The replacement front wheelhouse is serviced as a complete assembly. Parts in the assembly include the front, middle, and rear wheelhouse panels, and the inner upper fender rail and the rail extension. It is necessary to remove and replace the upper fender rails when replacing either wheelhouse assembly.

The right and the left upper fender rails are not included and must be ordered separately.

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

1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.




Important: When replacing the wheelhouse assembly, it is necessary to remove the upper fender rail.

3. Remove all related components including the upper fender rail. For the left side wheelhouse replacement, also remove the vacuum brake booster. Refer to the following procedures:

•	Front Fender Upper Rail Replacement

•	Power Vacuum Brake Booster Replacement in Hydraulic Brakes

4. Repair as much of the damage as possible to factory specifications. Refer to Motor Compartment in Dimensions - Body .

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

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




Important: Do NOT damage the inner panels or the reinforcements.

6. Locate and drill out all factory welds on the upper fender rail. Note the number and location of the welds for installation of the wheelhouse assembly.



7. Locate and drill out all factory welds on the wheelhouse extension. Note the number and location of the welds for installation of the wheelhouse assembly.




Important: Do NOT damage the inner panels or the reinforcements.

8. Locate and drill out all factory welds on the outer apron. Note the number and location of the welds for installation of the upper tie bar.



9. Verify the existence of structural weld-through adhesive. Refer to Structure Adhesive Identification . If necessary use a chisel to separate the upper tie bar from the right and left front wheelhouse assembly.



10. With a reciprocating saw or equivalent, cut the wheelhouse panel assemblies approximately 26 mm (1 in) in front of the body side panel (1) as shown.



11. With the aid of an assistant, remove the damaged wheelhouse assembly.



12. Locate and drill completely through all factory welds on the inboard apron extensions as shown.




Important: Do NOT drill into the wheelhouse panel.

13. Locate and drill out all factory welds on the lower wheelhouse outboard extension (1).



14. With a reciprocating saw or equivalent, and using the outboard wheelhouse extension (1) as a guide, cut along the side of the extension down to the floor crossmember (2) as shown.



15. Locate and drill completely through all factory welds which attach the outboard wheelhouse extensions (1) to the body side panel (2) and to the front floor crossmember (3).
16. Remove and discard the outboard wheelhouse extensions.



17. Cut a slot into the wheelhouse panel (1) approximately 152 mm (6 in) above the front floor crossmember (2).



18. Apply ¾ inch masking tape from the slot (1) up and around the plenum (2) as shown. Line up the front edge of the tape with the back edge of the remaining holes in the wheelhouse panel.




Important: The tape edge facing the front of the vehicle is the proper cut location to create a weld flange for the service wheelhouse assembly.

19. With a cut-off wheel or equivalent, cut the remaining portions of the wheelhouse panels along the front edge of the masking tape as shown.



20. Remove and discard the wheelhouse panels.



21. Drill 8 mm (5/16 in) plug weld holes approximately 26 mm (1 in) apart in both the right and the left weld flanges as shown.
22. Prepare all mating surfaces as necessary.
23. Apply 3M® Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

Important: Trim the backs of the wheelhouse panel (1) to create the proper size weld flange for installation of the service front end kit.

1. Using a reciprocating saw or equivalent, remove approximately 38 mm (1.5 in) of the back of the wheelhouse panel as shown.



2. Remove and discard the trimmed wheelhouse flange (1).



3. Locate and drill completely through all factory welds on the wheelhouse panel. The left panel is shown, the right panel is similar.
4. Prepare all mating surfaces as necessary.
5. Apply 3M® Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted on the original panel.
2. Replace the structural adhesive with an additional plug weld between existing plug welds where necessary.
3. Prepare all mating surfaces as necessary.
4. Apply 3M® Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.



5. Position the wheelhouse assembly. Refer to Motor Compartment in Dimensions - Body .



6. Plug weld accordingly.
7. Install all related panels, including the upper fender rail. Refer to Front Fender Upper Rail Replacement or to Front Fender Upper Rail Sectioning .
8. Clean and prepare all welded surfaces.
9. Apply the sealers and the anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
10. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
11. Install all related components including the upper fender rail. For the left side wheelhouse replacement, also install the vacuum brake booster. Refer to the following procedures:

•	Front Fender Upper Rail Replacement

•	Power Vacuum Brake Booster Replacement in Hydraulic Brakes

12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
13. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.