Front Fender: Service and Repair

FRONT FENDER

REMOVAL

Fender

1. Remove the sill panel.

Fig. 30:

2. Remove the three screws and remove the door hinge cover. (Fig. 30)
3. Remove the screws attaching the fender grille to the fender and the sill.
4. Remove the front wheelhouse splash shield.

Fig. 31:

5. Remove the screws attaching the fender to the fascia. (Fig. 31)
6. Remove the rivets attaching the fender to the support bracket.
7. Remove the nuts where the hinge cover is attached.
8. Remove the rear screws.

Fig. 32:

9. Remove the upper bolts and remove the fender. (Fig. 32)

Fender Support

Fig. 33:

1. Remove the bolts attaching the support to the frame. (Fig. 33)
2. Remove the nut attaching the support to the front of dash panel.
3. Using a heat gun, heat attachment area to at least 121 degrees C (250 degrees F) to soften adhesive attaching fender support to frame.
4. Using a flat blade scraper, cut adhesive from between fender support and frame.
5. Remove the fender support.

INSTALLATION

Fender Support

CAUTION: Clean only the area of the frame where the old adhesive is present or corrosion resistance may be compromised.

1. Using a 3M(R) Purple Scotch-Brite(TM) Clean & Strip XT Disc or equivalent, clean adhesive residue from frame.

NOTE: Do not apply adhesive close to the inboard edge of the fender support when installed. Avoid unsightly "squeeze out".

Fig. 34:

2. Using a structural adhesive suitable for bonding carbon fiber to steel, apply adhesive bead 10 - 15 mm (3/8 in. to 5/8 in.) to the bonding surfaces on frame from front to rear in the locations indicated. (Fig. 34)

NOTE: Adhesive will begin to harden in approximately 3 1/2 minutes of first application.

3. Install the fender support and align with marks made previously.
4. Install and tighten the nut to 17 N.m (13 ft.lbs.).
5. Install the center screw and tighten to 17 N.m (13 ft.lbs.).
6. Install the front screw and tighten to 17 N.m (13 ft.lbs.).
7. Check for air gaps in adhesive.

Fender

1. Install the fender and loosely install the fasteners.

Fig. 35:

2. Tighten the upper bolts to 5 N.m (45 in.lbs.) using the sequence shown. (Fig. 35)
3. Install new rivets securing the fender to the support bracket.
4. Tighten the fender to headlamp support screws.
5. Tighten the screw securing the fender to the cowl.
6. Tighten the nuts attaching the fender to the front of dash panel to 5 N.m (45 in.lbs.).
7. Tighten the rear fender to sill bolt to 5 N.m (45 in.lbs.).
8. Tighten the rear fender screw.
9. Install the fender grille and install the upper screw attaching the grille to the fender.
10. Install the lower grille screw at the sill.
11. Install the door hinge cover and install the three screws to the fender.