For 1990-2009 cars

### 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. Remove all related panels and components.
4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body.
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. Remove the lower plenum.

Important: Do not damage any inner panels or reinforcements.

7. Locate and drill out all factory welds.

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

8. Remove the damaged front wheelhouse.

### Installation Procedure

Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 ½ in) apart.

Some panels may have structural weld-thru adhesive. It is necessary to replace the weld-thru adhesive with an additional spot weld between each factory spot weld.
1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original assembly.
2. Prepare the 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. Position the front wheelhouse to the vehicle using 3-dimensional measuring equipment. Clamp the wheelhouse in place.
5. Plug weld accordingly.
6. Install the lower plenum.
7. Clean and prepare all of the welded surfaces.
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. Install all related panels and components.
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
12. Enable the SIR system. Refer to SIR Disabling and Enabling.