GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Lumina Ute 🢒 Body Repair 🢒 Collision Repair 🢒 Front Wheelhouse Replacement

Removal Procedure

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

    Caution: Refer to Vehicle Lifting Caution in the Preface section.

    Caution: Refer to Safety Glasses Caution in the Preface section.

    Caution: Refer to Battery Disconnect 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.
  3. Remove the engine assembly. Refer to Engine Replacement for the 3.6L engine or Engine Replacement for the 6.0L engine.
  4. Remove the negative cable from the engine bay. Refer to Battery Negative Cable Replacement.
  5. Remove the positive cable from the engine bay. Refer to Battery Positive Cable Replacement.
  6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  7. Remove the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement.
  8. Remove the front wheel hub assembly. Refer to Front Wheel Bearing and Hub Replacement.
  9. Remove the front strut assembly. Refer to Strut Assembly Replacement.
  10. Lower the vehicle.
  11. Remove the brake lines. Refer to Brake Pipe Replacement.
  12. Remove the fender assembly. Refer to Front Fender Replacement.
  13. Remove the front fascia. Refer to Front Bumper Fascia Replacement.
  14. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement.
  15. Remove the front end module. Refer to Front End Panel Module Carrier Assembly Replacement.
  16. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement.
  17. Remove the plenum chamber. Refer to Air Inlet Assembly Replacement.
  18. Remove the relay box. Refer to Underhood Electrical Center or Junction Block Replacement.
  19. Remove the ABS unit. Refer to Brake Pressure Modulator Valve Assembly Replacement.
  20. Remove the brake master cylinder. Refer to Master Cylinder Replacement.
  21. Remove the instrument panel. Refer to Instrument Panel Carrier Replacement.
  22. Remove the HVAC. Refer to HVAC Module Assembly Replacement.
  23. Remove the front floor carpet. Refer to Front Floor Panel Carpet Replacement.

    24. Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

  24. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.

    25. Object Number: 1937497 Size: SH
  25. Locate, mark and drill out the inner factory welds (1) attaching the upper wheelhouse brace (2) to the wheelhouse assembly.
  26. Locate, mark and drill out the inner factory welds (3) attaching the upper wheelhouse brace (2) to the wheelhouse assembly.

    27. Object Number: 1937498 Size: SH
  27. Locate, mark and drill out the inner factory welds (1) attaching the wheelhouse assembly to the vehicle.

    28. Object Number: 1937499 Size: SH
  28. Locate, mark and drill out the factory welds (1) attaching the wheelhouse assembly to the cowl panel.

    29. Object Number: 1937501 Size: SH
  29. Locate, mark and drill out the factory welds (1) attaching the wheelhouse assembly to the upper wheelhouse brace.

    30. Object Number: 1937502 Size: SH
  30. Locate, mark and drill out the factory welds (1) attaching the wheelhouse assembly to the front chassis rail.

Installation Procedure
  1. Clean and prepare the mating surfaces of both parts of the front chassis rail.
  2. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original assembly.

    3. 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 32 mm (1¼ in).

  3. Position the body side on the vehicle. Verify correct alignment and position using three-dimensional measuring equipment.

    4. Object Number: 1937429 Size: SH
  4. Align the datum points (1) and (2) to the vehicle.

    5. Object Number: 1937307 Size: SH
  5. Weld (1) the wheelhouse assembly to the vehicle starting from the front chassis rail.

    6. Object Number: 1937308 Size: SH
  6. Weld (1) the wheelhouse assembly to the vehicle starting from the cowl panel.

    7. Object Number: 1937309 Size: SH
  7. Weld (2) the wheelhouse assembly to the vehicle starting from the front chassis rail.

    8. Object Number: 1937311 Size: SH
  8. Weld (1) the wheelhouse assembly to the upper wheelhouse brace.

    9. Object Number: 1937427 Size: SH
  9. Weld (1) the upper wheelhouse brace (2) to the wheelhouse assembly.
  10. Weld (3) the upper wheelhouse brace (2) to the wheelhouse assembly.
  11. Clean and prepare all welded surfaces.
  12. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
  13. Install the front floor carpet. Refer to Front Floor Panel Carpet Replacement.
  14. Install the HVAC. Refer to HVAC Module Assembly Replacement.
  15. If re-programming is required. Refer to Control Module References.
  16. Install the instrument panel. Refer to Instrument Panel Carrier Replacement.
  17. If re-programming is required. Refer to Control Module References.
  18. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
  19. Install the brake master cylinder. Refer to Master Cylinder Replacement.
  20. Install the ABS unit. Refer to Brake Pressure Modulator Valve Assembly Replacement.
  21. If re-programming is required. Refer to Control Module References.
  22. Install the relay box. Refer to Underhood Electrical Center or Junction Block Replacement.
  23. Install the plenum chamber. Refer to Air Inlet Assembly Replacement.
  24. Install the air inlet grille. Refer to Air Inlet Grille Panel Replacement.
  25. Install the front end module. Refer to Front End Panel Module Carrier Assembly Replacement.
  26. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement.
  27. Install the front fascia. Refer to Front Bumper Fascia Replacement.
  28. Install the fender assembly. Refer to Front Fender Replacement.
  29. Install the brake lines. Refer to Brake Pipe Replacement.
  30. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  31. Install the front strut assembly. Refer to Strut Assembly Replacement.
  32. Install the front wheel hub assembly. Refer to Front Wheel Bearing and Hub Replacement.
  33. Install the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement.
  34. Install the front wheels. Refer to Tire and Wheel Removal and Installation.
  35. Lower the vehicle.
  36. Install the engine assembly. Refer to Engine Replacement for the 3.6L engine or Engine Replacement for the 6.0L engine.
  37. Install the positive cable to the engine bay. Refer to Battery Positive Cable Replacement.
  38. Install the negative cable to the engine bay. Refer to Battery Negative Cable Replacement.
  39. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  40. Enable the SIR system. Refer to SIR Disabling and Enabling.
  41. If re-programming is required. Refer to Control Module References.