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.

Front Wheelhouse Panel Replacement
Special Tools
J 42058 Frame Adapter Clamp
Removal Procedure
Warning:Refer to Approved Equipment for Collision Repair Warning.
The front wheelhouse is comprised of 2 types of materials. These include sheet molded compound (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 and Enabling.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove all related panels and components.
4. Remove the wheelhouse by applying heat and pry to detach adhesive along the bonding surface(1).

5. Remove the wheelhouse(1) from the vehicle.
6. Save any and all brackets, mounting studs, and accessories for transfer to the new front wheelhouse.
7. Note the location of the adhesive and remove all remaining loose adhesive.
8. Inspect the front structure and frame rails for damage.
9. Repair as much of the damage as possible to the factory specifications.
10. Use J 42058 frame adapter clamp to secure the vehicle if pulling and straightening is required.
Installation 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 any bonding surface. Use primer only on bonding surfaces. Refer to adhesive manufacturer's recommendations.
2. Clean and scuff all bonding mating surfaces according to adhesive manufacturer's recommendations.
3. Inspect old wheelhouse for factory adhesive bond line. Apply a consistent bead of structural adhesive(1) 10mm (3/8in) in diameter to the wheelhouse
to mate with the front structure and frame rail. Refer to Sheet Molded Compound (SMC) Panel Bonding.

4. Install the wheelhouse(1) to the vehicle.
5. Apply pressure to the wheelhouse to set the adhesive.
6. Clamp or mechanically 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. Refer to Battery Negative Cable Disconnection and Connection.
10. Enable the SIR system. Refer to SIR Disabling and Enabling.

Front Hinge Pillar Body Replacement
Removal Procedure
Note: When welding cast aluminum recommend wire alloy is 4043 and the recommend wire size is 0.035. The shielding gas is 100 percent Argon.
The front hinge pillar panel is bolted, welded, and bonded with structural adhesive to the side structure and frame rail. The replacement front hinge pillar panel is
comprised of two types of materials. These include 6063 aluminum for the upper panel and A356 cast aluminum for the lower panel. You must remove and
replace the side door 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 the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove all related panels and components.
4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - BodyDimensions - Body (Motor Compartment - Corvette).
5. Note the location of the sealers and the anti-corrosion materials and remove these components from the repair area as necessary. Refer to Anti-
Corrosion Treatment and Repair.
6. Remove the bolts(1) attaching the front hinge pillar to the windshield frame.

Note: Do NOT damage the inner panels or the reinforcements.
Note: Hand tools, saw blades and abrasives used for aluminum repairs should be dedicated for aluminum only to prevent contamination.
7. Locate and remove all factory welds(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 number and location of the welds for installation of the new hinge pillar.
9. Locate and remove all factory welds(1) from the inner hinge pillar. Note the number and location of the welds for installation of the new hinge pillar.

10. Remove the damaged hinge pillar.
11. Note the location of the adhesive and remove all remaining loose adhesive.
Installation Procedure
1. Before applying the adhesive, dry fit the hinge pillar for proper fit and alignment.
Note: Use primer only on bonding surfaces. Do NOT top coat any bonding surfaces. Refer to the adhesive manufacture's recommendation.
2. Clean and prepare all bonding mating surfaces according to the adhesive manufacturer's recommendations.
3. Apply a consistent bead of structural adhesive 10mm (3/8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 Fastener Caution.
5. Install the bolts(1) that attach the windshield frame to the front hinge pillar and tighten to 25Y(18lbft).
Note: Use a stainless steel brush to remove the oxide layer prior to welding.
6. Prepare all welding attachment surfaces as necessary.
Note: Recommend wire alloy is 4043 and wire size is 0.035. The shielding gas is 100 percent Argon. A 2 minute cooling down period is recommend for
every 2 minutes or 100 mm (4 in) of welding.
Using a PULSED-MIG welder, tack weld the hinge pillar to the vehicle.

7. Using a PULED-MIG welder, stitch weld the front outer hinge pillar to the vehicle in the locations noted on the original panel.
8. Using a PULED-MIG welder, stitch weld the rear outer hinge pillar to the vehicle in 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 anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
11. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems.
12. Install all related panels and components.

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.

Body Lock Pillar Outer Panel 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. 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 Striker Pillars Warning.
5. Note the location of the sealers and anti-corrosion materials and remove these components from the repair area as necessary. Refer to Anti-Corrosion
Treatment and Repair.
6. Locate and remove all factory welds(1). Note the number and the location of the welds for installation of the replacement part.

7. Remove the damaged outer lock pillar.
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 pillar (1) as noted from the original panel.