Cruze

Quarter Outer Panel Sectioning - MAG-Welding, 5-Door Hatchback 68

Special Tools

For equivalent regional tools, refer to Special Tools .

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. Locate and mark all the necessary factory welds of the body lock pillar lower reinforcement.



7. Create cut lines on the quarter outer panel (1).




Note : Do not damage any inner panels or reinforcements.

8. Cut the quarter outer panel (1) where sectioning is to be performed.



9. Open the wheelhouse flanging.
10. Locate and mark all the necessary factory welds of the quarter outer panel.



11. Drill all factory welds of the quarter outer panel (1). Note the number and location of welds for installation of the service assembly.



12. Remove the damaged quarter outer panel (1).

1. Cut the quarter outer 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 quarter outer panel (1).
3. Prepare all mating surfaces as necessary.



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



8. Plug weld the quarter outer 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 quarter outer panel (1) accordingly.
11. Pre-flanging the flange with the BO-6396 pliers and the BO-6392 tool kit .



12. Finish closing the wheelhouse flanging.
13. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
14. Install all related panels and components.
15. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
16. Enable the SIR system. Refer to SIR Disabling and Enabling .