Chevrolet Sonic Repair Manual: Front Hinge Pillar Body Sectioning

Removal Procedure

Warning:

Refer to Approved Equipment for Collision Repair Warning.

Warning:

Refer to Collision Sectioning Warning.

Warning:

Refer to Glass and Sheet Metal Handling Warning.

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 the 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.




Note:

Sectioning can be done anywhere in the straight area along the rocker panel.

6. Create cut lines?€‰(1) on the front hinge pillar body.



Note:

Do not damage any inner panels or reinforcements.

7. Cut the panel where sectioning is to be performed (1).
8. Locate and mark all the necessary factory welds of the front hinge pillar body.


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


10. Remove the damaged front hinge pillar body (1).

Installation Procedure

1. Cut the front hinge pillar body in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to overlap the remaining original panel by 25?€‰mm (1?€‰in)

   at each joint location (1).

2. Prepare all mating surfaces as necessary.


3. Drill 8 mm (5/16 in)

   holes for plug welding along the edges of the front hinge pillar body as noted from the original panel (1).

4. Clean and prepare the attaching surfaces for welding.


5. Position the front hinge pillar body on the vehicle (1).
6. Verify the fit of the front hinge pillar body.
7. Clamp the front hinge pillar body into position.


8. Plug weld accordingly (1).
9. To create a solid weld at the sectioning joint, with minimum heat distortion, make 25?€‰mm (1?€‰in)

   stitch welds along the seam with 25?€‰mm (1?€‰in)

   gaps between them. Then go back and complete the stitch weld.

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

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