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Rocker Inner Panel Replacement

Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure will perform the following tasks:

   • Identify how to disable high voltage.
   • Identify how to test for the presence of high voltage.
   • Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.
Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:
   • Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.
   • Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.
      - Visually and functionally inspect the gloves before use.
      - Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energised or not.
Failure to follow the procedures exactly as written may result in serious injury or death.

Removal Procedure

    Warning : Refer to Approved Equipment for Collision Repair Warning in the Preface section.

    Warning : Refer to Collision Sectioning Warning in the Preface section.

    Warning : Refer to Glass and Sheet Metal Handling Warning in the Preface section.

  1. Disable the SIR System. Refer to SIR Disabling and Enabling .
  2. Inspect the high voltage system. Refer to High Voltage System Inspection .
  3. Remove all related panels and components.
  4. Visually inspect the damage. Repair as much of the damage as possible.
  5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

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  6. Create cut lines on the body side inner panel (1).

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    Note : Do not damage any inner panels or reinforcements.

  7. Cut the body side inner panel (1) where sectioning is to be performed.

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  8. Locate and mark all the necessary factory welds of the body side inner panel (1).
  9. Drill all factory welds. Note the number and location of welds for installation of the service assembly.

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  10. Remove the body side inner panel (1).

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  11. Locate and mark all the necessary factory welds of the rocker inner panel (1).
  12. Drill all factory welds. Note the number and location of welds for installation of the service assembly.

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  13. Remove the damaged rocker inner panel (1).

Installation Procedure
  1. Align the rocker inner panel.

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  2. Drill 8 mm (5/16 in) for plug welding along the edges of the rocker inner panel (1) as noted from the original panel.
  3. Clean and prepare the attaching surfaces for welding.
  4. Position the rocker inner panel on the vehicle.
  5. Verify the fit of the quarter outer panel.
  6. Clamp the rocker inner panel into position.

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  7. Plug weld the sill inner panel (1) accordingly.

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  8. Plug weld the body side inner panel (1) accordingly.
  9. To create a solid weld with minimum heat distortion, make 25 mm (1 in) stitch welds along the seam with 25 mm (1 in) gaps between them. Then go back and complete the stitch weld.
  10. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
  11. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
  12. Install all related panels and components.
  13. If disabled, enable the high voltage system. Refer to High Voltage Enabling .
  14. Enable the SIR system. Refer to SIR Disabling and Enabling .
   


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