Spark

Rear Rail Sectioning

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. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
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 .



6. Create cut lines on the rear side rail.




Note: Do not damage any other panels or reinforcements.

7. Cut the panel where sectioning is to be performed.



8. Locate and mark all the necessary factory welds of the rear side rail.
9. Drill all factory welds. Note the number and location of welds for installation of the service assembly.



10. Remove the damaged rear side rail.

1. Cut the rear side rail in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of one-and-one-half-times the metal thickness at the sectioning joint.
2. Create a 50 mm (2 in) backing plate from the unused portion of the service part.
3. Drill 8 mm (5/16 in) along the sectioning cut on the remaining original part. Locate these holes 13 mm (1/2 in) from the edge of part and spaced 40 mm (1 1/2 in) apart.
4. Prepare all mating surfaces as necessary.
5. Fit the backing plates halfway into the sectioning joints, clamp in place and plug weld to the vehicle.
6. Align the rear side rail.



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



9. Position the rear side rail on the vehicle.
10. Verify the fit of the rear side rail.
11. Clamp the rear side rail into position.



12. Plug the weld accordingly.
13. 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.
14. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
15. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
16. Install all related panels and components.
17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
18. Enable the SIR system. Refer to SIR Disabling and Enabling .