GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Uplander 🢒 Body Repair 🢒 Collision Repair 🢒 Rear Outer Wheelhouse Replacement

Removal Procedure

    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. Object Number: 861586 Size: SH
  3. Remove all related panels and components.
  4. Restore as much of the damage as possible to factory specifications. Refer to Dimensions - Body.

    5. Warning: Refer to Foam Sound Deadeners Warning 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.
  6. Perform the necessary procedures to gain access to repair. Refer to Quarter Panel Replacement - Lower.

    7. Object Number: 680979 Size: SH

    Note: Do not damage any inner panels or reinforcements.

  7. Trim off the damaged rear wheelhouse to gain access to the weld flange.
  8. Locate and drill out all factory welds. Note the number and location of welds for installation of the rear outer wheelhouse.

    9. Object Number: 680981 Size: SH
  9. Remove the damaged rear outer wheelhouse.

Installation Procedure

    Object Number: 680983 Size: SH

    Note: 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 40 mm (1 ½ in) apart.

  1. Drill 8 mm (5/16 in) plug weld holes as necessary in locations noted from the original rear outer wheelhouse.
  2. Prepare all 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. Object Number: 680987 Size: SH
  4. Position the rear outer wheelhouse.
  5. Plug weld accordingly.

    6. Object Number: 861590 Size: SH
  6. Complete the necessary procedures. Refer to Quarter Panel Replacement - Lower.
  7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
  8. Paint the repair 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.