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Resistance Spot Welded Full Panel Replacement

Note : Use this procedure for all panels that are replaced at the factory seams, unless a specific procedure exists in the Collision Repair section of this vehicle's service information.

Removal Procedure

Warning : Refer to Approved Equipment for Collision Repair 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. Repair as much of the damage as possible to factory specifications.
  5. Warning : Refer to Foam Sound Deadeners Warning in the Preface section.

  6. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

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    Note : Do not damage any inner panels or reinforcements.

  8. Locate and drill out all factory welds (1). Note the number and location of the welds for installation of the service part.

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  10. Remove the damaged part (1).

Installation Procedure

    Note : If the location of the original plug weld holes cannot be determined, space the plug weld holes every 40 mm (1½ in) apart. Where structural adhesive was present, space the plug weld holes every 20 mm (3/4 in) apart.

  1. Prepare all mating surfaces as necessary.
  2. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair .
  3. Position the service part. Clamp in place.

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  5. Apply welds accordingly (1).
  6. Clean and prepare all welded surfaces.
  7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
  8. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems .
  9. Install all related panels and components.
  10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  11. Enable the SIR system. Refer to SIR Disabling and Enabling .
   


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