Removal and Installation - Rear Wheelhouse Outer Panel

Special Service Tools / General Equipment

Materials

Removal

NOTICE: Battery electric vehicles (BEV), hybrid electric vehicles (HEV) and plug-in hybrid electric vehicles (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery, it must be removed to prevent damage.

1. 1
   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   Refer to: High-Voltage Systems Health and Safety Precautions — Overview (100-00 General Information, Description and Operation).
2. 2
   Remove the quarter panel.
   Refer to: Quarter Panel (501-30 Rear Body Sheet Metal Repair, Removal and Installation).
3. 3
   Remove the push pins and fuel tank filler neck.

   

4. 4
   Remove the welds.
   Use common equipment: spot weld drill bit

   

5. 5
   Carefully cut the outer wheelhouse as shown in the illustration.
   Use common equipment: air saw
   Use common equipment: spherical cutter

   

6. 6
   Remove the outer wheelhouse section.
   Use common equipment: heat gun.

   

Installation

NOTICE: Battery electric vehicles (BEV), hybrid electric vehicles (HEV) and plug-in hybrid electric vehicles (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery, it must be removed to prevent damage.

NOTICE: The high-voltage battery in a battery electric vehicle (BEV), hybrid electric vehicle (HEV) or plug-in hybrid electric vehicle (PHEV) can be affected and damaged by excessively high temperatures. Temperatures in the paint booths of some body shops may exceed 60 °C. Therefore, during paint work the paint booth temperature must be set to 60 °C or lower, with a bake time of 45 minutes or less. A temperature above 60 °C or a bake longer than 45 minutes requires removing the high-voltage battery from the vehicle before placing it in the paint booth.

NOTICE: If the paint curing temperature exceeds 60 °C, the charge port indicator ring on plug-in vehicles must be removed.

1. 1
   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   Refer to: High-Voltage Systems Health and Safety Precautions — Overview (100-00 General Information, Description and Operation).
2. 2
   Remove the welds and carefully cut the replacement panel slightly larger than the section removed from the vehicle, creating a lap joint weld.
   Use common equipment: spot weld drill bit
   Use common equipment: air saw
   Use common equipment: spherical cutter

   

3. 3
   Drill the plug weld holes.
   Use common equipment: 8 mm drill bit.

   

4. 4
   Install, position and secure the outer wheelhouse section.
   Use common equipment: locking pliers

   

5. 5
   Install the welds.
   Use primary equipment: resistance spot welding equipment.

   

6. 6
   Install the welds.
   Use common equipment: MIG/MAG welding equipment

   

7. 7
   If necessary, dress all welds using standard metal finishing methods.
8. 8
   Completely seal the sectional joint.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

   

9. 9
   Apply NVH foam to the areas marked during removal.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

   

10. 10
    Install the fuel tank bracket, push pins and seal.
    Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

    

11. 11
    Install the quarter panel.
    Refer to: Quarter Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
12. 12
    Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repair - General Information, General Procedures).