Body Lock Pillar Outer Panel Reinforcement Sectioning. Chevrolet Cobalt 2009

For 1990-2009 cars only

Makes 🢒 Chevrolet 🢒 2009 🢒 Cobalt 🢒 Body Repair 🢒 Collision Repair 🢒 Body Lock Pillar Outer Panel Reinforcement Sectioning

Removal Procedure

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

Warning: 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.

Disable the SIR system. Refer to SIR Disabling and Enabling.
Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
Remove all related panels and components.
Repair as much of the damaged area as possible. Refer to Dimensions - Body.
Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.

For the sedan pillar, perform the following steps:

6.1.	On the center pillar reinforcement, locate and mark the center of the third hole down (b).

6.2.	Measure up from the center of that hole 100 mm (4 in) (a). This is the cut line.

Note: Do not damage any inner reinforcements.

6.3.	Cut the panel at the mark made previously.

For the coupe pillar, perform the following steps:

7.1.	Measure down from the hole in the front lower corner of the rear quarter window 127 mm (5 in) (A). This is the cut line. Mark the cut line location.

Note: Do not damage any inner reinforcements.

7.2.	Cut the panel at the mark made previously.

7.3.	Locate and drill out all factory welds. Note the number and location of the welds for installation of the service part.

Remove the damaged center pillar.

Installation Procedure

For the sedan pillar, perform the following steps:

1.1.	Mark a line through the center of the third hole (b) down from the top on the center pillar reinforcement service part.

1.2.	Measure 127 mm (5 in) (a) up from the previously made mark. This is the cut line for the service part.

For the coupe pillar, measure down 100 mm (4 in) (A) from the hole in the front lower corner of the quarter panel window. Mark the cut line location for the service part.

Cut the replacement service part at the marked line.

At the cut area of the service part, notch the weld flange areas down 25 mm (1 in) (a).

The sedan is shown; the coupe is similar.

Drill 8 mm (5/16 in) plug weld holes along the sectioning cut on the original reinforcement. Locate these holes 10 mm (½ in) from the edge.
Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the corresponding locations noted on the original panel.
Prepare all mating surfaces for welding as necessary.
Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair.
Slide the top sectioning joint together by sliding the service part under the original part at the sectioning area.
Position the service part on the vehicle using 3-dimensional measuring equipment. Clamp the part in place.
Plug weld accordingly.
To create a solid weld with minimum heat distortion, make 25 mm (1 in) stitch welds along the sectioning joint seam with gaps of 25 mm (1 in). Go back and complete the stitch weld.
Clean and prepare all of the welded surfaces.
Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
Install all of the related panels and components.
Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
Enable the SIR system. Refer to SIR Disabling and Enabling.