Volt

Rocker Outer Panel Sectioning

Warning : Refer to Approved Equipment for Collision Repair 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 .

Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure will perform the following tasks:

•	Identify how to disable high voltage.

•	Identify how to test for the presence of high voltage.

•	Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

Failure to follow the procedures exactly as written may result in serious injury or death.
2. Disable the high voltage system. Refer to High Voltage Disabling .
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.



6. Create cut lines on the rocker outer panel (1)



7. Cut the rocker outer panel (1) where the sectioning is to be performed.



8. Locate and mark all the necessary factory welds of the rocker outer panel (1).
9. Drill all factory welds. Note the number and location of welds for installation of the service assembly.



10. Open the wheelhouse flanging of the rocker outer panel (1).



11. Remove the rocker outer panel (1) cut the adhesive (2) with a suitable tool.

1. Cut the body side 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. Create 28 5x 8 mm slots for MIG-brazing to the rocker outer panel (1).
3. Prepare all mating surfaces as necessary.
4. Clean and prepare the attaching surfaces for spot welding and brazing.



5. Apply structural adhesive (1).



6. Position the rocker outer panel (1) on the vehicle.
7. Verify the fit of the rocker outer panel.
8. Clamp the rocker outer panel into position.



9. Spot weld the rocker outer panel (1) accordingly.

9.1.	Flange front side door opening (2) - 18 spot welds

9.2.	Flange rear side door opening (3) - 16 spot welds




10. Braze the rocker outer panel (1) accordingly.

10.1.

Rocker outer panel / front hinge pillar (2) - 230 mm

10.2.

Rocker outer panel / centre pillar (3) - 340 mm

10.3.

Rocker outer panel / quarter outer panel (4) - 300 mm

10.4.

Rocker outer panel (5) - 28 5x18 mm slot brazes

11. To create a solid braze with minimum heat distortion, make 25 mm stitch brazes along the seam with 25 mm gaps between them. Then go back and complete the stitch braze.
12. Apply the sealers and anti-corrosion materials to the repair area as necessary.
13. Paint the repaired area.
14. Install all related panels and components.
15. Enable the high voltage system. Refer to High Voltage Enabling .
16. Enable the SIR system. Refer to SIR Disabling and Enabling .