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‌SPECIFICATIONS

DIMENSIONS - BODY

ACCESSORIES & EQUIPMENT

Collision Repair - Volt

Point-to-point measurements are for reference only. All measurements are given in millimeters. Use these measurements for diagnosing and estimating. Point-to-point measurements are duplicated with tram bar pointers set at equal lengths. All die marks, holes, slots, and fasteners are measured to the center. All dimensions are symmetrical unless otherwise specified.

Point-to-Point Measurements

Engine Compartment

Fig. 1: Engine Compartment Dimensions Courtesy of GENERAL MOTORS COMPANY

Side

Fig. 2: Side Dimensions

Courtesy of GENERAL MOTORS COMPANY

Rear End

Fig. 3: Rear End Dimensions

Courtesy of GENERAL MOTORS COMPANY

Rear End Upper

Fig. 4: Rear End Upper Dimensions

Courtesy of GENERAL MOTORS COMPANY

VISUAL IDENTIFICATION

STRUCTURE IDENTIFICATION

View Front

Fig. 5: Front View Structure

Courtesy of GENERAL MOTORS COMPANY

View Side Inner

Fig. 6: Side Inner View Structure

Courtesy of GENERAL MOTORS COMPANY

View Side Outer

Fig. 7: Side Outer View Structure

Courtesy of GENERAL MOTORS COMPANY

View Side

Fig. 8: Side View Structure

Courtesy of GENERAL MOTORS COMPANY

View Rear

Fig. 9: Rear View Structure

Courtesy of GENERAL MOTORS COMPANY

REPAIR INSTRUCTIONS

FRONT END UPPER TIE BAR REPLACEMENT

WARNING: 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 includes the following steps: 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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

1. Disable the SIR system. SIR Disabling and Enabling .

2. Inspect the high voltage system. High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Anti-Corrosion Treatment and Repair .

Fig. 10: Front End Upper Tie Bar

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

6. Remove all factory welds from front end upper tie bar (1).

Fig. 11: Front End Upper Tie Bar

Courtesy of GENERAL MOTORS COMPANY

7. Remove the damaged front end upper tie bar (1) from vehicle (2).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

8. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 12: Front End Upper Tie Bar

Courtesy of GENERAL MOTORS COMPANY

2. Position the front end upper tie bar (1) on the vehicle (2) using 3-dimensional measuring equipment.

3. Verify the fit of the front end upper tie bar (1).

4. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding.

Fig. 13: Front End Upper Tie Bar

Courtesy of GENERAL MOTORS COMPANY

5. Clamp the front end upper tie bar (1) into position.

6. Weld the front end upper tie bar (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Anti-Corrosion Treatment and Repair .

8. Install the body side outer panel as necessary.

9. Paint the repaired area. Basecoat/Clearcoat Paint Systems .

10. Install all related panels and components.

11. If disabled, enable the high voltage system. High Voltage Enabling .

12. Enable the SIR System. SIR Disabling and Enabling .

FRONT END LOWER TIE BAR REPLACEMENT

WARNING: 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 includes the following steps:

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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: Left shown, right similar.

1. Disable the SIR System. Refer to SIR Disabling and Enabling .

2. Inspect the high voltage system. Refer to High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti- Corrosion Treatment and Repair .

Fig. 14: Front End Lower Tie Bar

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Refer to Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

6. Remove all factory welds from the front end lower tie bar (1).

Fig. 15: Front End Lower Tie Bar

Courtesy of GENERAL MOTORS COMPANY

7. Remove the damaged front end lower tie bar (2) from vehicle (1).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

8. Remove the impact resistant adhesive from the repair area, as necessary. Refer to Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 16: Front End Lower Tie Bar

Courtesy of GENERAL MOTORS COMPANY

2. Position the front end lower tie bar (2) on the vehicle (1) using 3-dimensional measuring equipment.

3. Verify the fit of the front end lower tie bar (2).

Fig. 17: Front End Lower Tie Bar

Courtesy of GENERAL MOTORS COMPANY

4. Apply the impact resistant adhesive to the repair area, as necessary. Refer to Metal Panel Bonding.

5. Clamp the front end lower tie bar (1) into position.

6. Weld the front end lower tie bar (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

8. Install the body side outer panel as necessary.

9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .

10. Install all related panels and components.

11. If disabled, enable the high voltage system. Refer to High Voltage Enabling .

12. Enable the SIR system. Refer to SIR Disabling and Enabling .

FRONT WHEELHOUSE PANEL REPLACEMENT

WARNING: 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 includes the following steps: 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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: Left shown, right similar.

1. Disable the SIR system. SIR Disabling and Enabling .

2. Inspect the high voltage system. High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area as necessary. Anti-Corrosion Treatment and Repair .

Fig. 18: Front Wheelhouse Panel

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

6. Remove all factory welds from the front wheelhouse panel (1).

Fig. 19: Front Wheelhouse Panel

Courtesy of GENERAL MOTORS COMPANY

7. Remove the damaged front wheelhouse panel (2) from vehicle (1).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

8. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 20: Front Wheelhouse Panel

Courtesy of GENERAL MOTORS COMPANY

2. Position the front wheelhouse panel (2) on the vehicle (1) using 3-dimensional measuring equipment.

3. Verify the fit of the front wheelhouse panel (2).

4. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding.

Fig. 21: Front Wheelhouse Panel

Courtesy of GENERAL MOTORS COMPANY

5. Clamp the front wheelhouse panel (1) into position.

6. Weld the front wheelhouse panel (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area as necessary. Anti-Corrosion Treatment and Repair .

8. Paint the repaired area. Basecoat/Clearcoat Paint Systems .

9. Install all related panels and components.

10. If disabled, enable the high voltage system. High Voltage Enabling .

11. Enable the SIR System. SIR Disabling and Enabling .

FRONT WHEELHOUSE EXTENSION REPLACEMENT

WARNING: 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 includes the following steps:

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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: Left shown, right similar.

1. Disable the SIR system. SIR Disabling and Enabling

2. Inspect the high voltage system. High Voltage System Inspection

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Anti-Corrosion Treatment and Repair

Fig. 22: Front Wheelhouse Extension

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Structure Identification

NOTE: Record the number and location of the original welds for installation of the service assembly.

6. Remove all factory welds from the front wheelhouse extension (1).

Fig. 23: Front Wheelhouse Extension

Courtesy of GENERAL MOTORS COMPANY

7. Remove the damaged front wheelhouse extension (2) from vehicle (1).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

8. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 24: Front Wheelhouse Extension

Courtesy of GENERAL MOTORS COMPANY

2. Position the front wheelhouse extension (2) on the vehicle (1) using 3-dimensional measuring equipment.

3. Verify the fit of the front wheelhouse extension (2).

Fig. 25: Front Wheelhouse Extension

Courtesy of GENERAL MOTORS COMPANY

4. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding

5. Clamp the front wheelhouse extension (1) into position.

6. Weld the front wheelhouse extension (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Anti-Corrosion Treatment and Repair

8. Install the body side outer panel as necessary.

9. Paint the repaired area. Basecoat/Clearcoat Paint Systems

10. Install all related panels and components.

11. If disabled, enable the high voltage system. High Voltage Enabling

12. Enable the SIR System. SIR Disabling and Enabling FRONT WHEELHOUSE PANEL BRACE REPLACEMENT

WARNING: 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 includes the following steps: 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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: Left shown, right similar.

1. Disable the SIR system. SIR Disabling and Enabling

2. Inspect the high voltage system. High Voltage System Inspection

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Anti-Corrosion Treatment and Repair

Fig. 26: Front Wheelhouse Panel Brace Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Structure Identification

NOTE: Record the number and location of the original welds for installation of the service assembly.

6. Remove all factory welds from the front wheelhouse panel brace (1).

Fig. 27: Front Wheelhouse Panel Brace Courtesy of GENERAL MOTORS COMPANY

7. Remove the damaged front wheelhouse panel brace (2) from vehicle (1).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

8. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 28: Front Wheelhouse Panel Brace Courtesy of GENERAL MOTORS COMPANY

2. Position the front wheelhouse panel brace (2) on the vehicle (1) using 3-dimensional measuring equipment.

3. Verify the fit of the front wheelhouse panel brace (2).

4. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding

Fig. 29: Front Wheelhouse Panel Brace Courtesy of GENERAL MOTORS COMPANY

5. Clamp the front wheelhouse panel brace (1) into position.

6. Weld the front wheelhouse panel brace (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Anti-Corrosion Treatment and Repair

8. Install the body side outer panel as necessary.

9. Paint the repaired area. Basecoat/Clearcoat Paint Systems

10. Install all related panels and components.

11. If disabled, enable the high voltage system. High Voltage Enabling

12. Enable the SIR System. SIR Disabling and Enabling

FRONT COMPARTMENT UPPER SIDE RAIL REPLACEMENT

WARNING: 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 includes the following steps:

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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: Left shown, right similar.

1. Disable the SIR System. Refer to SIR Disabling and Enabling .

2. Inspect the high voltage system. Refer to High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti- Corrosion Treatment and Repair .

Fig. 30: Front Compartment Upper Side Rail Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Refer to Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

6. Remove all factory spot welds from front compartment upper side rail (1).

Fig. 31: Front Compartment Upper Side Rail Brazing Welds Courtesy of GENERAL MOTORS COMPANY

7. Remove all factory brazing welds (1) from front compartment upper side rail.

Fig. 32: Front Compartment Upper Side Rail Courtesy of GENERAL MOTORS COMPANY

8. Remove the damaged front compartment upper side rail (1) from vehicle (2).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

9. Remove the impact resistant adhesive from the repair area, as necessary. Refer to Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

NOTE: MIG Brazing Welds equivalent to the factory brazing welds are recommended.

1. Prepare all mating surfaces for welding as necessary.

Fig. 33: Front Compartment Upper Side Rail Courtesy of GENERAL MOTORS COMPANY

2. Apply the impact resistant adhesive to the repair area, as necessary. Refer to Metal Panel Bonding.

3. Position the front compartment upper side rail (1) on the vehicle (2) using 3-dimensional measuring equipment.

4. Verify the fit of the front compartment upper side rail (1).

Fig. 34: Front Compartment Upper Side Rail Courtesy of GENERAL MOTORS COMPANY

5. Clamp the front compartment upper side rail (1) into position.

6. Weld the front compartment upper side rail (1) accordingly.

Fig. 35: Front Compartment Upper Side Rail Brazing Welds Courtesy of GENERAL MOTORS COMPANY

7. Replace factory brazing welds with MIG brazing welds (1) on front compartment upper side rail accordingly.

8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

9. Install the body side outer panel as necessary.

10. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .

11. Install all related panels and components.

12. If disabled, enable the high voltage system. Refer to High Voltage Enabling .

13. Enable the SIR system. Refer to SIR Disabling and Enabling .

WINDSHIELD INNER UPPER FRAME REINFORCEMENT REPLACEMENT

WARNING: 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 includes the following steps:

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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: The windshield inner upper frame reinforcement is an ultra-high strength dual phase steel and cannot be sectioned or repaired. Ultra High Strength Steel.

NOTE: There are sectioning procedures available for various locations of the body side outer panel. The sectioning procedure and location should be chosen based on the extent of damage to the vehicle and any additional inner reinforcements that need to be replaced. Refer to the body side outer panel sectioning procedures for the specific location where sectioning is required.

NOTE: Left shown right similar.

1. Disable the SIR system. SIR Disabling and Enabling .

2. Inspect the high voltage system. High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Anti-Corrosion Treatment and Repair .

6. Section the body side outer panel as required for access to replace the windshield inner upper frame reinforcement.

Fig. 36: Windshield Inner Upper Frame Reinforcement Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Refer to Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

7. Remove all factory welds from the windshield inner upper frame reinforcement (1).

Fig. 37: Windshield Inner Upper Frame Reinforcement Courtesy of GENERAL MOTORS COMPANY

8. Remove the damaged windshield inner upper frame reinforcement (1) from vehicle (2).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

9. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 38: Windshield Inner Upper Frame Reinforcement Courtesy of GENERAL MOTORS COMPANY

2. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding.

3. Position the windshield inner upper frame reinforcement (1) on the vehicle (2) using 3-dimensional measuring equipment.

4. Verify the fit of the windshield inner upper frame reinforcement (1).

5. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding

Fig. 39: Windshield Inner Upper Frame Reinforcement Courtesy of GENERAL MOTORS COMPANY

6. Clamp the windshield inner upper frame reinforcement (1) into position.

7. Weld the windshield inner upper frame reinforcement (1) accordingly.

8. Apply the sealers and anti-corrosion materials to the repair area as necessary. Anti-Corrosion Treatment and Repair .

NOTE: Before refinishing, refer to Adhesive Installation of Windshields , and Adhesive Installation of Liftgate Windows .

9. Install the body side outer panel as necessary

10. Paint the repaired area. Basecoat/Clearcoat Paint Systems .

11. Install all related panels and components.

12. If disabled, enable the high voltage system. High Voltage Enabling .

13. Enable the SIR System. SIR Disabling and Enabling .

FRONT HINGE PILLAR BODY REPLACEMENT

WARNING: 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 includes the following steps: 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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: The front hinge pillar is an ultra-high strength steel and cannot be sectioned or repaired. Refer to Ultra High Strength Steel.

NOTE: There are sectioning procedures available for various locations of the body side outer panel. The sectioning procedure and location should be chosen based on the extent of damage to the vehicle and any additional inner reinforcements that need to be replaced. Refer to the body side outer panel sectioning procedures for the specific location where sectioning is required.

NOTE: Left shown right similar.

1. Disable the SIR System. Refer to SIR Disabling and Enabling .

2. Inspect the high voltage system. Refer to High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti- Corrosion Treatment and Repair .

6. Section the body side outer panel as required for access to replace the front hinge pillar.

Fig. 40: Front Hinge Pillar Body

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Refer to Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

7. Remove all factory welds from front hinge pillar body (1).

Fig. 41: Front Hinge Pillar Body

Courtesy of GENERAL MOTORS COMPANY

8. Remove the damaged front hinge pillar body (1) from vehicle (2).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

9. Remove the impact resistant adhesive from the repair area, as necessary. Refer to Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 42: Front Hinge Pillar Body

Courtesy of GENERAL MOTORS COMPANY

2. Position the front hinge pillar body (1) on the vehicle (2) using 3-dimensional measuring equipment.

3. Verify the fit of the front hinge pillar body (1).

Fig. 43: Front Hinge Pillar Body

Courtesy of GENERAL MOTORS COMPANY

4. Apply the impact resistant adhesive to the repair area, as necessary. Refer to Metal Panel Bonding.

5. Clamp the front hinge pillar body (1) into position.

6. Weld the front hinge pillar body (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

8. Install the body side outer panel as necessary.

9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .

10. Install all related panels and components.

11. If disabled, enable the high voltage system. Refer to High Voltage Enabling .

12. Enable the SIR system. Refer to SIR Disabling and Enabling .

ROOF OUTER PANEL REPLACEMENT

WARNING: 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 includes the following steps: 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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

1. Disable the SIR system. SIR Disabling and Enabling .

2. Inspect the high voltage system. High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area as necessary. Anti-Corrosion Treatment and Repair .

Fig. 44: Roof Outer Panel

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

6. Remove all factory welds (1) from the roof outer panel (2).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

7. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding.

Fig. 45: Roof Outer Panel

Courtesy of GENERAL MOTORS COMPANY

8. Remove the damaged roof panel (1) from vehicle (2).

Installation Procedure

Fig. 46: Roof Outer Panel

Courtesy of GENERAL MOTORS COMPANY

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Dry fit the roof panel (1) to the vehicle (2).

2. Remove roof panel (1) from vehicle (2) and prepare all mating surfaces for welding as necessary.

Fig. 47: Apply Anti-Flutter Foam To Roof Bows Courtesy of GENERAL MOTORS COMPANY

3. Apply anti-flutter foam-slow set 40 - 50 minute working time, or equivalent, to roof bows (1) as noted form original roof bows.

Fig. 48: Roof Outer Panel

Courtesy of GENERAL MOTORS COMPANY

4. Position the roof outer panel (1) on the vehicle (2) using 3-dimensional measuring equipment.

5. Verify the fit of the roof outer panel (1).

6. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding

7. Clamp the roof outer panel (1) to the vehicle (2).

Fig. 49: Roof Outer Panel

Courtesy of GENERAL MOTORS COMPANY

8. Weld the front and rear roof outer panel (1) accordingly to the vehicle (2).

9. Weld both sides of the roof outer panel to the vehicle (2). To create a solid weld 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. Anti-Corrosion Treatment and Repair .

NOTE: Before refinishing, refer to Adhesive Installation of Windshields , and Adhesive Installation of Liftgate Windows .

11. Paint the repaired area. Basecoat/Clearcoat Paint Systems

12. Install all related panels and components.

13. If disabled, enable the high voltage system. High Voltage Enabling .

14. Enable the SIR System. SIR Disabling and Enabling .

ROOF INNER SIDE RAIL REPLACEMENT

WARNING: 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 includes the following steps: 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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: The roof inner side rail is an ultra-high strength dual phase steel and cannot be sectioned or repaired. Ultra High Strength Steel.

NOTE: There are sectioning procedures available for various locations of the body side outer panel. The sectioning procedure and location should be chosen based on the extent of damage to the vehicle and any additional inner reinforcements that need to be replaced. Refer to the body side outer panel sectioning procedures for the specific location where sectioning is required.

NOTE: Left shown right similar.

1. Disable the SIR system. SIR Disabling and Enabling .

2. Inspect the high voltage system. Refer to High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area as necessary. Anti-Corrosion Treatment and Repair .

6. Section the body side outer panel as required for access to replace the roof inner side rail.

Fig. 50: Roof Inner Side Rail

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

7. Remove all factory welds from the roof inner side rail (1).

Fig. 51: Roof Inner Side Rail

Courtesy of GENERAL MOTORS COMPANY

8. Remove the damaged roof inner side rail (1) from vehicle (2).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

9. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 52: Roof Inner Side Rail

Courtesy of GENERAL MOTORS COMPANY

2. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding.

3. Position the roof inner side rail (1) on the vehicle (2) using 3-dimensional measuring equipment.

4. Verify the fit of the roof inner side rail (1).

5. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding

Fig. 53: Roof Inner Side Rail

Courtesy of GENERAL MOTORS COMPANY

6. Clamp the roof inner side rail (1) into position.

7. Weld the roof inner side rail (1) accordingly.

8. Apply the sealers and anti-corrosion materials to the repair area as necessary. Anti-Corrosion Treatment and Repair .

9. Install the body side outer panel as necessary.

NOTE: Before refinishing, refer to Adhesive Installation of Windshields , and Adhesive Installation of Liftgate Windows

10. Paint the repaired area. Basecoat/Clearcoat Paint Systems .

11. Install all related panels and components.

12. If disabled, enable the high voltage system. High Voltage Enabling .

13. Enable the SIR System. SIR Disabling and Enabling .

ROCKER INNER PANEL REPLACEMENT

WARNING: 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 includes the following steps: 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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: The rocker outer panel reinforcement is an ultra-high strength dual phase steel and cannot be sectioned or repaired. Ultra High Strength Steel

NOTE: There are sectioning procedures available for various locations of the body side outer panel. The sectioning procedure and location should be chosen based on the extent of damage to the vehicle and any additional inner reinforcements that need to be replaced. Refer to the body side outer panel sectioning procedures for the specific location where sectioning is required.

NOTE: Left shown right similar

1. Disable the SIR system. SIR Disabling and Enabling .

2. Inspect the high voltage system. High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Anti-Corrosion Treatment and Repair .

6. Section the body side outer panel as required for access to replace the rocker inner panel.

Fig. 54: Rocker Inner Panel

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

7. Remove all factory welds from the rocker inner panel (1).

Fig. 55: Rocker Inner Panel

Courtesy of GENERAL MOTORS COMPANY

8. Remove the damaged rocker inner panel (1) from vehicle.

NOTE: If impact resistant adhesive is present remove and replace as necessary.

9. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 56: Rocker Inner Panel

Courtesy of GENERAL MOTORS COMPANY

2. Position the rocker inner panel (1) on the vehicle using 3-dimensional measuring equipment.

3. Verify the fit of the rocker inner panel (1).

4. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding.

Fig. 57: Rocker Inner Panel

Courtesy of GENERAL MOTORS COMPANY

5. Clamp the rocker inner panel (1) into position.

6. Weld the rocker inner panel (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area as necessary. Anti-Corrosion Treatment and Repair .

8. Install the body side outer panel as necessary.

9. Paint the repaired area. Basecoat/Clearcoat Paint Systems .

10. Install all related panels and components.

11. If disabled, enable the high voltage system. High Voltage Enabling .

12. Enable the SIR System. SIR Disabling and Enabling .

ROCKER OUTER PANEL REINFORCEMENT REPLACEMENT

WARNING: 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 includes the following steps:

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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: The rocker outer panel reinforcement is an ultra-high strength dual phase steel and cannot be sectioned or repaired. Ultra High Strength Steel

NOTE: There are sectioning procedures available for various locations of the body side outer panel. The sectioning procedure and location should be chosen based on the extent of damage to the vehicle and any additional inner reinforcements that need to be replaced. Refer to the body side outer panel sectioning procedures for the specific location where sectioning is required.

NOTE: Left shown right similar.

1. Disable the SIR system. SIR Disabling and Enabling

2. Inspect the high voltage system. High Voltage System Inspection

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage

to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Anti-Corrosion Treatment and Repair

6. Section the body side outer panel as required for access to replace the rocker outer panel reinforcement.

Fig. 58: Rocker Outer Panel Reinforcement Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Structure Identification

NOTE: Record the number and location of the original welds for installation of the service assembly.

7. Remove all factory welds from the rocker outer panel reinforcement (1).

Fig. 59: Rocker Outer Panel Reinforcement Courtesy of GENERAL MOTORS COMPANY

8. Remove the damaged rocker outer panel reinforcement (2) from vehicle (1).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

9. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 60: Rocker Outer Panel Reinforcement Courtesy of GENERAL MOTORS COMPANY

2. Position the rocker outer panel reinforcement (2) on the vehicle (1) using 3-dimensional measuring equipment.

3. Verify the fit of the rocker outer panel reinforcement (2).

4. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding

Fig. 61: Rocker Outer Panel Reinforcement Courtesy of GENERAL MOTORS COMPANY

5. Clamp the rocker outer panel reinforcement (1) into position.

6. Weld the rocker outer panel reinforcement (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Anti-Corrosion Treatment and Repair

8. Install the body side outer panel as necessary.

9. Paint the repaired area. Basecoat/Clearcoat Paint Systems

10. Install all related panels and components.

11. If disabled, enable the high voltage system. High Voltage Enabling

12. Enable the SIR System. SIR Disabling and Enabling

BODY SIDE FRAME UPPER FRONT EXTENSION REPLACEMENT

WARNING: 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 includes the following steps:

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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: The body side frame upper front extension reinforcement is an ultra-high strength steel and cannot be sectioned or repaired. Ultra High Strength Steel.

NOTE: There are sectioning procedures available for various locations of the body side outer panel. The sectioning procedure and location should be chosen based on the extent of damage to the vehicle and any additional inner reinforcements that need to be replaced. Refer to the body side outer panel sectioning procedures for the specific location where sectioning is required.

NOTE: Left shown right similar.

1. Disable the SIR system. SIR Disabling and Enabling .

2. Inspect the high voltage system. High Voltage System Inspection .

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. Anti-Corrosion Treatment and Repair .

Fig. 62: Body Side Frame Upper Front Extension Reinforcement Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

6. Remove all factory welds from the body side frame upper front extension reinforcement (1).

Fig. 63: Body Side Frame Upper Front Extension Reinforcement Courtesy of GENERAL MOTORS COMPANY

7. Remove the body side frame upper front extension reinforcement (1) from vehicle (2).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

8. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 64: Body Side Frame Upper Front Extension Reinforcement Courtesy of GENERAL MOTORS COMPANY

2. Position the body side frame upper front extension reinforcement (1) on the vehicle (2) using 3-dimensional measuring equipment.

3. Verify the fit of the body side frame upper front extension reinforcement (1).

4. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding

Fig. 65: Body Side Frame Upper Front Extension Reinforcement Courtesy of GENERAL MOTORS COMPANY

5. Clamp the body side frame upper front extension reinforcement (1) into position.

6. Weld the body side frame upper front extension reinforcement (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area as necessary. Anti-Corrosion Treatment and Repair .

NOTE: Before refinishing, refer to Adhesive Installation of Windshields , and Adhesive Installation of Liftgate Windows .

8. Paint the repaired area. Basecoat/Clearcoat Paint Systems .

9. Install all related panels and components.

10. If disabled, enable the high voltage system. High Voltage Enabling .

11. Enable the SIR System. SIR Disabling and Enabling .

BODY SIDE OUTER PANEL REPLACEMENT

WARNING: 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 includes the following steps: 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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: Left shown right similar.

1. Disable the SIR system. SIR Disabling and Enabling .

2. Inspect the high voltage system. High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area as necessary. Anti-Corrosion Treatment and Repair .

Fig. 66: Body Side Outer Panel

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

6. Remove all factory welds from the body side outer panel (1).

Fig. 67: Body Side Outer Panel

Courtesy of GENERAL MOTORS COMPANY

7. Remove the damaged body side outer panel (1) from vehicle (2).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

8. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 68: Body Side Outer Panel

Courtesy of GENERAL MOTORS COMPANY

2. Position the body side outer panel (1) on the vehicle (2) using 3-dimensional measuring equipment.

3. Verify the fit of the body side outer panel (1).

Fig. 69: Body Side Outer Panel

Courtesy of GENERAL MOTORS COMPANY

4. Apply the impact resistant adhesive to the repair area, as necessary. Refer to Metal Panel Bonding.

5. Clamp the body side outer panel (1) into position.

6. Weld the body side outer panel (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area as necessary. Anti-Corrosion Treatment and Repair .

NOTE: Before refinishing, refer to Adhesive Installation of Windshields , and Adhesive Installation of Liftgate Windows .

8. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .

9. Install all related panels and components.

10. If disabled, enable the high voltage system. High Voltage Enabling .

11. Enable the SIR System. SIR Disabling and Enabling .

BODY SIDE OUTER PANEL SECTIONING

WARNING: 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 includes the following steps: 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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: Left shown right similar.

1. Disable the SIR system. SIR Disabling and Enabling .

2. Inspect the high voltage system. High Voltage System Inspection .

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. Anti-Corrosion Treatment and Repair .

Fig. 70: Body Side Outer Panel Sectioning Areas Courtesy of GENERAL MOTORS COMPANY

6. Section the body side outer panel within the recommended areas (1).

Fig. 71: Center Pillar Of Body Side Outer Panel Sectioning Area Courtesy of GENERAL MOTORS COMPANY

7. Section the center pillar of the body side outer panel within the recommended area (1).

NOTE: The following steps are to be used for both the body side outer and the center pillar sections.

8. Locate and remove all factory welds. Note the number and location of welds for installation of the body side outer section.

NOTE: Do not damage any other panel or reinforcements when cutting at the marked locations.

9. Cut the body side outer panel at the recommended areas (1).

10. Remove the body side outer section.

NOTE: If impact resistant adhesive is present remove and replace as necessary.

11. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding. Installation Procedure

Fig. 72: Body Side Outer Panel Sectioning Areas Courtesy of GENERAL MOTORS COMPANY

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

NOTE: If MIG/MAG is going to be used drill 8 mm (5/16 in) plug weld holes as necessary in locations noted from the original body side outer panel (1).

1. From the service part, cut the body side outer panel in corresponding locations (1) to overlap the remaining original panel by 25 mm (1 in) at each joint locations.

Fig. 73: Center Pillar Of Body Side Outer Panel Sectioning Area Courtesy of GENERAL MOTORS COMPANY

2. From the service part, cut the body side outer panel for the center pillar section in corresponding locations

(1) to overlap the remaining original panel by 25 mm (1 in) at each joint locations.

NOTE: The following steps are to be used for both the body side outer and the center pillar sections.

3. Prepare all mating surfaces for welding, as necessary.

4. Apply GM - approved Weld-Thru coating or equivalent to all mating surfaces. Anti-Corrosion Treatment and Repair .

5. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding.

6. Position the new service panel and clamp in place.

7. Weld accordingly.

8. Clean and prepare all welded surfaces.

9. Apply the sealers and anti-corrosion materials to the repair area as necessary. Anti-Corrosion Treatment and Repair .

NOTE: Before refinishing, refer to Adhesive Installation of Windshields , and Adhesive Installation of Liftgate Windows .

10. Paint the repaired area. Basecoat/Clearcoat Paint Systems .

11. Install all related panels and components.

12. Enable the SIR System. SIR Disabling and Enabling .

13. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection .

REAR FLOOR PANEL SECTIONING

WARNING: 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 includes the following steps: 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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

1. Disable the SIR system. Refer to SIR Disabling and Enabling .

2. Inspect the high voltage system. Refer to High Voltage System Inspection .

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 .

Fig. 74: Marking Cut Location Rearward From No. 5 Bar Courtesy of GENERAL MOTORS COMPANY

6. Measure 40 mm rearward from the rear edge of the #5 bar (1). Mark the cut location (2).

Fig. 75: Marked Cut Location

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Refer to Structure Identification.

7. Cut the floor at the marked location (1).

Fig. 76: Rear Floor Panel Section

Courtesy of GENERAL MOTORS COMPANY

8. Remove all factory welds (1).

9. Remove floor section (2) from vehicle.

NOTE: If impact resistant adhesive is present remove and replace as necessary.

10. Remove the impact resistant adhesive from the repair area, as necessary. Refer to Metal Panel Bonding.

Fig. 77: Cutting Service Part In Corresponding Location Courtesy of GENERAL MOTORS COMPANY

NOTE: The service part is supplied as a complete floor and will need to be cut at the proper location for sectioning. The service part will overlap the original floor panel by approximately 40 mm at the cut location.

11. Locate rear edge of the #5 bar location (1). Mark the cut location.

12. Cut the service part at the marked location (1).

Installation Procedure

Fig. 78: Marking Service Part For Plug Welding Locations Courtesy of GENERAL MOTORS COMPANY

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Create 1 row of plug welds in the service part as follows. Measure 20 mm from the front edge of the service part (1). Mark a straight line across the width of the service part (2).

Fig. 79: Drilling Plug Weld Holes

Courtesy of GENERAL MOTORS COMPANY

2. Drill 8 mm (5/16 in) plug weld holes, every 40 mm along the marked row.

3. Prepare all mating surfaces for welding, as necessary.

4. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair .

5. Apply the impact resistant adhesive to the repair area, as necessary. Refer to Metal Panel Bonding.

Fig. 80: Rear Floor Panel Section

Courtesy of GENERAL MOTORS COMPANY

6. Position the rear floor section (2) to the vehicle using 3-dimensional measuring equipment. Clamp the part in place.

7. Weld accordingly (1).

8. Clean and prepare all welded surfaces for painting.

9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .

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. If disabled, enable the high voltage system. Refer to High Voltage Enabling .

14. Enable the SIR system. Refer to SIR Disabling and Enabling .

REAR WHEELHOUSE INNER PANEL REPLACEMENT

WARNING: 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 includes the following steps: 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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: Left shown right similar.

1. Disable the SIR System. Refer to SIR Disabling and Enabling .

2. Inspect the high voltage system. Refer to High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti- Corrosion Treatment and Repair .

Fig. 81: Rear Wheelhouse Inner Panel Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Refer to Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

6. Remove all factory welds from the rear wheelhouse inner panel (1).

Fig. 82: Rear Wheelhouse Inner Panel Courtesy of GENERAL MOTORS COMPANY

7. Remove the damaged rear wheelhouse inner panel (2) from vehicle (1).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

8. Remove the impact resistant adhesive from the repair area, as necessary. Refer to Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 83: Rear Wheelhouse Inner Panel Courtesy of GENERAL MOTORS COMPANY

2. Position the rear wheelhouse inner panel (2) on the vehicle (1) using 3-dimensional measuring equipment.

3. Verify the fit of the rear wheelhouse inner panel (2).

Fig. 84: Rear Wheelhouse Inner Panel Courtesy of GENERAL MOTORS COMPANY

4. Apply the impact resistant adhesive to the repair area, as necessary. Refer to Metal Panel Bonding.

5. Clamp the rear wheelhouse inner panel (1) into position.

6. Weld the rear wheelhouse inner panel (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

8. Install the body side outer panel as necessary.

9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .

10. Install all related panels and components.

11. If disabled, enable the high voltage system. Refer to High Voltage Enabling .

12. Enable the SIR system. Refer to SIR Disabling and Enabling .

REAR WHEELHOUSE OUTER PANEL REPLACEMENT

WARNING: 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 includes the following steps: 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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: There are sectioning procedures available for various locations of the body side outer panel. The sectioning procedure and location should be chosen based on the extent of damage to the vehicle and any additional inner reinforcements that need to be replaced. Refer to the body side outer panel sectioning procedures for the specific location where sectioning is required.

NOTE: Left shown right similar.

1. Disable the SIR System. Refer to SIR Disabling and Enabling .

2. Inspect the high voltage system. Refer to High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti- Corrosion Treatment and Repair .

6. Section the body side outer panel as required for access to replace the rear wheelhouse outer panel.

Fig. 85: Rear Wheelhouse Outer Panel Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Refer to Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

7. Remove all factory welds from rear wheelhouse outer panel (1).

Fig. 86: Rear Wheelhouse Outer Panel Courtesy of GENERAL MOTORS COMPANY

8. Remove the damaged rear wheelhouse outer panel (2) from vehicle (1).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

9. Remove the impact resistant adhesive from the repair area, as necessary. Refer to Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 87: Rear Wheelhouse Outer Panel Courtesy of GENERAL MOTORS COMPANY

2. Position the rear wheelhouse outer panel (2) on the vehicle (1) using 3-dimensional measuring equipment.

3. Verify the fit of the rear wheelhouse outer panel (2).

Fig. 88: Rear Wheelhouse Outer Panel Courtesy of GENERAL MOTORS COMPANY

4. Apply the impact resistant adhesive to the repair area, as necessary. Refer to Metal Panel Bonding.

5. Clamp the rear wheelhouse outer panel (1) into position.

6. Weld the rear wheelhouse outer panel (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

8. Install the body side outer panel as necessary.

9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .

10. Install all related panels and components.

11. If disabled, enable the high voltage system. Refer to High Voltage Enabling .

12. Enable the SIR system. Refer to SIR Disabling and Enabling .

FLOOR PANEL NUMBER 5 CROSS BAR REPLACEMENT

WARNING: 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 includes the following steps: 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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

1. Disable the SIR System. Refer to SIR Disabling and Enabling .

2. Inspect the high voltage system. Refer to High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti- Corrosion Treatment and Repair .

Fig. 89: Floor Panel Number 5 Cross Bar Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Refer to Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

6. Remove all factory welds from the floor panel number 5 cross bar (1)..

Fig. 90: Floor Panel Number 5 Cross Bar Courtesy of GENERAL MOTORS COMPANY

7. Remove the damaged floor panel number 5 cross bar (1) from vehicle (2).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

8. Remove the impact resistant adhesive from the repair area, as necessary. Refer to Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 91: Floor Panel Number 5 Cross Bar Courtesy of GENERAL MOTORS COMPANY

2. Position the floor panel number 5 cross bar (1) on the vehicle (2) using 3-dimensional measuring equipment.

3. Verify the fit of the floor panel number 5 cross bar (1).

Fig. 92: Floor Panel Number 5 Cross Bar Courtesy of GENERAL MOTORS COMPANY

4. Apply the impact resistant adhesive to the repair area, as necessary. Refer to Metal Panel Bonding.

5. Clamp the floor panel number 5 cross bar (1) into position.

6. Weld the floor panel number 5 cross bar (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

8. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .

9. Install all related panels and components.

10. If disabled, enable the high voltage system. Refer to High Voltage Enabling .

11. Enable the SIR system. Refer to SIR Disabling and Enabling .

FLOOR PANEL NUMBER 5 CROSS BAR EXTENSION REPLACEMENT

WARNING: 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 includes the following steps:

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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: Left shown right similar.

1. Disable the SIR system. SIR Disabling and Enabling .

2. Inspect the high voltage system. High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Anti-Corrosion Treatment and Repair .

Fig. 93: Floor Panel Number 5 Cross Bar Extension Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

6. Remove all factory welds from the floor panel number 5 cross bar extension (1).

Fig. 94: Floor Panel Number 5 Cross Bar Extension Courtesy of GENERAL MOTORS COMPANY

7. Remove the damaged floor panel number 5 cross bar extension (1) from vehicle (2).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

8. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 95: Floor Panel Number 5 Cross Bar Extension Courtesy of GENERAL MOTORS COMPANY

2. Position the floor panel number 5 cross bar extension (1) on the vehicle (2) using 3-dimensional measuring equipment.

3. Verify the fit of the floor panel number 5 cross bar extension (1).

Fig. 96: Floor Panel Number 5 Cross Bar Extension Courtesy of GENERAL MOTORS COMPANY

4. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding.

5. Clamp the floor panel number 5 cross bar extension (1) into position.

6. Weld the floor panel number 5 cross bar extension (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area as necessary. Anti-Corrosion Treatment and Repair .

8. Install the body side outer panel as necessary.

9. Paint the repaired area. Basecoat/Clearcoat Paint Systems .

10. Install all related panels and components.

11. If disabled, enable the high voltage system. High Voltage Enabling .

12. Enable the SIR System. SIR Disabling and Enabling .

BODY REAR END PANEL REPLACEMENT

WARNING: 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 includes the following steps: 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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

1. Disable the SIR system. SIR Disabling and Enabling .

2. Inspect the high voltage system. High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Anti-Corrosion Treatment and Repair .

Fig. 97: Body Rear End Panel

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Structure Identification

NOTE: Record the number and location of the original welds for installation of the service assembly.

6. Remove all factory welds from body rear end panel (1).

Fig. 98: Body Rear End Panel

Courtesy of GENERAL MOTORS COMPANY

7. Remove the damaged body rear end panel (1) from vehicle (2).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

8. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Resistance Type Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 99: Body Rear End Panel

Courtesy of GENERAL MOTORS COMPANY

2. Position the body rear end panel (1) on the vehicle (2) using 3-dimensional measuring equipment.

3. Verify the fit of the body rear end panel (1).

4. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding

Fig. 100: Body Rear End Panel

Courtesy of GENERAL MOTORS COMPANY

5. Clamp the body rear end panel (1) into position.

6. Weld the body rear end panel (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area as necessary. Anti-Corrosion Treatment and Repair .

8. Paint the repaired area. Basecoat/Clearcoat Paint Systems .

9. Install all related panels and components.

10. If disabled, enable the high voltage system. High Voltage Enabling .

11. Enable the SIR System. SIR Disabling and Enabling .

FRONT RAIL REPLACEMENT

WARNING: 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 includes the following steps:

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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

Removal Procedure

WARNING: Refer to Approved Equipment for Collision Repair Warning . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: The front rail is an ultra-high strength steel and cannot be sectioned or repaired. Ultra High Strength Steel

NOTE: Left shown, right similar.

1. Disable the SIR system. SIR Disabling and Enabling .

2. Inspect the high voltage system. High Voltage System Inspection .

3. Remove all related panels and components.

4. Repair as much of the damage as possible to factory specifications. Dimensions - Body.

5. Note the location and remove the sealers and anti-corrosion materials from the repair area. Anti- Corrosion Treatment and Repair .

Fig. 101: Front Rail

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage any inner panels or reinforcements.

6. Locate and remove out all factory welds. Note the number and location of the welds for installation of the front rail (1).

Fig. 102: Front Rail

Courtesy of GENERAL MOTORS COMPANY

7. Remove the damaged front rail (2) from the vehicle (1).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

8. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

Fig. 103: Service Part Front Rail

Courtesy of GENERAL MOTORS COMPANY

NOTE: If the location of the original plug weld holes cannot be determined, space the plug weld holes every 40 mm (1 1/2 in) apart.

1. Drill 8 mm (5/16 in) plug weld holes in the service part front rail (1) as necessary in the locations noted from the original panel.

2. Prepare all mating surfaces as necessary.

3. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Anti-Corrosion Treatment and Repair .

Fig. 104: Front Rail

Courtesy of GENERAL MOTORS COMPANY

4. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding.

5. Position the front rail (1) to the vehicle (2) using 3-dimensional measuring equipment. Clamp the rail in place.

Fig. 105: Front Rail

Courtesy of GENERAL MOTORS COMPANY

6. Weld the front rail (1) accordingly.

7. Clean and prepare all welded surfaces.

8. Install all related panels and components.

9. Apply the sealers and anti-corrosion materials to the repair area as necessary. Anti-Corrosion Treatment and Repair .

10. Paint the repaired area. Basecoat/Clearcoat Paint Systems .

11. If disabled, enable the high voltage system. High Voltage Enabling .

12. Enable the SIR System. SIR Disabling and Enabling .

REAR RAIL END REPLACEMENT

WARNING: 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 includes the following steps:

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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: Left shown right similar.

1. Disable the SIR system. SIR Disabling and Enabling .

2. Inspect the high voltage system. High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area as necessary. Anti-Corrosion Treatment and Repair .

Fig. 106: Rear Rail End

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

6. Remove all factory welds from rear rail end (1).

Fig. 107: Rear Rail End

Courtesy of GENERAL MOTORS COMPANY

7. Remove the damaged rear rail end (1) from vehicle (2).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

8. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 108: Rear Rail End

Courtesy of GENERAL MOTORS COMPANY

2. Position the rear rail end (1) on the vehicle (2) using 3-dimensional measuring equipment.

3. Verify the fit of the rear rail end (1).

Fig. 109: Rear Rail End

Courtesy of GENERAL MOTORS COMPANY

4. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding.

5. Clamp the rear rail end (1) into position.

6. Weld the rear rail end (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area as necessary. Anti-Corrosion Treatment and Repair .

8. Paint the repaired area. Basecoat/Clearcoat Paint Systems

9. Install all related panels and components.

10. If disabled, enable the high voltage system. High Voltage Enabling

11. Enable the SIR System. SIR Disabling and Enabling .

BODY HINGE PILLAR INNER PANEL REPLACEMENT

WARNING: 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 includes the following steps:

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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: There are sectioning procedures available for various locations of the body side outer panel. The sectioning procedure and location should be chosen based on the extent of damage to the vehicle and any additional inner reinforcements that need to be replaced. Refer to the body side outer panel sectioning procedures for the specific location where sectioning is required.

NOTE: The Roof side rail reinforcement is a High strength low alloy steel. High Strength Low Alloy Steel.

NOTE: Left shown right similar.

1. Disable the SIR system. SIR Disabling and Enabling .

2. Inspect the high voltage system. High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage

to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area as necessary. Anti-Corrosion Treatment and Repair .

6. Section the body side outer panel as required for access to replace the Front Hinge Pillar.

Fig. 110: Body Hinge Pillar Inner

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

7. Remove all factory welds from body hinge pillar inner (1).

Fig. 111: Body Hinge Pillar Inner

Courtesy of GENERAL MOTORS COMPANY

8. Remove the damaged body hinge pillar inner (1) from vehicle (2).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

9. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 112: Body Hinge Pillar Inner

Courtesy of GENERAL MOTORS COMPANY

2. Position the body hinge pillar inner (1) on the vehicle (2) using 3-dimensional measuring equipment.

3. Verify the fit of the body hinge pillar inner (1).

Fig. 113: Body Hinge Pillar Inner

Courtesy of GENERAL MOTORS COMPANY

4. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding.

5. Clamp the body hinge pillar inner (1) into position.

6. Weld the body hinge pillar inner (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area as necessary. Anti-Corrosion Treatment and Repair .

8. Install the body side outer panel as necessary.

NOTE: Before refinishing, refer to Adhesive Installation of Windshields , or Adhesive Installation of Liftgate Windows .

9. Paint the repaired area. Basecoat/Clearcoat Paint Systems .

10. Install all related panels and components.

11. If disabled, enable the high voltage system. High Voltage Enabling .

12. Enable the SIR System. SIR Disabling and Enabling .

CENTER PILLAR INNER PANEL REPLACEMENT

WARNING: 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 includes the following steps: 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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: The center pillar inner panel is an ultra-high strength steel and cannot be sectioned or repaired. Ultra High Strength Steel.

NOTE: There are sectioning procedures available for various locations of the body side outer panel. The sectioning procedure and location should be chosen based on the extent of damage to the vehicle and any additional inner reinforcements that need to be replaced. Refer to the body side outer panel sectioning procedures for the specific location where sectioning is required.

NOTE: Left shown right similar.

1. Disable the SIR system. SIR Disabling and Enabling .

2. Inspect the high voltage system. High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Anti-Corrosion Treatment and Repair .

6. Section the body side outer panel as required for access to replace the center inner panel.

Fig. 114: Center Inner Panel

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

7. Remove all factory welds from the center inner panel (1).

Fig. 115: Center Inner Panel

Courtesy of GENERAL MOTORS COMPANY

8. Remove the damaged center inner panel (1) from vehicle (2).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

9. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 116: Center Inner Panel

Courtesy of GENERAL MOTORS COMPANY

2. Position the center inner panel (1) on the vehicle (2) using 3-dimensional measuring equipment.

3. Verify the fit of the center inner panel (1).

Fig. 117: Center Inner Panel

Courtesy of GENERAL MOTORS COMPANY

4. Apply the impact resistant adhesive to the repair area, as necessary. Refer to Metal Panel Bonding.

5. Clamp the center inner panel (1) into position.

6. Weld the center inner panel (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area as necessary. Anti-Corrosion Treatment and Repair .

8. Install the body side outer panel as necessary.

9. Paint the repaired area. Basecoat/Clearcoat Paint Systems .

10. Install all related panels and components.

11. If disabled, enable the high voltage system. Refer to High Voltage Enabling .

12. Enable the SIR System. SIR Disabling and Enabling .

CENTER PILLAR REPLACEMENT

WARNING: 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 includes the following steps: 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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: The front hinge pillar is an ultra-high strength steel and cannot be sectioned or repaired. Refer to Ultra High Strength Steel.

NOTE: There are sectioning procedures available for various locations of the body side outer panel. The sectioning procedure and location should be chosen based on the extent of damage to the vehicle and any additional inner reinforcements that need to be replaced. Refer to the body side outer panel sectioning procedures for the specific location where sectioning is required.

NOTE: Left shown right similar.

1. Disable the SIR System. Refer to SIR Disabling and Enabling .

2. Inspect the high voltage system. Refer to High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti- Corrosion Treatment and Repair .

6. Section the body side outer panel as required for access to replace the center pillar.

Fig. 118: Center Pillar

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Refer to Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

7. Remove all factory welds from center pillar (1).

Fig. 119: Center Pillar

Courtesy of GENERAL MOTORS COMPANY

8. Remove the damaged center pillar (1) from vehicle (2).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

9. Remove the impact resistant adhesive from the repair area, as necessary. Refer to Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 120: Center Pillar

Courtesy of GENERAL MOTORS COMPANY

2. Position the center pillar (1) on the vehicle (2) using 3-dimensional measuring equipment.

3. Verify the fit of the center pillar.

Fig. 121: Center Pillar

Courtesy of GENERAL MOTORS COMPANY

4. Apply the impact resistant adhesive to the repair area, as necessary. Refer to Metal Panel Bonding.

5. Clamp the center pillar (1) into position.

6. Weld the center pillar (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

8. Install the body side outer panel as necessary.

9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .

10. Install all related panels and components.

11. If disabled, enable the high voltage system. Refer to High Voltage Enabling .

12. Enable the SIR system. Refer to SIR Disabling and Enabling .

FRONT SIDE DOOR OUTER PANEL REPLACEMENT

WARNING: 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 includes the following steps: 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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

Removal Procedure

WARNING: Refer to Approved Equipment for Collision Repair Warning .

NOTE: Before beginning the repair, refer to Metal Panel Bonding for proper adhesive applicator preparations and general information.

1. Disable the SIR system. Refer to SIR Disabling and Enabling .

2. Inspect the high voltage system. Refer to High Voltage System Inspection .

3. Remove the door from the vehicle. Refer to Front Side Door Replacement .

4. Remove the outer door handle.

5. Remove the outside rearview mirror.

Fig. 122: Door Shell

Courtesy of GENERAL MOTORS COMPANY

6. Grind the edges of the door outer panel to separate the outer door panel from the door shell (1).

Fig. 123: Outer Door Panel And Door Shell Courtesy of GENERAL MOTORS COMPANY

WARNING: Inspection of the door guard beam for damage must be performed before replacement of the door outer panel. If damage to the door guard beam is found the door must be replaced. Failure to do so may compromise the structural integrity of the vehicle and may cause personal injury if the vehicle is involved in a collision.

7. Remove the outer door panel (2) from the door shell (1).

8. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti- Corrosion Treatment and Repair .

Fig. 124: Door Shell

Courtesy of GENERAL MOTORS COMPANY

9. Straighten the edges of the door shell (1).

Installation Procedure

Fig. 125: Door Shell

Courtesy of GENERAL MOTORS COMPANY

1. Using a grinding disk grind the surface of the door shell (1) mating flanges to bare steel.

Fig. 126: Door Outer Panel

Courtesy of GENERAL MOTORS COMPANY

2. Scuff the opposing mating surfaces of the door outer panel (1) to remove the gloss of the E-Coat.

3. Clean the mating surfaces.

Fig. 127: Apply Anti-Flutter Foam On Inner Safety Beam Courtesy of GENERAL MOTORS COMPANY

4. Apply anti-flutter foam-slow set 40 - 50 minute working time, or equivalent, in 4 - 6 evenly spaced on the inner safety beam (1).

Fig. 128: Apply Bead Of Metal Panel Bonding Adhesive To Mating Surfaces Courtesy of GENERAL MOTORS COMPANY

NOTE: The adhesive has a 40 - 50 minute working time. Do not allow the door to totally cure off the vehicle, as proper alignment of the door outer panel to the door shell will be difficult.

5. Apply a 3 - 6 mm (1/8 - 1/4 in) bead of metal panel bonding adhesive Metal Panel Bonding, to both of the mating surfaces.

6. Using a small acid brush, spread a coat of adhesive to cover all the bare metal surfaces to ensure corrosion protection.

Fig. 129: Outer Door Panel And Door Shell Courtesy of GENERAL MOTORS COMPANY

NOTE: Do NOT pull the panels apart after joined together. If necessary, slide the panels against each other to realign the panels.

7. Install the door outer panel (1) to the door shell (2).

Fig. 130: Door Shell

Courtesy of GENERAL MOTORS COMPANY

8. Clamp the door outer panel into position, as required.

9. Using a hammer, re-hem the hem flanges around the door shell (1). Continue to hammer in stages along the hem flanges.

10. Using lacquer thinner remove the excess adhesive from the door panel area.

11. Install the door to the vehicle. Inspect the door outer panel for proper alignment. Adjust the alignment, as required. Refer to Front Side Door Replacement .

12. Clean and prepare all welded surfaces.

13. Apply sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

14. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .

15. Install the outer door handle.

16. Install the outside rearview mirror.

17. Install the door to the vehicle. Refer to Front Side Door Replacement .

18. Enable the SIR system. Refer to SIR Disabling and Enabling .

19. If disabled, enable the high voltage system. Refer to High Voltage Enabling .

REAR SIDE DOOR OUTER PANEL REPLACEMENT

WARNING: 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 includes the following steps: 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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

Removal Procedure

WARNING: Refer to Approved Equipment for Collision Repair Warning .

NOTE: Before beginning the repair, refer to Metal Panel Bonding for proper adhesive applicator preparations and general information.

1. Disable the SIR system. Refer to SIR Disabling and Enabling .

2. Inspect the high voltage system. Refer to High Voltage System Inspection .

3. Remove the door from the vehicle. Refer to Rear Side Door Replacement .

4. Remove the outer door handle.

Fig. 131: Door Shell

Courtesy of GENERAL MOTORS COMPANY

5. Grind the edges of the door outer panel to separate the outer door panel from the door shell (1).

Fig. 132: Outer Door Panel And Door Shell Courtesy of GENERAL MOTORS COMPANY

WARNING: Inspection of the door guard beam for damage must be performed before replacement of the door outer panel. If damage to the door guard beam is found the door must be replaced. Failure to do so may compromise the structural integrity of the vehicle and may cause personal injury if the vehicle is involved in a collision.

6. Remove the outer door panel (2) from the door shell (1).

7. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti- Corrosion Treatment and Repair .

Fig. 133: Door Shell

Courtesy of GENERAL MOTORS COMPANY

8. Straighten the edges of the door shell (1).

Installation Procedure

Fig. 134: Door Shell

Courtesy of GENERAL MOTORS COMPANY

1. Using a grinding disk grind the surface of the door shell (1) mating flanges to bare steel.

Fig. 135: Door Outer Panel

Courtesy of GENERAL MOTORS COMPANY

2. Scuff the opposing mating surfaces of the door outer panel (1) to remove the gloss of the E-Coat.

3. Clean the mating surfaces.

Fig. 136: Apply Anti-Flutter Foam To Inner Safety Beam Courtesy of GENERAL MOTORS COMPANY

4. Apply anti-flutter foam-slow set 40 - 50 minute working time, or equivalent, in 4 - 6 evenly spaced on the inner safety beam (1).

Fig. 137: Apply Bead Of Metal Panel Bonding Adhesive To Mating Surfaces Courtesy of GENERAL MOTORS COMPANY

NOTE: The adhesive has a 40 - 50 minute working time. Do not allow the door to totally cure off the vehicle, as proper alignment of the door outer panel to the door shell will be difficult.

5. Apply a 3 - 6 mm (1/8 - 1/4 in) bead of metal panel bonding adhesive Metal Panel Bonding, to both of the mating surfaces.

6. Using a small acid brush, spread a coat of adhesive to cover all the bare metal surfaces to ensure corrosion protection.

Fig. 138: Outer Door Panel And Door Shell Courtesy of GENERAL MOTORS COMPANY

NOTE: Do NOT pull the panels apart after joined together. If necessary, slide the panels against each other to realign the panels.

7. Install the door outer panel (2) to the door shell (1).

Fig. 139: Door Shell

Courtesy of GENERAL MOTORS COMPANY

8. Clamp the door outer panel into position, as required.

9. Using a hammer, re-hem the hem flanges around the door shell (1). Continue to hammer in stages along the hem flanges.

10. Using lacquer thinner remove the excess adhesive from the door panel area.

11. Install the door to the vehicle. Inspect the door outer panel for proper alignment. Adjust the alignment, as required. Refer to Rear Side Door Replacement .

12. Clean and prepare all welded surfaces.

13. Apply sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

14. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .

15. Install the outer door handle.

16. Install the door to the vehicle. Refer to Front Side Door Replacement .

17. Enable the SIR system. Refer to SIR Disabling and Enabling .

18. If disabled, enable the high voltage system. Refer to High Voltage Enabling .

ROOF SIDE RAIL REINFORCEMENT REPLACEMENT

WARNING: 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 includes the following steps: 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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: There are sectioning procedures available for various locations of the body side outer panel. The sectioning procedure and location should be chosen based on the extent of damage to the vehicle and any additional inner reinforcements that need to be replaced. Refer to the body side outer panel sectioning procedures for the specific location where sectioning is required.

NOTE: The roof side rail reinforcement is a High strength low alloy steel. High Strength Low Alloy Steel.

NOTE: Left shown right similar.

1. Disable the SIR system. SIR Disabling and Enabling .

2. Inspect the high voltage system. High Voltage System Inspection .

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. Anti-Corrosion Treatment and Repair .

Fig. 140: Roof Side Rail Reinforcement Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

6. Remove all factory welds from the roof side rail reinforcement (1).

Fig. 141: Roof Side Rail Reinforcement Courtesy of GENERAL MOTORS COMPANY

7. Remove the roof side rail reinforcement (1) from vehicle (2).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

8. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 142: Roof Side Rail Reinforcement Courtesy of GENERAL MOTORS COMPANY

2. Position the roof side rail reinforcement (1) on the vehicle (2) using 3-dimensional measuring equipment.

3. Verify the fit of the roof side rail reinforcement (1).

4. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding

Fig. 143: Roof Side Rail Reinforcement Courtesy of GENERAL MOTORS COMPANY

5. Clamp the roof side rail reinforcement (1) into position.

6. Weld the roof side rail reinforcement (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area as necessary. Anti-Corrosion Treatment and Repair .

NOTE: Before refinishing, refer to Adhesive Installation of Windshields , and Adhesive Installation of Liftgate Windows .

8. Paint the repaired area. Basecoat/Clearcoat Paint Systems .

9. Install all related panels and components.

10. If disabled, enable the high voltage system. High Voltage Enabling .

11. Enable the SIR System. SIR Disabling and Enabling .

REAR RAIL REPLACEMENT

WARNING: 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 includes the following steps: 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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

Removal Procedure

WARNING: Refer to Approved Equipment for Collision Repair Warning . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: Left shown, right similar.

1. Disable the SIR system. SIR Disabling and Enabling .

2. Inspect the high voltage system. High Voltage System Inspection .

3. Remove all related panels and components.

4. Repair as much of the damage as possible to factory specifications. Dimensions - Body.

5. Note the location and remove the sealers and anti-corrosion materials from the repair area. Anti- Corrosion Treatment and Repair .

Fig. 144: Rear Rail

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements.

6. Locate and remove out all factory welds. Note the number and location of the welds for installation of the rear rail (1).

Fig. 145: Rear Rail

Courtesy of GENERAL MOTORS COMPANY

7. Remove the damaged rear rail (2) from the vehicle (1).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

8. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

NOTE: If the location of the original plug weld holes cannot be determined, space the plug weld holes every 40 mm (1 1/2 in) apart.

1. Drill 8 mm (5/16 in) plug weld holes in the service part front rail as necessary in the locations noted from

the original panel.

2. Prepare all mating surfaces as necessary.

3. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Anti-Corrosion Treatment and Repair .

Fig. 146: Rear Rail

Courtesy of GENERAL MOTORS COMPANY

4. Position the rear rail (1) to the vehicle using 3-dimensional measuring equipment.

5. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding

6. Clamp the rail into position.

Fig. 147: Rear Rail

Courtesy of GENERAL MOTORS COMPANY

7. Weld the rear rail (1) accordingly.

8. Clean and prepare all welded surfaces.

9. Install all related panels and components.

10. Apply the sealers and anti-corrosion materials to the repair area as necessary. Anti-Corrosion Treatment and Repair .

11. Paint the repaired area. Basecoat/Clearcoat Paint Systems .

12. If disabled, enable the high voltage system. High Voltage Enabling .

13. Enable the SIR System. SIR Disabling and Enabling .

RAIL REPLACEMENT - REAR SECTION

WARNING: 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 includes the following steps:

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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: Right shown, left similar.

1. Disable the SIR system. SIR Disabling and Enabling .

2. Inspect the high voltage system. High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Anti-Corrosion Treatment and Repair .

Fig. 148: Rear Rail Section

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

6. Remove all factory welds from rear rail section (1).

Fig. 149: Rear Rail Section

Courtesy of GENERAL MOTORS COMPANY

7. Remove the damaged rear rail section (2) from vehicle (1).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

8. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 150: Rear Rail Section

Courtesy of GENERAL MOTORS COMPANY

2. Position the rear rail section (2) on the vehicle (1) using 3-dimensional measuring equipment.

3. Verify the fit of the rear rail section (2).

Fig. 151: Rear Rail Section

Courtesy of GENERAL MOTORS COMPANY

4. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding.

5. Clamp the rear rail section (1) into position.

6. Weld the rear rail section (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area as necessary. Anti-Corrosion Treatment and Repair .

8. Paint the repaired area. Basecoat/Clearcoat Paint Systems .

9. Install all related panels and components.

10. If disabled, enable the high voltage system. High Voltage Enabling .

11. Enable the SIR System. SIR Disabling and Enabling .

REAR FLOOR PANEL FILLER REPLACEMENT

WARNING: 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 includes the following steps:

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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

NOTE: Left shown right similar.

1. Disable the SIR System. Refer to SIR Disabling and Enabling .

2. Inspect the high voltage system. Refer to High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti- Corrosion Treatment and Repair .

Fig. 152: Rear Floor Panel Filler

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Refer to Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

6. Remove all factory welds from rear floor panel filler (1).

Fig. 153: Rear Floor Panel Filler

Courtesy of GENERAL MOTORS COMPANY

7. Remove the damaged rear floor panel filler (1) from vehicle (2).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

8. Remove the impact resistant adhesive from the repair area, as necessary. Refer to Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces as necessary.

Fig. 154: Rear Floor Panel Filler

Courtesy of GENERAL MOTORS COMPANY

2. Position the rear floor panel filler (1) on the vehicle (2) using 3-dimensional measuring equipment.

3. Verify the fit of the rear floor panel filler (1).

Fig. 155: Rear Floor Panel Filler

Courtesy of GENERAL MOTORS COMPANY

4. Apply the impact resistant adhesive to the repair area, as necessary. Refer to Metal Panel Bonding.

5. Clamp the rear floor panel filler (1) into position.

6. Weld the rear floor panel filler (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

8. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems , Basecoat/Clearcoat Paint Systems .

9. Install all related panels and components.

10. If disabled, enable the high voltage system. Refer to High Voltage Enabling .

11. Enable the SIR system. Refer to SIR Disabling and Enabling .

REAR FLOOR PANEL FILLER REPLACEMENT - LEFT SIDE

WARNING: 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 includes the following steps: 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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

1. Disable the SIR System. Refer to SIR Disabling and Enabling .

2. Inspect the high voltage system. Refer to High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti- Corrosion Treatment and Repair .

Fig. 156: Rear Floor Panel Filler

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Refer to Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

6. Remove all factory welds from the rear floor panel filler (1).

Fig. 157: Rear Floor Panel Filler

Courtesy of GENERAL MOTORS COMPANY

7. Remove the damaged rear floor panel filler (1) from vehicle (2).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

8. Remove the impact resistant adhesive from the repair area, as necessary. Refer to Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 158: Rear Floor Panel Filler

Courtesy of GENERAL MOTORS COMPANY

2. Position the rear floor panel filler (1) on the vehicle (2) using 3-dimensional measuring equipment.

3. Verify the fit of the rear floor panel filler (1).

Fig. 159: Rear Floor Panel Filler

Courtesy of GENERAL MOTORS COMPANY

4. Apply the impact resistant adhesive to the repair area, as necessary. Refer to Metal Panel Bonding.

5. Clamp the rear floor panel filler (1) into position

6. Weld the rear floor panel filler (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

8. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .

9. Install all related panels and components.

10. If disabled, enable the high voltage system. Refer to High Voltage Enabling .

11. Enable the SIR system. Refer to SIR Disabling and Enabling .

REAR FLOOR PANEL FILLER REPLACEMENT - RIGHT SIDE

WARNING: 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 includes the following steps:

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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

1. Disable the SIR System. Refer to SIR Disabling and Enabling .

2. Inspect the high voltage system. Refer to High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti- Corrosion Treatment and Repair .

Fig. 160: Rear Floor Panel Filler

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Refer to Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

6. Remove all factory welds from the rear floor panel filler (1).

Fig. 161: Rear Floor Panel Filler

Courtesy of GENERAL MOTORS COMPANY

7. Remove the damaged rear floor panel filler (1) from vehicle (2).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

8. Remove the impact resistant adhesive from the repair area, as necessary. Refer to Metal Panel Bonding.

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces for welding as necessary.

Fig. 162: Rear Floor Panel Filler

Courtesy of GENERAL MOTORS COMPANY

2. Position the rear floor panel filler (1) on the vehicle (2) using 3-dimensional measuring equipment.

3. Verify the fit of the rear floor panel filler (1).

Fig. 163: Rear Floor Panel Filler

Courtesy of GENERAL MOTORS COMPANY

4. Apply the impact resistant adhesive to the repair area, as necessary. Refer to Metal Panel Bonding.

5. Clamp the rear floor panel filler (1) into position

6. Weld the rear floor panel filler (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

8. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .

9. Install all related panels and components.

10. If disabled, enable the high voltage system. Refer to High Voltage Enabling .

11. Enable the SIR system. Refer to SIR Disabling and Enabling .

BATTERY TRAY REPLACEMENT

WARNING: 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 includes the following steps:

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.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

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 . CAUTION: Refer to Collision Repair Anchoring Caution .

1. Disable the SIR system. SIR Disabling and Enabling .

2. Inspect the high voltage system. High Voltage System Inspection .

3. Remove all related panels and components.

4. Visually inspect the vehicle for additional damage to the vehicle structure. Repair as much of the damage to the vehicle structure as possible, prior to replacing any damaged parts.

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Anti-Corrosion Treatment and Repair .

Fig. 164: Battery Tray

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage or cut attaching panels and reinforcements. Structure Identification.

NOTE: Record the number and location of the original welds for installation of the service assembly.

6. Remove all factory welds from battery tray (1).

Fig. 165: Battery Tray

Courtesy of GENERAL MOTORS COMPANY

7. Remove the damaged battery tray (1) from vehicle (2).

NOTE: If impact resistant adhesive is present remove and replace as necessary.

8. Remove the impact resistant adhesive from the repair area, as necessary. Metal Panel Bonding

Installation Procedure

NOTE: Squeeze Type Resistance Spot Welds equivalent to the factory spot welds are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG plug welds may be used, to replace those specific welds.

1. Prepare all mating surfaces as necessary.

Fig. 166: Battery Tray

Courtesy of GENERAL MOTORS COMPANY

2. Position the battery tray (1) on the vehicle (2) using 3-dimensional measuring equipment.

3. Verify the fit of the battery tray (1).

4. Apply the impact resistant adhesive to the repair area, as necessary. Metal Panel Bonding

Fig. 167: Battery Tray

Courtesy of GENERAL MOTORS COMPANY

5. Clamp the battery tray (1) into position.

6. Weld the battery tray (1) accordingly.

7. Apply the sealers and anti-corrosion materials to the repair area as necessary. Anti-Corrosion Treatment and Repair .

8. Paint the repaired area. Basecoat/Clearcoat Paint Systems .

9. Install all related panels and components.

10. If disabled, enable the high voltage system. High Voltage Enabling .

11. Enable the SIR System. SIR Disabling and Enabling .

RESISTANCE SPOT WELDED FULL PANEL REPLACEMENT

NOTE: Use this procedure for all panels that are replaced at the factory seams, unless a specific procedure exists in the Collision Repair section of this vehicle's service information.

Removal Procedure

WARNING: Refer to Approved Equipment for Collision Repair 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 related panels and components.

4. Repair as much of the damage as possible to factory specifications.

WARNING: Refer to Foam Sound Deadeners Warning .

5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

Fig. 168: Drilling Out Factory Welds (Full Panel) Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage any inner panels or reinforcements.

6. Locate and drill out all factory welds (1). Note the number and location of the welds for installation of the service part.

Fig. 169: Damaged Part (Full Panel)

Courtesy of GENERAL MOTORS COMPANY

7. Remove the damaged part (1).

Installation Procedure

NOTE: If the location of the original plug weld holes cannot be determined, space the plug weld holes every 40 mm (1 1/2 in) apart. Where structural adhesive was present, space the plug weld holes every 20 mm (3/4 in) apart.

1. Prepare all mating surfaces as necessary.

2. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair .

3. Position the service part. Clamp in place.

Fig. 170: Welding New Part (Full Panel) Courtesy of GENERAL MOTORS COMPANY

4. Apply welds accordingly (1).

5. Clean and prepare all welded surfaces.

6. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

7. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems .

8. Install all related panels and components.

9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

10. Enable the SIR system. Refer to SIR Disabling and Enabling .

MIG WELDED FULL PANEL REPLACEMENT

Removal Procedure

WARNING: Refer to Approved Equipment for Collision Repair Warning .

NOTE: Use this procedure for all panels that are replaced at the factory seams, unless a specific procedure exists in the Collision Repair section of this vehicle's

service information.

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. Repair as much of the damage as possible to factory specifications.

WARNING: Refer to Foam Sound Deadeners Warning .

5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

Fig. 171: Drilling Out Factory Welds (Full Panel) Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not damage any inner panels or reinforcements.

6. Locate and drill out all factory welds (1). Note the number and location of the welds for installation of the service part.

Fig. 172: Damaged Part (Full Panel)

Courtesy of GENERAL MOTORS COMPANY

7. Remove the damaged part (1).

Installation Procedure

Fig. 173: Drilling Plug Weld Holes (Full Panel) Courtesy of GENERAL MOTORS COMPANY

NOTE: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart. Where structural adhesive was present, space the plug weld holes every 20 mm (3/4 in) apart.

1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel (1).

2. Prepare all attachment surfaces as necessary.

3. Prepare all mating surfaces as necessary.

4. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair .

5. Position the service part. Clamp in place.

Fig. 174: Plug Welding Service Part (Full Panel) Courtesy of GENERAL MOTORS COMPANY

6. Plug weld accordingly (1).

7. Clean and prepare all welded surfaces.

8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

9. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems .

10. Install all related panels and components.

11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

12. Enable the SIR system. Refer to SIR Disabling and Enabling .

DESCRIPTION AND OPERATION

DUAL PHASE STEEL

This information provides repair recommendations and general guidelines for steel classified as Dual Phase Steel, also known as DP. This type of steel normally has a tensile strength below 780 MPa.

General Motors recommends the following when repairing or replacing this type of steel during collision repair.

NOTE: The use of heat to repair damage is not recommended for this classification of steel.

Recommended Repairs

Cold repairs can be performed on this type of steel, unless the damage includes kinks. If the damage includes kinks, the part should be replaced.

Sectioning or partial replacement of this type of steel is recommended only at approved locations, in a specific sectioning procedure.

When recommended in a specific sectioning procedure, this type of steel can be used as a weld plate for reinforcing the sectioning location.

Squeeze Resistance Spot Welding can be used to replace factory spot welds, where applicable. MIG plug welding and MIG stitch welding can be used on this type of steel.

MIG Brazing can be used on this type of steel.

HIGH STRENGTH LOW ALLOY STEEL

This information provides repair recommendations and general guidelines for steel classified as High Strength Low Alloy Steel, also known as HSLA. This type of steel normally has a tensile strength range from 300 - 700 MPa.

General Motors recommends the following when repairing or replacing this type of steel during collision repair.

Recommended Repairs

Cold repairs can be performed on this type of steel, unless the damage includes kinks. If the damage includes kinks, the part should be replaced.

Controlled use of heat can be used to repair damage, if the heat does not exceed 650°C (1200°F). The heat should be applied a maximum of 2 times, for up to 90 seconds.

Sectioning or partial replacement of this type of steel is recommended only at approved locations, in a specific sectioning procedure.

When recommended in a specific sectioning procedure, this type of steel can be used as a weld plate for reinforcing the sectioning location.

Squeeze Resistance Spot Welding can be used to replace factory spot welds, where applicable. MIG plug welding and MIG stitch welding can be used on this type of steel.

MIG Brazing can be used on this type of steel.

METAL PANEL BONDING

This information is intended to provide general guidelines for adhesive bonding of steel panels. Panel bonding of steel is only recommended when the panel is originally bonded to the vehicle.

The adhesives listed in this document are known to meet the General Motors specifications and requirements for bonding of steel body panels.

Bonding procedures in general are applicable only at factory joints.

The use of adhesive to section steel panels is not recommended by General Motors.

Rivets, or other mechanical fasteners, may be used in combination with adhesive bonding of steel panels. The

specified rivets, or fasteners, should be used with adhesive, when replacing the original panel.

Two types of adhesives are listed here. Impact Resistant Adhesive is used in joints in frame rail assemblies and strut tower assemblies and other body structure joints that have critical strength requirements. The factory applied Impact Resistant Adhesive is purple in color when cured. The Impact Resistant adhesives available for servicing these joints are considerably stronger once cured than panel bonding adhesives. The other bonding adhesives are non-impact resistant, offer a lower strength rating and can be used in all other joints that are not originally made with Impact Resistant Adhesive.

NOTE: Always follow the adhesive manufacturer's instructions for application, handling, and curing for the specific product.

Adhesives currently meeting the performance requirements include the adhesive products listed below meet these guidelines:

Steel Panel Bonding Impact Resistant

Steel Panel Bonding

MILD STEEL

This information provides repair recommendations and general guidelines for steel classified as Mild Steel. This type of steel normally has a tensile strength less than 270 MPa. This includes the common steel names of:

Mild Steel

Bake Hardenable Steel (BH)

Solid Solution Strengthened Steel

General Motors recommends the following when repairing or replacing this type of steel during collision repair.

Recommended Repairs:

Cold repairs can be performed on this type of steel, unless the damage includes kinks. If the damage includes kinks, the part should be replaced.

Controlled use of heat can be used to repair damage, if the heat does not exceed 650°C (1200°F). The heat should be applied a maximum of 2 times, for up to 90 seconds.

Sectioning or partial replacement of this type of steel is recommended only at approved locations, in a specific sectioning procedure.

When recommended in a specific sectioning procedure, this type of steel can be used as a weld plate for reinforcing the sectioning location.

Squeeze Resistance Spot Welding can be used to replace factory spot welds, where applicable MIG plug welding and MIG stitch welding can be used on this type of steel.

MIG Brazing can be used on this type of steel.

ULTRA HIGH STRENGTH DUAL PHASE STEEL

This information provides repair recommendations and general guidelines for steel classified as Ultra High Strength Dual Phase Steel, also known as DPX. This type of steel normally has a tensile strength of 780 MPa, or greater.

General Motors recommends the following when repairing or replacing this type of steel during collision repair.

NOTE: Repair of this type of steel is not recommended.

This type of steel should be replaced at factory joints only. Sectioning or partial replacement is not recommended.

The use of heat to repair damage is not recommended for this type of steel.

Stitch Welding is not recommended for this type of steel (unless replacing a factory installed stitch weld).

This type of steel should not be used as a weld plate for reinforcing the sectioning location.

Recommended Repairs:

Squeeze Resistance Spot Welding can be used to replace factory spot welds, where applicable. MIG plug welding can be used to replace factory spot welds.

MIG Brazing can be used to replace factory spot welds.

ULTRA HIGH STRENGTH STEEL

This information provides repair recommendations and general guidelines for steel classified as Ultra High Strength Steel, also known as UHSS. This type of steel normally has a tensile strength of 780 MPa, or greater.

This includes the common steel names of

Ultra High Strength Dual Phase Steel (DPX)

Martensitic Steel (M)

Boron/Press Hardened Steel (B) Multi-Phase Steel (MP)

TRIP Steel (TR)

General Motors recommends the following when repairing or replacing this type of steel during collision repair.

NOTE: Repair of this type of steel is not recommended.

This type of steel should be replaced only, at factory joints. Sectioning or partial replacement is not recommended.

The use of heat to repair damage is not recommended for this type of steel.

Stitch Welding is not recommended for this type of steel (unless replacing a factory installed stitch weld).

This type of steel should not be used as a weld plate for reinforcing the sectioning location.

Recommended Repairs

Squeeze Resistance Spot Welding can be used to replace factory spot welds, where applicable. MIG plug welding can be used to replace factory spot welds.

MIG Brazing can be used to replace factory spot welds.

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