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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 406 (BODY FRONT END)REPAIR INSTRUCTIONSFENDER REPLACEMENT - FRONT - RIGHTINSTALLATION PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Installation Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Installation Procedure
WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the fender to vehicle.
    2. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the rear lower fender bolt.

    Tighten:  Tighten the rear lower fender bolt to 25 N.m (18 lb ft).

    3. Fig 1: Rear Right Lower Fender Bolt
    GM629325Courtesy of GENERAL MOTORS CORP.
  3. Install the fender to radiator support bolts.

    Tighten:  Tighten the radiator support bolts to 25 N.m (18 lb ft).

    Fig 2: Right Fender To Radiator Support Bolts
    GM629322Courtesy of GENERAL MOTORS CORP.
  4. Fasten the right front grille clip to the fender.
    5. Fig 3: Grille Ends To Fender Fasteners
    GM370264Courtesy of GENERAL MOTORS CORP.
  5. Install the fender to door hinge bolts.

    Tighten:  Tighten the door hinge bolts to 25 N.m (18 lb ft).

    Fig 4: Right Fender To Door Hinge Bolts
    GM629320Courtesy of GENERAL MOTORS CORP.
  6. Install the fender to upper cowl bracket bolt.

    Tighten:  Tighten the upper cowl bracket bolt to 25 N.m (18 lb ft).

    7. Fig 5: Fender To Upper Cowl Bracket & Bolt
    GM629315Courtesy of GENERAL MOTORS CORP.
  7. Install the push-in retainers (2) in order to attach the wheelhouse panel (1) to the fender (3).
    8. Fig 6: Wheelhouse Panel, Fender & Push-In Retainers
    GM629339Courtesy of GENERAL MOTORS CORP.
  8. Install the wheelhouse panel bracket, if equipped.

    Tighten: 

    • Tighten the wheelhouse panel bracket nuts to 25 N.m (18 lb ft).
    • Tighten the wheelhouse panel bracket bolts to 9 N.m (80 lb in).

    Fig 7: Wheelhouse Panel Bracket
    GM402051Courtesy of GENERAL MOTORS CORP.
  9. Install the right side battery tray, if equipped. Refer to Battery Tray Replacement in Engine Electrical.
  10. Install the coolant surge tank. Refer to Surge Tank Replacement in Engine Cooling.
  11. Install the air filter housing. Refer to Air Cleaner Assembly Replacement in Engine Controls - 4.8L, 5.3L and 6.0L.
  12. Install the right fender to cowl support brace, if equipped.

    Tighten:  Tighten the cowl support brace bolts to 9 N.m (80 lb in).

    13. Fig 8: Right Fender To Cowl Support Brace
    GM629328Courtesy of GENERAL MOTORS CORP.
  13. Install the right hood spring assembly. Refer to Hood Link Replacement .
  14. Install the hood. Refer to Hood Replacement .
  15. Install the right outboard cowl vent grille trim piece.
    16. Fig 9: Right Cowl Vent Grille Panel Outboard Section
    GM629332Courtesy of GENERAL MOTORS CORP.
  16. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.