Service Procedure

CAUTION
This procedure should only be performed in temperatures above 32°F (0°C). Ensure that all surfaces are completely dry and free of moisture before applying cavity wax.

WARNING
Procedure must be performed in a well ventilated area. Safety glasses must be worn at all times.





1. Remove the spare tire assembly that is located next to the muffler.

The spare tire release knob is located in the rear cargo box. Turn this knob counter-clockwise to drop down the spare tire.





Spare tire location shown in the photo on the right.

2. Lift up the vehicle on a hoist.





Remove the muffler shielding by removing the four (4) 10 mm bolts as indicated in the circles.





3. Remove the two (2) 19 mm flange nuts (A) and then remove muffler and pipe assembly (B) from the three (3) donut hangers (C).

CAUTION
When reinstalling muffler, be sure to use a new muffler gasket, and if necessary replace the exhaust flange nuts.





4. Remove the four (4) 10 mm fuel tank heat protector bolts and the remove the fuel tank heat protector (D) as shown in the photo.





5. Remove the four (4) 14 mm rear stabilizer bar mounting bolts on both sides, and then let the rear stabilizer bar hang down.





6. Use a 5 mm drill bit to drill a hole in the rear cross member through the stabilizer bar mounting upper hole on the right side.

CAUTION
Adjust the length of the exposed drill bit to approximately 1-3/4 inches (45 mm). If length is over 1-3/4 inches (45 mm), damage may occur to the fuel tank lower panel when drilling.





7. Insert the drill bit straight through the stabilizer bar mounting upper hole until it dead ends and start drilling a hole in the rear cross member.

CAUTION
While drilling, be careful not to damage the stabilizer bar upper mounting hole.





8. Blow out any foreign materials, dust and debris through the rear cross member drain openings and the drilled hole by using the air blow gun that was provided.





LOCATION OF SIXTEEN (16) DRAIN OPENINGS AND ONE (1) DRILLED HOLE





9. Blow out the six (6) openings on the LH side.

Make sure to apply shop air over seconds per opening. Ensure interior surfaces are dry.

*NOTICE
Use a screwdriver to remove any PVC coating on hole # 12 for vehicles produced July 2, 2009 to October 15, 2011.

CAUTION
Turning the air gun nozzle in all directions, apply shop air into the holes to completely remove foreign materials and debris.





10. Blow out the three (3) openings on the RH side.





11. Blow out the three (3) center openings.





12. Blow out the four (4) holes and one (1) drilled as indicated in the photo.

13. Cavity Wax Application

Before spraying cavity wax, block the (LH, RH and Center) drain openings (used for blowing out foreign materials and debris in the previous procedure) as shown in the photo using the tape supplied in the tool kit. This is to avoid wax from flowing down through the holes while spraying wax.





*NOTICE
It is not necessary to tape the five (5) holes on the rear side.

CAUTION
Uncured cavity wax should not be exposed to ignition sources. Keep away from sparks, flames or excessive heat.





14. Spread shop towels or tarp under the fuel tank as shown in the photo to avoid wax, dirt and debris on the shop floor.





15. Cut holes in the tape for the nine (9) drain openings shown above prior to applying cavity wax. You will be spraying cavity wax through these openings.





16. Spray cavity wax through the twelve (12) holes indicated in the photo above. Three (3) cavity wax aerosol cans are required to perform this task per vehicle, so use one (1) can of cavity wax per four (4) openings.





17. Shake cavity wax aerosol can for at least 20 seconds, and then spray enough wax through the three (3) holes (1. 2, and 3) on the RH side.

CAUTION
To evenly apply cavity wax, turn the nozzle in all directions while spraying.

Cavity wax in extremely flammable, use caution when spraying cavity wax.

*NOTICE
Use three (3) cans for all four (4) sides. Distribute one (1) can evenly between the four (4) openings; spray for approximately 1 minute per hole.





18. Spray cavity wax through three (3) openings (7, 10 and 12).





19. Spray cavity wax through three (3) center openings (4, 5, and 6).

CAUTION
To evenly apply cavity wax, turn the nozzle in all directions while spraying.





20. Spray cavity wax through three (3) rear openings (13, 16 and 17).





21. Wait until cavity wax stops flowing down through the holes (it takes approximately 20 minutes).





22. Remove the tape from the fuel tank.





23. Spray black undercoating wax around the drain holes on the bottom of the fuel tank as indicated in the photo.

Reinstall all removed parts in reverse order of removal.