GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2006 🢒 Malibu 🢒 Body 🢒 Body Front End 🢒 Front Fender Replacement

Removal Procedure
  1. Remove the front fender liner. Refer to Front Fender Liner Replacement .
  2. Remove the rocker panel molding. Refer to Rocker Panel Molding Replacement in Exterior Trim.
  3. Remove the headlamp assembly. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement in Lighting Systems.

    4. Object Number: 1315809 Size: SH
  4. Remove the rear of the front fascia from the fender support bracket.

    5. Object Number: 1315807 Size: SH
  5. Remove the bolts from the bottom, front, and top of the fender.
  6. Remove the fender from the front compartment side rail.
  7. If the fender requires replacement, remove the fender brace.

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.

  1. If the fender requires replacement, install the fender brace.

    2. Tighten
    Tighten the fender brace bolts to 10 N·m (89 lb in).


    Object Number: 1315807 Size: SH
  2. Position the fender on the front compartment side rail.
  3. Align the fender to the door and the hood.

    4. Object Number: 1315809 Size: SH
  4. Install the bolts which secure the fender to the front body hinge pillar.

    5. Tighten
    Tighten the bolt to 8 N·m (71 lb in).

  5. Install the following bolts:
    6. • The bolts which secure the fender flange to the upper compartment side rail.
    • The bolts which secure the fender to the fender brace.
    • The bolts which secure the rear lower fender to the support.

    Tighten
    Tighten the fender brace bolts to 10 N·m (89 lb in).


    Object Number: 864046 Size: SH
  6. Position the fascia to the fender. Push the fascia into place until the fascia is fully seated.
  7. Install the headlamp assembly. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement in Lighting Systems.
  8. Install the rocker panel. Refer to Rocker Panel Molding Replacement in Exterior Trim.
  9. Install the front fender liner. Refer to Front Fender Liner Replacement .