Rear Inner Wheelhouse Replacement for Chevrolet Express - AWD 2009

Note: Rear outer wheelhouse sectioning procedures have been developed to simplify repair when damage is limited to the outer wheelhouse. In the event the inner wheelhouse is to be replaced, install outer wheelhouse service panel at factory seams.

Warning: Refer to Approved Equipment for Collision Repair Warning 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.
3. Remove all related panels and components, including the quarter panel.

Warning: Refer to Collision Sectioning Warning in the Preface section.

4. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Basecoat/Clearcoat Paint Systems.
5. Visually inspect and repair as much of the damage as possible.




Note: Do not damage any inner panels or reinforcements.

6. Locate, mark, and drill out all factory spot welds attaching the inner wheelhouse to the vehicle.
7. Remove the damaged inner wheelhouse.

Note: If the location of the original plug weld holes can not be determined, space the plug weld holes 40 mm (1½ in) apart.

1. Drill 8 mm (5/16 in) holes for plug welding every 40 mm (1½ in) along the cut edge.



2. Prepare mating surfaces as necessary.
3. Apply GM-approved weld-thru coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair.



4. Position the service part and inspect for proper fit.
5. Plug weld accordingly.
6. Clean and prepare all welded surfaces.
7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
8. Paint and repair the area. Refer to Basecoat/Clearcoat Paint Systems.
9. Install all related panels and components.
10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
11. Enable the SIR system. Refer to SIR Disabling and Enabling.