Saturn Coupes/Sedans/Wagons 1991-1998 Repair Guide

Fenders

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REMOVAL & INSTALLATION



1991-95 Sedan and Wagon

See Figures 1, 2, 3, 4 and 5

  1. Remove the plastic retainers from the wheelhouse liner-to-lower fender extension.
  2.  
  3. Remove the plastic retainers from the bottom of the fender extension-to-fender support.
  4.  
  5. Detach the fender extension from the lower portion of the fender by exerting pressure at the bottom of the extension and carefully inserting a flat screwdriver into the groove. Using the screwdriver, depress the tab and pull the extension outward and from the vehicle.
  6.  
  7. Remove the plastic retainers from the bottom of the fender.
  8.  
  9. Remove the bolts at the fender upper-to-lower joint which thread into the support bracket on the front body hinge pillar. The bolts are driven vertically upward.
  10.  
  11. Remove the plastic retainers from the wheel liner-to-fender joint.
  12.  
  13. If the fender is being replaced, remove the rubber seals from the rear of the fender, the Saturn emblem and the metal bracket from the top of the rear fender.
  14.  
  15. Remove the fender-to-fascia stud plate at the horizontal joint by removing the rear bolt and the front nuts.
  16.  
  17. Remove the headlamp housing.
  18.  
  19. Remove the fender-to-fascia stud plate and reinforcement at the vertical joint.
  20.  
  21. Remove the bolt from the rear upper corner of the fender-to-front body hinge pillar support bracket.
  22.  
  23. Remove the bolts from the fender flange-to-upper engine compartment rail, then remove the fender from the vehicle.
  24.  

To install:
  1. If the fender is being replaced, install the metal bracket on the top rear of the fender, the Saturn emblem and the rubber seals to the fender rear flange.
  2.  
  3. Position the fender onto the engine compartment side rail.
  4.  
  5. Align the fender to the door and hood, then install the fender flange bolts using the sequence shown in the illustration.
  6.  
  7. Install the fender-to-front body hinge pillar support bracket bolt, then install the fender-to-fascia stud plate and vertical joint reinforcement.
  8.  
  9. Align the fender-to-fascia and tighten the nuts to the vertical stud plate. Install the headlamp housing.
  10.  
  11. Install the fender-to-fascia upper support bracket assembly along the horizontal joint using the nuts and bolts.
  12.  
  13. Install the wheelhouse liner to the fender using the plastic retainers.
  14.  
  15. Install the fender-to-body hinge pillar lower bracket bolts.
  16.  
  17. Install the plastic retainers at the bottom of the fender.
  18.  
  19. Align the fender lower extension to the fender and push it rearward to engage the retaining tabs.
  20.  
  21. Install the plastic retainers at the bottom of the fender extension-to-fender support.
  22.  
  23. Install the wheel liner-to-fender extension plastic retainers.
  24.  
  25. Check and adjust headlamp aim, as necessary.
  26.  



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Fig. Fig. 1: Using a small prying tool, pull up on the center of the plastic pushpin retainers ...



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Fig. Fig. 2: ... then pull out the pushpin retainers from the wheelhouse liner-to-lower fender extension



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Fig. Fig. 3: The fender lower extension must be removed before the fender can be removed from the vehicle



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Fig. Fig. 4: Install the fender retaining bolts in the proper sequence



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Fig. Fig. 5: Install the wheelhouse liner to the fender using the plastic retainers

1996-98 Sedan and Wagon

See Figures 6, 7 and 8

  1. Remove the plastic retainers from the outer wheelhouse liner.
  2.  
  3. Remove the front and middle mounting fasteners on the rocker panel cover and lower the front end of the cover. Remove the bottom rear fender mounting bolt.
  4.  
  5. Remove the windshield frame filler panel mounting bolt and slide the panel upward.
  6.  
  7. Slide the front fascia forward and disengage it from the fender bolts.
  8.  
  9. Remove the rear upper fender corner-to-front body hinge piller bolt.
  10.  
  11. Remove the top fender-to-spaceframe mounting bolts.
  12.  
  13. Remove the two fender-to-fender reinforcement bracket bolts. Remove the fender from the vehicle.
  14.  

To install:
  1. If the fender is being replaced, transfer the Saturn emblem and any rubber flange seals.
  2.  
  3. Place the fender in position on the upper spaceframe and align to the door and hood.
  4.  
  5. Install the fender-to-front body hinge pillar bolt and tighten to 89 inch lbs. (10 Nm).
  6.  
  7. Install all spaceframe side rail, bottom rear and fender-to-fender reinforcement bracket bolts. Tighten all the bolts to 89 inch lbs. (10 Nm).
  8.  
  9. Position the front fascia and slide it into place.
  10.  
  11. Install the windshield frame filler panel and mounting bolt.
  12.  
  13. Install the front and middle mounting fasteners which retain the front rocker panel cover.
  14.  
  15. Install the plastic retainers to the outer wheelhouse liner.
  16.  



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Fig. Fig. 6: Removal of the plastic fasteners from the rocker panel cover



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Fig. Fig. 7: Location of the windshield frame filler panel



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Fig. Fig. 8: Exploded view of the front fender and mounting fasteners

1991-96 Coupe

See Figures 9 and 10

  1. Remove the plastic retainers from the wheelhouse liner-to-fender extension.
  2.  
  3. Remove the plastic retainers from the bottom of the fender extension-to-fender support.
  4.  
  5. Disconnect the fender extension from the lower portion of the fender by exerting pressure at the bottom of the extension and carefully inserting a flat screwdriver into the groove. Using the screwdriver, depress the tab and pull the extension outward and from the vehicle.
  6.  
  7. Remove the wheelhouse liner-to-fascia and front fender fasteners.
  8.  
  9. Remove the retainers from the bottom of the fender.
  10.  
  11. Remove the bolts at the fender upper-to-lower joint which thread into the support bracket on the front body hinge pillar. The bolts are driven vertically upward.
  12.  
  13. Remove the nuts and reinforcement plate from the horizontal fender-to-fascia joint, then remove the stud plate.
  14.  
  15. Remove the bolt from the rear upper corner of the fender-to-front body hinge pillar support bracket.
  16.  
  17. Remove the fender-to-headlamp housing assembly and fender-to-engine compartment rail bolts, then remove the fender from the vehicle.
  18.  
  19. If replacing the fender, remove the Saturn emblem.
  20.  

To install:
  1. If the fender is being replaced, install the Saturn emblem.
  2.  
  3. Position the fender onto the engine compartment side rail, then align the fender with the door and hood.
  4.  
  5. Install the fender-to-engine compartment side rail fasteners, fender-to-headlamp housing assembly fasteners and the fender-to-front body hinge pillar support bracket bolts. Tighten all the bolts to 89 inch lbs. (10 Nm) using the sequence shown in the illustration.
  6.  
  7. Attach the fender-to-fascia by lowering the stud plate through the bracket and fender, then install the reinforcement plate and nuts. Align the fender-to-fascia and tighten the nuts.
  8.  
  9. Install the vertically driven fender bolts to the support bracket on the lower front body hinge pillar.
  10.  
  11. Install the retainers to the bottom of the fender.
  12.  
  13. Install the wheelhouse-to-front fascia and the front fender fasteners.
  14.  
  15. Align the fender lower extension to the fender and push it rearward to engage the retaining tabs.
  16.  
  17. Install the plastic retainers at the bottom of the fender extension-to-fender support.
  18.  
  19. Install the wheel liner-to-fender extension plastic retainers.
  20.  



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Fig. Fig. 9: Remove the lower fender extension from the fender and body



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Fig. Fig. 10: Tighten the fender bolts in the proper sequence

1997-98 Coupe

See Figures 11, 12 and 13

  1. Remove the plastic retainers from the outer wheelhouse liner.
  2.  
  3. Remove the plastic pushpin fasteners from the rocker panel cover.
  4.  
  5. Slide the cover forward to disengage it from the front fender, rocker cover support and quarter panel. Remove the panel from the vehicle.
  6.  
  7. Remove the bottom rear fender mounting bolts.
  8.  
  9. Remove the top middle plastic pushpin retainers from the front fascia.
  10.  
  11. Remove the windshield frame filler panel mounting bolt and slide the panel upward.
  12.  
  13. Slide the front fascia forward and disengage it from the fender bolts.
  14.  
  15. Remove the front fender bracket shoulder bolts.
  16.  
  17. Remove one outer headlamp mounting bolt. Slide the outer side of the headlamp assembly forward to gain access to the forward front fender-to-spaceframe mounting bolt.
  18.  
  19. Remove the rear upper fender corner-to-front body hinge piller bolt.
  20.  
  21. Remove the top fender-to-spaceframe mounting bolts.
  22.  
  23. Remove the two fender-to-fender reinforcement bracket bolts. Remove the fender from the vehicle.
  24.  

To install:
  1. If the fender is being replaced, transfer the Saturn emblem and any rubber bumper or flange seals.
  2.  
  3. Place the fender in position on the upper spaceframe and align to the door and hood.
  4.  
  5. Install the fender-to-front body hinge pillar bolt and tighten to 89 inch lbs. (10 Nm).
  6.  
  7. Install all spaceframe side rail, bottom rear and fender-to-fender reinforcement bracket bolts. Tighten all of the bolts to 89 inch lbs. (10 Nm).
  8.  
  9. Install the headlamp mounting bolt and tighten to 61 inch lbs. (7 Nm).
  10.  
  11. Position the front fascia and slide it into place.
  12.  
  13. Install the front fascia plastic pushpin retainers.
  14.  
  15. Install the windshield frame filler panel and mounting bolt.
  16.  
  17. Place the rocker cover in position, aligning the panel tabs to the slots in the front fender, rear quarter panel and rocker cover support. Slide the rocker cover panel rearward to lock the panel into position, then install the plastic pushpin retainers.
  18.  
  19. Install the plastic retainers to the outer wheelhouse liner.
  20.  



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Fig. Fig. 11: Exploded view of the rocker panel cover assembly



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Fig. Fig. 12: Remove the headlamp assembly mounting bolt for front fender mounting bolt access



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Fig. Fig. 13: Exploded view of the front fender and mounting fasteners

 
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