GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2007 🢒 HHR 🢒 Body Repair 🢒 Collision Repair 🢒 Rocker Inner Panel Replacement

Removal Procedure

    Caution: Refer to Approved Equipment for Collision Repair Caution 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 damaged area as possible. Refer to Dimensions - Body .

    5. Object Number: 1581895 Size: SH
  5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

    6. Important: Note the number and location of the factory welds for installation of the inner rocker panel.

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

    7. Object Number: 1581897 Size: SH
  7. Locate and drill out the spot welds on the lower dog leg of the body side inner panel to allow relocating the lower portion to gain access to the rocker inner.

    8. Object Number: 1625894 Size: SH
  8. Remove the inner rocker panel.

Installation Procedure

    Object Number: 870906 Size: SH

    Important: If the location of the original plug weld holes cannot 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 locations noted from the original panel.
  2. Prepare all mating surfaces, as necessary.
  3. Apply 3M® Weld-Thru coating P/N 05916 or equivalent to all mating surfaces.

    4. Object Number: 1625894 Size: SH
  4. Position the inner rocker panel and clamp the panel in place.

    5. Object Number: 1581895 Size: SH
  5. Plug weld accordingly.

    6. Object Number: 1581897 Size: SH
  6. Place the relocated portion of the body side inner panel into position.
  7. Plug weld accordingly.
  8. Clean and prepare all of the welded surfaces.
  9. Install all of the related panels and components.
  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. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  13. Enable the SIR system. Refer to SIR Disabling and Enabling .