GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Cobalt 🢒 Body Repair 🢒 Collision Repair 🢒 Rear Rail Underbody Reinforcement Replacement

Removal Procedure

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

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

    6. Object Number: 874161 Size: SH

    Note: Note the number and location of the factory welds for installation of the underbody reinforcement of the rear rail.

  6. Locate and drill out all the necessary factory welds.

    7. Object Number: 874164 Size: SH
  7. Remove the underbody reinforcement of the rear rail.

Installation Procedure

    Object Number: 874160 Size: SH

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

  1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the corresponding locations noted on the original panel.
  2. Prepare all mating surfaces as necessary.
  3. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair.

    4. Object Number: 874164 Size: SH
  4. Position the underbody reinforcement to the rear rail and clamp in place.

    5. Object Number: 874161 Size: SH
  5. Plug weld accordingly.
  6. Clean and prepare all of the welded surfaces.
  7. Install all of the related panels and components.
  8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
  9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
  10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  11. Enable the SIR system. Refer to SIR Disabling and Enabling.