Plenum Panel Replacement - Lower
Plenum Panel Replacement - LowerRemoval Procedure
CAUTION:
- To avoid personal injury when exposed to welding flashes or to galvanized (Zinc Oxide) metal toxic fumes while grinding/cutting on any type of metal or sheet molded compound, you must work in a properly ventilated area, wearing an approved respirator, eye protection, earplugs, welding gloves, and protective clothing.
- When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling and Enabling Zones. Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs.
1. Disable the SIR system.
CAUTION: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.
2. Disconnect the negative battery cable.
IMPORTANT: This panel is replaced at factory seams.
3. Remove all related panels and components.
4. Repair as much of the damage as possible.
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary.
6. Locate and drill out all the necessary factory welds.
7. Locate and drill out all of the necessary factory welds at the following locations:
- The dash panel to the lower plenum
- The inside ends of the lower plenum
- On the top rear portion of the front upper rail to the plenum
8. Pull the body side panel outward and upward.
9. Remove the lower plenum panel from the vehicle.
Installation Procedure
IMPORTANT:
- The service part comes as an assembly that includes the lower dash panel. If the repair does not require the dash panel, remove the dash panel before you install the lower plenum panel.
- If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart.
1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the corresponding locations noted on the original panel.
2. Prepare all mating surfaces as necessary.
3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
4. Position the lower plenum panel to the vehicle.
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.
9. Paint the repaired area.
10. Connect the negative battery cable.
11. Enable the SIR system.