Plenum Upper Panel Replacement

Removal Procedure

Plenum Upper Panel Replacement — figure 1

Warning

Refer to Approved Equipment for Collision Repair Warning.

Warning

Refer to Collision Sectioning Warning.

Warning

Refer to Glass and Sheet Metal Handling Warning.

Note

Squeeze Type Resistance Spot Welds (STRSW) are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG 8 mm (5/16 in) plug welds may be used, to replace those specific welds, unless otherwise noted:

Note

The upper plenum is mild steel. Mild Steel

Note

Refer to Collision Repair Specifications

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

Plenum Upper Panel Replacement — figure 2

Note

Do not damage or cut attaching panels and reinforcements

5. Remove spot welds (1). [37X]

Plenum Upper Panel Replacement — figure 3

Note

Do not damage or cut attaching panels and reinforcements.

Note

The 8 mm (5/16”) holes will be used for MIG/MAG welds.

Note

Left shown, right similar.

6. Drill 8 mm (5/16”) hole to remove all spot welds (1). [2X]

Plenum Upper Panel Replacement — figure 4

Note

Left shown, right similar.

7. Reposition body side outer (1) on upper plenum (2) as necessary to remove upper plenum.

Plenum Upper Panel Replacement — figure 5

Note

Do not damage or cut attaching panels and reinforcements.

Note

Left shown, right similar.

8. Remove spot weld (1). [1X]

Plenum Upper Panel Replacement — figure 6

9. Remove upper plenum (1) from the vehicle. Installation Procedure

Note

Prepare upper plenum before installation.

1. Prepare upper 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

4. Position upper plenum (1) to vehicle using 3–dimensional measuring equipment and clamp into place.

Plenum Upper Panel Replacement — figure 7

5. Install spot welds (1). [39X]

Plenum Upper Panel Replacement — figure 8

Note

Left shown, right similar.

6. Reposition body side outer (1) as necessary to install upper plenum.

Plenum Upper Panel Replacement — figure 9

Note

Left shown, right similar.

7. Install MIG/MAG welds (1). [2X]
8. Apply the sealers and anti-corrosion materials to the repair area as necessary. Anti-Corrosion Treatment and Repair

Note

Before refinishing, refer to Anti-Corrosion Treatment and Repair.

9. Paint the repaired area. Basecoat/Clearcoat Paint Systems.
10. Install all related panels and components.
11. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection
12. Enable the SIR System. SIR Disabling and Enabling.