GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2009 🢒 Astra 🢒 Body Repair 🢒 Bolted Exterior Body Panels and Closures 🢒 Front Fender Replacement

Removal Procedure
  1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement.
  2. Remove the headlamps. Refer to Headlamp Replacement.
  3. Remove the front fender liner of the fender. Refer to Front Fender Liner Replacement.
  4. Remove the fender insulation.

    5. Object Number: 1941457 Size: SH
  5. Remove the repeater lamp (1).
    6. • Disengage the repeater lamp (1) from the inside (3).
    • Disconnect the wiring harness plug (2).

    Object Number: 1936355 Size: LF
  6. When replacing the fender, transfer or replace the fascia support bracket.

    7. Drill out the 4 blind rivets (1).


    Object Number: 1941415 Size: LF
  7. Remove the front fender (1) from the outer windshield frame.

    8. Remove the adhesive (2) from the A-pillar (3).


    Object Number: 1936496 Size: LF

    Note: Protect the edges of the fender with adhesive tape to avoid damaging the paint.

  8. Remove the fender.

    9. Remove the 7 bolts (arrow).


    Object Number: 1941461 Size: LF
  9. Remove the small parts.
    10. • Remove the plastic nut.
    • Remove the additional hood seal.
    • Remove the fender (1).
    • Remove the bracket (2) from fender.

Installation Procedure

    Note: Observe protective wax corrosion protection measures.

  1. When replacing the fender, seal cavity.

    2. Note: Observe corrosion protection measures for PVC protection.

  2. Apply an underseal.

    3. Object Number: 1941432 Size: SH
  3. Replace the fender adhesive tape (1).

    4. Replace the 5 cm (2 in) double-sided adhesive tape (1).

    Caution: Refer to Fastener Caution in the Preface section.

    Note: Protect the edges of the fender with adhesive tape to avoid damaging the paint.

  4. Slide the fender under the windshield trim.
  5. Install the fender.
    6. • Bond the fender to the windshield frame.
    • Install the fender bracket.
    • Install the 7 bolts.

    Object Number: 1936414 Size: LF
  6. Adjust the fender.
    7. • (I) 4.5+/-1.0 mm (0.18+/-0.04 in)
    • (II) 3.5+/-0.8 mm (0.14+/-0.03 in)
    • (III) 3.0+/-1.0 mm (0.19+/-0.04 in)
    • (IV) 3.8+/-0.8 mm (0.15+/-0.03 in)

    Object Number: 1936496 Size: LF
  7. Install the fender.

    8. Tighten
    Tighten the 7 bolts (arrow) to 8 N·m (71 lb in).

  8. Mark the heads of the 8 bolts with paint.
  9. Connect the small parts.
    10. • Install the additional hood seal.
    • Install the plastic nut.
  10. Connect the guide rails.
    11. • Install the guide rail.
    • Rivet on the 4 blind rivets.
  11. Install the repeater lamp.
    12. • Connect the wiring harness plug.
    • Install the repeater lamp.
  12. Install the fender insulation to the A-pillar.
  13. Install the front fender liner. Refer to Front Fender Liner Replacement.
  14. Install the headlamps. Refer to Headlamp Replacement.
  15. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement.