Chevrolet Cruze Repair Manual: Headlamp Mount Panel Replacement (MAG-Welding)

Note: According to different corrosion warranties, only the regional mandatory joining methods are allowed.

Removal Procedure

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

Warning: Refer to Glass and Sheet Metal Handling 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. Visually inspect the damage. Repair as much of the damage as possible.
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.

6. Locate and mark all the necessary factory welds of the headlamp mount panel.
7. Drill all factory welds. Note the number and location of welds for installation of the service assembly.

8. Cut the adhesive (1) with an appropriate tool.

9. Remove the headlamp mount panel.

Installation Procedure

1. Drill 8 mm (5/16 in) for plug welding instead of the adhesive noted   from the original panel.
2. Drill 8 mm (5/16 in) for plug welding along the edges of the headlamp mount panel as noted from the original panel.
3. Clean and prepare the attaching surfaces for welding.

4. Position the headlamp mount panel on the vehicle.
5. Verify the fit of the headlamp mount panel.
6. Clamp the headlamp mount panel into position.

7. Plug weld accordingly.
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. Install all related panels and components.
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
12. Enable the SIR system. Refer to SIR Disabling and Enabling.