Removal and Replacement
Spare Wheel Carrier Replacement
Special Tools
J-36020 Stationary Glass Removal Tool
Removal Procedure
Warning:In order to reduce the risk of personal injury when exposed to toxic fumes while grinding, cutting, or applying repair material on any type of sheet molded compound or RIM rigid plastic, observe the following guidelines:
-Work in a properly ventilated area
-Apply protective cream to any exposed skin
-Remove any mixture that comes into contact with skin
-Wash skin with cold water to remove glass and resin dust
-Use a sander with a vacuum attachment
-Follow the repair material manufacturer's instructions
Also, always wear the following:
-An approved respirator, or air supplied respirator
-Eye protection
-Rubber gloves
-Earplugs
-Protective clothing
1.Remove the rear compartment floor carpet. Refer to Rear Compartment Floor Panel Carpet Replacement .
2.Remove the spare wheel and emergency kit from the rear compartment.
3.Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement Rear Bumper Fascia Replacement .
Note:Take care when cutting to avoid damage to adjacent panels and other parts of the vehicle.
Note:The spare wheel carrier panel is a single use item. The spare wheel well panel must be discarded after use.
4.Cut along the spare wheel carrier panel (1) with a suitable tool.
5.Remove the cutout section of the spare wheel carrier panel (1) from the vehicle.
Note:Stationary glass removal tool J-36020 (1) is used to cut the urethane adhesive between the remaining part of the spare wheel carrier panel (2) and the vehicle body (3).
Note:Use a suitable tool to install the piano wire of stationary glass removal tool J-36020 (1) through the urethane at a suitable corner of the spare wheel carrier compartment (2).
6.Install stationary glass removal tool J-36020 (1) to the vehicle.
Note:Keep the outside handle of stationary glass removal tool J-36020 (1) against the vehicle body (3) and cycle the full length of the piano wire to prevent heat build up.
7.Cut through the urethane adhesive between the remaining part of the spare wheel carrier panel (2) and vehicle body (3) with the aid of an assistant.
Discard the remaining section of the spare wheel carrier panel (2).
Installation Procedure
1.Clean the rear compartment panels of all remaining adhesive (1) using a suitable cleaning solution.
Note:Make sure that the spare wheel carrier panel datum pins (1) are correctly located in the rear compartment panels.
2.Test fit the spare wheel carrier panel to the rear compartment panels and carry out any adjustments as required.
Note:If air drying the primer, allow at least 60 minutes in a well ventilated area for the primer to dry fully.
Note:If hot drying the primer, the oven temperature needs to be between 94 �C (200 �F) and 121 �C (250 �F), for 10 minutes.
3.Thoroughly clean the bonding area of the spare wheel carrier using Isopropyl Alcohol, Prepsol or Equivalent.
4.Brush a continuous line of primer with a minimum width of 25mm (1in) to GM specification GM9985813 (or alternatively Lord 459X) on the bonding area of the spare wheel carrier.
5.Allow the primer to dry.
Note:Make sure that the rear compartment panels and the spare wheel carrier panel are free of any contaminants.
6.Apply a continuous bead of urethane GMW3041 (1) or equivalent approximately 10 millimetres in diameter to the bonding area of the spare wheel carrier (2).
Note:Fit the spare wheel carrier panel to the rear compartment panels within 30 minutes of applying the adhesive to the spare wheel carrier panel.
Note:Do not allow the adhesive bead to come into contact with the vehicle body until the spare wheel carrier panel is correctly aligned with the rear compartment panels.
7.With the aid of an assistant install the NEW spare wheel carrier panel (1) to the vehicle.
8.Make sure that the adhesive all around the spare wheel carrier panel (1) makes contact with the rear compartment panels.
Note:DO NOT drive the vehicle for 24 hours after fitting the spare wheel carrier panel to allow the adhesive to fully cure.
Note:Installing the spare wheel to the spare wheel carrier panel aids with the adhesion of the spare wheel carrier panel to the rear compartment panels.
9.Install the spare wheel to the spare wheel carrier panel (3).
10.Place one kilogram weights (1) along the edges of the spare wheel carrier panel (3) to aid with the adhesion of the spare wheel carrier panel to the rear compartment panels.
11.Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement Rear Bumper Fascia Replacement .
12.Install the emergency kit to the rear compartment.
13.Install the rear compartment floor carpet. Refer to Rear Compartment Floor Panel Carpet Replacement .