Chevrolet Sonic Repair Manual: Center Pillar Reinforcement Replacement

Removal Procedure

Warning:

Refer to Approved Equipment for Collision Repair Warning.

Warning:

Refer to Glass and Sheet Metal Handling Warning.

Note:

The center pillar upper stiffener is made of Dual Phase Steel and should be replaced only at factory joints. Repairing or sectioning of this part is not recommended. Refer to Dual Phase Steel.

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. 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. Refer to Anti-Corrosion Treatment and Repair.
6. Locate and mark all the necessary factory welds of the center pillar reinforcement.


7. Drill all factory welds (1). Note the number and location of welds for installation of the service assembly.


8. Remove the damaged center pillar reinforcement (1).

Installation Procedure

1. Prepare all mating surfaces as necessary.
2. Align the center pillar reinforcement.


3. Drill a 8?€‰mm (5/16?€‰in)

   holes for plug welding along the edges of the center pillar reinforcement as noted from the original panel (1).

4. Clean and prepare the attaching surfaces for welding.


5. Position the center pillar reinforcement on the vehicle (1).
6. Verify the fit of the center pillar reinforcement.
7. Clamp the center pillar reinforcement into position.


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