1. Preparation:
* Gather Tools: You'll need a socket set (metric), wrenches (metric), screwdrivers (Phillips and flathead), a hammer, a pry bar (plastic is best to avoid scratching), a wire brush, safety glasses, gloves, jack stands, jack, wheel chocks, and possibly a fender removal tool (though a pry bar can often suffice). A torque wrench is highly recommended.
* Safety First: Park on a level surface, engage the parking brake, and chock the rear wheels. Disconnect the negative battery terminal.
* Remove the Wheel: Loosen the lug nuts before jacking up the vehicle. Securely support the vehicle with jack stands before removing the wheel completely.
2. Removing the Old Fender:
* Disconnect Components: This is the most crucial and variable step. You'll need to disconnect anything attached to the fender:
* Headlight assembly: This may involve removing some screws and possibly unplugging electrical connectors.
* Turn signal/parking light: Similar to the headlight, you'll need to disconnect electrical connectors and remove retaining screws or clips.
* Fender liner: This plastic liner often needs to be partially or completely removed to access fasteners. It's typically held in place with clips and screws.
* Hood latch cable (if applicable): The cable might run through or be attached to the fender.
* Wiper linkage (if applicable): Depending on the extent of rust/damage, parts of the wiper mechanism might need to be detached.
* Any other brackets or trim pieces: Carefully inspect and remove anything attached to the fender. Take photos as you go to aid reassembly.
* Remove Fender Fasteners: The fender is likely held on by bolts, screws, and possibly spot welds. Carefully remove all visible fasteners. Use a pry bar cautiously to separate the fender from the body. Work your way around the fender, releasing it from its mounting points. Be gentle to avoid damaging the surrounding body panels. Some fasteners may be hidden under trim pieces or rubber seals.
* Inspect for Rust: This is a common issue with older vehicles. Address any rust you find before installing the new fender. This might involve wire brushing, rust treatment, and potentially some bodywork.
3. Installing the New Fender:
* Position the New Fender: Carefully align the new fender with the body, ensuring it sits flush and all mounting holes line up.
* Attach the Fender: Install the fasteners in the reverse order of removal. Use new fasteners if necessary.
* Reconnect Components: Reattach all components (headlight, turn signal, etc.) that you disconnected earlier. Double-check all electrical connections.
* Test Fit: Before tightening everything down completely, check to ensure the fender is properly aligned and all components fit correctly.
4. Final Steps:
* Tighten Fasteners: Use a torque wrench to tighten all fasteners to the manufacturer's specifications (look up your Suburban's specifications in a repair manual).
* Reinstall Wheel and Tire: Put the wheel back on and carefully lower the vehicle. Tighten the lug nuts to the specified torque.
* Check Alignment: Double-check the fender's alignment and ensure everything is functioning properly (headlights, turn signals).
Important Considerations:
* Repair Manual: A repair manual specific to your 1989 Chevy Suburban is highly recommended. It will provide detailed diagrams and instructions, making the process significantly easier.
* Rust Repair: If your old fender was rusted, it's vital to address any rust on the body before installing the new one.
* Bodywork: If you've sustained significant damage to the surrounding body panels, you might need additional bodywork and paint to achieve a seamless finish.
* Professional Help: If you're uncomfortable with any aspect of this process, it's best to seek the help of a qualified mechanic.
This is a general overview. The exact procedure might vary slightly depending on the specific condition of your vehicle and the type of replacement fender you're using. Always prioritize safety and take your time to avoid damaging your vehicle.
