Chevrolet Cruze Repair Manual: Installation Procedure

1. Cut the rear side rail in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of one-and-one-half-times the metal thickness at the sectioning joint.
2. Create a 50 mm (2 in) backing plate from the unused portion of the service part.
3. Drill 8 mm (5/16 in) along the sectioning cut on the remaining original part. Locate these holes 13 mm (1/2 in) from the edge of part and spaced 40 mm (1½ in) apart.
4. Prepare all mating surfaces as necessary.
5. Fit the backing plates halfway into the sectioning joints, clamp in place and plug weld to the vehicle.
6. Align the rear side rail.

7. Drill 8 mm (5/1 in) for plug welding along the edges of the rear side rail as noted from the original panel.
8. Clean and prepare the attaching surfaces for welding.

9. Position   the rear side rail on the vehicle.
10. Verify the fit of the rear side rail.
11. Clamp the rear side rail into position.

12. Plug weld accordingly.
13. To create a solid weld with minimum heat distortion, make 25 mm (1 in) stitch welds along the seam with 25 mm (1 in) gaps between them. Then go back and complete the stitch weld
14. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
15. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
16. Install all related panels and components.
17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
18. Enable the SIR system. Refer to SIR Disabling and Enabling.