Plenum Upper Panel Replacement

Plenum Upper Panel Replacement

Removal Procedure

Warning: Refer to Approved Equipment for Collision Repair Warning Approved Equipment for Collision Repair Warning.

1. Disable the SIR system. Refer to SIR Disabling and Enabling Service and Repair.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.
3. Remove all related panels and components.
4. Repair as much of the damage as possible. Refer to Dimensions - Body (Convertible) Dimensions - Body (Coupe) Dimensions - Body (Sedan) .
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .





Note: Note the number and location of the factory welds for installation of the upper plenum panel.

6. Locate and drill out all the necessary factory welds.




7. Remove the upper plenum panel.

Installation Procedure





Note: If you cannot determine the location of the original plug weld holes, space the plug weld holes every 40 mm (11/2 in) apart.

1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
2. Prepare all mating surfaces as necessary.
3. Apply GM-approved weld-thru coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair .




4. Position the upper plenum panel to the vehicle using 3-dimensional measuring equipment. Clamp the panel in place.




5. Plug weld accordingly.
6. Clean and prepare all of the welded surfaces.
7. Install all of the related panels and components.
8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.
11. Enable the SIR system. Refer to SIR Disabling and Enabling Service and Repair.