1997-2005 Buick CenturyOldsmobile Intrigue Collision Body Repair Manual Issues

Buick Century/Oldsmobile Intrigue Collision Repair Issues 1

TABLE OF CONTENTS ␣

Panel Identification ............................................... 2

Radiator Support Assembly .................................... 4

Front Upper Rail ..................................................... 5

Front Wheelhouse Assembly ................................. 7

Front Lower Rail ..................................................... 8

Door Frame Opening ........................................... 14

Door Service ......................................................... 23

Roof Panel ............................................................ 24

Quarter Panel ....................................................... 25

Rear Outer Wheelhouse ....................................... 27

Rear Rail Assembly ............................................... 29

Rear Floor ............................................................. 32

Rear End Panel Assembly ..................................... 34

Body Dimensions ................................................. 35

BUICK CENTURY/OLDSMOBILE INTRIGUECOLLIS ION REPAIR ISSUES

2 Buick Century/Oldsmobile Intrigue Collision Repair Issues

The lower rails are made ofhigh-strength, low-alloy steel.

1. PANEL IDENTIF ICATION

MS10961.1

— 1997 Buick Century —

TSGS

TSGS

TPO

TPO

PrimarilyTSGS

TSGS

TSGS

TSGS

HSLA

HSLA

TSGS

TSGS

TSGS = Two-Sided Galvanized Steel

HSLA = High-Strength Low-Alloy Steel

TPO = Thermoplastic Olefin


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

MS10961.2

— 1998 Oldsmobile Intrigue —

TSGS

TSGS

TPO

PrimarilyTSGS

TPO

TSGSTSGS

TSGS

HSLA

HSLA

TSGS

TSGS

TSGS = Two-Sided Galvanized Steel

HSLA = High-Strength Low-Alloy Steel

TPO = Thermoplastic Olefin

The lower rails are made ofhigh-strength, low-alloy steel.


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2. RADIATOR SUPPORT ASSEMBLY

The radiator support can be serviced as acomplete assembly. The radiator supportis made up of five major components: fourupper and one lower (figure␣ 2-1).

Upper Radiator SupportThe upper radiator support is an assemblyconsisting of four components: a two-pieceupper tie bar, and left and right enginecompartment front panels.

Lower Radiator SupportThe lower radiator support is available as aseparate replaceable component if necessary.Remove or Disconnect

1 Remove all related panels and components.2 Visually inspect and restore as much of the

damage as possible to factory specifications.3 Locate, mark, and drill out all factory welds.

Note the number and location of welds forinstallation of the service assembly.

4 Remove the damaged radiator support assembly.

Install or Connect

1 Prepare the mating surfaces as necessary, andcheck for proper fit of the service assembly.

2 Drill 8mm (5⁄1 6␣ in) plug weld holes asnecessary in the locations noted from theoriginal assembly.

3 Position the service assembly usingthree-dimensional measuring equipment,plug weld accordingly with frequent measure-ments to ensure proper fit and alignment.

4 Clean and prepare all welded surfaces. Primewith two-part catalyzed primer. Apply sealersand corrosion protection materials as neces-sary. Do not combine paint systems. Refer topaint manufacturer’s recommendations.

5 Install all related panels and components.

MS10962.1

Figure 2-1:Radiator Support Service Part


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Outer Rail

Inner Reinforcement

Figure 3-1:Front Upper Rail Service Parts

Inner Rail

3. FRONT UPPER RAIL

The front upper rail is serviced as twocomponents: inner and outer panels. Theouter panel is serviced as a sub-assemblywhich includes an inner reinforcement(figure␣ 3-1). After the outer rail has beenremoved, the inner rail is completelyaccessible and can be serviced at thefactory seams.

— NOTICE —Sectioning of the front upper rails is not

recommended.

Remove or Disconnect


damage as possible to factory specifications.3 Remove sealers and corrosion protection

materials as necessary.4 Locate, mark, and drill out all factory welds

attaching the outer rail. Remove the damagedouter rail.

5 With the outer rail removed, locate, mark, anddrill out the welds attaching the inner rail.

6 Remove the damaged inner rail.

MS10963.1


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Figure 3-2:Plug Weld the Outer Rail

F R O N T U P P E R R A I L

4 When the service panels are correctlypositioned, remove the outer panel, and plugweld the inner panel as necessary. Repositionthe outer rail with frequent measurements toensure proper fit and alignment, and plugweld accordingly (figure␣ 3-2).

5 Clean and prepare all welded surfaces. Primewith two-part catalyzed primer. Apply sealersand corrosion protection materials as neces-sary. Do not combine paint systems. Refer topaint manufacturer’s recommendations.


Front Upper Rail Service Procedure (cont’d)

MS10963.2

Install or Connect

1 Prepare the mating surfaces as necessary.2 Drill 8mm (5⁄1 6␣ in) plug weld holes as

necessary in the locations noted from theoriginal panels. NOTE: If original locationsare damaged beyond recognition, locateholes for plug welding 40mm (11⁄2␣ in) apart.

3 Temporarily position the inner and outerrails on the vehicle. Using three-dimensionalmeasuring equipment, locate and mark frontfender mounting bolt holes in the outer rail.Drill 5.5mm (7⁄32␣ in) holes for self-tappingbolts as marked.


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Figure 4-1:Front Wheelhouse Service Parts

Where the wheelhouse iswelded to the cowl, inspectthe surface for damage.

4. FRONT WHEELHOUSE ASSEMBLY

— NOTICE —Sectioning of the front wheelhouse assembly

is not recommended.

The front wheelhouse service panel is servicedas a complete assembly, which includes theupper front strut mounting surface (figure␣ 4-1).The upper strut mounting surface is a dimen-sionally critical area, and three-dimensionalmeasuring equipment should be used to locatethe front wheelhouse assembly. The frontapron close-out panel is available and servicedseparately.Remove or Disconnect

1 Remove all related panels and components,including the upper rail outer and inner panels.

— NOTICE —Some interior components must be removed toaccess the welds attaching the wheelhouse tothe front of the cowl panel. Be sure to inspectthe front of the cowl for damage. If the metalsurface is damaged, the cowl panel must berepaired to restore the structural integrity of

the vehicle.

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

3 Remove sealers and corrosion protectionmaterials as necessary.

4 Locate, mark, and drill out all factory welds.Note the number and location of welds forinstallation of the service assembly.

5 Remove the damaged wheelhouse assembly.

MS10.964.1

Install or Connect

1 Prepare the mating surfaces as necessary.2 Drill 8mm (5⁄1 6␣ in) plug weld holes as necessary

in the locations noted from the originalassembly. NOTE: If the original locations aredamaged beyond recognition, locate holes forplug welding 40mm (11⁄2␣ in) apart.

3 Position the wheelhouse on the vehicle.Check for proper fit using three-dimensionalmeasuring equipment.

4 When the service assembly is correctlypositioned, plug weld accordingly, measuringfrequently to ensure proper fit and alignment.

— NOTICE —Some of the plug welding may be performed

from inside the vehicle. Make sure beforewelding that there is no chance of damage to

components or panels from welding sparks andheat. Take necessary fire prevention precautions.

5 Clean and prepare all welded surfaces. Primewith two-part catalyzed primer. Apply sealersand corrosion protection materials as neces-sary. Do not combine paint systems. Refer tothe paint manufacturer’s recommendations.


Apron Close-Out Panel


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Figure 5-1:Die Mark Indicates Sectioning Location

MS10965.2

Die Mark

5. FRONT LOWER RAIL

Lower Rail Sectioning

— NOTICE —If the damage exceeds the recommended area

for sectioning and the rail cannot be straightened,the complete rail must be replaced.

Sectioning procedures have been developed to simplifyrepair of the lower rails, providing the majority of thedamage can be returned to factory specifications. Thisallows the damaged front section to be replaced withoutperforming a full rail replacement. The rails aremanufactured with die-marks inboard and outboard toindicate the location for the sectioning joint (figure␣ 5-1).

— NOTICE —Failure to follow the instructions included with the service railmay lead to improper rail sectioning, which may compromise

the structural integrity of the vehicle.


Figure 5-2:Use Straight Edge to Scribe Cut Line

at Front Edge of Die Mark

F R O N T L O W E R R A I L

Figure 5-3:Cut the Rail for Sectioning

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MS10965.3

MS10965.4

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Lower RailSectioning Procedures (cont’d)Remove or Disconnect

1 With the powertrain assembly supported,lower the cradle away from the rail.

— IMPORTANT —It is not necessary to completely remove the

powertrain or engine cradle for rail sectioning.

2 Remove all other related panels andcomponents, including the strut and axleassemblies as necessary.



5 Locate the die-marks in the rail. Using astraight edge to scribe lines around the rail(figure␣ 5-2), mark and cut the damaged railat the die-marks (figure␣ 5-3). Remove thedamaged section of the rail.


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Figure 5-4:Mark Service Part


Figure 5-6:Weld Four Corners

Weld Here

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Figure 5-5:Cut Flanges

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5mm Gap

MS10965.5

20mm Flange

MS10965.6

MS10965.7

Lower RailSectioning Procedures (cont’d)Install or Connect

1 Measure from the die-marks to add 20mm(3⁄4␣ in) in length to the service part. Alignmarks with a straight edge and scribe linefor sectioning cut (figure␣ 5-4).

2 Cut the service part along the marked lines.

— NOTICE —Be sure to leave 20mm (3⁄4␣ in) added length

to the service part for sectioning overlap.

3 Cut and remove approximately 20mm(3⁄4␣ in) of the outboard and downwardturned flanges of the service part. Cut a5mm (3⁄1 6␣ in) gap approximately 20mm(3⁄4␣ in) along the corners of the service partto create tabs on the four sides of the rail(figure␣ 5-5).

4 Step the top, bottom and the side tabs inwardto allow the service part to fit inside theoriginal rail. Weld the tabs together along thecorners of the service part (figure␣ 5-6).


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Figure 5-7:Drill Holes for Plug Welding

Figure 5-8:Stitch Weld Joint

Lower RailSectioning Procedures (cont’d)5 Drill 8mm (5⁄1 6␣ in) plug weld holes in the

top, bottom and sides of the original railapproximately 10mm (3⁄8␣ in) from thesectioning cut (figure␣ 5-7).

6 Clean and prepare the mating surfaces asnecessary.

7 Position the stepped tabs of the modifiedservice part inside the original rail, allowing20mm (3⁄4␣ in) of overlap. Align and check fitusing three-dimensional measuringequipment and plug weld accordingly withfrequent measurements to ensure proper fitand alignment.

8 Stitch weld along the entire sectioningjoint. Make 25mm (1␣ in) welds along theseam with 25mm (1␣ in) gaps between them(figure␣ 5-8). Then go back and complete thestitch weld. This will create a solid jointwith minimal heat distortion.

9 Clean and prepare welded surfaces. Primewith two-part catalyzed primer. Applysealers and corrosion protection materialsas necessary. Do not combine paintsystems. Refer to paint manufacturer’srecommendations.



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Figure 5-9:Front Lower Rail Service Parts

Mid-RailReinforcement

Close-Out Panel

Bumper Bracket

MS10965.1


Lower Rail Sub-AssemblyThe lower rail service part comes as a sub-assembly, which consists of seven bracketsand panels. Instruction sheets are alsoincluded. The front bumper brackets areavailable and serviced separately. Die-markshave been added to the rails to indicatesectioning locations (figure␣ 5-9).

Lower Rail Close-Out PanelThe lower rail close-out panel is attached tothe lower edge of the cowl on the outboardside of the lower rail. The mid-section of thelower rail is sandwiched between the close-outpanel and the floor pan for added vehiclestrength and rigidity (figure␣ 5-9). Whenperforming a full rail replacement, the close-out panel must be removed and installed, orreplaced if necessary.

— IMPORTANT —The mid-rail reinforcement panel must be

purchased separately for full rail replacement.

Die Mark



Lower RailReplacement ProceduresRemove or Disconnect

— IMPORTANT —The powertrain and engine cradle

must be removed from the vehicle toperform the full rail replacement.

1 Remove all other related panels andcomponents, including the strut and axleassemblies as necessary.


3 Remove sealers, sound deadeners, andcorrosion protection materials as necessary.

4 The close-out panel must be removed toaccess all of the factory welds attaching therail to the vehicle (figure␣ 5-9).

5 Locate, mark, and drill out all factorywelds. Note the number and location ofwelds for installation of the service railand components.

6 Remove the damaged rail.

Install or Connect

1 Prepare the mating surfaces as necessary.2 Position the service rail sub-assembly on the

vehicle. Check fit using three-dimensionalmeasuring equipment.

— IMPORTANT —Position the mid-rail reinforcement to the new

service rail and plug weld as necessary asnoted from the original rail (figure␣ 5-9).

3 When the service rail is correctlypositioned, plug weld accordingly, withfrequent measurements to ensure properfit and alignment.

4 Position the front bumper mountingbrackets using three-dimensional measuringequipment and weld accordingly.

— IMPORTANT —Two of the bumper mounting holes are

provided. The third hole is to be located usingthree-dimensional measuring equipment.

Mark and drill accordingly.

5 Clean and prepare all welded surfaces.Prime with two-part catalyzed primer. Applysealers and corrosion protection materialsas necessary.

6 Apply sound deadening materials, as neces-sary. Use Dominion Sure Seal PaintableSound Deadening Pads (part #110900, orderby phoning 1-800-265-0790), or equivalent.

7 Do not combine paint systems. Refer topaint manufacturer’s recommendations.



Figure 6-1:Door Frame Opening Service Parts

DO NOT SECTIONIN SHADED AREAS

6. DOOR FRAME OPENING

The outer door frame can be replacedas a complete service part or varioussegments can be sectioned (figure␣ 6-1).Complete service part replacementrequires the removal of the roof panel.Sectioning the outer and inner doorframe reinforcement is usually muchfaster and more cost effective. Sincethe outer door frame is manufacturedas a single component, service parts forsectioning must be cut from the servicepanel and modified as necessary.

— NOTICE —The specific areas to be sectioned

are determined by the extent of the damageto the vehicle. Sectioning should take place onlyin the recommended areas. Failure to do so may

compromise the structural integrity of the vehicle.

— NOTICE —When replacing panels that involve servicing stationaryglass, refer to GM Service Bulletin no. 43-10-48 before

performing any priming or refinishing.

MS10966.1

Buick Century

Olds Intrigue


Gap = one and one-half timesthe thickness of the metal.

100mm (4″)Backing Plate

Figure 6-2:General Sectioning Procedures Can Be Used in Areas Shown

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

Outer Door FrameGeneral Sectioning ProceduresRemove or Disconnect


damage as possible.3 Remove sealers and anti-corrosion materials

as necessary.4 Cut the panel in the areas where the

sectioning is to take place (figure␣ 6-2).Sectioning should be performed only in therecommended areas.

— NOTICE —Use due care not to cut the inner reinforcements

when cutting the outer door frame.


6 Remove the damaged outer door frameopening.

MS10966.2

Buick

Oldsmobile



Outer Door Frame General SectioningProcedures (cont’d)Install or Connect

1 On the service part, mark a horizontal lineto leave a gap of one and one-half times thethickness of the metal at the sectioningjoint. Cut the outer door frame openingservice part along this line (figure␣ 6-3).

2 Cut a 100mm (4␣ in) piece from the unusedportion of the service part for a backingplate. Remove the flange on each side ofthe backing plate so that it will fit behindthe sectioning joint (figure␣ 6-3).

— NOTICE —When sectioning the outer door frame at thelower front hinge pillar or at the center lockpillar, the inner reinforcement panel can be

used as backing plate. (See Lower Front HingePillar Sectioning Procedures or Center Lock

Pillar Sectioning Procedures.)

3 Drill 8mm (5⁄1 6␣ in) holes for plug welding inthe service part in the locations noted fromthe original panel. Also, drill holesfor plug welding along the sectioning cutson both the service part and the originalpanel (figure␣ 6-3). Locate these holesapproximately 25mm (1␣ in) from the edgeof the sectioning cuts.

4 Prepare the mating surfaces and positionthe backing plates with 50mm (2␣ in) ofthe backing plate exposed, and plug weld.Position the service part to overlap theexposed 50mm (2␣ in) of the backing plate,check fit using three-dimensional measuringequipment, and plug weld accordingly.

5 Stitch weld along the sectioning joint.Make 25mm (1␣ in) welds along the seamwith 25mm (1␣ in) gaps between. Then goback and complete the stitch weld. Thiswill create a solid joint with minimalheat distortion.

6 Complete all other welds and sectioningprocedures as necessary.

7 Clean and prepare welded surfaces. Primewith two-part catalyzed primer. Applysealers and corrosion protection materials,as necessary. Do not combine paintsystems. Refer to paint manufacturer’srecommendations.


Figure 6-3:General Sectioning of Outer Door Frame

Except at Front Hinge Pillar and Center Lock Pillar


100mm (4″)Backing Plate


OriginalDoor Frame Opening

Inner Reinforcement

MS10966.3

Figure 6-4:Sectioning of the Outer Door Frame

at the Front Hinge Pillar

50mm

NewDoor Frame Opening


Lower Front Hinge PillarSectioning Procedures

— NOTICE —Sectioning of the inner reinforcement panel can onlytake place with the outer door frame replacement orsectioning procedures. Sectioning of the outer doorframe at the front hinge pillar requires a 40mm

(11⁄2␣ in) offset from the inner reinforcementsectioning joint. The inner reinforcement can serveas a backing plate for the outer panel sectioning.

— NOTICE —When sectioning the outer door frame at the lowerfront hinge pillar, the inner reinforcement panel

can be used as a backing plate.

— NOTICE —Sectioning the outer rocker panel requires a

100mm (4␣ in) backing plate for reinforcement(figure␣ 6-3). There are key structural areas on theouter rocker panel where sectioning should not beperformed (figure␣ 6-1). Sectioning in these areasmay compromise the structural integrity of thevehicle. (See General Sectioning Procedures.)

— NOTICE —Use care not to cut the inner reinforcements when

cutting the outer door frame.


1 Remove all related panels and componentsincluding the front door and position allwiring out of the way to prevent damage.



4 On the original outer door frame measuredown from the large wiring harness hole inthe hinge pillar 50mm (2␣ in) and mark ahorizontal line. Cut the outer door framealong this line for sectioning (figure␣ 6-4).

5 Perform additional sectioning procedures asnecessary to remove damaged areas of thedoor frame opening (see General SectioningProcedures).

6 Locate, mark, and drill out all necessaryfactory welds. Note the number and locationof welds for installation of the service panel.

7 Remove the damaged section of the doorframe opening.

Install or Connect

1 On the service part, mark a horizontal lineto leave a gap of one and one-half times thethickness of the metal at the sectioningjoint. Cut the service panel along this line.

2 Drill 8mm (5⁄1 6␣ in) holes for plug welding inthe service part in the locations noted fromthe original panel. Also, drill holes for plugwelding along the sectioning cut on theservice part (figure␣ 6-4). Locate these holesapproximately 13mm (1⁄2␣ in) from the edgeof the sectioning cut.

3 Using the inner reinforcement as a backingplate, stitch weld along the entire joint.Make 25mm (1␣ in) welds along the seamwith 25mm (1␣ in) gaps between. Then goback and complete the stitch weld. Thiswill create a solid joint with minimal heatdistortion.





Lower Front Hinge PillarInner ReinforcementSectioning Procedures

— NOTICE —Use due care not to cut adjacent panels when

cutting the inner reinforcements.





4 On the original reinforcement panel,measure 120mm (43⁄4␣ in) down from thelarge wiring harness hole in the hinge pillarand mark a horizontal line. Cut the innerreinforcement along this line (figure␣ 6-5).

5 Locate, mark, and drill out all necessaryfactory welds. Note the number andlocation of welds for installation of theservice part.

6 Remove the damaged section of the innerreinforcement.

Install or Connect

1 Cut and remove 30mm (13⁄1 6␣ in) fromthe flanges on either side of the remainingsection of the original hinge pillar to create30mm (13⁄1 6␣ in) flange. Cut 5mm (3⁄1 6␣ in) widegaps in the bottom corners (figure␣ 6-6).

2 Step the tabs inward to allow the door frameinner reinforcement service section to fit overthe original inner reinforcement. Weld thetabs together along the edges (figure␣ 6-7).

5mm

30mm

Figure 6-6:Cut Original Hinge Pillar Reinforcement

Figure 6-7:Weld Corners


MS10966.5

Weld Together

MS10966.6

120mm

OriginalReinforcement

MS10966.4

Figure 6-5:Cutting the Hinge Pillar Reinforcement

InnerReinforcement

USE CARE WHEN CUTTINGTHE DOOR FRAME NOT TO

CUT OR DAMAGE THEINNER PANELS.


Figure 6-8:Cut New Service Panel

Figure 6-9:Drill Plug Weld Holes in Service Part

90mm

NewService Panel

NewService Panel

OriginalPanel

OriginalPanel

NewService Panel

30 mmof overlap


MS10966.6

MS10966.8

MS10966.9

Figure 6-10:Weld Sectioning Joint

Lower Front Hinge PillarInner ReinforcementSectioning Procedures (cont’d)3 On the service part, measure 90mm (31⁄2␣ in)

down from the large wiring harness hole inthe hinge pillar and mark a horizontal line.Cut the hinge pillar along this line (figure␣ 6-8).

4 Drill 8mm (5⁄1 6␣ in) plug weld holes asnecessary in the locations noted from theoriginal panel. Also drill plug weld holesalong the sectioning cut of the service part.These should be located approximately15mm (9⁄1 6␣ in) from the edge of the cut(figure␣ 6-9).

5 Prepare mating surfaces and position theservice section over the stepped tab on theoriginal inner reinforcement, allowing30mm (13⁄1 6␣ in) of overlap. Check and makesure the door hinge bolt holes are properlylocated, and plug weld accordingly.

6 Stitch weld along the entire joint. Make25mm (1␣ in) welds along the seam with25mm (1␣ in) gaps between. Then go backand complete the stitch weld. This willcreate a solid joint with minimal heatdistortion (figure␣ 6-10).




Figure 6-11:Outer Door Frame Center Pillar Sectioning Location


Outer Door Frame Center Lock PillarSectioning ProceduresRemove or Disconnect




4 On the original outer door frame measuredown from the lower edge of the dooropening 200mm (8␣ in) and mark ahorizontal line. Cut the outer door framealong this line for sectioning (figure␣ 6-11).

Use inner reinforcement forbacking plate when sectioningupper door frame outer panel.Gap = one and one-half times

the thickness of the metal.

MS10966.10

5 Locate, mark, and drill out all necessaryfactory welds. Note the number andlocation of welds for installation of theservice section.

6 Perform additional sectioning procedures asnecessary to remove the center lock pillar(see General Sectioning Procedures).

7 Remove the damaged section of the doorframe opening.

Service Part

200mm

THE SECTIONING LOCATIONS FORTHE DOOR FRAME OPENING AND

THE INNER REINFORCEMENT MUSTBE OFFSET BY 55MM (23⁄1 6␣ IN).

Center Pillar Door FrameOuter Panel

Roof



Outer Door Frame Center Lock PillarSectioning Procedures (cont’d)Install or Connect

1 On the service part, mark a horizontal lineto leave a gap of one and one-half times thethickness of the metal at the sectioningjoint. Cut the service panel along this line(figure␣ 6-11).

2 Drill 8mm (5⁄1 6␣ in) holes for plug welding inthe service part in the locations noted fromthe original panel. Also, drill holes for plugwelding along the sectioning cuts on theservice part. Locate these holesapproximately 13mm (1⁄2␣ in) from the edgeof the sectioning cuts (figure␣ 6-11).

3 Prepare the mating surfaces and positionthe service part using three-dimensionalmeasuring equipment, and plug weldaccordingly.

4 Using the inner reinforcement as a backingplate, stitch weld along the entiresectioning joint. Make 25mm (1␣ in) weldsalong the seam with 25mm (1␣ in) gapsbetween. Then go back and complete thestitch weld. This will create a solid jointwith minimal heat distortion.




Inner Center LockPillar ReinforcementSectioning Procedures

— IMPORTANT —The striker plate is mounted in a cage that

allows some degree of adjustment independentof the outer panel’s position. Use body

dimensions to ensure that the striker mountinglocation falls within the plate’s range of

adjustment.



damage as possible.3 Remove sealers and corrosion protection

materials as necessary.

— NOTICE —Sectioning should be performed only in the

recommended areas.

4 Cut the reinforcement panel 255 mm(10␣ in) from the lower edge of the dooropening (figure␣ 6-12).

— NOTICE —When sectioning both the inner and the

outer panels this should result in a 55mm(23⁄1 6␣ in) offset in the sectioning joints.


6 Remove the damaged center pillarreinforcement.


Inner Center LockPillar ReinforcementSectioning Procedures (cont’d)Install or Connect

1 On the service part, mark a horizontal lineto leave a gap of one and one-half times thethickness of the metal at the sectioningjoint. Cut the service reinforcement panelalong this line (figure␣ 6-12).

2 Cut a 50mm (2␣ in) piece from the unusedportion of the service part for a backingplate. Remove the flange on each side ofthe backing plate so that it will fit behindthe sectioning joint.

3 Drill 8mm (5⁄1 6␣ in) holes for plug welding inthe service part in the locations noted fromthe original panel. Also, drill holes for plugwelding along the sectioning cuts on boththe service part and the original panel(figure␣ 6-12). Locate these holesapproximately 13mm (1⁄2␣ in) from the edgeof the sectioning cuts.


4 Prepare the mating surfaces and position thebacking plates with 25mm (1␣ in) of thebacking plate exposed, then plug weld.Position the service part to overlap theexposed 25mm (1␣ in) of the backing plate,and plug weld accordingly.

5 Stitch weld along the sectioning joint.Make 25mm (1␣ in) welds along the seamwith 25mm (1␣ in) gaps between. Then goback and complete the stitch weld. This willcreate a solid joint with minimal heatdistortion.

6 Clean and prepare welded surfaces. Primewith two-part catalyzed primer. Applysealers and corrosion protection materials, asnecessary. Do not combine paint systems.Refer to paint manufacturer’srecommendations.


Figure 6-12:Center Pillar Inner Reinforcement Sectioning Location

255mm


50mm (2␣ in) backing plate

Center Pillar Door FrameOuter Panel

Inner Reinforcement

Service Panel

THE SECTIONING LOCATIONS FORTHE DOOR FRAME OPENING AND

THE INNER REINFORCEMENT MUSTBE OFFSET BY 55MM (23⁄1 6␣ IN).

Roof

MS10966.12


Figure 7-1:Door Service Parts

Two-Piece Hinge

The doors may be serviced as completeassemblies (figure␣ 7-1), or the outer doorpanels may be serviced separately. Useconventional service procedures whenrepairing the doors.

The doors feature HSLA door beams foradded strength and unique foam pads foroccupant protection in the event of a sideimpact. One is attached to the HSLA doorbeam and the other is attached to theinner door shell.

These foam pads are designed and installedfor added occupant safety and must beproperly located to ensure the margin ofsafety they offer. They should be inspectedand replaced if damaged. The foam pads areavailable as separate components from GMService Parts Operations.

All the doors feature bolt-on hinges. The hingesbolt together allowing the door-side hingestrap or the body-side hinge strap to be servicedseparately (figure␣ 7-1).

Door Assembly

Door Outer Panel

7. DOOR SERVICE


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FRTFigure 8-1:Roof Panels

8. ROOF PANEL

— IMPORTANT —On vehicles equipped with a sunroof, take care not

to damage the drain tubes. The drain tubes arelocated between the inner and outer body

components.

The roof panel is serviced as a completeassembly, including the outer panel and theinner reinforcements. The roof panel isattached by a number of welds which must bedrilled to remove the outer panel and innerreinforcements for servicing (figure␣ 8-1).

— NOTICE —The headliner, windshield, and backglass must beremoved prior to the removal of the roof assembly.Protect the interior of the vehicle by covering it or

removing it, and use care when working nearadjacent panels, glass, weatherstrips and

moldings. It is recommended the seats be removedto avoid damage due to the overhead welding

required to service the roof assembly.


1 Remove all related panels and componentsnecessary to access the welds attaching theroof assembly to the vehicle.

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



— NOTICE —A second person may be needed to safely

remove the roof assembly and preventdamage to the vehicle.

5 Remove the damaged roof panel assembly.Install or Connect

1 Clean and prepare the mating surfaces asnecessary.

2 Position the roof panel on the vehicle.Check fit and alignment.

3 When the service assembly is correctlypositioned, plug weld accordingly.

4 Clean and prepare all welded surfaces.Prime with two-part catalyzed primer.Apply sealers and corrosion protectionmaterials as necessary. Do not combinepaint systems. Refer to paint manufacturer’srecommendations.


MS10968.1


9. QUARTER PANEL

The quarter panel is serviced as a one pieceservice assembly which includes the lockpillar and the lower rear quarter close-outpanel (figure␣ 9-1). Replacement of the quarterpanel requires removal of the back glass. Dueto the manner in which the quarter panelattaches to the door frame opening, a specialsectioning procedure has been developed forimproved serviceability.

— NOTICE —When replacing panels that involve servicing

stationary glass, refer to GM Service Bulletin no. 43-10-48 before performing any priming or refinishing.

Quarter Panel Service ProcedureRemove or Disconnect

1 Remove all related panels and components,including the back glass.



4 Note the size of the service part and locatethe sectioning joints at the ‘sail panel’ androcker panel accordingly. Mark and cut asnecessary (figure␣ 9-2).


6 Perform additional sectioning procedures asnecessary (See General Sectioning Procedures).

7 Remove the damaged quarter panel.

Figure 9-1:Quarter Panel Service Parts

MS10969.1

Buick Century quarter panel is separatedfrom door frame opening for service.

Olds Intrigue quarter panel is a singlestamping that is available for service.


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

Quarter Panel Service Procedure (cont’d)Install or Connect

1 Prepare the mating surfaces as necessary.2 Temporarily position the service panel on

vehicle. Trim the original panel to leave a gapof one and one-half times the thickness ofthe metal at the sectioning joint (figure␣ 9-3).

3 Cut 100mm (4␣ in) piece from the originalquarter panel for backing plates. Removethe flange on each side of the backingplates so that they will fit behind thesectioning joints.

4 Drill 8mm (5⁄1 6␣ in) plug weld holes asnecessary in the locations noted from theoriginal panel. Also drill plug weld holes alongthe sectioning cuts of the servicepart. These should be located approximately25mm (1␣ in) from the edge of the cuts(figure␣ 9-3).

5 Prepare the mating surfaces and position thebacking plates with 50mm (2␣ in) of thebacking plates exposed, and plug weld.Position the service part to overlap theexposed 50mm (2␣ in) of the backing plates,check for proper fit and alignment, and plugweld accordingly.

6 Stitch weld along the entire joints. Make 25mm(1␣ in) welds along the seam with 25mm (1␣ in)gaps between them. Then go back andcomplete the stitch welds. This will create solidjoints with minimal heat distortion.


8 Clean and prepare all welded surfaces. Primewith two-part catalyzed primer. Apply sealersand corrosion protection materials asnecessary. Do not combine paint systems.Refer to paint manufacturer’srecommendations.

9 Install all related panels and components.Silicon-BronzeFactory Joint

Figure 9-2:Locate Sectioning Joints

According to Service Part

MS10969.2

TO SERVICE THE INTRIGUE QUARTER PANEL, SECTION 50MM (2␣ IN) BELOW THESILICON-BRONZE FACTORY JOINT.

Buick Century

Oldsmobile Intrigue

TO SERVICE THE CENTURY QUARTER PANEL,SECTION 130MM (53⁄16␣ IN) DOWN FROM

THE REAR EDGE OF THE ROOF.

Figure 9-3:“Sail Panel” Sectioning Location

Factory Joint

50mm

130mm

Buick Century: Measure130mm from rear edgeof roof panel to locatesectioning cut.

Olds Intrigue: Measure50mm down panel fromfactory silicon-bronze jointto locate sectioning cut.

100mmBacking Plate


Reinforcement Panel

25mm (1″) Masking Tape

Figure 10-1:Apply Masking Tape Along Wheelhouse

10. REAR OUTER WHEELHOUSE

Although full replacement of the rear outerwheelhouse can be performed, sectioningprocedures have been developed for use whendamage permits.

Rear Outer WheelhouseSectioning ProceduresRemove or Disconnect

1 Remove all related panels and componentsincluding the quarter panel.



4 After removing the quarter panel, locate,mark, and drill out the welds attaching thereinforcement panel to the outerwheelhouse and the quarter panel.

5 Apply a strip of 25mm (1␣ in) masking tapealong the horizontal surface of the bend inthe wheelhouse (figure␣ 10-1).

6 Cut along the outboard side of themasking tape to create a 25mm (1␣ in) flange(figure␣ 10-1).

7 Remove the damaged section of thewheelhouse.

MS109610.1

Original Wheelhouse


Cut wheelhouse flangealong the edge of the bend

Figure 10-2:Remove Flange from Service Part

MS109610.2

R E A R O U T E R W H E E L H O U S E

Rear Outer WheelhouseSectioning Procedures (cont’d)Install or Connect

1 Cut the wheelhouse service part along thecorner of the bend (figure␣ 10-2). Removeand discard the unused section of thewheelhouse.

2 On the service part, drill 8mm (5⁄1 6␣ in) plugweld holes every 40mm (11⁄2␣ in) along thecut.

3 Prepare mating surfaces and position theservice part. Check for proper fit and plugweld accordingly (figure␣ 10-3). Take carenot to warp or distort the metal.

4 Repair or replace the outer wheelhousereinforcement as necessary. Position thereinforcement panel as noted from theoriginal panel location and plug weldaccordingly.



MS109610.3

Figure 10-3:Plug Weld the Service Part

Service Part

Original Wheelhouse

Service Wheelhouse


Control ArmMounting Bracket

Reinforcement

Remove welds from inside vehicle andbend upward to remove.

Rail Outer Panel Bumper Mounting Brackets

Figure 11-1:Lower Rail Service Parts

11. REAR RAIL ASSEMBLY

The rear rails are available as a sub-assembly.Each consists of an outer panel, two innerreinforcements, and the bumper mountingbracket (figure␣ 11-1). The outer panel and rearbumper mounting brackets are also availableseparately to facilitate sectioning. Additionally,there is a crossbar that connects the two rearrails for added strength and rigidity.

Rear Rail Full Replacement Procedure

— IMPORTANT —Full rail replacement will require theremoval of either the crossbar or an

inner wheelhouse assembly.


1 Remove all related panels and componentsincluding the rear suspension and seat.



4 Locate, mark, and drill out all the factorywelds attaching the control arm mountingbracket and the rear rail to the vehicle.

5 The factory welds attaching the control armmounting bracket to the inner rocker panelmust be drilled out from inside the vehicle(figure␣ 11-1). NOTE: The corner of the floorpanel above this area will need to bepositioned out of the way.

6 Locate, mark and drill out all factory welds.Note the number and location of welds forinstallation of the service assembly.

7 Remove the damaged rear rail assembly.

MS109611.1 Die markon lower surface of rail


FRT

Figure 11-2:Remove Damaged Section of Rail

Original RailAssembly

MS109611.2

R E A R R A I L A S S E M B L Y

Rear RailFull Replacement Procedure (cont’d)Install or Connect

1 Clean and prepare the mating surfaces andcheck for proper fit of the rear rail serviceassembly.

2 On the service assembly, drill 8mm (5⁄1 6␣ in)plug weld holes as necessary in thelocations noted from the original assembly.

3 Position the service assembly, check fitusing three-dimensional measuringequipment, and plug weld accordingly withfrequent measurements to ensure proper fit.

4 After plug welding the control armmounting bracket to the inner rocker,reposition the floor panel into its originallocation, and weld as necessary.

— NOTICE —The bumper mounting holes must be properlylocated and drilled using three-dimensional

measuring equipment.

5 Clean and prepare all welded surfaces.Prime with two-part catalyzed primer.Apply sealers and corrosion protectionmaterials as necessary.

6 Apply sound deadening materials to restoresound deadening quality as manufactured.Use Dominion Sure Seal Paintable SoundDeadening Pads (part #110900, order byphoning 1-800-265-0790), or equivalent.Do not combine paint systems. Refer topaint manufacturer’s recommendations.


Rear Rail Sectioning ProcedureSectioning procedures can be used to repairthe rear rail if just the portion rearward ofthe crossbar is damaged. The rails aremanufactured with die-marks for sectioninglocation. Unique service parts are availablefor sectioning. The sub-assembly consists ofthe outer rail panel with the bumpermounting brackets attached.

— NOTICE —If damage exceeds the recommended area for

sectioning and the rail cannot be straightened, thecomplete rail must be replaced.




materials as necessary.4 Locate, mark, and drill out all factory welds.

Note the number and location of welds forinstallation of the service assembly.

5 Locate the die-mark in the rail, use astraight edge to scribe a line around therail, mark, and cut the damaged railaccordingly (figure␣ 11-2).

6 Remove the damaged section of the rail.

Die Mark onLower Surface of Rail


Weld Flanges Together

Figure 11-4:On New Service Rail,

Step Flanges Together and Weld

MS109611.4

R E A R R A I L A S S E M B L Y

Rear Rail Sectioning Procedure (cont’d)Install or Connect

1 Locate the die-marks on the service part,measure forward to add 30mm (13⁄1 6␣ in) tothe service part length, and mark cut lines.

2 Cut the service part and discard the unusedportion.

3 Cut and remove 30mm (13⁄1 6␣ in) from theflanges on either side of the service railto create 30mm (13⁄1 6␣ in) tabs. Cut 5mm(3⁄1 6␣ in) wide gaps in the bottom corners(figure␣ 11-3).

4 Step the tabs inward to allow the servicesection to fit inside of the original rail. Weldthe tabs together along the edges (figure␣ 11-4).

5 Clean and prepare the mating surfaces,and position the service part. Check fitusing three-dimensional measuringequipment and plug weld accordingly withfrequent measurements to ensure proper fit.

6 Stitch weld along the entire joint. Make25mm (1␣ in) welds along the seam with25mm (1␣ in) gaps between. Then go backand complete the stitch weld. This willcreate a solid joint with minimal heatdistortion (figure␣ 11-5).

— IMPORTANT —The bumper mounting holes must

be properly located and drilled usingthree-dimensional measuring equipment.



Flanges

5mm x 30mm Gap

New Service Rail

Figure 11-3:On New Service Rail, Cut Flanges as Shown

MS109611.3

Figure 11-5:Install New Service Rail, Check Fit and Weld

New Service Rail

Original Assembly

MS109611.5

New Service Rail


12. REAR FLOOR

The damaged floor is cut along the rearwardedge of the rear crossbar, and the service partis cut so that the new floor section extendsto the front edge of the rear crossbar (figure12-1). This allows the two sections to overlapwhere the crossbar is attached.

— NOTICE —The service part is supplied cut to length.

The cut will be about 865mm (345⁄8␣ in) fromthe rear edge of the panel (figure␣ 12-1).

Rear FloorSectioning ProcedureRemove or Disconnect

1 Remove all related panels and components,including the rear end panel, quarter panelsand quarter panel extensions as necessary.


3 Remove sealers, sound deadeners andcorrosion protection materials as necessary.

4 Locate, mark, and drill out all factory weldsrearward of the rear crossbar including thosealong the lower edge of the wheelhouse.Note the number and location of welds forinstallation of the floor service assembly.

— NOTICE —Only drill out the factory welds rearward of

the crossbar. Do not drill out the weldsattaching the floor to the crossbar.

5 Cut the damaged floor along the rear edgeof the crossbar, taking care not to damagethe rear rails, crossbar or wheelhouse.

6 Remove the damaged floor section.

865mm

NOTE:THE FLOOR PANEL

IS PRE-CUT FOR SERVICE.

Figure 12-1:Floor Panel Service Part

MS109612.1

Crossbar Location


FRT

R E A R F L O O R

Rear Floor Sectioning Procedure (cont’d)Install or Connect

1 Prepare mating surfaces and check forproper fit of the floor service assembly,allowing it to overlap the original floor ontop of the rear crossbar. Mark the locationof the rear rail and crossbar flanges on thebottom of the floor service assembly.

2 Drill 8mm (5⁄1 6␣ in) plug weld holes asnecessary in the locations noted from theoriginal floor. Also drill weld holes wherethe new floor section attaches to the rearrail and crossbar flanges. These should beplaced approximately 40mm (11⁄2␣ in) apart.

3 Position the service assembly, check for properfit and plug weld accordingly (figure␣ 12-2).

4 Clean and prepare all welded surfaces.Prime with two-part catalyzed primer.Apply sealers and corrosion protectionmaterials as necessary.

5 Apply sound deadening materials, asnecessary. Use Dominion SureSeal Paintable Sound Deadening Pads(part #110900, order by phoning1-800-265-0790), or equivalent. Do notcombine paint systems. Refer to paintmanufacturer’s recommendations.

— NOTICE —The rear crossbar area must be properly

sealed from moisture and dirt.Use a full-bodied caulk, such as 3M’s

Ultra Pro Seam Sealer (part #08360-1), toseal both the front and rear edges of the

crossbar as well as the inner seam.


Figure 12-2:Install New Floor Panel and Weld

Cut damaged floor atrear edge of crossbar.

Original Panel

New service paneloverlaps crossbar.

MS109612.2

Crossbar Location


13. REAR END PANEL ASSEMBLYThe rear end panel is supplied as a completeassembly (figure␣ 13-1). Quarter panelextensions attach to the outside cornersof the rear end panel. Service for this panelis performed at factory seams.Remove or Disconnect



materials as necessary.4 Locate, mark, and drill out all factory welds.

Note the number and location of welds forinstallation of the service panel.

5 Remove the damaged rear panel.

Figure 13-1:Rear End Panel Service Part (Olds Intrigue)

Install or Connect

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

2 On the new panel, drill 8mm (5⁄1 6␣ in) plugweld holes as necessary in the locationsnoted from the original panel.

3 Position the service panel, check fit usingthree-dimensional measuring equipment,and plug weld accordingly with frequentmeasurements to ensure proper fit.




ALL DIMENSIONS ARE MEASURED FROM A ZERO LINE,CENTER LINE, AND A COMMON DATUM.

ALL DIMENSIONS ARE SYMMETRICAL UNLESS OTHERWISE SPECIFIED.SEE PAGE 42 FOR HOLE IDENTIFICATION.

14. BODY DIMENS IONS

U N D E R B O D Y

0 0

C LC L

L:11

87W

: 53

8H:

58

6

AL:

1018

W:

542

H:

586

C

L:10

85W

: 53

8H:

59

6

BL:

0W

: 44

3H:

35

1

D

L:66

0W

: 43

9H:

36

5

EL:

1604

W:

486

H:

405

FL:

1842

W:

619

H:

463

G

L:29

90W

: 48

8H:

62

0

J

L:28

45W

: 48

8H:

62

0

I

L:23

80W

: 39

1H:

63

5

H

FRT


B O D Y D I M E N S I O N S

F R O N T

FRT

KL: 1104W: 236H: 927

K

L: 1104W: 210H: 927

L: 1219W: 616H: 675

M

L: 1219W: 616H: 606

L

L: 1255W: 450H: 606

L

KK

K




L: 1106W: 468H: 922

L: 988W: 710H: 921

OL: 401W: 664H: 1054

P

L: 371W: 664H: 1053

P

L: 155W: 754H: 1064

R

L: 448W: 551H: 1043

Q

L: 442W: 546H: 1041

Q

L: 328W: 546H: 1036

Q

L: 325W: 552H: 1037

Q

L: 1132W: 319H: 924

N

FRT

0

0

N


E N G I N E C O M P A R T M E N T





BUICK CENTURY DOOR FRAME OPENING

0

0

L: 56W: 802H: 975

S

L: 78W: 801H: 998

S

L: 1143W: 814H: 637

S

L: 1123W: 813H: 660

S

L: 57W: 808H: 645

S

L: 77W: 808H: 622

S

L: 1104W: 788H: 819

T

L: 2104W: 812H: 1024

T

SL: 1126W: 802H: 973

L: 1147W: 801H: 996

S





OLDSMOBILE INTRIGUE DOOR FRAME OPENING

0

0

L: 56W: 802H: 939

S

L: 77W: 802H: 962

S

L: 1143W: 814H: 637

S

L: 1123W: 813H: 660

S

L: 57W: 808H: 612

S

L: 78W: 809H: 589

S

L: 1105W: 788H: 819

T

L: 2104W: 812H: 1024

T

SL: 1126W: 802H: 973

L: 1147W: 801H: 996

S

L: 2835W: 669H: 1149

U







R E A R

BUICK CENTURY

L: 3199W: 512H: 929

V

L: 3124W: 555H: 616

X

L: 3124W: 412H: 647

X

L: 3124W: 555H: 678

X

L: 3169W: 629H: 1021

V

L: 3142W: 746H: 929

W

OLDSMOBILE INTRIGUE

L: 3190W: 568H: 950

V

L: 3124W: 555H: 616

X

L: 3124W: 412H: 647

X

L: 3124W: 555H: 678

X

L: 3190W: 568H: 1029

V

L: 3120W: 706H: 977

W





LengthTo ‘0’ line

ALL MEASUREMENTS ARE READ FROM FORMED SURFACE AND CENTER OF HOLE

F O R M A N D P I E R C E

HeightTo datum line

WidthTo center line

FRONT RAIL DIE MARK REAR RAIL DIE MARK

DIE MARKS TO INDICATE SECTIONING


Buick Century/Oldsmobile IntrigueHole Identification Chart

Letter Quantity Feature Size Usage

A 1 per side 38mm Gage hole

B 1 per side 22mm Cradle attach

C 1 per side 12mm x 18mm slot Gage slot

D 1 per side 12mm Gage hole

E 3 per side 16mm Gage hole

F 2 per side 19mm Gage hole

G 1 per side 12mm Gage hole

H 1 per side 30mm Gage hole

I 1 per side 18mm x 21mm slot Gage slot

J 1 per side 19mm x 23mm slot Gage slot

K 3 per side 7mm (punched hole) Upper engine mounting attach

L 2 per side 16mm Bumper bar attach

M 1 per side 9mm x 18 mm Bumper bar attach

N 2 per side Weld nuts Support brace

O 6 per side 5mm (punched hole) Fender attach

P 1 per side 12mm Front suspension attach

Q 2 per side 12mm x 15mm slot Front suspension attach

R 2 per side Weld nuts Hood hinge attach

S 8 per side Hinge mount Door attach

T 4 per side Clinch nut Lock striker attach

U 3 per side Weld nuts Deck lid hinge attach (Intrigue)

V 2 per side 11mm pierced hole Tail light attach5mm pierced hole

W 1 per side 5mm x 11mm slot Tail light attach

X 3 per side 16mm Rear bumper attach


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Documents

1997-2005 Buick CenturyOldsmobile Intrigue Collision Body Repair Manual Issues