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Chevrolet Corvette 2016, Service Manual

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Chevrolet Corvette 2016 Service Manual Download Page 38

14.

Install the upper plenum

 

(1) to the windshield frame.

15.

Install the close-end rivets, in the factory locations, securing the upper plenum to the windshield frame.

16.

Remove any excess adhesive.

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

.

Summary of Contents for Corvette 2016

Page 1: ...ion Repair Specifications Fastener Specifications Fastener Specifications Application Specification Application Metric English Cross Car Brace Mounting Bolts 25 Y 18 lb ft Windshield Frame Mounting Bo...

Page 2: ...imeters 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...

Page 3: ...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 fastener...

Page 4: ...ndshield Frame Aluminum Windshield Frame Replacement 3 Front Wheelhouse Sheet Molded Compound SMC Panel Bonding Front Wheelhouse Panel Replacement 4 Side Door Frame Opening Sheet Molded Compound SMC P...

Page 5: ...lacement 3 Front 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 Fro...

Page 6: ...Rail Replacement Front Section Rear Rail Replacement Rear Section 8 Rear Rail Replacement Rear Section Aluminum Rear Rail Replacement Front Section Rear Rail Replacement Rear Section 9 Rear Bumper Imp...

Page 7: ...er 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 th...

Page 8: ...fore 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 ba...

Page 9: ...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 repai...

Page 10: ...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 Replacemen...

Page 11: ...d SMC for the inner panel and carbon fiber for the outer panel The wheelhouse is bonded to the front structure and frame rail with structural adhesive 1 Disable the SIR system Refer to SIR Disabling a...

Page 12: ...nstallation Procedure Note Shims may be necessary to achieve proper panel alignment 1 Before applying adhesive dry fit the wheelhouse fender and hood for proper fit and alignment Note DO NOT top coat...

Page 13: ...fasten the wheelhouse into place as necessary 7 Remove any excess adhesive and let dry to manufactures specifications 8 Install all related panels and components 9 Connect the negative battery cable R...

Page 14: ...oor opening panel in order to replace the front hinge pillar Warning Refer to Approved Equipment for Collision Repair Warning 1 Disable the SIR system Refer to SIR Disabling and Enabling 2 Disconnect...

Page 15: ...1 from the front outer hinge pillar Note the number and location of the welds for installation of the new hinge pillar 8 Locate and remove all factory welds 1 from the rear outer hinge pillar Note the...

Page 16: ...8 in in diameter to mate with the bonding surfaces Refer to Sheet Molded Compound SMC Panel Bonding 4 Position the hinge pillar to the vehicle using 3 dimensional measuring equipment Caution Refer to...

Page 17: ...n the locations noted on the original panel 1 9 Using a PULED MIG welder stitch weld the inner hinge pillar to the vehicle in the locations noted on the original panel 10 Apply the sealers and the ant...

Page 18: ...13 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 14 Enable the SIR system Refer to SIR Disabling and Enabling...

Page 19: ...components 4 Repair as much of the damage as possible to factory specifications Refer to Dimensions BodyDimensions Body Motor Compartment Corvette Warning Refer to Sound Deadener Foam in the Lock Stri...

Page 20: ...Installation Procedure 1 Position the outer lock pillar 2 Clean and prepare all mating surfaces as necessary for welding 3 Drill 8 mm 5 16 in for plug welding around the perimeter of the outer lock pi...

Page 21: ...k pillar to the structure duplicating the factory welds 1 7 Apply the sealers and the anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 8 Paint the...

Page 22: ...mage as possible to the factory specifications 6 Use J 42058 frame adapter clamp to secure the vehicle if pulling and straightening are required 7 Note the location and remove the sealers and anti cor...

Page 23: ...and deburr the rail ends Keep the perimeter and shape of the rail ends as original as possible Installation Procedure 1 Temporarily position the impact bar for proper fit and alignment 2 Clean and pre...

Page 24: ...ve manufacturer s recommendations 8 Clean and prepare all bonding mating surfaces according to adhesive manufacturer s recommendations 9 Apply a consistent bead of structural adhesive to the top impac...

Page 25: ...adapter clamp or equivalent to secure the vehicle if pulling and straightening are required 8 Inspect the front of the dash panel floor panels and all other sheet molded compound SMC and carbon fiber...

Page 26: ...ill release from the structure by applying heat to approximately 200 C 400 F A noticeable popping sound can normally be heard when the adhesive releases 15 Locate and remove all factory welds from the...

Page 27: ...7 Remove the screws from the floor panel bracket 1 18 Remove the bolts from the frame rail 1 19 Favoring the center rail cut the weld from the cast rail section using a cut off wheel or equivalent too...

Page 28: ...el upper support and lower the frame rail extensions To complete the removal of the frame rail apply heat to the upper support and lower frame rail extensions to cause the adhesive to release and then...

Page 29: ...screws in the front floor panel upper support 1 Note Pre Drill holes with 7 32 or 5 6 mm drill before installation of service screw As noted from original part 3 Install the service screws in the low...

Page 30: ...stitch weld the outer and lower rail duplicating the factory welds 1 6 Using a P MIG welder stitch weld the rail on the inside duplicating the factory welds 1 Note Pre Drill holes with 7 32 or 5 6 mm...

Page 31: ...r Panel Replacement 12 Install the front impact bar Refer to Front Bumper Impact Bar Replacement 13 Apply the sealers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosi...

Page 32: ...s or areas that may need to be repaired or resealed 7 Remove the damaged section of frame rail Cut the welds around the perimeter using a cut off wheel or equivalent tool Grind off the remaining weld...

Page 33: ...ding gas is 100 percent Argon A two minute cooling down period is recommended for every 2 minutes or 100 mm 4 in of welding 6 Apply the sealers and anti corrosion materials to the repair area Refer to...

Page 34: ...ended 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...

Page 35: ...shield frame to the front hinge pillars 11 Remove the windshield frame 1 by applying heat and pry to detach the adhesive along the bonding surface 12 Save any and all brackets mounting studs and acces...

Page 36: ...alignment Note DO NOT top coat any bonding surface Use primer only on bonding surfaces Refer to adhesive manufacturer s recommendations 2 Clean and prepare all bonding mating surfaces according to ad...

Page 37: ...ets to secure the lower plenum to the windshield frame while adhesive cures 9 Apply the structural adhesive to the area where the cross car brace bonds to the center tunnel assembly Refer to Sheet Mol...

Page 38: ...ry locations securing the upper plenum to the windshield frame 16 Remove any excess adhesive 17 Install all related panels and components 18 Connect the negative battery cable Refer to Battery Negativ...

Page 39: ...Verify that the fuel inlet is sealed before proceeding with repair procedure 5 Remove the door frame by applying heat and pry to detach the adhesive 1 along the bonding surface 6 Remove the door fram...

Page 40: ...olded Compound SMC Panel Bonding 6 Install the door frame on the vehicle 7 Apply pressure to the door frame to set the adhesive 8 Clamp or tape the door frame in place as necessary 9 Remove any excess...

Page 41: ...ry Refer to Anti Corrosion Treatment and Repair 6 Repair as much of the damage as possible to the factory specifications 7 Inspect the floor panels and all other sheet molded compound SMC for cracks o...

Page 42: ...ds for installation of the new extension panel 12 Remove the screws from the extension panel bracket 1 13 Remove the screws from the floor panel bracket 1 14 Favoring the center rail cut the welds aro...

Page 43: ...nel bracket 1 Refer to Sheet Molded Compound SMC Panel Bonding 2 Install the screws for the floor panel bracket 1 Refer to Sheet Molded Compound SMC Panel Bonding Note Recommended wire alloy is 5554 a...

Page 44: ...n The shielding gas is 100 percent Argon 6 Using a P MIG welder plug weld the outer body extension panel 1 duplicating the factory welds Note Pre Drill holes with 7 32 or 5 6 mm drill before installat...

Page 45: ...frame rail Cut the welds around the perimeter using a cut off wheel or equivalent tool Grind off the remaining weld from the casting 1 Installation Procedure Warning Refer to Collision Sectioning Warn...

Page 46: ...shielding gas is 100 percent Argon A two minute cooling down period is recommended for every 2 minutes or 100 mm 4 in of welding 6 Apply the sealers and anti corrosion materials to the repair area Ref...

Page 47: ...fer to Battery Negative Cable Disconnection and Connection 3 Remove all related panels and components 4 Remove or reposition electrical components and wiring harness as necessary to avoid damage 5 Rem...

Page 48: ...proper fit and alignment Note DO NOT top coat any bonding surface Use primer only on bonding surfaces Refer to adhesive manufacturer s recommendations 2 Clean and prepare all bonding mating surfaces a...

Page 49: ...erimeter of floor panel from underside of vehicle to form a consistent leak proof seal 8 Clamp or mechanically fasten the front end panel into place as necessary 9 Remove any excess adhesive 10 After...

Page 50: ...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 Warn...

Page 51: ...pry to detach the adhesive along the bonding surface 10 Remove the rear compartment panel 11 Save all brackets mounting studs and accessories for transfer to the new rear compartment panel 12 Note the...

Page 52: ...Bonding The top of the frame rails The backside of the lock pillars Over the fuel filler neck To all original bonding surfaces Note The rear compartment panel is positioned to the frame rail using 2 d...

Page 53: ...p or mechanically fasten the rear compartment panel in place as necessary 9 Remove any excess adhesive 10 Install the rear compartment frame panels Refer to Rear Compartment Panel Frame Replacement 11...

Page 54: ...ipment 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...

Page 55: ...ignment Use care to keep shims out of adhesive path 1 Before applying the adhesive dry fit the rear compartment frame for proper fit and alignment 2 Clean and prepare all bonding mating surfaces accor...

Page 56: ...ve 6 Clamp or mechanically fasten the rear compartment frame into place 7 Remove any excess adhesive 8 Install all related panels and components 9 Connect the negative battery cable Refer to Battery N...

Page 57: ...ther mechanical fasteners may be required in combination with adhesive bonding if they were used on the original panel or recommended in the specific service procedure The recommended rivets fasteners...

Page 58: ...trength requirements The factory applied Impact Resistant Adhesive is purple in color when cured The Impact Resistant adhesives available for servicing these joints are considerably stronger once cure...

Page 59: ...urers can produce unsatisfactory results DO NOT top coat any adhesive bonding mating surface Use primer only on bonding surfaces Refer to adhesive manufacturer s recommendations for priming applicatio...

Page 60: ...Special Tools and Equipment Special Tools Illustration Tool Number Description J 42058 Frame Adapter Clamp...

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