GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 HHR 🢒 Body Repair 🢒 Collision Repair 🢒 Back Body Opening Upper Frame Replacement

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.

  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. Object Number: 1607825 Size: SH
  3. Remove all of the related panels and the components.
  4. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
  5. Repair as much of the damage as possible. Refer to Dimensions - Body.

    6. Object Number: 1607879 Size: SH
  6. Locate the notch in the window opening pinchweld flange.

    7. Object Number: 1607880 Size: SH

    Note: Do not section the rail in any area other than location given.

  7. Align a sliding square or similar tool to the top portion of the notch and scribe a line across the reinforcement.

    8. Object Number: 1607888 Size: SH
  8. Use the same tool to transfer this scribed line onto the back side of the reinforcement.

    9. Object Number: 1607887 Size: SH
  9. Cut at the marked location.

    10. Object Number: 1607882 Size: SH
  10. Remove the damaged component from the vehicle.

    11. Object Number: 1607886 Size: SH
  11. Drill 2 8 mm (5/16 in) plug weld holes on each of the 2 sides of the reinforcement. Position the center of the holes 10 mm (3/8 in) from the cut edge.

Installation Procedure
  1. Locate the notch on the service part.

    2. Object Number: 1607880 Size: SH
  2. Align a sliding square or similar tool to the top of the notch in the window opening pinchweld flange. Scribe a line across the service part.
  3. Use the same tool to transfer this scribed line onto the back side of the service part.

    4. Object Number: 1607881 Size: SH
  4. Place a mark 25 mm (1 in) above the scribed line on all 2 sides of the service part.
  5. Use the tool to scribe a line on all  sides of the service part.
  6. Cut at the top scribed line created on the service part.

    7. Object Number: 1607884 Size: SH
  7. Remove the service part portion of the reinforcement.

    8. Object Number: 1607885 Size: SH
  8. Cut the upper outer flanges of the reinforcement at the section joint on the service part. Cut the flanges (a) down 25 mm (1 in) and remove the tabs.
  9. Cut the radius corner (b) of the service part down 25 mm (1 in) also and remove the small corner piece.

    10. Object Number: 1608090 Size: SH
  10. Bend the bottom side of the service part at the sectioning location inward slightly by aligning a vice grip flanging tool or similar tool at the lower scribed line at the top of the notch.
  11. Prepare the service part for welding.
  12. Apply 3M® Weld-Thru coating P/N 05916 or equivalent to all mating surfaces.

    13. Object Number: 1607882 Size: SH

    Note: The service part sectioning joint is to go inside the original reinforcement with a 25 mm (1 in) overlap.

  13. Position the rear rail section using 3-dimensional measuring equipment. Clamp the service part in place.
  14. Tack weld the part into position.
  15. Inspect the service part for proper dimensions, using 3-dimensional measuring equipment.
  16. Plug weld at each 8 mm plug weld hole location.
  17. Stitch weld along the entire sectioning joint. Make welds along the seam with 25 mm (1 in) gaps between. Weld the gaps.
  18. Clean and prepare the welded surfaces.
  19. Install all of the related panels and components.
  20. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
  21. Paint the repaired area. Refer to Anti-Corrosion Treatment and Repair.
  22. Enable the SIR system. Refer to SIR Disabling and Enabling.
  23. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.