Cruze

Body Side Inner Panel Sectioning - MAG-Welding, 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. Remove the body lock pillar upper reinforcement . Refer to Body Lock Pillar Upper Reinforcement Replacement .
7. Locate and mark all the necessary factory welds of the body lock pillar lower reinforcement.



8. Drill all factory welds of the body lock pillar lower reinforcement (1). Note the number and location of welds for installation of the service assembly.



9. Remove the body lock pillar lower reinforcement (1).



10. Create cut lines on the body side inner panel (1).




Note : Do not damage any inner panels or reinforcements.

11. Cut the body side inner panel (1) where sectioning is to be performed.
12. Locate and mark all the necessary factory welds of the body side inner panel.



13. Drill all factory welds of the body side inner panel (1). Note the number and location of welds for installation of the service assembly.



14. Remove the damaged body side inner panel (1).

1. Cut the body side inner 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. Drill 8 mm (5/16 in) for plug welding to the body side inner panel (1).
3. Prepare all mating surfaces as necessary.



4. Apply structural adhesive (1).
5. Align the body side inner panel.
6. Verify the fit of the body side inner panel.
7. Clamp the body side inner panel into position.



8. Plug weld the body side inner panel (1) accordingly.
9. 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.



10. Spot weld the body side inner panel (1) accordingly.



11. Drill 8 mm (5/16 in) for plug welding to the body lock pillar lower reinforcement (1).
12. Align the body lock pillar lower reinforcement.
13. Verify the fit of the body lock pillar lower reinforcement.
14. Clamp the body lock pillar lower reinforcement into position.



15. Plug weld the body lock pillar lower reinforcement (1) accordingly.
16. 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.



17. Spot weld the body lock pillar lower reinforcement (1) accordingly.
18. Install the body lock pillar upper reinforcement. Refer to Body Lock Pillar Upper Reinforcement Replacement .
19. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
20. Install all related panels and components.
21. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
22. Enable the SIR system. Refer to SIR Disabling and Enabling .