Service Procedure
1. Disconnect battery.2. Raise vehicle on hoist.
3. Remove LH rear wheel cover if present. Remove LH rear tire & wheel assembly.
4. Using a putty knife or other appropriate tool, carefully remove undercoating/ deadener material from the wheelhouse panel area as shown in figure 1. Do not remove paint or primer.
5. Measure the distance from the bottom of the wheelhouse outer panel flange to the bottom of the wheelhouse inner panel flange. See figure 1, view A.
- If this measurement is 10 MM (25/64") or less, no repair is necessary.
* Apply two-part, anti-corrosion primer such as DP90 to any bare sheet metal. Follow paint manufacturer's recommendations for cure time.
* Apply 3M Underseal Rubberized Undercoating (P/N 08883) or equivalent to the area where undercoating/deadener material was removed.
* Lower vehicle and install tire and wheel assembly. Tighten wheel nuts to 120 Nm (89 Lbs.Ft). Install wheel cover if necessary.
* Proceed to step 31 of this procedure.
- If this measurement is more than 10 MM, (25/64") proceed to step 6 of this procedure.
6. Lower vehicle. Open trunk and remove the LH upper cargo net hook or carpet retainer and move the trunk carpet clear from the LH wheelhouse panel area.
NOTICE:
MAKE SURE THAT TRUNK CARPET AND ALL OTHER POTENTIALLY FLAMMABLE MATERIAL IS MOVED AND RETAINED CLEAR OF THE WHEELHOUSE AREA. A WELDING BLANKET SHOULD BE PLACED IN THE TRUNK OVER THE WHEELHOUSE TO CONTAIN ANY WELDING SPARKS.
7. Raise vehicle.
NOTICE:
TO AVOID ACCIDENTAL DAMAGE TO THE REAR COMPARTMENT (TRUNK) LID, MAKE SURE THERE IS SUFFICIENT OVERHEAD CLEARANCE TO RAISE THE VEHICLE WITH THE TRUNK OPEN. IF THERE IS NOT ENOUGH CLEARANCE, BE SURE TO CLOSE THE TRUNK BEFORE RAISING THE VEHICLE.
8. Using a rotary steel wire brush or equivalent, remove paint and primer (down to bare metal) from the wheel house panel flanges in the area to be welded as shown in figure 1.
9. Measure and mark the locations of the welds on the wheelhouse sheet metal as shown in figure 2.
10. To prevent weld contamination, remove seam sealer tape from between the wheel house panel flanges at the locations marked to be MIG-welded. Seam sealer tape should be removed for an additional 10 mm on each end of the weld locations.
11. Using vice grips or other appropriate clam g devices, clamp the flanges together, placing a small piece of 3 mm (.118") thick mild steel behind the flanges to serve as a heat sink. See figure 2.
IMPORTANT:
TO MINIMIZE THE CHANCE OF BURN-THRU, SOME SAMPLE WELDS SHOULD BE TRIED ON SOME SCRAP PIECES OF SIMILAR THICKNESS. ADJUST THE MIG WELDER TO THE LOWEST POSSIBLE HEAT SETTING THAT WILL ALLOW GOOD WELDS.
12. CAUTION:
BEFORE PROCEEDING WITH WELDING, MAKE SURE THAT NO FLAMMABLE LIQUIDS OR VAPORS ARE PRESENT. ANY FUEL LEAKS MUST BE CORRECTED BEFORE ANY WELDING IS PERFORMED.
Weld the inner wheelhouse panel flange to the outer wheelhouse panel flange with three, twenty (20) mm (.787") long MIG welds as shown in figure 2.
- Do not attempt to fill any gaps that may be present at the top of the die relief notches in the wheelhouse outer panel.
- First weld to be at the center, or top of the wheelhouse panels.
- Second and third welds to be placed 50 mm (2") forward and 50 mm (2") rearward of first weld as shown in figure 2.
13. Remove the clamps and steel heat sink from the flanges.
14. Lower vehicle.
15. Inspect wheelhouse flange area (inside trunk) for any blistered or peeling paint due to heat from welding. Remove any blistered or peeling paint and apply two-part, anti-corrosion primer such as DP90. Follow paint manufacturer's recommendations for cure time.
16. Apply a urethane caulk to the areas shown in figures 3 and 4. Use Kent High Tech Clear seam sealer (P/N 10195 - stock # CHT-C) or equivalent.
IMPORTANT:
IT MAY BE NECESSARY TO ATTACH A LONG, THIN EXTENSION TUBE ON THE CAULKING TUBE TO APPLY ADEQUATE SEALER TO THE JOINT AREA COVERED BY THE QUARTER PANEL TOWING BRACE, AND TO THE JOINT AREA FORWARD OF THE TOWING BRACE. IT IS VERY IMPORTANT THAT THIS JOINT BE PROPERLY SEALED WHERE INDICATED IN FIGURE 3.
17. Open LH rear door. Using a fine-tip marker, carefully trace around the rear door striker to clearly mark its location.
18. Remove the striker (two torx 40 bolts).
19. While shining a penlight type flashlight through one of the striker mounting holes, visually inspect the top of the wheelhouse flanges to be sure adequate sealer is applied at and forward of the towing brace.
20. Raise vehicle (close trunk if necessary due to insufficient overhead clearance)
21. To assure proper primer adhesion, clean and prepare all welded surfaces using 3M Roloc Clean 'N Strip Disc (disc P/N 07466, Roloc holder P/N 07500) or equivalent.
22. Apply two-part, anti-corrosion primer such as DP90 to bare sheet metal. Follow paint manufacturer's recommendations for cure time.
23. Apply 3M Ultrapro Seam Sealer (P/N 08361-gray) or equivalent full-bodied urethane caulk to the entire repaired area, duplicating original appearance and protection. Make sure the three die relief notches are fully sealed. Fully work sealer/caulk into any gaps between the flanges to assure proper joint sealing. Smooth sealer/caulk as required to leave a finished appearance. Let sealer/caulk dry until fully skinned over (at least 30 minutes) per manufacturer's instructions.
24. Lower vehicle part way to check for complete sealing of flanges.
25. Place a shop light (a tube-type fluorescent light will work best) in the trunk, behind the quarter inner panel and visually examine the flange from outside of the vehicle, looking for any areas that may not be completely sealed.
Position a shop light under the repaired area (outside the vehicle), and visually examine the inside of the flange, looking for any areas that may not be completely sealed.
Reseal any areas found to be not sealed.
26. Apply 3M Underseal Rubberized Undercoating (P/N 08883) or equivalent to the wheelhouse flanges.
27. Lower vehicle.
28. Install tire and wheel assembly. Tighten wheel nuts to 120 Nm (89 Lbs. Ft.). Install wheel covers if necessary.
29. Reposition trunk carpet and secure cargo net hook or carpet retainer.
30. Install LH rear door striker assembly to previously marked location.
Tighten bolts to 22 Nm (16 Lbs.Ft). Check for proper door operation/striker alignment. Adjust as necessary. Clean up any marker or pencil marks from area around striker.
31. Connect battery.
32. Install the GM campaign identification label.