Volt

Rear End Lower 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 rear end lower panel reinforcement (1).
7. Drill all factory welds. Note the number and location of welds for installation of the service assembly.



8. Remove the damaged rear end lower panel reinforcement (1).

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



3. Create 3 5x18 mm (2, 3) slots for brazing to the rear end lower panel reinforcement (1).



4. Apply structural adhesive to rear end lower panel reinforcement (1).



5. Position the rear end lower panel reinforcement (1) on the vehicle.
6. Verify the fit of the rear end lower panel reinforcement.
7. Clamp the rear end lower panel reinforcement into position.



8. Spot weld the rear end lower panel reinforcement (1) accordingly.

8.1.	Upper flanges rear end lower panel reinforcement (2) - 2 spot welds

8.2.	Flanges to body side inner panel (3) - twice 5 spot welds

8.3.	Flange to rear compartment filler (4) - 3 spot welds

8.4.	Rear bumper energy anchor plate to rear rail (5) - 7 spot welds

8.5.	Lower flange rear end lower panel reinforcement (6) - 7 spot welds

8.6.	Rear bumper energy anchor plate to rear rail (7) - 7 spot welds

8.7.	Flange to rear compartment filler (8) - 3 spot welds




9. Braze the rear end lower panel reinforcement (1) accordingly.

9.1.	Rear end lower panel reinforcement / body side inner panel extension (2) - 3 5x18 mm

9.2.	Rear end lower panel reinforcement / body side inner panel extension (3) - 3 5x18 mm

10. Apply the sealers and anti-corrosion materials to the repair area as necessary.
11. Paint the repaired area.
12. Install all related panels and components.
13. Enable the high voltage system. Refer to High Voltage Enabling .
14. Enable the SIR system. Refer to SIR Disabling and Enabling .