Front Wheelhouse Replacement Sectioning

1. Remove the panels and the components as necessary for access.



2. Visually inspect and restore to factory specifications as much of the damage as possible.
3. Remove all sealers and anti-corrosion materials as necessary.
4. Place a piece of 25 mm (1 in) wide masking tape on the forward contour of the wheelhouse at the flange where it attaches to the cowl panel.
5. Cut the wheelhouse along the forward edge of the masking tape to leave a 25 mm (1 in) tab extending forward from the cowl panel(1). This will provide an overlap for welding the service part to the original wheelhouse without welding directly to the cowl panel.
6. Locate, mark and drill out the factory welds which attach the wheelhouse assembly at the :

•	Upper rail inner panel

•	Cowl panel

•	Radiator support

•	Lower front rails

7. Remove the damaged wheelhouse assembly.

1. When preparing the service part (1), cut the forward apron well beyond the 35 mm (1 5/32 in) overlap needed for sectioning (2).
2. Temporarily position the new wheelhouse section on the outboard side of the vehicle.
3. Clean and prepare surfaces to be welded.
4. Cut the flange off the service part that is normally welded to the cowl panel (1).



5. Drill 8 mm (5/16 in) holes for plug welding in the locations noted from the original assembly. Drill holes for plug welding every 40 mm (1 1/2 in) along the cut edge to be attached to the tab remaining from the original assembly.
6. Position the new wheelhouse assembly using 3-dimensional measuring.

Caution: Foam sound deadeners must be removed from areas within 152.4 mm (6 in) of where flame is to be used for body repairs. When reinstalling foam sound deadeners, avoid inhaling fumes as bodily injury may result.

7. Plug the weld accordingly as necessary.
8. Clean and prepare the bare-metal surfaces.

Important: Prior to refinishing, refer to publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

9. Apply the following as necessary:

•	Sealers and anti-corrosion materials

•	Sound deadeners

•	Two-part catalyzed primer

•

Top-coat

10. Reinstall all of the related panels and components.