GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2008 🢒 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

    Important: 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

    Important: Observe protective wax corrosion protection measures.

  1. When replacing the fender, seal cavity.

    2. Important: 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).

    Notice: Refer to Fastener Notice in the Preface section.

    Important: 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 .