GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Holden 🢒 2009 🢒 Epica 🢒 Body Repair 🢒 Collision Repair 🢒 Front Wheelhouse Replacement

Removal Procedure

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

    Note: The front wheelhouse component is constructed as a unit with the shock absorber tower panel. Therefore, replacement of the component affects the front wheel alignment. When assembling it, either use a jig or follow dimensions on the body repair chart for positioning. It must be welded carefully.

  1. Disable the SIR system. Refer to SIR Disabling and Enabling.
  2. Disconnect the negative battery cable.

    3. Note: 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 wheelhouse can be serviced as a complete assembly for both the left and right wheelhouses. A wheelhouse front panel is also available to service separately on the left or the right sides.

  3. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.

    4. Note:  Be sure to inspect the front of the air inlet and dash panel for damage. If the metal surface is damaged, the air inlet panel must be repaired to restore the structural integrity of the vehicle.

  4. Visually inspect the damaged area. Repair as much of the damage as possible. Refer to Dimensions - Body.

    5. Object Number: 867495 Size: SH

    Note: Note the number and location of welds for installation of the front wheelhouse.

  5. Locate and drill out all factory welds.

    6. Object Number: 867507 Size: SH
  6. Remove the front wheelhouse from the vehicle.

Installation Procedure

    Object Number: 865277 Size: SH

    Note: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1½ in) apart.

  1. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original assembly.
  2. Prepare the mating surfaces as necessary.
  3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
  4. Position the front wheelhouse in the vehicle using 3-dimensional measuring equipment. Clamp the wheelhouse in place.

    5. Object Number: 867495 Size: SH
  5. Plug weld accordingly.
  6. Clean and prepare all of the welded surfaces.
  7. Install all related panels and components.
  8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
  9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
  10. Connect the negative battery cable.
  11. Enable the SIR system. Refer to SIR Disabling and Enabling.