Cruze

Front Compartment Upper Side Rail Sectioning - MIG-Brazing

Note : According to different corrosion warranties, only the regional mandatory joining methods are allowed.

Warning : Refer to Approved Equipment for Collision Repair Warning in the Preface section.

Warning : Refer to Collision Sectioning 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 front compartment upper side rail.




Note : Do not damage any inner panels or reinforcements.

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



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



10. Remove the damaged front compartment upper side rail.

1. Cut the front compartment upper 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 5 x 18 mm (4/16 x 11/16 in) slots for MIG-brazing where the spotwelder is not applicable.
3. Prepare all mating surfaces as necessary.
4. Align the front compartment upper side rail.
5. Clean and prepare the attaching surfaces for spot welding and brazing.

Note : In MIG-brazing areas 50 mm (2 in) must be kept clear of structural adhesive.

6. Apply structural adhesive to all attaching surfaces.



7. Position the front compartment upper side rail on the vehicle.
8. Verify the fit of the front compartment upper side rail.
9. Clamp the front compartment upper side rail into position.



10. Braze accordingly.



11. Spot weld accordingly.
12. To create a solid braze with minimum heat distortion, make 25 mm (1 in) stitch brazes along the seam with 25 mm (1 in) gaps between them. Then go back and complete the braze.
13. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
14. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
15. Install all related panels and components.
16. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
17. Enable the SIR system. Refer to SIR Disabling and Enabling .