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Body Rear End 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 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. Locate and mark all the necessary factory welds of the body rear end outer panel (1).

    7. Note : Note the number and location of welds for installation of the service assembly.

  7. Drill all factory welds.

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  8. Remove the body rear end panel (1).

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  9. Locate and mark all the necessary factory welds of the body rear end panel (1).

    10. Note : Note the number and location of welds for installation of the service assembly.

  10. Drill all factory welds.

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  11. Remove the body rear end panel (1).

Installation Procedure

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    Note : If the location of the original plug weld holes cannot be determined, space the plug weld holes every 40 mm (1 1/2 in).

  1. Drill 8 mm (5/16 in) for plug welding along the edges of the body rear end panel (1) as noted from the original panel.
  2. Clean and prepare the attaching surfaces for welding.

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  3. Position the rear end panel (1) to the vehicle using 3-dimensional measuring equipment. Clamp the rear end panel into place.

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  4. Plug weld the body rear end panel (1) accordingly.

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  5. Position the rear end outer panel (1) to the vehicle using 3-dimensional measuring equipment. Clamp the rear end panel into place.

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  6. Plug weld the body rear end outer panel (1) accordingly.
  7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
  8. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
  9. Install all related panels and components.
  10. If disabled, enable the high voltage system. Refer to High Voltage Enabling .
  11. Enable the SIR system. Refer to SIR Disabling and Enabling .
   


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