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

Important: Inspect the cowl panel for damage where the wheelhouse is attached. If the panels have been separated, it will be necessary to repair the cowl panel and replace the wheelhouse at factory seams. If panels have not been separated and there is no damage in this location, the wheelhouse can be serviced as follows.

1. Remove all related panels and components.
2. Visually inspect and restore as much of the damage as possible to factory specifications.
3. Remove all sealers and anti-corrosion materials as necessary.
4. Measure forward 75 mm (3 in) at wheelhouse to cowl panel joint.
5. Mark a vertical line from the strut cap to the frame rail DO NOT CUT INTO THE STRUT CAP.
6. Cut the wheelhouse along this line, from the rail up to the strut cap.

Important: Drill through the strut cap welds to locate the areas to be re-welded at the cowl panel.

7. Locate, mark and drill out the factory welds which attach the wheelhouse assembly to the following:

•	Cowl panel

•	Radiator support

•	Lower front rails

8. Remove the damaged wheelhouse assembly.

1. Clean and prepare surfaces to be welded.
2. Trim and discard tab off the service part which is normally welded to the cowl panel.
3. Drill 8 mm (5/16 in) holes for plug welding in the locations noted from the original assembly.
4. Drill six holes for plug welding every 40 mm (1 ½ in) along the overlap which attaches the service part to the flange remaining from the original assembly.
5. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.



6. Check the position of the wheelhouse assembly using 3-dimensional measuring equipment.
7. Plug weld accordingly.
8. Install one weld in the tab from the cowl to the strut cap.

Important: The welds which attach the strut cap (2) to the cowl (1) can be installed from the cowl plenum side of the joint.

9. Clean and prepare all welded surfaces.

Important: Prior to refinishing refer to GM 4901MD-99 Refinish Manual for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

10. Locate 2 fender mounting holes in the new wheelhouse using 3-dimensional measuring equipment.
11. Drill holes.
12. Apply approved anti-corrosion primer.
13. Apply sealers and sound deadeners and finish as necessary.
14. Install threaded inserts at fender mounting locations. Kent-Moore tools: Riv-nut™ Kit  P/N J421151-MS. Use original fasteners or equivalent.
15. Install all related panels and components.