Chevrolet Corvette 2016 User manual

Body Repair
Collision Repair
Specifications
Fastener 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
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.