Volt

Body Side Outer Panel Reinforcement Replacement

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. Locate and mark all the necessary factory welds of the body side outer panel rear reinforcement (1).
7. Drill all factory welds. Note the number and location of welds for installation of the service assembly.



8. Remove the body side outer panel rear reinforcement (1).



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



11. To remove the damaged body side outer panel reinforcement (1) cut the adhesive (2) with a suitable tool.

1. Prepare all mating surfaces as necessary.
2. Clean and prepare the attaching surfaces for spot welding.



3. Apply structural adhesive (1).



4. Position the body side outer panel reinforcement (1) on the vehicle.
5. Verify the fit of the body side outer panel reinforcement.
6. Clamp the body side outer panel reinforcement into position.



7. Spot weld the body side outer panel reinforcement (1) accordingly.

7.1.	Flange front side door opening (2) - 9 spot welds

7.2.	Flange rear side door opening (3) - 6 spot welds

7.3.	Lower flange (4) - 32 spot welds




8. Position the body side outer panel rear reinforcement (1) on the vehicle.
9. Verify the fit of the body side outer panel rear reinforcement.
10. Clamp the body side outer panel rear reinforcement into position.



11. Install the body side outer panel rear reinforcement (1) with 10 Spot welds and 6 10 mm brazed edge seams accordingly.
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 .