00 complete manual

General Motors.The Collision RepairIndustry Leader.This booklet provides you with detailed repair information.

It is important to note that serviceability has been an integral part of the development of thesevehicles. General Motors has made every effort to take the technician’s concerns intoconsideration and to make sure we are providing quality information for quality technicalrepairs.

General Motors recognizes the important role that each of you plays in keeping customershappy and satisfied with our vehicles. That is why we have dedicated all our service resourcesto giving you the knowledge, information and tools you need to accurately and efficientlyservice these vehicles. We feel confident that working together with you, we have what it takesto achieve total customer satisfaction.

Service information is also available on the web.

• This website includes service repair information for the total vehicle and is asubscription based site. (www.acdelcotechconnect.com)

• This website includes select collision repair information only and is downloadableand free to the user. (www.techinfo.gmgoodwrench.com)

TABLE OF CONTENTSGeneral Information ....................................... 1-1

Actions to Take When Working withFuel Caution ............................................... 1-1

Approved Equipment for CollisionRepair Caution ............................................ 1-1

Battery Disconnect Caution ............................. 1-1Collision Sectioning Caution ............................ 1-1Foam Sound Deadeners Caution .................... 1-1Glass and Sheet Metal Handling Caution ........ 1-1Safety Glasses Caution ................................... 1-1SIR Caution .................................................... 1-1Sound Deadener Foam in the Lock Striker Pillars

Caution ....................................................... 1-1Fastener Notice .............................................. 1-1

2006 Chevrolet Corvette Z06 ........................ 2-1Structure Identification ..................................... 2-1Dimensions - Body (Motor Compartment -

Corvette) ..................................................... 2-3Dimensions - Body (Z06) ................................ 2-4Impact Bar Replacement - Front

Bumper (Z06) ............................................. 2-5Hood Plate Stud Replacement (Z06) ............... 2-7Wheelhouse Replacement - Front (Z06) ........ 2-10Pillar Lock Front Door Replacement -

Outer (Z06) ............................................... 2-11Impact Bar Replacement - Rear

Bumper (Z06) ............................................ 2-14Rail Replacement - Front (Z06) ..................... 2-20Rail Replacement - Front Section (Z06) ........ 2-22Rail End Replacement - Front (Z06) .............. 2-30Rail End Replacement - Rear (Z06) .............. 2-34Sleeved Butt Joint Repair (Z06) .................... 2-36Windshield Frame Replacement .................... 2-38Door Opening Frame Replacement - Side ...... 2-41

Rail Replacement - Rear (Z06) ..................... 2-43Rail Replacement - Rear Section (Z06) ......... 2-46Floor Panel Replacement (Z06) ..................... 2-53Compartment Panel Replacement -

Rear (Corvette) ......................................... 2-56Compartment Panel Frame Replacement -

Rear (Corvette) ......................................... 2-59Sheet Molded Compound (SMC) Panel

Bonding .................................................... 2-62

2006 Pontiac Solstice/2007 Saturn SKY ........................... 3-1

Dimensions - Body (Door Openings) ............... 3-1Dimensions - Body (Motor Compartment) ........ 3-2Hinge Pillar Body Reinforcement

Replacement - Front .................................... 3-3Hinge Pillar Body Replacement - Front ............ 3-5Windshield Frame Header Panel

Replacement - Front .................................... 3-7Pillar Lock Front Door Replacement -

Outer ........................................................ 3-10Pillar Lock Front Door Replacement -

Inner ........................................................ 3-12Quarter Panel Replacement - Outer ............... 3-15Impact Bar Replacement - Rear Bumper ....... 3-18Rail Replacement - Front Section .................. 3-21Sleeved Butt Joint Repair .............................. 3-25Windshield Panel Replacement - Lower ......... 3-26Door Opening Frame Replacement - Side ...... 3-29Rail Replacement - Rear Section .................. 3-31Floor Panel Replacement .............................. 3-35Compartment Panel Replacement - Rear ....... 3-38Panel Replacement - Rear End ..................... 3-40Sheet Molded Compound (SMC) Panel

Bonding .................................................... 3-43

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General Information

Actions to Take When Working with FuelCautionCaution: Fuel Vapors can collect while servicingfuel system parts in enclosed areas such as atrunk. To reduce the risk of fire and increasedexposure to vapors:

• Use forced air ventilation such as a fan setoutside of the trunk.

• Plug or cap any fuel system openings in orderto reduce fuel vapor formation.

• Clean up any spilled fuel immediately.• Avoid sparks and any source of ignition.• Use signs to alert others in the work area that

fuel system work is in process.

Approved Equipment for Collision RepairCautionCaution: To avoid personal injury when exposedto welding flashes or to galvanized (Zinc Oxide)metal toxic fumes while grinding/cutting onany type of metal or sheet molded compound, youmust work in a properly ventilated area, wearingan approved respirator, eye protection, earplugs,welding gloves, and protective clothing.

Battery Disconnect CautionCaution: Before servicing any electricalcomponent, the ignition key must be in the OFF orLOCK position and all electrical loads must beOFF, unless instructed otherwise in theseprocedures. If a tool or equipment could easilycome in contact with a live exposed electricalterminal, also disconnect the negative batterycable. Failure to follow these precautionsmay cause personal injury and/or damage to thevehicle or its components.

Collision Sectioning CautionCaution: Sectioning should be performed only inthe recommended areas. Failure to do so maycompromise the structural integrity of the vehicleand cause personal injury if the vehicle is in acollision.

Foam Sound Deadeners CautionCaution: Foam sound deadeners must be removedfrom areas within 152.4 mm (6 in) of where flameis to be used for body repairs. When reinstallingfoam sound deadeners, avoid inhaling fumesas bodily injury may result.

Glass and Sheet Metal Handling CautionCaution: When working with any type of glassor sheet metal with exposed or rough edges, wearapproved safety glasses and gloves in order toreduce the chance of personal injury.

Safety Glasses CautionCaution: Wear safety glasses in order to avoid eyedamage.

SIR CautionCaution: When performing service on or near theSIR components or the SIR wiring, the SIRsystem must be disabled. Refer to SIR Disablingand Enabling Zones. Failure to observe the correctprocedure could cause deployment of the SIRcomponents, personal injury, or unnecessary SIRsystem repairs.

Sound Deadener Foam in the Lock StrikerPillars CautionCaution: Sound deadener foam in the lock strikerpillars can be a fire hazard. Create a weld flangeto avoid welding directly to the lock striker pillarsas damage to the vehicle and serious bodilyinjury may result.

Fastener NoticeNotice: Use the correct fastener in the correctlocation. Replacement fasteners must be the correctpart number for that application. Fasteners requiringreplacement or fasteners requiring the use ofthread locking compound or sealant are identified inthe service procedure. Do not use paints, lubricants, orcorrosion inhibitors on fasteners or fastener jointsurfaces unless specified. These coatings affectfastener torque and joint clamping force and maydamage the fastener. Use the correct tighteningsequence and specifications when installing fastenersin order to avoid damage to parts and systems.

General Information 1-1

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Specifications

Dimensions - Body (Door Openings)

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Dimensions - Body (Motor Compartment)

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3-2 2006 Pontiac Solstice/2007 Saturn SKY

Repair Instructions

Hinge Pillar Body ReinforcementReplacement - Front

Removal ProcedureCaution: Refer to Approved Equipment forCollision Repair Caution on page 1-1.

1. Disable the SIR system. Refer to SIR Disablingand Enabling Zones.

2. Disconnect the negative battery cable. Refer toBattery Negative Cable Disconnect/ConnectProcedure.

3. Remove all related panels and components.4. Repair as much of the damage as possible to

factory specifications.5. Remove the side door frame and quarter panel.

Refer to Door Opening Frame Replacement -Side on page 3-29.

Caution: Refer to Foam Sound Deadeners Cautionon page 1-1.

6. Note the location and remove the sealers andanti–corrosion materials from the repair area,as necessary. Refer to Anti-Corrosion Treatmentand Repair.

Important: Do not damage any inner panels orreinforcements.

7. Locate and drill out all factory rivets. Note thenumber and location of rivets for installation ofthe hinge pillar body reinforcement.

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8. Remove the damaged hinge pillar bodyreinforcement.

Installation Procedure1. Position the hinge pillar body reinforcement.

2. Install rivets accordingly.3. Clean and prepare all surfaces.4. Apply the sealers and anti-corrosion materials to

the repair area, as necessary. Refer toAnti-Corrosion Treatment and Repair.

5. Paint the repair area. Refer to Basecoat/ClearcoatPaint Systems.

6. Install the side door frame and quarter panel.Refer to Door Opening Frame Replacement -Side on page 3-29.

7. Install all related panels and components.8. Connect the negative battery cable. Refer to

Battery Negative Cable Disconnect/ConnectProcedure.

9. Enable the SIR system. Refer to SIR Disablingand Enabling Zones.

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Hinge Pillar Body Replacement - Front

Removal ProcedureThe front hinge pillar panel is bolted and welded to theside structure and frame rail. The replacement fronthinge pillar panel is serviced as an assembly.You must remove and replace the side door openingpanel in order to replace the front hinge pillar.

Caution: Refer to Approved Equipment forCollision Repair Caution on page 1-1.




factory specifications. Refer to Dimensions -Body (Door Openings) on page 3-1 or Dimensions- Body (Motor Compartment) on page 3-2.

5. Note the location of the sealers and theanti-corrosion materials and remove thesecomponents from the repair area as necessary.Refer to Anti-Corrosion Treatment and Repair.

6. Remove the bolts (1) attaching the front hingepillar to the windshield frame.

Important: Do NOT damage the inner panels or thereinforcements.

7. Locate and remove all factory welds (1) from theouter hinge pillar. Note the number and location ofthe welds for installation of the new hinge pillar.

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8. Locate and remove all factory welds (1) from theinner hinge pillar. Note the number and location ofthe welds for installation of the new hinge pillar.

9. Remove the damaged hinge pillar.10. Note the location of the adhesive and remove all

remaining loose adhesive.

Installation Procedure1. Prepare all welding attachment surfaces as

necessary.2. Apply 3M® Weld-Thru Coating P/N 05916 or

equivalent to all mating surfaces.3. Position the hinge pillar to the vehicle using

3-dimensional measuring equipment.

Notice: Refer to Fastener Notice on page 1-1.4. Install the bolts.

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5. Using a metal inert gas (MIG) welder, stitch weldthe inner hinge pillar to the vehicle in the locationsnoted on the original panel.

6. Using a MIG welder, stitch weld the outer hingepillar to the vehicle in the locations noted on theoriginal panel.

7. Apply the sealers and the anti-corrosion materialsto the repair area, as necessary. Refer toAnti-Corrosion Treatment and Repair.





Windshield Frame Header PanelReplacement - Front




3. Remove all related panels and components.Caution: Refer to Foam Sound Deadeners Cautionon page 1-1.


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5. Locate and drill out all factory welds. Note thenumber and location of welds for installation ofthe header panel.

6. Using a grinder or an equivalent tool, remove thesilicon bronze welds on each end of the header.

7. Remove the damaged header panel.

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Installation Procedure1. Drill 8 mm (5/16 in) plug weld holes in the service

part as necessary at the locations noted from theoriginal header panel.

2. Prepare all mating surfaces as necessary.3. Apply 3M® Weld-Thru coating P/N 05916 or

equivalent to all mating surfaces.

4. Position the header panel.

5. Plug weld accordingly.6. Continuous weld each side of the outer

header panel.7. Clean and prepare all welded surfaces.8. Apply the sealers and anti-corrosion materials to






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Pillar Lock Front DoorReplacement - Outer

Removal ProcedureThe replacement inner lock panel is serviced as anassembly. You must remove and replace theouter body side panel in order to replace the outerlock pillar.




3. Remove all related panels and componentsincluding the outer body side panel. Refer to DoorOpening Frame Replacement - Side onpage 3-29.


4. Note the location and remove the sealers andanti-corrosion materials from the repair area, asnecessary. Refer to Anti-Corrosion Treatment andRepair.


5. Locate and drill out all factory welds. Note thenumber and location of the welds for installationof the replacement part.

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6. Remove the damaged inner lock pillar.


part as necessary in the locations noted on theoriginal panel.

2. Prepare all attachment surfaces as necessary.3. Apply 3M® Weld-Thru Coating P/N 05916 or


4. Position the inner lock pillar.

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5. Plug weld accordingly.6. Install all related panels.7. Clean and prepare all welded surfaces.8. Apply the sealers and the anti-corrosion materials

to the repair area, as necessary. Refer toAnti-Corrosion Treatment and Repair.


10. Install all related components.11. Connect the negative battery cable. Refer to



Pillar Lock Front Door Replacement - Inner

Removal ProcedureThe replacement inner lock panel is serviced as anassembly. You must remove and replace theouter body side panel and the roof mounting bracketin order to replace the inner lock pillar. The outer bodyside panel and the roof mounting bracket must beordered separately.





factory specifications. Refer to Door Openingand Roof Stowage Dimensions in Dimensions -Body (Door Openings) on page 3-1 or Dimensions- Body (Motor Compartment) on page 3-2.


5. Note the location and remove the sealers andanti-corrosion materials from the repair area, asnecessary. Refer to Anti-Corrosion Treatment andRepair.

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6. Locate and drill out all factory welds. Note thenumber and location of the welds for installationof the replacement part.

7. Verify the existence of structural weld-throughadhesive. Refer to Structure Adhesive -Identification. If necessary use a chisel to separatethe inner rocker from the adjacent panels.

8. Remove the damaged inner lock pillar.

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part as necessary in the locations noted on theoriginal panel.

2. Replace the structural adhesive with an additionalplug weld between the existing plug welds ifnecessary.

3. Prepare all attachment surfaces as necessary.4. Apply 3M® Weld-Thru Coating P/N 05916 or


5. Position the inner lock pillar. Refer to DoorOpening section of Dimensions - Body (DoorOpenings) on page 3-1 or Dimensions - Body(Motor Compartment) on page 3-2.

6. Plug weld accordingly.

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Important: Proper alignment of the roof mountingbracket is critical for proper folding top operation andalignment.

7. Position the roof mounting bracket.8. Plug weld accordingly.9. Install all related panels.

10. Clean and prepare all welded surfaces.11. Apply the sealers and the anti-corrosion materials



13. Install all related components.14. Connect the negative battery cable. Refer to



Quarter Panel Replacement - Outer

Tools RequiredJ 42058 Frame Adapter Clamp

Removal ProcedureCaution: Refer to Approved Equipment forCollision Repair Caution on page 1-1.The side door frame and the quarter panel are madeof stamped sheet metal, and are bonded to theside structure and the frame rails with the combinationof structural adhesive dollops and urethane.



3. Remove all related panels and components.

Caution: Refer to Actions to Take When Workingwith Fuel Caution on page 1-1.

4. Make sure the fuel inlet is sealed beforeproceeding with repair procedure.

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5. Apply heat and pry to detach the adhesives alongthe bonding surfaces.


6. Locate and drill out all factory welds that attachthe quarter outer panel to the trunk gutter.

7. Remove the door frame and quarter panel fromthe vehicle.

8. Note the location of the adhesives. Remove allremaining loose adhesive.

9. Inspect the side structure and frame rails fordamage.

10. Restore as much of the damage as possible tothe factory specifications.

11. Use J 42058 to secure the vehicle if pulling andstraightening is required.

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Installation Procedure1. Before applying adhesives, use shims to dry fit

the door frame and quarter panel for proper fitand alignment.

2. Clean and prepare all bonding mating surfacesaccording to adhesive manufacturer’srecommendations.

Important: DO NOT top coat any bonding surface.Use primer only on bonding surfaces. Refer toadhesive manufacturer’s recommendations.

3. Apply a consistent bead of urethane 20 mm(13/16 in) in diameter to the inner surface ofthe door frame and the quarter panel to mate withthe side structure and frame rail and to allareas originally bonded. Refer to Sheet MoldedCompound (SMC) Panel Bonding on page 3-43.

4. Apply structural adhesive dollops 20 mm (3/4 in)in diameter to the inner surface of the door frameand the quarter panel in areas originally bonded.

5. Position the door frame and the quarter panel tothe vehicle.

6. Apply pressure to the door frame and the quarterpanel to set the adhesive.

7. Clamp or tape the door frame and the quarterpanel in place as necessary.

8. Remove any excess adhesive.9. Install all related panels and components.

10. Connect the negative battery cable. Refer toBattery Negative Cable Disconnect/ConnectProcedure.


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Impact Bar Replacement - Rear Bumper





3. Remove all related panels and components.4. Remove or reposition the wiring to avoid damage.5. Repair as much of the damage as possible to

the factory specifications.6. Use J 42058 to secure the vehicle if pulling and

straightening are required.7. Locate the area inside the rear tub (1) over the

top welds of the rear bar.

8. Cut out an access hole (1) over the top welds ofthe rear bar.

9. Save the cut-out piece to patch the hole.10. Note the location and remove the sealers and

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

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Important: Do not cut into the frame rails.

11. Cut the welds around the perimeter of the framerail ends. Cut the welds favoring the impact barside of the joint.

12. Remove the damaged impact bar.

13. Extract pieces of the impact bar which are leftattached to the rail ends.

14. Straighten and deburr the rail ends. Keep theperimeter and shape of the rail ends as originalas possible.

Installation Procedure1. Temporarily position the impact bar for proper fit

and alignment.2. Clean and prepare all of the welded surfaces.3. Apply 3M® weld-thru coating P/N 05916 or

equivalent as necessary and to the inside ofthe rail ends.

4. Position the bumper impact bar to the vehicleusing three-dimensional measuring equipment.

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Important: If no trace of the original welds arepresent, follow the pattern specified for welding theside rails to the impact bar.

5. Using a metal inset gas (MIG) welder, stitch weldthe rear bar to the frame rail ends.

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

7. Use the original cut-out piece to patch theaccess hole.

8. Apply adhesive bonding material as necessary tothe repair area of the floor and the patch. Refer toSheet Molded Compound (SMC) Panel Bondingon page 3-43.

9. Position the patch and press firmly into place.

Important: A leak proof seal is necessary sothat exhaust and fuel fumes cannot enter the vehicle.10. Smooth out the adhesive around the

repaired area.11. Verify that no voids or gaps occur in the adhesive.12. Paint the repair area. Refer to Basecoat/Clearcoat

Paint Systems.13. Install all related panels and components.14. Connect the negative battery cable. Refer to


15. Enable SIR system. Refer to SIR Disabling andEnabling Zones.

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Rail Replacement - Front Section


Caution: Sectioning should be performed only inthe recommended areas. Failure to do so maycompromise the structural integrity of the vehicleand cause personal injury if the vehicle is in acollision.



3. Remove all related panels and components.4. Repair as much of the damage as possible. Refer

to Dimensions - Body (Door Openings) onpage 3-1 or Dimensions - Body (MotorCompartment) on page 3-2.

5. Remove the sealers and anti-corrosion materialsfrom the repair area, as necessary. Refer toAnti-Corrosion Treatment and Repair.

6. Locate the area on the rail where therecommended sectioning repair will be performed.

Important: Note the number and location of thefactory welds for installation of the service rail.

7. Locate all necessary factory welds. Using a diegrinder with a cut-off wheel or similar tool,remove the factory welds.

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8. Using a sliding square and scribe tool, scribe aline on the outer side surface of the rail.

9. Using the mark made in the previous step as astarting point, use a sliding square to transfer aline on the top, side, and bottom of the rail.

10. Cut the rail at the marked location.

11. Remove the damaged section of the rail.

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Installation Procedure1. On the service rail, determine the sectioning

location.2. Using the mark made in the previous step as a

starting point, use a sliding square and scribingtool to transfer a line on all of the way around therail. This is the same process as in the RemovalProcedure.

3. Cut the service part at the marked location.

4. Make a 50–mm (2–in) weld backer sleeve. Referto Sleeved Butt Joint Repair on page 3-25.

5. Grind the existing frame rail sectioning locationand the service rail sectioning location to a45–degree angle.

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6. Install the backing plate.

7. Position the rail to the vehicle, using 3-dimensionalmeasuring equipment. Clamp the rail in place.

8. Stitch and plug weld accordingly.9. Clean and prepare all of the welded surfaces.

10. Install all of the related panels and components.11. Apply the sealers and anti-corrosion materials


12. Paint the repaired area. Refer toBasecoat/Clearcoat Paint Systems.



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Sleeved Butt Joint RepairCaution: Refer to Approved Equipment forCollision Repair Caution on page 1-1.

Caution: Refer to Collision Sectioning Caution onpage 1-1.

Important: When determining the area to perform thesectioning near a riv-nut within the recommendedareas, choose a location that centers the sleevethrough the hole. This will ensure that riv-nut fastenersremain straight during installation.

1. From the new unused portion of the service framerail, measure, mark, and cut 50 mm (2 in) offrame rail to be used as a sleeve (backing plate)for the sectioning joint.

2. Cut through each side of the sleeve to createfour individual L-shaped pieces that can beinstalled in the new frame rail section.

3. Install the four pieces, one at a time.4. Trim the pieces as necessary, to provide a flush

fit along the inner surface of the new frame railsection.

5. Tac weld all four L-shaped pieces together.6. Remove the sleeve from the rail.7. Drill 8 mm (5/16 in) holes 13 mm (1/2 in) from the

sectioning edge on the rail on the vehicle and theservice rail.

8. Clean and prepare all of the welded surfaces.9. Apply 3M weld-thru coating P/N 05916 or

equivalent as necessary.10. Using a metal inert gas (MIG) welder, tack weld

the four pieces to the inner surface of the newframe rail section.

11. Grind the sleeve as necessary to allow foraccurate alignment of the existing frame rail.

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12. Install the new frame rail section to the existingframe rail to create the butt joint while maintaininga gap of one and one half frame rail metalthickness at the sleeve butt-joint.

13. Inspect the new frame rail section usingthree-dimensional measurements.

Important: Use a 25 mm (1 in) stitch weld to avoidminimal heat distortion.

14. Using a MIG welder, weld completely around thesleeve joint.

Windshield Panel Replacement - LowerRemoval ProcedureCaution: Refer to Approved Equipment forCollision Repair Caution on page 1-1.




factory specifications.Caution: Refer to Foam Sound Deadeners Cautionon page 1-1.


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6. Locate and drill out all factory welds. Note thenumber and location of welds for installation ofthe windshield frame side panel.

7. Using a grinder or an equivalent tool, remove thesilicon bronze welds at the upper windshieldframe side panel and header location.

8. Remove the damaged windshield frameside panel.

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part as necessary at the locations noted from theoriginal windshield frame side panel.

2. Prepare all mating surfaces as necessary.3. Apply 3M® Weld-Thru coating P/N 05916 or


4. Position the windshield frame side panel.

5. Plug weld accordingly.6. Continuous weld the upper windshield frame side

panel to the header joint.7. Clean and prepare all welded surfaces.8. Apply the sealers and anti-corrosion materials to






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Door Opening Frame Replacement - Side


Removal ProcedureCaution: Refer to Approved Equipment forCollision Repair Caution on page 1-1.The side door frame and the quarter panel are madeof stamped sheet metal, and are bonded to theside structure and the frame rails with the combinationof structural adhesive dollops and urethane.





4. Make sure the fuel inlet is sealed beforeproceeding with repair procedure.

5. Apply heat and pry to detach the adhesives alongthe bonding surfaces.

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6. Locate and drill out all factory welds that attachthe quarter outer panel to the trunk gutter.

7. Remove the door frame and quarter panel fromthe vehicle.

8. Note the location of the adhesives. Remove allremaining loose adhesive.

9. Inspect the side structure and frame rails fordamage.

10. Restore as much of the damage as possible tothe factory specifications.

11. Use J 42058 to secure the vehicle if pulling andstraightening is required.

Installation Procedure1. Before applying adhesives, use shims to dry fit

the door frame and quarter panel for proper fitand alignment.


Important: DO NOT top coat any bonding surface.Use primer only on bonding surfaces. Refer toadhesive manufacturer’s recommendations.

3. Apply a consistent bead of urethane 20 mm(13/16 in) in diameter to the inner surface ofthe door frame and the quarter panel to mate withthe side structure and frame rail and to allareas originally bonded. Refer to Sheet MoldedCompound (SMC) Panel Bonding on page 3-43.

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4. Apply structural adhesive dollops 20 mm (3/4 in)in diameter to the inner surface of the door frameand the quarter panel in areas originally bonded.

5. Position the door frame and the quarter panel tothe vehicle.

6. Apply pressure to the door frame and the quarterpanel to set the adhesive.

7. Clamp or tape the door frame and the quarterpanel in place as necessary.

8. Remove any excess adhesive.9. Install all related panels and components.



Rail Replacement - Rear Section




3. Remove all related panels and components.4. Remove the rear impact bar. Refer to Impact Bar

Replacement - Rear Bumper on page 3-18.5. Remove the quarter panel. Refer to Quarter Panel

Replacement - Outer on page 3-15.

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6. Remove the rear compartment. Refer toCompartment Panel Replacement - Rearon page 3-38.

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

8. Repair as much of the damage as possible to thefactory specifications.

Caution: Refer to Collision Sectioning Caution onpage 1-1.

9. Detrmine the sectioning joint location.10. Locate 5 mm (5/32 in) hole on the outboard

surface, rearward of the rear suspensionmounting.

11. Measure 25 mm (1 in) (a) rearward from thehole (a).

12. Mark the top of the frame rail at the sectioninglocation.

13. At the mark align a sliding square or similar toolsquare to surface to the vertical walls of theframe rail.

14. Scribe a line to both sides of the frame rail.

15. Apply masking tape (1) to the scribe linecompletely around the frame rail.

16. Cut the frame rail at the rear edge of the tape lineusing a reciprocating saw or equivalent tool (1).

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17. Remove the damaged frame rail end section (1).

Installation Procedure1. Locate the 5 mm (5/32 in) hole on the outboard

surface of the service rail.2. Measure rearward from the hole 25 mm (1 in).

Mark the location (a) in the same manner as inthe Removal Procedure.

3. Using the mark made in the previous step as astarting point, use a sliding square and a scribingtool to transfer a line all of the way around theservice rail.

4. Cut the service rail at the marked location.

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5. Grind the existing frame rail and the new servicepart seam to taper the seam at a 45-degree angle.

6. Clean and prepare all of the welded matingsurfaces.

7. Apply 3M weld-thru coating P/N 05916 orequivalent as necessary to all bare metal surfaces.

8. Make a 50 mm weld-backer sleeve. Refer tiSleeved Butt Joint Repair on page 3-25.

9. Position the service frame section to theexisting frame.

10. Maintain a gap of one and one half frame railmetal thickness at the sectioning joint (1) andclamp in place.

11. Inspect the frame measurementsthree-dimensional to ensure proper position of theservice frame.

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Important: Use a 25-mm (1-in) stitch weld to avoidminimal heat distortion.

12. Using a MIG welder, weld completely around thesleeve joint.

13. Install the rear impact bar. Refer to Impact BarReplacement - Rear Bumper on page 3-18.

14. Install the quarter panel. Refer to Quarter PanelReplacement - Outer on page 3-15.

15. Install the rear compartment. Refer toCompartment Panel Replacement - Rear onpage 3-38.

16. Apply the sealers and anti-corrosion materials tothe repair area. Refer to Anti-Corrosion Treatmentand Repair.

Important: DO NOT top coat any bonding surface.Use primer only on bonding surfaces. Refer toadhesive manufacturer’s recommendations.17. Paint the repair area. Refer to Basecoat/Clearcoat

Paint Systems. in Paint and Coating.18. Install all related panels and components.19. Connect the negative battery cable. Refer to



Floor Panel Replacement



1. Use the J 42058 to secure the vehicle if pullingand straightening is required.



4. Remove all related panels and components.5. Remove or reposition electrical components and

wiring harness as necessary to avoid damage.6. Remove wiring harness clips for transfer to new

floor panel.7. Repair as much of the damage as possible to the

factory specifications.

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8. Remove the outer reinforcements that attach tothe floor panel and the frame rail.

9. Locate and drill out all necessary factory welds.

10. Remove the floor panel from the vehicle.11. Save all brackets, mounting studs, and

accessories for transfer to the new floor.

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Installation Procedure

Important: If the location of the original plug weldholes can not be determined, space the plugweld holes every 40 mm (1 1/2 in).

1. Drill 8 mm (5/16 in) plug weld holes in the servicepart as necessary in the locations noted on theoriginal panel.

2. Prepare all mating surfaces as necessary.3. Apply 3M® Weld-Thru Coating P/N 05916 or


4. Install the floor panel to the vehicle.

5. Plug weld accordingly.6. Install the floor panel reinforcements.7. Clean and prepare all welded surfaces.8. Install all of the related panels and components.9. Apply the sealers and the anti-corrosion materials






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Compartment Panel Replacement - Rear


Removal ProcedureCaution: Refer to Approved Equipment forCollision Repair Caution on page 1-1.The rear compartment panel is made of sheet moldedcompound (SMC), and is bonded to the rearstructure and frame rails with structural adhesive.





4. Ensure that the fuel inlet is sealed beforeproceeding with the repair procedure.

5. Remove the right and left quarter panels. Refer toQuarter Panel Replacement - Outer on page 3-15.

6. Remove bolts attaching the rear compartmentpanel to the frame rails.

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Important: The front edge of the rear compartmentpanel is also bonded across the seatback area andalong the top of the rear right and left rails.

7. Remove the rear compartment panel by applyingheat to the inside of the rear compartment alongthe bonding surface (1) as indicated.

8. Pry to detach adhesive along the bonding surface.

9. Remove the rear compartment panel.10. Save any and all brackets, mounting studs, and

accessories for transfer to the new rearcompartment panel.

11. Note the location of the adhesive and remove allremaining loose adhesive.

12. Inspect the rear structure and frame rails fordamage.

13. Repair as much of the damage as possible to thefactory specifications.

Installation Procedure1. Before applying adhesive dry fit the rear

compartment panel for proper fit and alignment.

Important: DO NOT top coat any bonding surface.Use primer only on bonding surfaces. Refer toadhesive manufacturer’s recommendations. Therecommended adhesive is windshield urethane. Referto Adhesive Service Kit Description.


3. Apply a consistent bead of windshield urethane12 mm (1/2 in) in diameter to the top surface ofthe rear frame rails (1), to the attaching surface ofthe seat back, and to the original bondingsurfaces (2). Refer to Sheet MoldedCompound (SMC) Panel Bonding on page 3-43.

4. Apply windshield urethane 20 mm (3/4 in) indiameter in spots to the fuel tank support bar (3).

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5. Install the rear compartment panel to the vehicle.6. Apply pressure to the rear compartment panel to

set the adhesive.

7. Install the screws attaching the rear compartmentpanel to the frame rails.

8. Clamp or mechanically fasten the rearcompartment panel into place as necessary.

9. Remove any excess adhesive.10. Install the right and left quarter panels. Refer to

Quarter Panel Replacement - Outer on page 3-15.11. Install all related panels and components.12. Connect the negative battery cable. Refer to



Panel Replacement - Rear End






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4. Remove the bolts holding the rear end panel tothe rear end compartment.

5. Remove the rear end panel by applying heat, andprying to detach the adhesive along the bondingsurface (a).

6. Remove the rear end panel.7. Note the location of the adhesive and remove all

remaining loose adhesive.8. Inspect the rear structure and frame rails for

damage.9. Repair as much of the damage as possible to the

factory specifications.10. Use J 42058 to secure the vehicle if pulling and

straightening is required.

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Installation Procedure

Important: Shims may be necessary to achieveproper panel alignment.

1. Before applying the adhesive, dry fit the rear endpanel for proper fit and alignment.

2. Clean and prepare all bonding mating surfacesaccording to the adhesive manufacturer’srecommendations.

3. Apply a consistent bead of structural adhesive10 mm (3/8 in) in diameter to the rearcompartment panel in order to mate with the rearend panel.

4. Apply a consistent bead of structural adhesive10 mm (3/8 in) in diameter to both the right andthe left tail lamp pocket locations.Install the rear compartment frame (1).

5. Clamp or mechanically fasten the rearcompartment frame into place.

6. Remove any excess adhesive.7. Install all related panels and components.8. Connect the negative battery cable. Refer to



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Description and OperationSheet Molded Compound (SMC) PanelBondingThis is intended to provide general guidelines forsheet molded compound (SMC) adhesive bonding offull panel replacement in regards to collision repairprocedures:Sectioning, partial panel of full panels, is not supportedby General Motors unless specifically documentedin a Service Bulletin or Manual:

Important: Prepare the surfaces to be bondedaccording to adhesive manufacturer’srecommendations. Many adhesive manufacturers havedifferent preparation methods. Do not intermixadhesive manufacturers systems. Mixing materialsfrom different manufacturers can produceunsatisfactory results.

Important: DO NOT top coat any adhesive bondingmating surface. Use primer only on bonding surfaces.Refer to adhesive manufacturer’s recommendationsfor priming applications.

Adhesives currently meeting the performancerequirements include General Motors materials andproducts manufactured by Ashland and Lord Fusor. Atthis time, ONLY the adhesive products listed belowmeet this guideline:

Sheet Molded Compound (SMC) Panel Bonding

GM Goodwrench® GMSPO of CanadaAshland Pliogrip

Structure AdhesiveLord Fusor Structural

Adhesive Product Type

89020330 8902332 7770B 127 EZ Medium Set

N/A N/A 7779B N/A Fast Set

Canadian applications may use U.S. part numbers. Refer to your GM Dealer Parts Department for the correct part numberapplications.

Special Tools and Equipment

Illustration Tool Number/ Description

181147

J 42058Adapter Clamp forConv. Anchoring System


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NOTES


00 complete manual

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