Cruze

Roof Rear Header Panel Replacement - MIG-Brazing, 5-Door Hatchback 68

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 battery negative 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 roof rear header panel (1).




Note : Do not damage any inner panels or reinforcements.

7. Cut the roof rear header panel (1) where sectioning is to be performed.
8. Locate and mark all the necessary factory welds of the roof rear header panel .



9. Drill all factory welds of the roof rear header panel (1). Note the number and location of welds for installation of the service assembly.



10. Remove the damaged roof rear header panel (1).

1. Cut the roof rear header panel (1) 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. Prepare all mating surfaces as necessary.
3. Align the roof rear header panel.
4. Verify the fit of the roof rear header panel.
5. Clamp the roof rear header panel into position.
6. Use the holes of the drilled spot welds and create 5 x 18 mm (3/16 x 11/16 in)slots for brazing.



7. Braze the roof rear header panel (1) accordingly.
8. 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 stitch braze.
9. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
10. Install all related panels and components.
11. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
12. Enable the SIR system. Refer to SIR Disabling and Enabling .