Chevrolet Corvette 2016 Manuel utilisateur

Body Repair

Collision Repair

Specifications

Fastener Specifications

Application SpecificationApplication

Metric English

Cross-Car Brace Mounting Bolts 25Y18lbft

Windshield Frame Mounting Bolts 25Y18lbft

Dimensions - Body

Point-to-point measurements are for reference only. All measurements are given in millimeters. Use these measurements for diagnosing and estimating. Point-to-

point measurements are duplicated with tram bar pointers set at equal lengths. All die marks, holes, slots, and fasteners are measured to the center. All

dimensions are symmetrical unless otherwise specified

Point to Point Measurements

Dimensions - Body (Motor Compartment - Corvette)

Point-to-point measurements are for reference only. All measurements are given in millimeters. Use these measurements for diagnosing and estimating. Point-to-

point measurements are duplicated with tram bar pointers set at equal lengths. All die marks, holes, slots, and fasteners are measured to the center. All

dimensions are symmetrical unless otherwise specified

Point to Point Measurements

VisualIdentification

Structure Identification

Number Description Material Procedure

1Rear Compartment Panel Frame Sheet Molded Compound (SMC)

Panel Bonding

Rear Compartment Panel Frame

Replacement

2Windshield Frame Aluminum Windshield Frame Replacement

3Front Wheelhouse Sheet Molded Compound (SMC)

Panel Bonding

Front Wheelhouse Panel

Replacement

4Side Door Frame Opening Sheet Molded Compound (SMC)

Panel Bonding

Side Door Opening Frame

Replacement

5Floor Panel Sheet Molded Compound (SMC)

Panel Bonding

Floor Panel Replacement

6Rear Compartment Panel Sheet Molded Compound (SMC)

Panel Bonding

Rear Compartment Panel

Replacement

Structure Identification

Number Description Material Procedure

1Hood Plate Stud Aluminum Hood Plate Stud Replacement

2Front Bumper Impact Bar Aluminum Front Bumper Impact Bar

Replacement

3Front Rail (Front Section) Aluminum Front Rail Replacement (Rear

Section)Front Rail Replacement

(Front Section)

4 Front Rail Section (Rear Section) Aluminum Front Rail Replacement (Rear

Section)Front Rail Replacement

(Front Section)

5Front Body Hinge Pillar Aluminum Front Hinge Pillar Body Replacement

6Front Door Lock Pillar Aluminum Body Lock Pillar Outer Panel

Replacement

7Rear Rail Replacement (Front

Section)

Aluminum Rear Rail Replacement (Front

Section)Rear Rail Replacement

(Rear Section)

8Rear Rail Replacement (Rear

Section)

Aluminum Rear Rail Replacement (Front

Section)Rear Rail Replacement

(Rear Section)

9Rear Bumper Impact Bar Aluminum Rear Bumper Impact Bar

Replacement

RepairInstructions

Front Bumper Impact Bar Replacement

Removal Procedure

Warning:Refer to Approved Equipment for Collision Repair Warning.

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. Note the location and remove the sealers and anti-corrosion materials from the repair area. Refer to Anti-Corrosion Treatment and Repair.

Note:

•Hand tools, saw blades and abrasives used for aluminum repairs should be dedicated for aluminum only to prevent contamination.

•When removing welds, favor the bumper bar side of the weld joint.

5. Locate and remove all factory welds(1) attaching the front bumper bar to the front frame rails. Note the location of the welds for installation of the new

bumper bar.

6. Remove the damaged bumper bar(1).

7. Remove pieces of the bumper bar which are left attached to the rail ends.

8. Straighten and deburr the rail ends. Keep the perimeter and shape of the rail end as original as possible.

Installation Procedure

1. Dry fit the bumper bar for proper fit and alignment before welding.

Note: Use a stainless steel brush to remove the oxide layer prior to welding.

2. Clean and prepare all of the welded mating surfaces.

3. Install the front bumper bar(1).

4. Position the bumper bar to the vehicle using 3-dimensional measuring equipment.

Note: Recommend wire alloy is 5554 and wire size is 0.035. The shielding gas is 100 percent Argon.

A two minute cooling down period is recommend for every 2 minutes or 100mm (4in) of welding.

5. Using a MIG welder, equipped with PULSE technology (P-MIG), weld(1) the bumper bar to the frame rail ends duplicating the factory welds.

6. Apply the sealers and anti-corrosion materials to the repair area. Refer to Anti-Corrosion Treatment and Repair.

7. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems.

8. Install all related panels and components.

9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.

10. Enable the SIR system. Refer to SIR Disabling and Enabling.

Hood Plate Stud Replacement

Removal Procedure

The hood anchor plate assembly is riveted to the inside of the front frame rail. Access to the hood plate assembly will require the removal of the welded front

bumper bar.

Warning:Refer to Approved Equipment for Collision Repair Warning.

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. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair

5. Remove the hood hinge. Refer to Hood Hinge Replacement.

6. Remove the front impact bar. Refer to Front Bumper Impact Bar Replacement.

7. Drill out the two retaining rivets (1) holding the hood hinge bolt bracket.

8. Remove the broken hinge bolt.

Installation Procedure

Note: Replacement fasteners used with aluminum frames requires a tin-zinc coating to prevent galvanic corrosion.

1. Install replacement part.

2. Install the hood hinge retaining bolt bracket rivets.

3. Install the front impact bar. Refer to Front Bumper Impact Bar Replacement.

4. Install the hood hinge. Refer to Hood Hinge Replacement.

5. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.

6. Apply the sealers and the anti-corrosion materials to the repaired area, as necessary. Refer to Anti-Corrosion Treatment and Repair.

7. Install all related panels and components.

8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.

9. Enable the SIR system. Refer to SIR Disabling and Enabling.

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