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

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. The upper strut mounting surface is a dimensionally critical area, and 3-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.

1. Remove all related panels and components, including the upper rail outer and inner panels.
2. Visually inspect and restore as much of the damage as possible to factory specifications.
3. Remove sealers and anti-corrosion protection materials as necessary.
4. Locate, mark, and drill out all factory welds. Note the number and location of welds for installation of the service assembly.

1. Prepare the mating surfaces as necessary. Inspect for proper fit of the service part.
2. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original assembly (2).

Important: If the original plug weld locations can not be determined, locate the holes for plug welding 40 mm (1½ in) apart.

3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
4. Position the wheelhouse on the vehicle. Check for proper fit using 3-dimensional measuring equipment.
5. When the service assembly is correctly positioned, plug weld accordingly.
6. Measure frequently to ensure proper fit and alignment.

Caution: Foam sound deadeners must be removed from areas within 152.4 mm (6 in) of where flame is to be used for body repairs. When reinstalling foam sound deadeners, avoid inhaling fumes as bodily injury may result.

7. 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.

8. Prime with 2-part catalyzed primer.
9. Apply sealers and anti-corrosion protection materials as necessary.
10. Install all related panels and components.