collision issues

8/4/2019 Collision Issues

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1CAVALIER/ SUNFIRE COLLISION REPAIR ISSUES

1 99 5 General M otors Corporation. All Rights Reserved.

1. PANEL IDENTIFICATION ___________________ 2

2. RADIATORSUPPORTASSEMBLY____________ 4

3. FRONTWHEELHOUSEASSEM BLY __________ 6

4. FRONTLOWERRAIL ASSEMBLY____________ 8

5. FRONTSUSPENSION SUPPORT(#1 BAR) __ 11

6. DOORFRAMEOPENING___________________14

7. DOORSERVICE___________________________ 20

8. ROOFPANEL_____________________________ 21

9. QUARTERPANEL_________________________ 22

10. O UTERREARWHEELHOUSE______________ 26

11. R EARRAIL _______________________________ 28

12. R EARFLOORASSEMBLY__________________ 31

13. R EARENDPANEL ________________________ 36

14. B ODYDIMENSIONS_______________________ 37

TABLE OF CONTENTS


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1. PANEL IDENTIFICATION

19 95 General M otors Corporation. All Rights Reserved.

TPO on Cavalier;RIM on Sunfire


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1 . P A N E L I D E N T I F I C A T I O N

KEY TO COMPONENTS:Reinforced injected molded (RIM) plastic

or thermoplastic olefin (TPO)

High-strength low-alloy (HSLA)steel parts

19 95 General M otors Corporation. All Rights Reserved.

TPO on Cavalier and Sunfire Sedan;RIM on Sunfire Coupe


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4CAVALIER/ SUNFIRE COLLISION REPAIR ISSUES 19 95 General M otors Corporation. All Rights Reserved.

2. RADIATOR SUPPORT ASSEMBLY

The rad iator supp ort assembly (Figure 2-1 ) consists of nine major components: fourupper and five low er. The center reinforcement and left and rig ht extensions areprea ssembled. This helps the technic ian to p roperly alig n the front structure. The

upper support is serviced separa tely for efficient installation. The low er support is heldin place w ith six bo lts. It attaches to four brackets that are w elded to the low er rails.These brackets are available as part of the lower rail service assembly or they canbe o rdered sepa rately.

FIGURE2-1

RADIATORSUPPORTASSEMBLY

Pre-assembled service part

Bolt-on lower support


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2 . R A D I A T O R S U P P O R T A S S E M B L Y

Remove or Disconnect1 . Remove all related pa nels and components.

2 . Visually inspect and restore as much of the da mage as possible tofactory specifications.

3 . Remove sealers, sound d eadeners and corrosion materials asnecessary.

4 . Loca te, mark and drill out all factory w elds. N ote the number ofwelds for installation of the service panels.

5 . Remove the damaged panels in the radia tor suppo rt assembly

Install or Connect

1 . Prepare mating surfaces and check for proper fit of the servicepanels.

2 . O n the service panels, dril l 8 mm (5 / 1 6 ") plug w eld holes asnecessary in the locations noted from the original assembly.

3 . Position the service panels, check fit using body d imensions, andplug weld accordingly with frequent measurements to ensure properfit.

4 . Clean and prepare welded surfaces. Prime with tw o-pa rt catalyzedprimer. Apply sealers and corrosion protection materials, asnecessary. Do not combine pa int systems. Refer to paintmanufacturers recommenda tions. Reinstall all related panels and

components.


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3 . FRON T WHEELH OUSE ASSEMBLY

Replacement of the wheelhouse assembly requires the removal of the upper outer rail reinforcement(Figure 3-1 ). Removal o f this panel a llow s access to the w elds that secure the strut cap to the cow l plenum.

The left and right front upper rails are pa rt of the wheelhouse service assembly. If da mage is limited to these

pa nels, they can be ordered and rep laced individua lly (Figure 3 -2 ). Fender mounting holes are pre-drilledon the upper rai ls, but lack the formed a reas found on the orig inal rails. Spacers can be used to properlyposition and fit the fender. In ad dition, the front portion of the aprons and the ba ttery tray can be orderedand replaced separately.

FIGURE3-2

FRONTWHEELHOUSEASSEMBLY

J11943.2

FIGURE3-1

UPPEROUTERRAILREINFORCEMENT


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3 . F R O N T W H E E L H O U S E A S S E M B L Y

Remove or Disconnect1 . Remove all related panels and components.

2 . Visually inspect and restore as much of the damag e as possible to factory specifica tions.

3 . Remove sealers, sound d eadeners and corrosion materials as necessary.

4 . Loca te, mark and d rill out all factory welds. N ote the number of welds for installation of the serviceassembly.

NoticeThere are five welds that secure the strut cap to the cowl plenum. Drill through only one layer ofmetal. Any holes drilled through the cowl plenum must be filled before installation of the new

wheelhouse assembly.

5 . Remove the damag ed front w heelhouse assembly.

CautionWhen servicing the wheelhouse assembly at the cowl plenum, it is advised you use a fire resistantwelding blanket (such as part #J41156 available from Kent-Moore) to help avoid damage to the

interior of the vehicle. Install the blanket between the cowl and the foam pad underneath the carpetwhere the assembly is attached.

Install or Connect

1 . Prepare mating surfaces and check for proper fit of the wheelhouse service assembly.

2 . O n the service assembly, drill 8 mm (5 / 1 6 ") plug w eld holes as necessary in the locations noted fromthe original assembly.

3 . Position the service assembly, check fit using b ody dimensions, a nd p lug and stitch weld a ccording lywith frequent measurements of the strut cap and fender mounting locations to ensure proper fit (Figure3-3).

4 . C lean and prepa re w elded surfaces. Prime w ith tw o-pa rt catalyzed primer. Apply sealers and

corrosion protection materials, as necessary. Do not combine paint systems. Refer to pa intmanufacturers recommendations. Reinstall all related panels and co mponents.

FIGURE3-3

INSTALLNEWWHEELHOUSEASSEMBLY


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4. FRONT LOWER RAIL ASSEMBLY

Lower Rail Sub-AssemblyReplacement of the engine compartment lower rail assemblies has beenimproved on the C ava lier and Sunfire through the use of a sub-assembly service

pa rt. This helps to simplify ordering , stocking and rep lacement procedures.The lower rail service part comes as a complete assembly, including allbrackets and reinforcements (Figure 4-1). Bumper mounting brackets can bereplaced sepa rately.

FIGURE4-1

LOWERRAIL SUB-ASSEMBLY

Bumper mounting bracketscan be ordered separately


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4 . F R O N T L O W E R R A I L A S S E M B L Y

Remove or Disconnect1 . Disconnect and suppo rt the engine and transmission w ith suitab le equipment. N ote that it is not

necessary to entirely remove the powertrain when servicing the lower rails.

2 . Remove all o ther related p anels and components, including the suspension a nd crossmember.

CautionLoosen and protect the fuel and brake lines during rail replacement.



5 . Locate, mark and d rill out factory w elds securing the front suspension support to the low er rail (Figure4 -2 ). N ote the number of welds for installation of the service assembly.

NoticeInspect the condition of the front suspension support where the crossmember is mounted. If thecagenut brackets have separated from the front suspension support, that assembly must also be

repaired or replaced (refer to page 11)

6 . Loca te, mark and drill out factory w elds along the low er flanges of the rail securing it to the cow l.Then separa te the low er rail from the floor extensions in the torque bo x area (Figure 4 -3 ).

7 . Loca te, mark and d rill out all remaining factory welds.

8 . Remove the damaged front low er rail. If the front suspension supp ort is not removed, the damag edrail must be pried out.

FIGURE4-2

DRILL OUTFACTORYWELDSSECURINGTHEFRONTSUSPENSIONSUPPORT

TOTHELOWERRAIL


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CautionWhen servicing the lower rail, it is advised you use a fire resistant weldingblanket (such as part #J41156 available from Kent-Moore) to help avoid

damage to the interior of the vehicle. Install the blanket between the floorpan and the foam pad underneath the carpet.

Install or Connect1 . Prepare mating surfaces and check for proper fit of the low er rail service

assembly.

2 . O n the service assembly, drill 8mm (5 / 1 6 ") plug w eld holes as necessary inthe locations noted from the original parts.

3 . Position the service assembly and check fit using body dimensions. M ake surethe suspension support properly mates over the low er rail bracket. Plug w eld

accordingly with frequent measurements to ensure proper fit.4 . C lean and prepa re w elded surfaces. Prime w ith tw o-pa rt catalyzed primer.

Apply corrosion protection materials and sealers, as necessary.

5 . Apply Dominion Sure Seal paintable sound d eadening pads (part # 1 1 0 9 0 0 )to the floor as necessary to match original sound deadening.

6 . Do not combine pa int systems. Refer to paint manufacturers recommenda tions.Reinstall all related panels and components.

7 . W hen reinstalling the suspension crossmember, torque a ll six fasteners to 1 3 0N m (9 6 lbs. ft.).

4 . F R O N T L O W E R R A I L A S S E M B L Y

FIGURE4-3

SEPARATETHELOWERRAILFROMTHECOWLAND

FLOOREXTENSIONS(UNDERBODYVIEW)


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5. FRONT SUSPENSION SUPPORT ASSEMBLY (#1 BAR)

The front suspension suppo rt ties the low er rails tog ether ac ross the low er po rtion o f the cow l. Located onthis panel assembly are tw o o f the six mounting locations for the suspension crossmember (Figure 5 -1 ). Thepanel assembly comes complete with the cagenut brackets installed. The cagenut brackets can also be

ordered and replaced separately.W hen the front lower rails are repaired or replaced , the front suspension support should be inspec ted for thefollowing:

Surface deformation in the suspension crossmember mounting areas

Any sepa ration in the welds securing the cagenut brackets to the support

If either of these condi tions exist, the cag enut brackets or front suspension support assembly must be rep laced.

FIGURE5-1

FRONTSUSPENSION SUPPORTASSEMBLY(#1 BAR)


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5 . F R O N T S U S P E N S I O N S U P P O R T ( # 1 B A R )

FULL REPLACEMENT OF THE FRONT SUSPENSION SUPPORT ASSEMBLY

Remove or Disconnect

1 . Remove all related panels and components, including the linkag e that passes through the frontsuspension support panel.



4 . Loca te, mark and d rill out factory welds on the damag ed assembly. N ote the number of w elds forinstallation of the service assembly.

5 . Remove the damaged suspension support assembly.

Install or Connect

1 . Prepa re mating surfaces and check for prop er fit of the suspension support service assembly.

2 . O n the service assembly, drill 8 mm (5 / 1 6 ") plug w eld holes as necessary in the locations noted fromthe original parts.

3 . Position the service assembly over the low er rail brackets and check fit using b ody dimensions (refer toFigure 4 -2 on pa ge 9 ). Plug weld according ly.

4 . C lean and prepa re w elded surfaces. Prime w ith tw o-pa rt catalyzed primer. Apply sealers andcorrosion p rotection materia ls, as necessary. Do no t combine p aint systems. Refer to p aintmanufacturers recommendations. Reinstall all related panels and co mponents.

FIGURE5-2

CUTA WINDOWINTHEFLOOR


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5 . F R O N T S U S P E N S I O N S U P P O R T ( # 1 B A R )

REPLACEMENT OF THE FRONT SUSPENSION SUPPORT CAGENUTBRACKETSIf da mage permits, it is possible to replace just the cagenut brackets. The replacement procedure is similar

to that used to rep lace b odymount cagenut assemblies on full-frame vehicles. This is done by cutting a w indowin the floor pan to access the cagenut bracket.

Remove or Disconnect1 . Remove all related panels and components, including the carpeting and center console if necessary.


3 . From the underside of the vehicle, run a centerpunch through the cagenut mounting b racket and strikew ith a hammer. This w ill mark the center of the w indo w to be cut in the floo r pan.

4 . W ith a heat gun and ga sket scraper, remove the sound deadener material from the floor pan within a200mm (8") radius of the dimple created in the previous step.

5 . M easure and mark a 1 0 0 mm (4 ") square centered around the dimple created in step # 4 . This w ill bethe window used to access the cagenut brackets.

6 . Cut three sides of the square marked in the previous step and pry the w indow tow ard the center of thevehicle (Figure 5 -2 ).

CautionWhen servicing the cagenut brackets, it is advised you use a fire resistant welding blanket (such as

part #J41156 available from Kent-Moore) to help avoid damage to the interior of the vehicle.

7 . Locate, centerpunch and drill out the tw o resistance w elds that secure the bracket to the frontsuspension support. Be careful to only drill through one layer of metal.

NoticeIt is important to leave a layer of metal for installation of the new cagenut bracket. If more than one

layer is drilled, fill the hole with a plug weld before installing the new bracket.

Install or Connect1 . Prepare mating surfaces and check for proper fit of the new ca genut bracket. Position the bracket

using body dimensions and secure it to the suspension support panel by temporarily installing andtightening the crossmember b olt.

2 . Plug w eld the new cag enut bracket and then remove the crossmember bo lt.

3 . C lean and prepa re w elded surfaces. Prime w ith tw o-pa rt catalyzed primer.

4 . Bend the access w indow back to its origina l position and stitch w eld the entire perimeter.

5 . C lean and prepa re w elded surfaces. Prime w ith tw o-pa rt catalyzed primer. Apply sealers andcorrosion protection materials, as necessary.

6 . App ly Dominion Sure Seal pa intable sound d eadening pads (part #1 1 0 9 0 0 ) to the floor as necessaryto match original sound deadening.

7 . Do not comb ine paint systems. Refer to paint manufacturers recommenda tions. Reinstall all relatedpanels and components.

8 . W hen reinstalling the suspension crossmember, torque all six fasteners to 13 0 N m (9 6 lbs. ft.).


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14CAVALIER/ SUNFIRE COLLISION REPAIR ISSUES 1 99 5 General M otors Corporation. All Rights Reserved.

6. DOOR FRAME OPENING

The side door frame openings feature a unique modular build sub-assembly designto improve manufacturing quality. They are compo sed o f numerous individua lcomponents that are pre-assembled and then attached to the vehicle as a single

unit.The door frame can be rep laced as a co mplete unit or various segments of it canbe sectioned , w hich is usually much faster and more cost effective. How ever,there are some key structural areas w here sectioning should not take p lace (Figures6 -1 and 6 -2 ). Since left and right door frame openings are only ava ilab le ascomplete assemblies, service parts for sectioning must be cut from the completeassembly and modified as necessary.

NoticeFour welds must be added on the lower hinge pillar when installing the

service assembly. These welds are essential to ensure the structuralintegri ty of the vehicle. Use the door frame opening weld template

provided with the service assembly to properly locate the position of thesewelds.

FIGURE6-1

COUPEDOORFRAMEOPENING

(SECTIONINGSHOULDNOTTAKEPLACE

INTHESHADED AREAS) FIGURE6-2

SEDAN DOORFRAMEOPENING

(SECTIONINGSHOULDNOTTAKEPLACE

INTHESHADED AREAS)


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6 . D O O R F R A M E O P E N I N G

DOOR FRAME OPENING FULLREPLACEMENT PROCEDURE

Remove or Disconnect1 . Remove all related pa nels and components

including the roof pa nel and upp er outer railreinforcement.

2 . Visually inspect and restore as much of thedamage as possible to factory specifications.

3 . Remove sealers, sound deadeners and corrosionmaterials as necessary.

4 . Locate, mark and dril l out all factory welds. N otethe number of welds for installation of the serviceassembly.

5 . Remove the damaged door frame opening.

Install or Connect1 . Prepare mating surfaces and check for proper fit of

the door frame opening service assembly.

2 . O n the service assembly, d ril l 8 mm (5 / 1 6 ") plugweld holes as necessary in the locations noted fromthe original assembly.

3 . Position the service assembly, check fit using b odydimensions, and plug weld accordingly withfrequent measurements to ensure proper fit.

4 . Inject expandable foam into the A pillar throughthe bottom interior trim mounting ho le (Figure 6-3 ).This helps reduce noise in the passengercompartment.

5 . Clean and prepare w elded surfaces. Prime withtw o-pa rt catalyzed p rimer. Apply sealers andcorrosion protection materials, as necessary.

6 . App ly a full-bod ied caulk along the surface of thebaffle to ensure a proper seal with the inner cowlplenum (Figure 6-4).

7 . Apply seam sealer, such as 3 M Ultra Pro 0 83 61 ,along the top edge of the A pillar joint at theroof line (Figure 6-3).

8 . Do not combine paint systems. Refer to paintmanufacturers recommendations. Reinstall allrelated panels and components.

FIGURE6-3

INJECTEXPANDABLEFOAM INTOTHE

A PILLARANDAPPLYSEAMSEALER

TOTHEJOINTATTHEROOFLINE

FIGURE6-4

APPLYSEALERTOTHEINNERCOWLPLENUM


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LOWER FRONT HINGE PILLAR SECTIONING PROCEDURESectioning is performed on the low er front hinge p illar between the tw o hinge mounting locations. The hingepillar inner reinforcement on the service part is used as a backing plate when welding the new section in

place.


2 . Visually inspect and restore as much of the damage a s possible to factory specifica tions.

3 . Remove sealers, sound deadeners and corrosion materials as necessary.

4 . Drill out and remove the access panel located on the upper outer rail reinforcement (Figure 6-5 ). Cutand pry the outer reinforcement away from the hinge pillar as necessary to provide room for thesectioning templa te (Figure 6 -6 ).

5 . Align the template provided w ith the service part and mark a line w here indicated. C ut the hingepillar and inner reinforcement along this line.

6 . Perform addi tional sectioning procedures as necessary to remove damaged areas of the door frameopening.

7 . Loca te, mark and d rill out all necessary factory welds. N ote the number of welds for installation ofthe service part.

8 . Remove the damaged section of the door frame opening and the hinge pillar inner reinforcement.

FIGURE6-5

REMOVETHEACCESSPANELONTHEFRONTLOWER

RAIL OUTERREINFORCEMENT

FIGURE6-6

CUTANDPRYOUTERREINFORCEMENT


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9 . Drill out the 4 w elds attaching the hingepillar to the inner reinforcement abovethe cut line. Remove the remaining

section of the inner reinforcement.(Figure 6 -7 )

Install or Connect1 . Align the template on the service part

and mark a cut line where indicated.

2 . Cut the service part along the markedline. Do not damage the hinge pillarinner reinforcement.

NoticeOnly cut the outer surface of the hinge

pillar service part. The innerreinforcement is used as a backing plate

when installing the new section.

3 . Drill out the 4 w elds attaching the hingepillar to the inner reinforcement abovethe cut line. Do not drill through theinner reinforcement.

4 . Perform additional sectioningprocedures as necessary to remove theunused a reas of the service pa rt. Drill8 mm (5 / 1 6 ") plug w eld holes asnecessary in the locations noted fromthe original section. Prepare all matingsurfaces for welding.

5 . Position the door frame opening servicepa rt. M ake sure the inner reinforcementextending from the top of the hingepillar service part is properly positionedwithin the existing hinge pillar section(Figure 6 -8 ). Check fit using body

dimensions and plug weld accordinglywith frequent measurements to ensure

proper fit.

NoticeTo ensure a secure weld, the hinge

pillar sectioning joint should have a gapof approximately one-and-a-half times

the thickness of the metal. Trim theparts as necessary to achieve this.

FIGURE6-8

POSITIONTHENEWDOORFRAMESECTION

FIGURE6-7

REMOVETHEREMAININGSECTIONOFTHE

INNERREINFORCEMENT


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6 . Stitch weld along the entire hinge pillar sectioning joint. M ake 25 mm (1 ") w elds along the seam with2 5 mm (1 ") ga ps between. Then go ba ck and

complete the stitch weld. This w ill create a solidjoint with minimal heat distortion.

7 . Straighten the upper outer rail reinforcement andweld seam.

NoticeLeave a gap at the forward edge of the baffle to

allow for proper water drainage.

8 . App ly a full-bod ied caulk along the surface of thebaffle to ensure a proper seal with the inner cowlplenum (Figure 6-9 ).

9 . Complete all other welds and sectioningprocedures as necessary.

1 0 . Clean and prepare welded surfaces. Prime withtw o-pa rt catalyzed p rimer. App ly sealers andcorrosion protection materials, as necessary. Donot combine paint systems. Refer to paintmanufacturers recommendations. Reinstall allrelated panels and components.

DOOR FRAME OPENING GENERAL SECTIONING

PROCEDURESW hen sectioning a reas other than the hinge p illar, a 1 0 0 mm (4 ") backing p late must beused behind the joint to ensure a solid and secure weld in areas where there is no innerreinforcement. Backing pla tes can usually be cut from the unused po rtion o f the servicepart or the damaged section of the door frame opening.

NoticeThere are some key areas where sectioning should not take place (Figures 6-1

and 6-2 on page 14). Sectioning in these areas may compromise the structuralintegrity of the vehicle.

Also, the rocker panel can be replaced in its entirety when the quarter panel has beenremoved.

FIGURE6-9

APPLYSEALERTOTHEINNERCOW L

PLENUM


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1 . Remove all related pa nels and components.



4 . Cut the door frame opening where it is to be sectioned. Do not damag e any inner panels orreinforcements.

5 . Loca te, mark and d rill out all necessary factory welds. N ote the number of welds for installation ofthe service part.

6 . Remove the damaged section of the door frame opening.

Install or Connect1 . Cut the service pa rt to match the damag ed section of the door frame opening and remove the unused

portion of the service part.

2 . Cut a 1 0 0 mm (4 ") backing p late from the unused portion of the service pa rt or damag ed section of

the door frame opening. M od ify the backing pla te as necessary so that it w ill fit behind thesectioning joint (Figure 6-10).

3 . O n the service part, d rill 8mm (5 / 1 6 ") plug w eld holes as necessary in the locations noted from theorig inal section. Also, drill plug w eld holes along the sectioning cut on bo th the service part and theremaining o riginal pa rt. These w ill be used to w eld the panel to the backing p late.

4 . Prepare mating surfaces and slide the backing p lates 5 0 mm (2 ") beneath the sectioning cuts on thevehicle and plug weld in place.

NoticeTo ensure a secure weld, the sectioning joints should have a gap of approximately one-and-a-half

times the thickness of the metal. Trim the parts as necessary to achieve this.


5 . Position the service part, allow ing it to overlap theexposed 50 mm (2 ") of the backing plates. Checkfit using b ody dimensions and p lug w eldaccording ly w ith frequent measurements to ensureproper fit (Figure 6-10).

6 . Stitch weld along the sectioning joints. M ake25mm (1") welds along the seam with 25mm (1")gaps between. Then go back and complete thestitch weld. This w ill create a solid joint withminimal hea t distortion.

7 . Complete all other welds as necessary.

8 . Clean and prepare w elded surfaces. Prime withtw o-pa rt catalyzed p rimer. Apply sealers andcorrosion protection materia ls, as necessary. Donot combine pa int systems. Refer to paintmanufacturers recommenda tions. Reinstall allrelated panels and components.

FIGURE6-10

INSTALLA BACKING PLATE

ANDPLUGWELDTHENEWPANEL


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7. DOOR SERVICE

The doors are available as completeassemblies (Figures 7-1 and 7-2).Additionally, the outer door panels are

ava ilab le sepa rately. Use conventiona lservice procedures when repairingdamage to the doo rs. All doors featurebo lt-on hinges and a n HSLA d oor beamfor added strength and occupantprotection in the event of a side collision.

FIGURE7-1

SEDAN DOORASSEMBLY

FIGURE7-2

COUPEDOORASSEMBLY


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8. ROOF PANEL

FIGURE8-1

ROOFASSEMBLY

The roof is made of steel and welded to the steel roof structure. The roof panel is suppliedas part of an assembly that includes the center roof support. The roof assemblies areunique to coupe and sedan models.

NoticeThe headliner, windshield and backglass must be removed prior to removal of

the roof assembly. Protect the interior of the vehicle by covering i t with blanketsand use care when working near adjacent panels, glass, weatherstrips and

moldings.

Remove or Disconnect1 . Remove all related panels and components to g ain proper access to the w elds

attaching the roof assembly to the vehicle.


3 . Locate, mark and drill out all factory w elds.

4 . Remove the roof panel and center roof support.

Install or Connect1 . Prepare mating surfaces and check for proper fit of the roof assembly.

2 . App ly urethane memory tape to front and rear roof bow s before installing roofpanel.

3 . Position the roof panel, check fit using body d imensions, and plug w eldaccordingly with frequent measurements to ensure proper fit.

4 . C lean and prepare w elded surfaces. Prime with tw o-part catalyzed primer.

Apply sealers and corrosion protection materials, as necessary. Do not comb inepaint systems. Refer to pa int manufacturers recommenda tions. Reinstall allrelated panels and components.

Center roof support


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9. QUARTER PANEL

To simplify repa irs, the quarter pa nels are only availab le as sub-assemblies including filler pa nels and taillightmounting panels (Figures 9 -1 and 9 -2 ). There are unique rep lacement proced ures for the coupe and sedanmodels. A key difference is that the rear wind ow can be left in place when performing quarter pa nel service

on the coupe mod el, but must be removed on the seda n model. Also, the seda n quarter panel serviceprocedure incorporates sectioning to simplify replacement.

COUPE QUARTER PANEL REPLACEMENT


1 . Remove all related p anels and components including the modular side g lass and close-out molding.

NoticeThe quarter window close-out molding is retained with two-sided tape and urethane. Use the E-Z

Strip Molding Tool (part # 217-80003) to remove this molding (call 1-800-GM-TOOLS).



4 . M ask the rear window lace and glass to protect them from possible damage.

5 . Loca te, mark and d rill out all accessible factory welds on the quarter panel assembly. N ote thenumber of welds for installation of the service assembly.

FIGURE9-1

COUPEQUARTERPANEL ASSEMBLY

FIGURE9-2

SEDANQUARTERPANELASSEMBLY

Gutter extension

Gutter extension


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6 . Cut a hole in the damag ed quarter panel to gain access to the inside surface o f the drip rail at theback glass to simplify removal (Figure 9-3).

7 . Loca te and drill out all factory welds along the quarter pa nel drip rail at the backglass.

8 . Remove the damag ed quarter panel assembly. N ote how the quarter panel assembly mates w ith therear gutter for installation of the new assembly.

CautionTake care not to damage the rear window when removing the quarter panel.

Install or Connect1 . Prepare mating surfaces and check for proper fit of the quarter panel service assembly.

2 . O n the service assembly, drill 8mm (5 / 1 6 ") plug w eld holes as necessary in the locations noted fromthe original assembly.

3 . Position the service assembly. Allow the quarter panel to w rap over the rear gutter and then slide theentire assembly forw ard so that the gutter extension slips benea th the rear gutter. Check fit usingbody dimensions, and plug weld accordingly with frequent measurements to ensure proper fit.

4 . Clean and prepare w elded surfaces. Prime with tw o-part catalyzed primer. App ly sealers andcorrosion p rotection materia ls, as necessary. Do no t combine p aint systems. Refer to paintmanufacturers recommendations. Reinstall all related p anels and components.

FUEL FILLER NECKCare must be taken to ensure that the fuel filler neck is properly sealed w hen replac ing the right quarter pa nel.Use SPO Sealing Strip (Part # 1 2 3 9 5 9 5 2 ) between the quarter pa nel and fuel filler neck. Install using theprovided instructions.

9 . Q U A R T E R P A N E L

FIGURE9-3

CUTACCESSHOLETOTHEDRIPRAIL


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SEDAN QUARTER PANELREPLACEMENTW hen replac ing the quarter panel assemblies

on the seda n models, a tab is created from theorig inal quarter panel at the joint w ith the roof.The service part is then modified to fit over thistab, which is used as a backing plate forw elding the new p anel in place.

Remove or Disconnect1 . Remove all related panels and

components including the rear window.Also pry up and remove the revealmolding at the roof line. It is held in

place with two-sided tape.2 . Visually inspect and restore as much of

the damage as possible to factoryspecifications.

3 . Remove sealers, sound dead eners andcorrosion materials as necessary.

4 . Locate, mark and dril l out all factorywelds around the perimeter of the

quarter panel assembly, except for thoseunder the reveal molding . N ote thenumber of welds for installation of the

service assembly.5. Cut a hole in the damaged quarterpanel to gain access to the insidesurface of the drip rail at the back glassto simplify removal (Figure 9 -4 ).

6. Apply a strip of 2 5 mm (1 ") maskingtape along the top edge of the quarterpanel where it meets the roof.

7. Cut along the bottom edge of themasking tape and remove the damagedquarter panel assembly, leaving a25mm (1") tab attached to the roof

(Figure 9-5).

FIGURE9-4 CUTACCESSHOLETOTHEDRIPRAIL

FIGURE9-5

CREATEA 25MM (1") TABFROMTHEORIGINAL

QUARTERPANEL

25mm (1") tab


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Install or Connect1 . Trim and discard the upper mounting flange

on the service assembly so that it can fit over

the 25mm (1") tab left from the original panel(Figure 9-6 ).

2. O n the service assembly, drill 8mm (5/ 1 6")plug weld holes as necessary in the locationsnoted from the origina l assembly. Also drillfour plug weld holes along the top edge ofthe new quarter panel for attachment to theone-inch tab (Figure 9-7)

3 . Position the service assembly from the topdow n. Check fit using body dimensions.

NoticeVerify fit of the pinch-flange molding. If thegap is unsatisfactory, adjust the one-inch tab

until correct alignment is achieved.

4 . W hen the assembly is correctly positioned,plug weld accordingly with frequentmeasurements to ensure prop er fit. Begin wi ththe welds over the 25mm (1") tab and thencontinue around the perimeter of theassembly.

5 . Clean and prepare welded surfaces. Prime

w ith tw o-pa rt catalyzed p rimer. Apply fillers,sealers and corrosion protection materials, asnecessary. Do not combine pa int systems.Refer to paint manufacturersrecommenda tions. Reinstall all related panelsand components.

NoticeApply seam sealer, such as 3M Ultra Pro

08361, along the top edge of the A pillarjoint at the roof line (Figure 9-8).

FUEL FILLER NECKCare must be taken to ensure that the fuel filler neckis properly sealed when replacing the right quarterpanel. Use G M Part # 1 2 3 9 9 1 1 7 between thequarter panel and fuel filler neck. Install using theprovided instructions.


FIGURE9-6

TRIMTHESERVICEPART

FIGURE9-7

DRILL PLUGWELDHOLESINTHESERVICE

ASSEMBLY

FIGURE9-8

APPLYSEAMSEALERTOTHEJOINTWITHTHEROOF


26/44


REAR WHEELHOUSESECTIONING PROCEDUREThe outer rear wheelhouse (Figures 10-1 and

10-2) is repaired by sectioning when damage tothe rest of the panel is minimal. C oupe mod elshave a beltline reinforcement that creates uniqueservice concerns. Therefore, templa tes have beendeveloped to ensure proper wheelhousesectioning on coupe models.

It is recommended that the service part beprepared before removing the damaged section ofthe pa nel from the vehicle. This w ill help youbecome familiar with the procedure and knowexactly where to cut the damaged panel for a

better fit of the new section.

Prepare the Service Part1. Apply a strip of 2 0mm (3/ 4 ") masking tape

along the vertical surface of the wheelhouseradius to form a welding flange.

2. O n coupe models, al ign the appropriatetemplate over the ga ge holes according tothe template instructions.

3. O n sedan models, cut along the top edgeof the tape. O n coupe models, cut along

the top edge of the tape and at the rad iusof the wheelhouse as indicated on thetemplate (Figure 10-3).

4 . Remove the excess portion of thewheelhouse.


2 . Visually inspect and restore as much of thedamage as possible to factoryspecifications.


4 . Drill out the factory w elds at the forw ardlower portion of the wheelhouse at therocker panel. O n coupe models, also drillout the four factory welds along theoutboard edge of the beltline reinforcement.

10. OUTER REAR WHEELHOUSE

FIGURE10-1

OUTERREARWHEELHOUSE(COUPE)

Beltline reinforcement

FIGURE10-2

OUTERREARWHEELHOUSE(SEDAN)

FIGURE10-3

APPLYTAPEANDCUTTHESERVICEPART

Trimmed accor

to template

Cut along top edge of tape


27/44



5. Apply a strip of 20 mm (3/ 4") maskingtape along the horizontal surface of thewheelhouse radius.

6 . Cut along the outboard side of themasking tape to create a tab for theweld flange on the new wheelhousesection (Figure 1 0 -4 ). O n coupemodels, cut the portion of thewheelhouse under the beltlinereinforcement from inside thew heelhouse. Simply connect the tw o cutlines on either side of the reinforcement.

7 . Remove the damaged section of thewheelhouse.

1 0 . O U T E R R E A R W H E E L H O U S E

Install or Connect

1 . Temporarily install the w heelhouse service pa rt andcheck fit. O n coupe models, first fit the forw ard low erportion then slide the weld flange over the tab on theoriginal section and under the beltline reinforcement.

2 . O n the service part, mark plug w eld holes every4 0 mm (1 -1 / 2 ") along the weld flange, a lternatingbetween the vertical and horizontal surfaces to ensure

uniform strength (Figure 10 -5 ).

3 . Remove the service part and drill 8mm (5 / 1 6 ") plugwelds where marked in the previous step.

4 . Prepare mating surfaces and position the service pa rt.Check fit using b ody d imensions and p lug w eldaccord ingly w ith frequent measurements to ensureproper fit. Take care not to wa rp or distort the metal.

5 . Plug w eld the factory welds at the forward lowerportion of the wheelhouse at the rocker panel (see step# 4 of Remove or Disconnect). O n coupe models, a lsoplug w eld the four factory w elds along the outboard

edge of the beltline reinforcement.6 . Clean and prepare welded surfaces. Prime with tw o-

pa rt catalyzed primer. Apply sealers and co rrosionprotection materials, as necessary. Do not combinepaint systems. Refer to pa int manufacturersrecommenda tions. Reinstall all related panels andcomponents.

FIGURE10-5

WELDTHENEWWHEELHOUSE

SECTION

20mm(3 4") tab

FIGURE10-4 APPLYTAPE, CUTANDREMOVEDAMAGED

PORTIONOFWHEELHOUSE


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11. REAR RAIL

The left and right rear rails are available as complete sub-assemblies and can bereplaced in their entirety similar to pa st model procedures. How ever, sectioning ca n beused to simplify repairs if damage is limited to the rear 600mm (24") of the rail.

Templates and instruction sheets are packaged with the parts to facilitate service.W hen replacing a rail in i ts entirety, the w eld flange that mates with the w heelhouse mustbe b ent upw ards. The service assembly is supp lied w ith this flange in a ho rizontalposition (Figure 11-1).

It is recommended that the service part be prepared before removing the damagedsection of the rail from the vehicle. This w ill help you become familiar w ith the procedureand know exactly where to cut the damaged rai l for a better fit of the new section. Itwill also help you locate the rear rail inner reinforcement.

REAR RAIL SECTIONING PROCEDURE

Prepare the Service Part1 . Invert the service pa rt and secure it to a b ench for cutting.

2 . Align the approp riate template on the underside of the rail. Use a center punchor an aw l to mark the rail by punching through the template. Remove thetemplate and connect the dots with a straight edge and scribe the cut line.

NoticeThe cut lines for the left and right sides are in different positions. Make sure to

use the appropriate template. Do not damage the template since it must also beused to mark the original rail. Attach it with a non-permanent spray adhesive

such as 3Ms Repositionable Adhesive (part #6091).

3 . Cut through the outer panel and inner reinforcement along the line and removethe excess portion of the service part.

4 . Drill out the welds attaching the inner reinforcement to the outer panel (typica llythree w elds). Remove the inner reinforcement.

FIGURE11-1

REARRAILASSEMBLY

Service assembly supplied with horizontalwheelhouse flange

Service assembly with wheelhouse flangebent upwards for installation


29/44



Remove or Disconnect1 . Remove all related pa nels and components

including the fuel tank, fuel filler neck and

exha ust system.2 . Visually inspect and restore as much of the

damage as possible to factory specifications.


4 . Align the appropriate template on theunderside of the rail. Use a center punch oran a w l to mark the rail by punching throughthe templa te. Remove the templa te andconnect the dots with a straight edge andscribe the cut line.

5 . Locate, mark and drill out the factory w eldsrearward of the marked cut line, includingthose securing the rear rail inner reinforcementto the outer panel. Do not drill through theinner reinforcement (Figure 11 -2 ).

6 . Cut the rail along the rough cut line. Removethe damaged section of the rear rail.

7 . Separate the side walls of the innerreinforcement from the outer panel of the railby slightly prying the reinforcement inwards.

8 . Cut the sides of the rail outer panel along the

final cut line, taking care not to damage theinner reinforcement. Cut along the bottom ofthe outer panel approximately 3/ 4 of themetal thickness deep.

NoticeBe careful not to cut the inner reinforcement.This reinforcement will act as a backing platewhen welding the new rail section in place.

9 . Bend the rail down and up until the outerpa nel breaks along the partial cut. Remove

the damaged section of the rear rail, leavingthe reinforcement extending from inside theremaining rail section (Figure 11-3)

1 1 . R EA R RA I L

FIGURE11-2

CUTANDREMOVETHEDAMAGEDSECTIONOF

THEREARRAIL

FIGURE11-3

LEAVEINNERREINFORCEMENT

EXTENDINGFROMORIGINALRAIL

"Final" cut line


30/44


1 1 . RE A R RA I L

Install or Connect1 . Prepare mating surfaces and p osition the service part, allow ing it to slide over

the inner reinforcement extending from the orig inal rai l section. Check fit using

body dimensions and plug weld accordingly with frequent measurements toensure proper fit.

NoticeMake sure to plug weld the inner reinforcement to the new rail section. Thismay require drawing the reinforcement flat against the rail using a screw.

It may be necessary to install backing plates on either side of the original railabove the inner reinforcement. These can be cut from the unused inner

reinforcement of the service part. Dril l holes and plug weld the backing platesin place (Figure 11-4).

5 . Stitch weld along the entire joint. M ake 25 mm (1 ") w elds along the seam with

2 5 mm (1 ") ga ps between. Then go b ack and complete the stitch weld. This w illcreate a solid joint with minimal heat distortion.

NoticeTo ensure a secure weld, the sectioning joints should have a gap of

approximately one-and-a-half times the thickness of the metal. Trim the parts asnecessary to achieve this.

6 . Clean and prepare w elded surfaces. Prime with tw o-part catalyzed primer.Apply sealers and corrosion protection materials, as necessary. Do not combinepaint systems. Refer to pa int manufacturers recommenda tions. Reinstall allrelated panels and components.

FIGURE11-4

INSTALLBACKINGPLATESANDWELDNEWSECTION


31/44



REAR FLOOR ASSEMBLY SECTIONING PROCEDURESectioning procedures are used to repa ir the rear floor. The rear floor is sold a s an assembly that includesthe low er rear rails and crossmember. The damaged ra ils must be cut so that the new ra il sections wi ll properly

mate with the original rails and inner reinforcement. Templates and procedures are included w ith the rearfloor service assembly. Keep the follow ing guidelines in mind when performing this procedure:

O verlap the original floor pan a minimum of 25 mm (1 ") w ith the service assembly floor pan.

Create a butt joint w hen mating the lower rails.

Use the original rail inner reinforcements as backing p lates w hen welding the service assembly.

The rear rail inner reinforcements are at different lengths in the left and right rails (Figure 12 -1 ).

There are 4 templates to facilitate the sectioning procedure: left rail, right rail, left floor and rightfloor.

12. REAR FLOOR ASSEMBLY

FIGURE12-1

REARRAILINNERREINFORCEMENTS


32/44


1 2 . R E A R F L O O R A S S E M B L Y

Remove or Disconnect1 . Remove all related panels and components.

2 . Visually inspect and restore as much of the damage as possible to factory specifications.


4 . Align the templates in the app ropriate loca tions. Use a center punch or an aw l to mark the assemblyby punching through the templates. Remove the templa tes, connect the dots w ith a straight edg e andscribe the cut lines.

Notice

The cut lines for the left and right sides are in different positions. Make sure to use the appropriatetemplates. Do not damage the templates since they must also be used to mark the service assembly.Attach them with a non-permanent spray adhesive such as 3Ms Repositionable Adhesive (part

#6091).

5 . Loca te mark and d rill out all related factory welds rearw ard of the cut lines.

6 . From the underside of the vehicle, cut the rails and floor pan along the rough cut line. Continue thiscut around the rad ius of the spa re tire tub. Remove the damaged section of the rear floor and ra ils(Figure 12-2).

FIGURE12-2

CUTANDREMOVETHEDAMAGEDSECTIONOFTHEREARFLOORPANANDRAILS


33/44




7 . Trim the floor pan to expose the rearrail inner reinforcements by cuttingalong the final cut line, taking care

not to damage the rails orreinforcements.

NoticeOnly cut the floor pan. Do not cut

through the rear rails or innerreinforcements. These reinforcements

will act as backing plates whenwelding the new rail section in place.

8 . Locate, mark and drill out the factorywelds securing the rear rail inner

reinforcements to the outer panelsbetween the rough cut and finalcut lines. Do not drill through theinner reinforcements.

9 . Separate the side wa lls of the innerreinforcement from the outer panel ofthe rail by slightly prying thereinforcements inwa rds (Figure 12 -3 ).

1 0 . Cut the sides of the rail outer panelalong the final cut lines, taking ca renot to damage the innerreinforcement. Cut along the bo ttom

of the outer panel approximately 3 / 4of the metal thickness deep.

1 1 . Bend the rail up and do w n until theouter panel breaks along the pa rtialcut. Remove the da maged section ofthe rear rail, leaving the reinforcementextending from inside the remainingrail section (Figure 12-4).

FIGURE12-4

LEAVETHE INNERREINFORCEMENTEXTENDING

FIGURE12-3

SEPARATETHESIDERAILSOFTHEREARRAILINNER

REINFORCEMENTFROMTHEOUTERPANEL

Rear rail "rough" cut line

Rear rail "final" cut line


34/44



Prepare the Service Assembly1 . Align the templates in the appropriate loca tions on the service assembly. Use a center punch or an

awl to mark the assembly by punching through the template along the service cut line on the floorpa n and the final cut line on the rai ls. Remove the templa tes, connect the do ts w ith a straight edg eand scribe the cut lines.

2 . Connect the left and right floor pan service cut lines around the forwa rd radius of the spa re tire tub.This wi ll ensure the co rrect overlap for service a ssembly installation (Figure 12 -5 ).

3 . Drill out the welds at the front edge of the spa re tire rad ius. Cut through bo th the floor pan and railsalong the floor pan service cut line. Discard the front po rtion of the assembly.

4 . Cut through the rails along the final cut line and remove the excess portions. Do not cut through thefloor pan.

5 . O n the remaining rail sections, d rill out the w elds attaching the inner reinforcements to the outerpanels (typ ically three w elds). Remove the inner reinforcements.

6 . Drill 8 mm (5 / 1 6 ") plug w eld holes as necessary in the locations noted from the original floor. Alsodrill weld holes along the overlap joint of the floor p an. These should be placed approximately4 0 mm (1 -1 / 2 ") apart.

FIGURE12-5

PREPARETHESERVICEASSEMBLY


35/44




Install or Connect1 . Prepare mating surfaces and check for proper fit of the rear floor service assembly section, a llow ing it

to overlap the origina l floor.

NoticeTo ensure a secure weld, the rear rail sectioning joints should have a gap of approximately one-

and-a-half times the thickness of the metal. Trim the parts as necessary to achieve this. Make sureto plug weld the inner reinforcement to the new rail section. This may require drawing the

reinforcement flat against the rail using a screw.It may also be necessary to install backing plates on either side of the original rails above the

reinforcements. These can be cut from the unused inner reinforcements of the service part. Drillholes in the rail and plug weld the backing plates in place.

2 . W ith the service assembly positioned, plug w eld the inner reinforcements to the rail service pa rts.

3 . Verify position of the service assembly using body dimensions and p lug w eld accordingly with

frequent measurements to ensure proper fit (Figure 12 -6 ).4 . Clean and prepare w elded surfaces. Prime with tw o-part catalyzed primer. App ly sealers and

corrosion p rotection materials, as necessary. C aulk both sides of the floor pan seam.

NoticeUse a full-bodied caulk, such as 3Ms Ultra Pro Seam Sealer (part #08360-1), to seal both sides of

the floor pan seam.

5 . Refinish as necessary. Do not combine paint systems. Refer to paint manufacturersrecommenda tions. Reinstall all related panels and components.

FIGURE12-6

WELDTHENEWSECTION

Overlap


36/44


13. REAR END PANEL

The rear end panel is supplied as a completeassembly consisting of three innerreinforcements and one outer panel on

Cavalier coupe a nd sedan and Sunfire sedan.The rear end panel on Sunfire coupe has asing le inner reinforcement. Tai llight mountingpanels, which attach to the outside corners ofthe rear end panel assembly, are availablesepara tely. Service for all of these pa nels isperformed at factory seams (Figure 13-1).

Remove or Disconnect1 . Remove all related panels and

components.

2 . Visually inspect and restore as much ofthe damage as possible to factory

specifications.


4 . Locate, mark and dril l out all factoryw elds. N ote the number of w elds forinstallation of the service assembly.

5 . Remove the damaged assembly.

Install or Connect

1 . Prepare mating surfaces and check forproper fit of the service a ssembly.

2 . O n the service assembly drill 8mm (5 /16") plug weld holes as necessary in thelocations noted from the originalassembly.

3 . Position the service assembly, check fitusing body dimensions, and plug weldaccordingly with frequent measurementsto ensure proper fit.

4. Clean and prepare welded surfaces.

Prime with two-part catalyzed primer.Apply sealers and corrosion protectionmaterials, as necessary. Do notcombine pa int systems. Refer to paintmanufacturers reco mmendations.Reinstall a ll related pa nels andcomponents.

FIGURE13-1

REARENDPANELASSEMBLY

Sunfire Coupe

Drill dimples forlatch mounting

Drill dimples forlatch mounting

Cavalier and Sunfire Sedan


37/44



14. BODY DIMENSIONS

CAVALIER/SUNFIRE UNDERBODY


38/44


1 4 . B O D Y D I M E N S I O N S

CAVALIER

/SUNFIREENGINECOMPARTMENT


39/44



1 4 . B O D Y D I M E N SI O N S

CAVALIER

/SUNFIREFRONT


40/44



CAVALIER

/SUNFIRESEDANSIDE


41/44



CAVALIER

/SUNFIRECOUPESIDE

1 4 . B O D Y D I M E N SI O N S


42/44



CAVALIER/SUNFIRE REAR


43/44



The following procedure has been developed to repair stripped or damaged cagenuts when full lower railreplacement is not necessary. It allow s the cagenuts to be serviced from the underside of the vehicle. Thisis done by gaining a ccess to and d rilling out the hidden w elds holding the cagenut bracket in place. The

damaged cagenut and bracket can then be removed through the rail slot (Figure 1).

REMOVE OR DISCONNECT1 . Remove all related p anels and components including the suspension crossmember

2 . Loca te the tw o factory welds that secure the cagenut to the low er rail surface. Insert a p ry barbetween the torque box closeout panel and the low er rail and bend the metal outw ard to expose thetwo factory welds (Figure 2).

3 . Center punch and drill through the welds with a 1 0 mm (3 / 8 ") drill bit.

4 . W rap a w ire through the cagenut to keep it from sliding do w n into the rail.

5 . Rotate the damag ed cagenut bracket and remove it through the rail slot.

FIGURE1

SLOTTEDLOWERRAIL

SLOTTED RAIL CAGENUT REPLACEMENT

Slotted rail viewed fromunderneath the vehicle


44/44

NoticeIf the rail slot is too narrow to remove thecagenut bracket, make it wider by slightly

grinding the edges of the gap. Do notremove more than 2mm of metal (Figure 3).

INSTALL OR CONNECT1 . Prep w eld areas for installation as noted from

the origina l pa rt.

2. W rap a wire through the new cagnut andinstall the cagenut bracket through the railslot.

3 . Position the new cagenut bracket and checkfit using body dimensions.

NoticeIt may be necessary to temporarily secure the

new cagenut bracket to the rail using thecrossmember mounting bolt.

4 . Plug w eld the cagenut bracket in place atorigina l loca tions.

5 . Clean and prepare welded surfaces. Prime

plug w elds using tw o-pa rt catalyzed primer.6 . Straighten the torque box closeout panel bent

outward in step #2 of Remove andDisconnect.

7 . Clean and prepare the lower rail surface. Donot combine paint systems. Refer to paintmanufacturers recommenda tions. Applycorrosion protection materials, as necessary.

8 . Reinstall all related pa nels and components.W hen reinstalling the suspensioncrossmember, torque all six fasteners to 1 3 0N m (9 6 lbs. ft.).

S L O T T E D R A I L C A G E N U T R E P L A C E M E N T

Do not remove more than 2mm

FIGURE2

PRYTHETORQUEBOXCLOSEOUTPANEL OUTWARDS

TOEXPOSEFACTORYWELDS

Hiddenwelds

collision issues

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