: SH
  12. Remove the bolt (6) holding the fender to the rocker assembly.
  13. Open the door.
  14. Remove the bolts (1) holding the fender to the door hinges.
  15. Remove the bolts holding the fender to the radiator support (9).
  16. Remove the fender from the vehicle.

Installation Procedure
  1. Install the fender to the vehicle.

    2. Object Number: 277527 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the bolts to the radiator support (12).

    3. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).

  3. Open the door.
  4. Install the bolts and the nuts holding the fender to the door hinges.

    5. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).


    Object Number: 277528 Size: SH
  5. Install the bolt (6) and the nut from the fender to the rocker assembly. Install the bolt by reaching up behind the wheelhouse.

    6. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).


    Object Number: 277524 Size: SH
  6. Install the bolts (5) through the wheelhouse to the fender.
  7. Install the auxiliary battery relay if equipped.
  8. Install the wiring harness into the clip on the fender.
  9. Install the hood release cable into the clips.
  10. Install the windshield washer reservoir. Refer to Windshield Washer Solvent Container Replacement in Wipers/Washer Systems.
  11. Install the battery and the tray, if equipped. Refer to Battery Tray Replacement in Engine Electrical.
  12. Install the hood link assembly. Refer to Hood Link Replacement .

    13. Object Number: 277523 Size: SH
  13. Install the outboard cowl grille section (1).
  14. Install the hood to the vehicle. Refer to Hood Replacement .
  15. Inspect the fender for proper clearance.
  16. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.