Repair steps guaranteed to keep subcompact cars from becoming big headaches

June 27, 2018
The size of subcompact cars can complicate typical repairs. Use the following tips and steps to iron out any issues and smooth the way for a great job.

If you’re old enough, you probably remember a time when buying an inexpensive, small car meant being banished to some kind of automotive purgatory. Buyers almost invariably ended up with a four-wheel something sporting cheap materials, a thin metal skin and whiney engine — maybe air conditioning was included. Also included was bland, boxy styling that, at best, helped one blend in with a sea of similar automotive outcasts. You wanted a cheap car, and that’s exactly what you got.

(Photo courtesy of GM) The 2017 Chevrolet Sonic and other competitors such as the Ford Fiesta and Honda Fit offer plenty of power, style and safety technology in small packages, keeping subcompacts significant players in the automotive market.

How things have changed. Today’s small cars offer power, performance, safety, punchy looks and a host of techno-gadgets designed to convince millennials and first-time buyers to hop in the driver’s seat while saving some money. They still come with a few issues, for repairers, that is. Their size can force shops to throw in a few wrinkles with typical repairs. Use the following tips and steps to iron out any complications and smooth the way for a great job.

Considerations

What’s so difficult about repairing subcompacts? Their compact sizes condense standard repair issues into much tighter spaces. Alternative and mixed material parts are packed closer together, as are highly sensitive electronic systems. Sectioning will remain an issue, and so will using the right joining techniques in smaller areas. Tighter spaces also make electronic systems even more vulnerable to collision damage.

Then there’s the matter of less vehicle volume available to absorb and transmit collision energy way from an accident area. This can translate into more severe and hidden damage, making accurate damage analysis and pre- and post-repair scans even more critical.

This fact is further complicated by the sheer level of technology packed away in these might mites. Subcompacts offer many of the same options as larger vehicles, including backup cameras and lane watch and lane departure warnings. They don’t come up short in passenger protection. The 2017 Chevrolet Sonic, whose repairs are noted below, arrives with ten standard air bags--including side-curtain air bags, pelvic/thorax side-impact air bags (front and rear) and front knee air bags.

These factors can add up to a greater likelihood that repair costs might exceed totaling thresholds, especially considering the modest value of these vehicles. You could end up helping owners find ways to reduce costs to ensure they can hold on to their cars.

Sonic Booms

The 2017 (and earlier model year) Chevrolet Sonic provides many of these challenges (as do vehicles like the Ford Fiesta and Honda Fit. The steps listed here (courtesy of GM) for three repairs take into account a number of material and electronic issues. Note how the steps are quite similar to those performed on larger vehicles. You’ll want to put extra attention on places where you need to inspect for or repair related damage since it may be more difficult to spot. Also, note the need to locate any and all factory welds in an accident area.

(Photo courtesy of Honda)
(Photo courtesy of GM) The Sonic and Fit come with multiple airbags, providing passengers with plenty of protection that also can drive up repair costs.

Body Side Frame Rocker Reinforcement Replacement

Removal Procedure

Before beginning, refer to the Approved Equipment for Collision Repair Warning Glass and Sheet Metal Handling Warning documentation.

Note: The body side frame rocker reinforcement is made of Ultra High Strength Dual Phase Steel and should be replaced only at factory joints.

Repairing or sectioning of this part is not recommended. Refer to Ultra High Strength Dual Phase Steel.

1. Disable the SIR system. Refer to SIR Disabling and Enabling document.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection document.

3. Remove all related panels and components.

4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body (4NB) or Dimensions - Body (5HB) documents, according to vehicle body type.

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (Base).

6. Locate and mark all the necessary factory welds of the body side frame rocker reinforcement.

7. Drill all factory welds. Note the number and location of welds for installation of the service assembly.

8. Remove the damaged body side frame rocker reinforcement.

Installation Procedure

1. Align the body side frame rocker reinforcement.

2. Drill a 8 mm (5/16 in) holes for plug welding along the edges of the quarter outer panel from the original panel.

3. Clean and prepare the attaching surfaces for welding.

4. Position the body side frame rocker reinforcement on the vehicle.

5. Verify the fit of the body side frame rocker reinforcement.

6. Clamp the body side frame rocker reinforcement into position.

7. Plug the weld.

8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (Base) document.

9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems document.

10. Install all related panels and components.

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

12. Enable the SIR system. Refer to SIR Disabling and Enabling document.

(Photo courtesy of GM) Subcompacts incorporate significant amounts of alternative materials that must be taken into account during repairs.

Front Side Door Outer Panel Replacement

Removal Procedure

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

1. Disable the SIR System. Refer to SIR Disabling and Enabling document.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection document.

3. Remove the front side door. Refer to Front Side Door Replacement document.

4. Remove the front side door outside handle. Refer to Front Side Door Outside Handle Replacement document.

5. Remove the outside rearview mirror. Refer either to Outside Rearview Mirror Replacement (Power) or Outside Rearview Mirror Replacement (Manual) document.

6. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (Base).

7. Grind the edges of the front side door outer panel to separate the outer door panel from the door shell.

Warning: Inspect the door guard beam for damage before replacement of the door outer panel. If damage to the door guard beam is found the door must be replaced. Failure to do so may compromise the structural integrity of the vehicle and may cause personal injury if the vehicle is involved in a collision.

8. Remove the front side door outer door panel.

9. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (Base) document.

10. Straighten the edges of the door shell.

Installation Procedure

1. Align the front side door outer panel.

2. Verify the fit of the front side door outer panel.

3. Clamp the front side door outer panel into position.

4. Continue to hammer in stages along the hem flanges.

5. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (Base) document.

6. Install the outside rearview mirror. Refer to Outside Rearview Mirror Replacement (Power)Outside Rearview Mirror Replacement (Manual) document.

7. Install the front side door outside handle. Refer to Front Side Door Outside Handle Replacement document.

8. Install the front side door. Refer to Front Side Door Replacement document.

9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems document.

10. Install all related panels and components.

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

12. Enable the SIR system. Refer to SIR Disabling and Enabling document.

(Photo courtesy of Honda) The Honda Fit and other subcompacts offer technology such as lane watch units that will need attention during pre- and post-repair scans

Quarter Inner Panel Sectioning (Hatchback model)

Removal Procedure

Before beginning, refer to the following three documents:

  • Approved Equipment for Collision Repair Warning.
  • Collision Sectioning Warning.
  • Glass and Sheet Metal Handling Warning.

1. Disable the SIR System. Refer to SIR Disabling and Enabling document.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection document.

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 (Base) document.

6. Create cut lines on the body lock pillar inner reinforcement.

Note: Do not damage any inner panels or reinforcements.

7. Cut the panel where sectioning is to be performed.

8. Locate and mark all the necessary factory welds of the body lock pillar inner reinforcement.

9. Drill all factory welds. Note the number and location of welds for installation of the service assembly.

10. Remove the damaged body lock pillar inner reinforcement.

11. Locate and mark all the necessary factory welds of the rear wheelhouse outer panel.

12. Drill all factory welds. Note the number and location of welds for installation of the service assembly.

13. Remove the damaged rear wheelhouse outer panel.

Installation Procedure

1. Drill 8 mm (5/16 in) holes for plug welding along the edges of the rear wheelhouse outer panel as noted from the original panel.

2. Clean and prepare the attaching surfaces for welding.

3. Position the rear wheelhouse outer panel.

4. Verify the fit of the panel.

5. Clamp the rear wheelhouse outer panel into position.

6. Plug weld accordingly.

7. Cut the body lock pillar inner reinforcement in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of one-and-one-half-times the metal thickness at the sectioning joint.

8. Create a 50 mm (2 in) backing plate from the unused portion of the service part.

9. Drill 8 mm (5/16 in) along the sectioning cut on the remaining original part. Locate these holes 13 mm (1/2 in) from the edge of part and spaced 40 mm (1 1/2 in) apart.

10. Prepare all mating surfaces as necessary.

11. Fit the backing plates halfway into the sectioning joints, clamp in place and plug weld to the vehicle.

12. Align the body lock pillar inner reinforcement.

13. Drill 8 mm (5/16 in) holes for plug welding along the edges of the body lock pillar inner reinforcement as noted from the original panel.

14. Clean and prepare the attaching surfaces for welding.

15. Position the body lock pillar inner reinforcement.

16. Verify the fit of the panel.

17. Clamp the body lock pillar inner reinforcement into position.

18. Plug weld accordingly.

19. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (Base).

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

21. Install all related panels and components.

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

23. Enable the SIR system. Refer to SIR Disabling and Enabling document.

Putting a bow on it

Obviously, these repairs are very much like those you would perform on larger vehicles. That’s one of the points here. The work is very much the same, but don’t let that fact cloud the need to address the added attention that come with subcompacts.

That level of care continues throughout the repair process. These vehicles might be small, but they hold a significance place in the eyes of their owners. Don’t underestimate their ability to challenge both the repair industry and the conception of just what a small car can offer.

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