Volt

MIG-Welded Full Panel Replacement

Warning : Refer to Approved Equipment for Collision Repair Warning in the Preface section.

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.

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.

Warning : Refer to Foam Sound Deadeners Warning in the Preface section.

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




Note : Do not damage any inner panels or reinforcements.

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



7. Remove the damaged part (1).

Note : If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart. Where structural adhesive was present, space the plug weld holes every 20 mm (3/4 in) apart.

1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel (1).
2. Prepare all attachment surfaces as necessary.
3. Prepare all mating surfaces as necessary.
4. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair .
5. Position the service part. Clamp in place.



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