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Tahoe / Yukon Service Manual

Plenum Lower Panel Replacement

Removal Procedure

Plenum Lower Panel Replacement — figure 1
Plenum Lower Panel Replacement — figure 1
  1. Disable the SIR system. SIR Disabling and Enabling
  2. Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
  3. Remove all related panels and components.
  4. Remove the sealers and anti-corrosion materials from the repair area as necessary. Anti-Corrosion Treatment and Repair
  5. Remove upper plenum panel. Plenum Upper Panel Replacement
Plenum Lower Panel Replacement — figure 2
Plenum Lower Panel Replacement — figure 2
  1. Remove all spot welds (1). [4x]
Plenum Lower Panel Replacement — figure 3
Plenum Lower Panel Replacement — figure 3
  1. Drill 8 mm (5/16”) hole to remove all spot welds (1). [2x]
Plenum Lower Panel Replacement — figure 4
Plenum Lower Panel Replacement — figure 4
  1. Remove all spot weld (1). [7x]
Plenum Lower Panel Replacement — figure 5
Plenum Lower Panel Replacement — figure 5
  1. Remove all spot welds (1). [31x]
Plenum Lower Panel Replacement — figure 6
Plenum Lower Panel Replacement — figure 6
  1. Remove lower plenum (1) from the vehicle. Installation Procedure
  1. Prepare lower plenum per installation requirements.
  2. Prepare all joining surfaces for welding as necessary.
  3. Apply weld-thru coating or equivalent to all welding surfaces. Anti-Corrosion Treatment and Repair
Plenum Lower Panel Replacement — figure 7
Plenum Lower Panel Replacement — figure 7
  1. Position lower plenum (1) to vehicle using 3-dimensional measuring equipment and clamp into place.
Plenum Lower Panel Replacement — figure 8
Plenum Lower Panel Replacement — figure 8
  1. Install spot welds (1). [29x]
Plenum Lower Panel Replacement — figure 9
Plenum Lower Panel Replacement — figure 9
  1. Install spot welds (1). [7x]
Plenum Lower Panel Replacement — figure 10
Plenum Lower Panel Replacement — figure 10
  1. Install spot welds (1). [5x]
Plenum Lower Panel Replacement — figure 11
Plenum Lower Panel Replacement — figure 11
  1. Install MIG/MAG welds (1). [2x]
  2. Install upper plenum panel. Plenum Upper Panel Replacement
Plenum Lower Panel Replacement — figure 12
Plenum Lower Panel Replacement — figure 12
  1. Apply the sealers and anti-corrosion materials to the repair area as necessary. Anti-Corrosion Treatment and Repair
  1. Paint the repaired area. Basecoat/Clearcoat Paint Systems.
  2. Install all related panels and components.
  3. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection
  4. Enable the SIR System. SIR Disabling and Enabling.