Operation 5 Replace Complete Wheel House
Kits Required: Kit A, Inner and Outer Wheel House Panels & Strut Mounting Bolt Nuts1. From inside the trunk remove:
^ All trim/finishers
^ The spare tire, jack, etc.
^ The anchor bolt for the left rear seat belt retractor.
2. From inside the rear cabin remove the:
^ Rear seat and cushion
^ High-mounted stop lamp
^ Parcel shelf board
^ Bolts that secure the left rear seat belt and remove the seat belt assembly
^ Weather strips
^ Rear pillar garnishes
^ Left and right rear plastic kick plates
^ Rear speakers
^ Rear amplifier, if equipped
^ ABS control unit, if equipped
3. On the Stanza only, remove the rear bumper.
4. To remove the left rear suspension struts and control arms, remove the following:
^ The rear stabilizer bolt
^ The parallel link bolt
^ The two bolts from the brake line bracket from the wheel house
^ The C-clip for the brake hose at the strut.
^ The three strut mounting bolt nuts. Use new nuts on installation (P/N 01225-00231).
A. If the vehicle is equipped with rear disc brakes:
Disconnect the rear brake caliper. Move it out of the way and support it with wire.
Disconnect the rear wheel anti-lock brake sensor.
NOTE:
On disc or drum brakes, the brake lines do not need to be removed and brake bleeding is not required.
5. Carefully lower the strut with the control arms and leave suspended from the frame.
6. Remove the fuel tank as follows (see Figure 26)
WARNING:
When removing the fuel tank, observe the following:
^ Do not smoke. Keep open flames and sparks away from work area.
^ Have a C0(2) fire extinguisher handy.
^ Put drained fuel in an explosion-proof container and put lid on securely.
CAUTION:
Before disconnecting fuel hose, release fuel pressure from the fuel line. Plug all hose and pipe openings to prevent entry of dust or dirt.
A. Disconnect, but do not remove the three exhaust hangers (rubber discs) from the frame to move the exhaust to the right. This will ease the fuel tank removal.
B. Remove the fuel pump inspection/access cover (cabin side).
C. Disconnect the fuel return hose and fuel outlet hose.
D. Disconnect the harness/connector for the fuel pump and gauge. Identify the wire locations to ease re-assembly.
E. Remove the fuel tank protector.
F. Remove the fuel filler tube as outlined in Fuel Filler Tube Removal.
G. Remove the fuel tank bands.
H. Remove the evaporative hose.
I. Remove the tank.
7. Remove the fuel filler lid opener and control.
8. Remove the trunk lid.
9. Remove the trunk lid hinges and torsion bars
IMPORTANT:
Pay special attention when disassembling the torsion bars. Mark the location and left/right sides of the torsion bars to ease re-assembly.
10. Disconnect the defogger and antenna wiring from the rear windshield. Identify the wire locations to ease assembly.
11. Remove the rear windshield.
12. Disconnect the power antenna connections. Identify the wire locations to ease assembly.
13. Disconnect all connectors/harnesses related to rear section. Identify the wire locations to ease re-assembly.
14. On the Maxima only remove the rear seat brace. Identify the top side of the brace to ease re-assembly.
15. Before any drilling and removal, use a tram gauge to measure and record the dimensions below (see Figure 31). Use a marker to identify the location on the rear fender joggle.
16. Carefully remove the rear parcel shelf as follows (the parcel shelf will be reused):
A. Drill through all the spot welds on the parcel shelf panel.
^ On the left side, drill through all panels.
^ On the right side, drill through top panel only.
17. Remove the rear wheel house panel as a one-piece - assembly as follows:
A. Drill through all the spot welds on the rear fender and rear wheel house.
B. Drill through all the spot welds on the rear door lock pillar from the top wheel house seam to the first seam on the door kick plate
C. Drill through all the spot welds on the inside bottom of the rear wheel house.
D. Drill through the spot welds around the fuel filler hole.
E. On Maxima only, from inside, drill through all the spot welds for the wheel house in the C-pillar reinforcement.
F. After all spot welds are drilled, use a chisel to cut out the rear wheel house to facilitate removal. The wheel house may be cut in several pieces for easier removal. Be careful not to damage the rear fender/quarter panel (see Figure 37).
G. Use a chisel to separate the panel from the fender. Be careful not to damage the mating panels. If the rear fender wheel arch is deformed, it is difficult to correct.
18. Cover all interior and door panel trim to prevent damage from sparks.
19. Grind clean the area where the spot welded panels were removed. Remove the paint from the areas to be welded. Remove all sealant.
20. Use a hammer and dolly to straighten and correct all mating flanges.
21. Apply a conductive, anti-corrosive (weld-through) primer on the welding surfaces.
NOTE:
Check local VOC regulations for applicable products in your area.
21. Install outer wheel house panel as follows:
A. Stamp or drill holes in the replacement panels for M.I.G. welding.
B. Apply conductive, anti-corrosive (weld-through) primer on the mating surfaces of there- placement outer wheel house panel.
C. On the Maxima only, trial fit the outer wheel house panel against the upper C-pillar to match and mark existing drill holes. Drill the matching holes in the replacement outer wheel house panel.
D. On the Stanza only, disconnect the rear gusset from the used outer wheel house panel. Use a hammer and dolly to straighten and correct all mating flanges. Apply conductive, anti-corrosive (weld-through) primer on the mating surfaces of the replacement outer wheel house panel and the gusset. Put the gusset in position on the replacement outer wheel house panel. Tack weld. Trial fit on the vehicle. Make any adjustments as necessary. Remove the panel and weld the gusset to the panel.
E. Use a Scotch-Brite pad to scuff the inside (fender side) of the replacement outer wheel house panel. Apply a conductive, anti-corrosive (weld-through) primer.
F. Apply Lord(R) Chemicals Fusor(R) Urethane Sealer/Adhesive P/N 800 to the fender lip on the quarter panel.
G. Put the replacement outer wheel house panel in position. Once in place, push back the outer panel and through the fuel filler hole, apply sealant around the fuel filler hole on the replacement outer panel.
H. On the Stanza only, install the replacement panels as follows:
1) Use the existing drill holes in the rear gusset to align the replacement outer wheel house panel. Clamp the panel.
2) Using the two panel alignment holes, put the inner panel in position and clamp
3) Using alignment holes and existing drill holes, put the parcel shelf in position and clamp.
4) Using the tram gauge, measure, record and compare the same dimensions as in step 15, page 16. The dimensions should be the same. Align as necessary.
5) Remove the parcel shelf and the inner wheel house panel.
IMPORTANT:
Do not disturb the outer wheel house panel location as defined by the rear gusset drill holes.
6) Weld the outer wheel house panel complete. Grind and clean the welds.
7) Apply conductive, anti-corrosive (weld-through) primer on the outer wheel house panel.
8) Using the two panel alignment holes, position the replacement inner wheel house panel and weld complete. Grind and clean the welds.
9) Apply conductive, anti-corrosive (weld-through) primer on the mating surfaces of the inner wheel house panel and the parcel shelf.
10) Using alignment holes and existing drill holes, put the parcel shelf in position and weld complete. Grind and clean the welds.
I. For the Maxima only, install the replacement panels as follows:
1) Put the outer wheel house in position using the body alignment holes and tack weld.
2) Apply conductive, anti-corrosive (weld-through) primer on the outer wheel house panel.
3) Put the inner panel in position using the alignment holes and clamp. Put the original parcel shelf panel in position and clamp.
4) Using the tram gauge, measure, record and compare the same dimensions as in step 15. The dimensions should be the same. Align as necessary.
5) When the measurements are satisfactory, tack weld the wheel house panels.
6) Remove parcel shelf. Weld the wheel house panels complete. Grind and clean all welds.
7) Apply conductive, anti-corrosive (weld-through) primer on the mating surfaces of the inner wheel house panel and the parcel shelf.
8) Put the parcel shelf in position. Clamp and weld complete. Grind and clean all welds.
22. Use body filler to fill tiny dents or irregularities.
23. Sand the filler.
24. Mask the surrounding areas to prevent overspray.
25. Apply epoxy primer to wheel house and quarter panel lip.
26. Apply sanding primer.
27. Apply sealant to the replaced panel joints from both sides (refer to the applicable body repair manual).
28. Apply paint to match the body color to the replaced panels as necessary using a feathering method to blend the paint well.
29. Install sound deadener material (e.g.: Q-pad) to the inner wheel house panel as shown.
30. Install the trunk lid. Check clearances, grades and parallelism.
31. Do not install, but keep in the vehicle:
^ Seat belt anchor bolt and spacer
^ Trunk finisher
^ Trunk carpet
^ Retractor cover
^ Original fuel filler tube in the plastic bag and cardboard box for dealer part retention
^ Replaced panels
^ Parcel shelf board
^ Rear seat and cushion
^ All C-pillar garnish
^ All trim/finishers
^ Weather stripping
^ Left and right plastic rear door kick plates
^ High-mounted stop lamp
32. Reinstall all other parts in reverse order of removal (e.g.: rear windshield, suspension, etc.).
33. Install the new fuel filler tube as outlined in Fuel Filler Tube Installation on pages 2-4. It may be necessary to re-seal any area disturbed by the fuel filler tube.
34. Prepare the vehicle for delivery back to the dealer.