GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Cobalt 🢒 Body 🢒 Collision Repair 🢒 Body Lock Pillar Outer Panel Sectioning

Removal Procedure

    Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

    Caution: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle and cause personal injury if the vehicle is in a collision.

  1. The body side outer panel is a one-piece assembly. You can perform any one of these replacement procedures separately or in any combination, depending upon the extent of the damage to the vehicle. Sectioning must take place in specified areas only.

    2. Remove all related panels and components.

  2. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
  3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  4. Remove the sealers and anti-corrosion materials from the repair area, as necessary and note their location. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
  5. Repair as much of the damaged area as possible. Refer to Dimensions - Body .

    6. Object Number: 1544708 Size: SH
  6. At the top of the center pillar, mark a line (a) through the center of the second outer trim attachment hole.

    7. Object Number: 1544709 Size: SH
  7. Measure down 50 mm (2 in) (b) from the mark created in the previous step. Mark the location.

    8. Object Number: 1544711 Size: SH
  8. Create cut lines on the rocker panel within the approved sectioning locations as needed.

    9. Object Number: 1544710 Size: SH

    Important: Sectioning procedures can only take place in the straight areas of the body side panel.

  9. Measure from any key feature in the panel. Lay out the cut line location on the body side panel.
  10. Cut the panel at the center pillar where the lay out line was previously formed.

    11. Object Number: 876974 Size: SH
  11. Cut the panel at the rocker panel area where sectioning is to be performed, within the straight sections only.

    12. Object Number: 1544712 Size: SH
  12. Locate and drill out all factory welds. Note the number and location of welds for installation of the service part.
  13. Remove the damaged center pillar.

Installation Procedure

    Object Number: 1544713 Size: SH
  1. Cut the outer center pillar in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of 1½ times the metal thickness at the sectioning joint.
  2. In all the rocker panel areas, create a 100 mm (4 in) backing plate from the unused portion of the service part. Trim the backing plates as necessary to fit behind the sectioning joint.
  3. In the upper center pillar area, cut a 50 mm (4 in) backing plate from the unused portion of the source part trim as necessary.

    4. Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1½ in) apart.

  4. Drill 8 mm (5/16 in) holes along the sectioning area on the service and original part. Locate these holes 13 mm (1/2 in) from the edge.
  5. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the corresponding locations noted on the original panel.
  6. Prepare all mating surfaces for welding as necessary.
  7. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
  8. Create backing plates 50 mm (2 in) for the upper center pillar and 100 mm (4 in) for the rocker panel. Create the backing plates from the unused portion of the service part.
  9. Trim the backing plates as necessary to fit behind the panel at the sectioning joints.
  10. Clamp the backing plates in place. Plug weld the backing plates to the vehicle.
  11. Position the outer center pillar to the vehicle using 3-dimensional measuring equipment. Clamp the pillar in place.
  12. Plug weld accordingly.

    13. Object Number: 876971 Size: SH
  13. To create a solid weld with minimum heat distortion, make a 25 mm (1 in) stitch weld along the seam with gaps of 25 mm (1 in). Go back and complete the stitch weld.
  14. Clean and prepare all of the welded surfaces.
  15. Apply sound deadening materials as necessary.
  16. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
  17. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
  18. Install all of the related panels and components.
  19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  20. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.