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. Create 5 x 18 mm (4/16 x 11/16) slots for MIG-brazing 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 braze to the vehicle.
6. Align the rear side rail.
7. Clean and prepare the attaching surfaces for brazing and spot welding.

Note: In MIG-brazing areas 50 mm (2 in) must be kept clear of structural adhesive.

8. Apply structural adhesive to all attaching surfaces.

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. Braze accordingly.
13. To create a solid braze with minimum heat distortion, make 25 mm (1 in) stitch brazes along the seam with 25 mm (1 in) gaps between them. Then go back and complete the stitch braze.

14. Spot weld accordingly.
15. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
16. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
17. Install all related panels and components.
18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
19. Enable the SIR system. Refer to SIR Disabling and Enabling.