Cruze

Body Lock Pillar Upper Reinforcement Replacement - MAG-Welding

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 tailgate opening drain gutter (1).




Note : Do not damage any inner panels or reinforcements.

7. Cut the tailgate opening drain gutter (1) where sectioning is to be performed.
8. Locate and mark all the necessary factory welds of the tailgate opening drain gutter .



9. Drill all factory welds of the tailgate opening drain gutter (1). Note the number and location of welds for installation of the service assembly.



10. Remove the damage tailgate opening drain gutter (1).



11. Create cut lines on the body lock pillar upper reinforcement (1).




Note : Do not damage any inner panels or reinforcements.

12. Cut the body lock pillar upper reinforcement (1) where sectioning is to be performed.
13. Locate and mark all the necessary factory welds of the body lock pillar upper reinforcement.



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



15. Remove the damage body lock pillar upper reinforcement (1).

1. Cut the body lock pillar upper reinforcement (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 lock pillar upper reinforcement (1).
3. Prepare all mating surfaces as necessary.



4. Apply structural adhesive (2) to body side inner panel (1).
5. Align the body lock pillar upper reinforcement.
6. Verify the fit of the body lock pillar upper reinforcement.
7. Clamp the body lock pillar upper reinforcement into position.



8. Weld the body lock pillar upper reinforcement (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 lock pillar upper reinforcement (1) accordingly.



11. Cut the tailgate opening drain gutter (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.



12. Weld the tailgate opening drain gutter (1) 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. Spot weld the tailgate opening drain gutter (1) accordingly.
15. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
16. Install all related panels and components.
17. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
18. Enable the SIR system. Refer to SIR Disabling and Enabling .