Gen3 Prius Fender Replacement Guide

I've compiled a list of videos I watched that I found helpful for replacing my passenger side fender. There are a couple on Youtube that don't really show the full process, so here's a list that hopefully details everything.

Tools and Supplies

• 10mm socket wrench (90 degree also needed)
• Philips head screwdriver
• Vehicle clip removal tool
  1. An additional flat head screwdriver is helpful to pry the large black clips holding the side skirt together.
• Needle nose pliers
• Adhesive for weatherstripping (I tore out some of the windshield rubber to access a bolt. This is to glue it back)
• New fender
• Extra clips (recommended)
  1. The existing clips are old and brittle so a couple of them broke off. I bought some cheap ones off Amazon but they are of low quality (I simply bought a bulk pack of assorted clips). Any recommendations for specific replacements are welcome!
• Masking tape (recommended to protect parts from metal edges)
  

General order of operations

1. Acquire a New Fender
   • I successfully sourced a passenger side (right hand RH) fender from a local scrap yard calling two different locations. (I cannot post links yet but I used the websites recommended in these forums that compile parts from various yards). The scrap yard had surprisingly good inventory management, making the whole process smooth. Cost was about ~$80
   • The price was around the same as an aftermarket fender, and I didn't need to paint it myself. I was worried that an aftermarket fender would have fitment issues.
2. Remove the Front Bumper
   • Refer to this video for guidance:
   • The translation was pretty rough but it gets to the point
   • Note: I did not fully detach the fog lights. I left the bumper hanging since I only needed access to the fender.
     
3. Remove the Headlights
   • Refer to this video for guidance:
   • Note: I did not fully detach the headlights. I left it hanging so that I can pull out the fender.
     
4. Remove the Side Skirt
   • You can opt to remove only 2/3 of the side skirt and push the rest aside.
     1. The black clips holding these together are very large. I used my clip pry tool and a flat head screw driver on opposite ends to pry these clips out.
        
   • Refer to this video (for a Toyota Camry, but the process is similar for a Prius):
     
     
     
5. Remove the Fender (including the Fender Liners)
   • Refer to this video:
   • Note: This video does not cover the removal of the side skirt, bumper, or headlights.

The most challenging aspect of the fender replacement is achieving the correct fit around
the triangular window. In my experience:

• I had to cut some of the metal on the new fender to ensure it fit snugly underneath the triangular window. Without this, the window butted up against the fender and caused large gaps (approximately 4mm). I used a hacksaw to cut deeper and a metal file to shave down the rough edges
  
  
  I also put masking tape around rough metal edges that bump around the glass and plastic:
  
  

 

oops, I think my YouTube links are broken, so here they are (cannot edit the thread though):

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