Corvette - G97119 TOC · 2011. 3. 30. · 1997/98 Chevrolet Corvette Collision Repair 3-3 View A View A 30mm 50mm 15mm 30mm 50mm 40mm C of vehicle L Fig.␣ 3.5 — Weld Perimeter

1997/98Corvette

Panel Identification .....................................................3-1

Front Bumper Impact Bar ...........................................3-2

Front Wheelhouse ........................................................3-4

Rail - Underbody Side Assembly .................................3-6

Front Side Door Opening Assembly..........................3-17

Windshield Frame Assembly .....................................3-19

Front Floor Panel .......................................................3-22

Roof Bow Service .......................................................3-24

Rear Compartment Panel ..........................................3-25

Rear Compartment Panel Frame ..............................3-30

Rear Bumper Impact Bar ...........................................3-33

SMC Repair Procedures ..............................................3-37

Body Dimensions ........................................................3-38

1997/98 Chevrolet Corvette Collision Repair 3-1

Panel Identification

* P

OLY

CA

RB

ON

ATE

= T

RA

NSL

UC

EN

T TA

RG

A T

OP

1R

RIM

= R

EIN

FOR

CE

D R

EA

CTI

ON

INJE

CTI

ON

MO

LDE

D2

TSG

S =

TW

O S

IDE

D G

ALV

AN

IZE

D S

TEE

L3

UH

SS =

ULT

RA

HIG

H S

TRE

NG

TH S

TEE

L4

SMC

= S

HE

ET

MO

LDE

D C

OM

POU

ND

5A

L =

ALU

MIN

UM

*

1

1

2

1

3

3

2

4

44

44

4

4

5

5

4

3-2 1997/98 Chevrolet Corvette Collision Repair

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Fig.␣ 3.1 — Ultra High Strength Steel Beam

Fig.␣ 3.2 — Adapter Clampfor Conventional Anchoring System

Fig.␣ 3.3 — Note Location of Welds forReinstallation

Frame AdapterClamp

Front Bumper Impact Bar

The front impact bar (bumper beam) is made ofUltra-High Strength steel. The impact bar is MIGwelded to the mild steel frame rails. The impactbar can be repaired if damage excludes kinks, ordamage which would require the use of heat tostraighten.

Replacing the bumper bar requires specialprocedures to access the welds attaching thebumper bar to the frame rails. This procedurewas developed to facilitate this repair whilemaintaining the integrity of the bumper system.The front bumper impact bar as supplied forservice includes riv-nuts pre-installed (Fig.␣ 3.1)for component mounting: (SIR sensors,fog-lamps, energy absorber, etc.) Replacementriv-nuts are available from Kent Moore Tools(Riv-Nut Kit: P/N J42151-8MS), if needed.— REMOVE OR DISCONNECT —

1 Remove all panels and components to gainaccess to the impact bar. This includes thebumper cover, impact absorbers, and foglamps.Notice: To increase accessibility to thefront impact bar, rotate the front brakeducts and manually raise the headlamps.

2 Visually inspect and restore as much of thedamage as possible to specifications usingthree-dimensional measuring procedures.Notice: Use Kent Moore Tools FrameAdapter Clamp (P/N J42058) to secure thevehicle if pulling and straighteningis required (Fig. 3.2).

Notice: Be sure to protect vehiclecomponents before cutting or grinding onthe bumper impact bar or frame rails.

3 Remove or reposition wiring as necessary toavoid damage.

4 Cut the welds around the perimeter of theframe rail (fishmouth) ends (Fig.␣ 3.3). Cutwelds favoring the impact bar side of thejoint. DO NOT cut into the frame rails.

5 Remove the damaged impact bar.6 Extract pieces of the impact bar left attached

to the rail ends (Fig.␣ 3.4). Keep the perimeterand shape of the rail end (fishmouth) asoriginal as possible.


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View A

View A

30mm50mm

15mm30mm

50mm40mm

C of vehicleL

Fig.␣ 3.5 — Weld Perimeter of Joint, as Indicated

Fig.␣ 3.4 — Remove Remaining Portionof Impact Bar in Frame Rail

Front Bumper Impact Bar

— INSTALL OR CONNECT —

1 Straighten and deburr the rail ends asnecessary to allow the service impact bar tofit properly.

2 Temporarily position the impact bar andscribe lines into the primer indicating wherethe welds will be made. Remove the primerfrom the areas to be MIG welded by sandingwith 80-grit paper on a ‘Dual-Action’ sander(DA). Do Not use a grinder to remove theprimer.

3 Prepare all bare metal surfaces and applyweld-through primer as necessary. Be sure toapply primer to the inside of the ‘fishmouth’area also.Notice: When installing the replacementbumper bar, weld the sides first in orderto ensure uniform contact with the framerails.

4 Position the bumper impact bar usingthree-dimensional measuring equipment andinstall per the original weld locations. Stitchweld around the ‘fishmouth’ joint. If no traceof the original welds are present, use Fig.␣ 3.5as a guide for welding the side rails to theimpact bar. This weld pattern will create asolid weld joint with minimal heat distortion.

5 Clean and prepare all welded surfaces, use3M’s Scotch-Brite Clean-N-Strip Discs (discPN 07460, mandrel P/N 07491) or equivalent.IMPORTANT: Prior to refinishing, refer toGM P/N 4901 M-D Refinish Manual forrecommended products.

6 Apply approved anti-corrosion primer. Donot combine paint systems. Refer to paintmanufacturer’s recommendations.

7 Install all related panels and components.


Fig.␣ 3.6 — Front Wheelhouse Service Assembly

Fig.␣ 3.7 — Service Assembly Can Be Separatedfor Outer Wheelhouse Panel Replacement

Fig.␣ 3.8 — Adapter Clamp for Anchoring System

Frame AdapterClamp

Front wheelhouse

The wheelhouse consists of two pieces, an outerportion that rivets and bonds to a larger innerportion (Fig.␣ 3.6). The wheelhouse is the innermounting structure for the front fender.The wheelhouse mounting surfaces vary from leftto right. The left side (driver’s side) has morebonded surface area than the right side, and isbonded to the cowl. Also, both sides bond andbolt to the front hinge pillar. The outerwheelhouse can be separated for partialinstallation (Fig.␣ 3.7).

Notice: Do not replace any SMC body panelsuntil the frame rails have been replaced orrepaired, mounting SMC panels requires therails to be positioned accurately.

— REMOVE OR DISCONNECT —

1 Remove all panels and components to gainaccess to the front wheelhouse. This mayinclude removing front wheel, fender, fendersplash panel, bumper cover, battery, andheadlamp mounting brackets.

2 Visually inspect, if any damage to the framerails or wheelhouse mounting areas exist,then restore as much of the damage aspossible to specifications usingthree-dimensional measuring procedures.Notice: Use Kent Moore Tools FrameAdapter Clamp (P/N J42058) to secure thevehicle if pulling and straightening isrequired (Fig.␣ 3.8).

3 Relocate wiring as necessary to avoiddamage.

4 Remove the four bracket bolts attaching thewheelhouse to the front hinge pillar (Fig.␣ 3.9).Heat and pry to remove or dislodge adhesivebeads attaching the wheelhouse to thevehicle, see Fig.␣ 3.10. Remove the damagedwheelhouse.


Fig.␣ 3.9 — Remove BoltsAttaching Brace to Hinge Pillar

Fig.␣ 3.10 — Note Use of Additional Bondon Left Wheelhouse at Cowl

Fig.␣ 3.11 — Apply Adhesive to Service Part

Front Wheelhouse


Important: Use US Chemical and Plastics821014B System 2000 Structural Adhesive, aPLIOGRIP® adhesive manufactured by AshlandChemical Company, or equivalent. Note the 9minute working time and 1 hour cure time.

Notice: DO NOT adjust the fender bycompromising the wheelhouse to rail gap. Thisgap must remain a nominal width to maintainthe correct adhesive strength. The gap shouldbe correct if the rails are properly located.

Notice: If possible, when prepping area forservice part leave small portions of originaladhesive in various places to act as shimmingfor wheelhouse spacing from frame rails. Iforiginal adhesive is not usable for shimming,use paint stir sticks, or equivalent, and shimaccording to body dimensions and body panelalignment.

1 Remove all remaining adhesive, and scuff allbonding surfaces to ensure proper adhesion.(Refer to SMC Repair Procedures.)

2 Clean and prepare all bonding surfaces asnecessary. (Refer to SMC Repair Procedures.)Important: Prior to refinishing, refer toGM P/N 4901 Refinish Manual forrecommended products.

3 Apply approved anti-corrosion primer.Notice: DO NOT top-coat any bondingsurface.

4 Temporarily attach the fender to thewheelhouse. Align the fender to door andhood by clamping the wheelhouse assemblyinto place. Scribe line on rail to locatewheelhouse.

5 Apply adhesive to the wheelhouse as shownin Fig.␣ 3.11. Position front wheelhouseservice part according to the scribe lines onthe rail. Install the four bracket bolts whichattach the wheelhouse to the front hingepillar, and clamp the wheelhouse to the rail.Install headlamp mounting bracket. Trowelaround perimeter of bonding area to removeexcess adhesive and restore originalappearance.



Fig.␣ 3.13 — Adapter Clamp forConventional Anchoring System

Frame AdapterClamp

Fig.␣ 3.12 — One-Piece Mild Steel Frame Rails

The corvette frame rails are made from one piecemild steel tubes that are contoured into shape byhydroforming (Fig.␣ 3.12). The frame rails play anintegral part of the fit and finish of the vehicleand must be three dimensionally correct forexterior panels to fit properly. The one pieceframe rails have 18x35 shipping slots that areused to secure a damaged vehicle to a bench forholding and dimensional straightening. Use KentMoore tools frame adapter clamp J42058, toprovide a downturned flange in the four torquebox areas for universal holding equipment use.

Notice: Sectioning should only be performedin the recommended areas, failure to do somay compromise the structural integrity ofthe vehicle.

Notice: Use Kent Moore Tools Frame AdapterClamp (P/N J42058) to secure the vehicle ifpulling and straightening is required(Fig.␣ 3.13).

Rail - Underbody Side Assembly


Rail-Underbody Side Assembly

1 Sleeved Butt Joint 2 Offset Lap Joint

Sleeve

Overlap

Sleeve

Min. 25 mm (1 in)Max. 50 mm (2 in)

Overlap


11

1

2 2

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Fig.␣ 3.14 — Section RailsWithin the Shaded Areas

Fig.␣ 3.15 — Use the Appropriate Sectioning Technique,as Indicated

Underbody Side Rail SectioningThe two methods recommended for frame railsectioning are the sleeved butt-joint and theoffset lap-joint. The sleeved butt-joint sectioningprocedure is recommended for the mid-rail andrail-end sectioning areas. The offset lap-jointsectioning procedure is recommended for therepairs front of dash and the repairs rear of seatback area (Fig’s. 3.14 and 3.15).

Notice: Always perform the recommendedsectioning method in the area recommendedfor that method.



Sleeve

Fig.␣ 3.17 — Cut Sleeve to MakeL-Shaped Pieces

Minimum: 25 mmMaximum: 50 mm

Fig.␣ 3.16 — Sleeved Butt-Joint

Sleeved Butt-Joint RepairThere are some areas on the rails that are bestrepaired using the sleeved butt-joint method.Use 25 to 50mm of material to act as a backingplate when installing the sectioned service part(Fig.␣ 3.16).

Notice: Use the sleeved butt-joint only in theareas designated.

Notice: When determining the area toperform sectioning near a riv-nut hole (withinthe recommended areas), trim the sleeve back3mm in the area for riv-nut clearance. Theriv-nuts are designed to crimp to one metalthickness only.

1 Cut the service part to appropriate length(according to dimensions), to replaceremoved section of damaged rail.

2 From unused portion of service part;measure, mark, and cut 25 to 50mm of rail tobe used as a sleeve (backing plate), at thesectioning joint.

3 Cut through each side of the sleeve to createfour individual “L” shaped pieces that can beinstalled in the undamaged portion of theframe rail (Fig.␣ 3.17).

4 Install the four pieces, one at a time, and trimthem as necessary to provide a flush fit alongthe butt-joint surface. Tack-weld the sleevesinto place.

5 Once the sleeves are in place, check the fit ofthe service part. Grind sleeve as necessary toallow for accurate alignment of the new part.Notice: Retain a gap of one and one halftimes the metal thickness at the butt-jointwhen attaching the service part to thevehicle.

6 Temporarily remove service part and prep allbare metal surfaces with a suitableweld-through primer.

7 Stitch weld along the entire sectioning joint.Make 50mm (2inch) welds on all four sides ofthe rail. Re-check the rails for properdimensions. Then go back and complete thestitch weld. This will create a solid joint withminimal heat distortion.



Offset Lap Joint RepairThe offset lap-joint is used in areas that haveextra internal bracing that won’t allow the servicepart to fit properly with an internal sleeve. Inthese areas use the offset overlap method whichwill provide for some adjustment as well as allowfor cut lines that may not be completely straight(Fig.␣ 3.18).

Notice: Use the offset lap-joint only in therecommended areas.

1 Determine the location to perform thesectioning (be sure to stay within therecommended areas), and cut the damagedrail accordingly.

2 Cut any additional welds as necessary andremove the damaged portion of the framerail.



Overlap Minimum: 50 mm Maximum: 100 mm

Fig.␣ 3.18 — Offset Lap Joint

Fig.␣ 3.19 — Modify Rail for Offset joint Repair

Overlap


Fig.␣ 3.20 —

3 Measure the service rail for sectioning,remember that the overlap of the servicepart and the original rail can be as large as100mm (4 inches). This 100mm (4 inch)tolerance provides an area to install plugwelds on the sides of the rail, as well as allowfor adjustment during the installationprocess.

4 Mark the location and cut the service rail assquare as possible.

5 Modify the portion of rail left on the vehicleto accept the service part. This is done bycutting 75mm (3 inch) slots in two oppositecorners of the rail Fig.␣ 3.19. Then slightly pryup the slots to accept the service part. Theslots allow the service part to overlap theexisting rail to form a lap surface for welding.Notice: Open the slots to create additionaladjustment if necessary. Do not exceed100mm (4 inch) overlap for offset lap-jointrepairs.

6 Drill three 8mm (5/16 inch) holes througheach of the sides and two holes each in thetop and bottom surface for plug welding, asin Fig.␣ 3.20.

7 Install the modified service part to form theoffset lap-joint. Align the service part usingthree dimensional measurements.

8 Plug weld along the overlap. Also, stitch weldalong the entire sectioning joint. Make 50mm(2 inch) welds on all four sides of the rail.Re-check the rails for proper dimensions.Then go back and complete the stitch welds.This will create a solid joint with minimal heatdistortion.

9 Clean and prepare welded surfaces, blend inexposed side of lap joint with GoodwrenchStructural Bonding Epoxy (GM P/N12345726), or an equivalent structural repairmaterial. Apply as necessary to achieveoriginal appearance.Important: Prior to refinishing, refer toGM P/N 4901 Refinish Manual forrecommended products.


11 Clean and prepare all bonding surfaces asnecessary. (Refer to SMC Repair Procedures.)


Rear Rail Front Rail

Center Rail

Fig.␣ 3.21 — Frame Rail Service Parts


Underbody Side RailSectioning LocationsService parts are available for replacing orrepairing the frame rails, allowing the least timeconsuming and most cost effective location to bedetermined by the extent of the damage. Serviceinformation has been developed for sectioningthe hydroformed rails, while maintaining thestructural integrity of the vehicle. Forward orrearward halves are available separately, withsuspension mounting brackets attached. Acenter section has been made availableseparately, also with brackets attached(Fig.␣ 3.21). The entire rail is also available forservice on a special order basis. Full railreplacement is recommended in the event thedamage to the rail is not limited to availableservice parts.

Front Rail-End RepairWhen front frame rail-end is kinked or damagedbeyond repair forward of the front crossmember.The service part must be cut from an underbodyside rail assembly.

Notice: Use the sleeved butt-joint method toinstall front frame ends.

1 Remove all related panels and components,support powertrain and remove frontcrossmember bolts as necessary.Notice: When determining the area toperform the sectioning near a riv-nut hole(within the recommended areas), choose alocation that centers the sleeve throughthe hole. This will ensure that riv-nutfasteners remain straight duringinstallation.

2 Determine sectioning joint location within therecommended area (see Sleeved Butt-JointMethod Repair Procedures).

3 Perform sleeved butt-joint sectioning asrequired (see Sleeved Butt-Joint SectioningProcedures).Important: Prior to refinishing, refer toGM P/N 4901 Refinish Manual forrecommended products.

4 Apply anti-corrosion materials to all innersurfaces as necessary. Do not combine paintsystems. Refer to paint manufacturer’srecommendations.

5 After sectioning repairs are completed,attach panels and components as necessary.



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Fig.␣ 3.23 — Pry Up Extension Panelto Expose Rail for Sectioning

Fig.␣ 3.22 — Check Front of DashBonding Areas for Cracks

Front Rail RepairWhen damage to the frame rail is limited to theportion forward of the cowl, “front of dash.” Thefront of dash sectioning area is exposed bymodifying floor pan extension panels to access toall sides of the rail. This repair can be performedwith the engine suspended in place.

Notice: Check SMC front of dash panel forcracks or areas that may need to be re-sealed(Fig.␣ 3.22). (Refer to SMC Repair Procedures.

Notice: Use the Offset Lap-Joint method toperform front rail repairs.


Notice: Save any and all brackets,mounting studs, and accessories for re-useas necessary.

1 Remove all related panels and componentsto provide access to the recommendedsectioning area of rail.

2 Locate stitch welds and resistance welds thatsecure the upper floor pan extension panelto the rail and the tunnel brace.

3 Remove welds as necessary and pry upextension panel to expose rail (Fig.␣ 3.23).

4 Apply 50mm (2 inch) tape to lower floorpanextension panel, (where SMC floor panelstops and floorpan extension begins) .


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2" Flange

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SMC Floor Pan

Fig.␣ 3.24 — Remove Majority ofLower Extension Panel to Access the Rail


Important: The lower floorpan extensionpanel is to be reinstalled two inchesforward of the SMC floorpan. This willeliminate the potential to de-bond thefloorpan when re-installing the floorpanextension panel (see Fig.␣ 3.24 below).

5 Using a die grinder, cut along the forwardedge of tape to create a 2” flange (Fig.␣3.24). Cut stitch welds along the rail and drillout the resistance welds along the tunnelbrace. Remove floorpan extension panel.

6 Determine the location to perform thesectioning (be sure to stay within therecommended areas), and cut the damagedrail accordingly. (See Sleeved Butt-JointMethod Repair Procedures)

7 Using a die grinder, cut through the stitchwelds that attach the tunnel brace to theframe rail. Make cuts favoring the rail side ofthe welds.

8 Remove the damaged rail portion.9 Clean and prepare all surfaces for assembly

as necessary.10 Perform offset lap-joint sectioning as

required. (Refer to Offset Lap-JointSectioning Procedures.)


Fig.␣ 3.25 — Positioning and Replacementof Floor Extension


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SMC Floor Pan

Stitch weld to rail

Plug weld at tunnel brace.


1 Replace lower floorpan extension panel. Trimto fit and tuck the new panel inside of the50mm (2 inch) flange created from theoriginal extension.

2 Locate and align gauge holes, stitch weld torail to duplicate factory welds, and plug weldto tunnel brace as necessary (Fig.␣ 3.25).

3 Check front of dash and floor panel areas forcracked or broken bonding, and repair andreseal as necessary.



Mid-Rail RepairWhen most of the front or rear half of the rail isdamaged beyond repair, this sectioningprocedure allows for the replacement of thedamaged rail half.

Notice: Use the Sleeved Butt-Joint method toperform mid-rail repairs.


1 Remove door side frame and the lock pillarextension panels. (Refer to Door Side FrameService Procedures.)

2 Remove floor panel and lower floor panelextension at factory seams. (Refer to FloorPanel Service Procedures.)

3 Perform sleeved butt-joint sectioning asrequired. (Refer to Sleeved Butt-JointSectioning Procedures.)



FRT

Fig.␣ 3.26 — Shaded Areas Are High-Strength Steel



1 Replace door side frame and the lock pillarextension panels. (Refer to Door Side FrameService Procedures.)

2 Replace floor panel and lower floor panelextension at factory seams. (Refer to FloorPanel Service Procedures.)


Rear Rail RepairWhen damage to the frame rail is limited to theportion rearward of the seat back area. The seatback sectioning area is exposed by modifying orremoving close-out panels and tunnel braces foraccess to all sides of the rail. There are some highstrength steel panels located in the rear of thevehicle which can be repaired if damage excludeskinks, or damage which would require the use ofheat to straighten (Fig.␣ 3.26).

Notice: Check front of dash panel, floorpanels, and all other SMC for cracks or areasthat may need to be repaired or resealed.(Refer to SMC Repair Procedures.)

Notice: Use the Offset Lap-Joint method toperform rear rail repairs.



25mm (1″)

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Access rail under panel

Fig.␣ 3.27 — Apply Tape to Front Edge of Panel

Fig.␣ 3.28 — Cut Panel to Create 25mm (1”) Flange

Fig.␣ 3.29 — Pry Up Extension Panel for Rail Access


1 Remove related panels and components,including rear compartment panel. Alsoremove the fuel tank from the damaged sideof the vehicle.Notice: Save any and all brackets,mounting studs, and accessories for re-useas necessary.

2 The outer lock pillar extension panel must beremoved to access the rail. Apply a piece of25mm (1 inch) tape along the lock pillar(Fig.␣ 3.27), and cut to create a weld flange forinstalling the new extension panel (Fig.␣ 3.28).Caution: Sound deadener foam in the lockpillar can be a fire hazard. Avoid weldingto the lock striker pillar.

3 Using a die grinder, cut along the edge oftape line. Cut stitch welds along the rail anddrill out the resistance welds along the tunnelbrace. Remove lock pillar extension panel.

4 The upper extension panel for the fuel tankmust be loosened and pried up for access tothe rest of the rail for sectioning (Fig.␣ 3.29).(Remove for replacement if damaged.)

5 Using a die grinder, cut through the stitchwelds that attach the tunnel brace to theframe rail. (Make cuts favoring the rail side ofthe welds.)

6 Determine the location to perform thesectioning (be sure to stay within therecommended areas), and cut the damagedrail accordingly. (See Offset Lap-JointMethod Repair Procedures).

7 Remove the damaged rail portion.8 Clean and prepare all surfaces for assembly

as necessary.9 Perform offset lap-joint sectioning as

required. (Refer to Offset Lap-JointSectioning Procedures.)



Fig.␣ 3.30 — Plug Weld New Panel to 1” FlangeCreated During Removal


1 Stitch weld the tunnel brace to the frame rail,duplicate factory welds.

2 Attach upper extension panel, and weld(duplicate factory welds as much as possible).(Replace extension panel if heat is requiredto straighten.)

3 Trim new lock pillar extension panel to fitproperly. Drill 8mm (5/16 inch) holes for plugwelding along the edge which will overlapthe flange created during removal (Fig.␣ 3.30).

4 Install lock pillar extension in factory locationand plug weld to original extension flangeand to tunnel brace. Stitch weld lower edgein factory locations to the frame rail.



Rear Rail-End RepairWhen the rear rail-end is kinked or damagedbeyond repair rearward of the rearcrossmember. The service part must be cut froman underbody side rail assembly.

Notice: Use the sleeved butt joint method toinstall rear frame ends.

Notice: When determining the area toperform the sectioning near a riv-nut hole(within the recommended areas), choose alocation that centers the sleeve through thehole. This will ensure that riv-nut fastenersremain straight during installation.

1 Determine sectioning joint location within therecommended area, (see Sleeved Butt-JointMethod Repair Procedures).

2 Perform sleeved butt-joint sectioning asrequired. (Refer to Sleeved Butt-JointSectioning Procedures.)



Full Rail ReplacementThe left and right frame rails are available ascomplete rails for service. This repair procedureis recommended only in the event the extent ofthe damage to the rail exceeds the limits ofpartial rail replacement. The complete side rail isavailable on a special order basis.

Full rail replacement is accomplished bycombining all of the sectioning locationprocedures as necessary to remove and install acomplete underbody side rail. To allow flexibility,a full rail may be sectioned in any of therecommended sectioning locations asdetermined by the extent of damage to thevehicle.

When determining frame rail repair location andmethod, consider the following:• Always straighten and locate rails prior to

attempting any SMC repairs• Always inspect SMC and adhesive bonds for

cracks and breaks• Always follow recommended repair

procedures for any panels involved inservicing the frame rail

• Always follow material and equipmentmanufacturers’ recommendations formaterials and equipment used in any repairprocedure

• Always follow repair procedures andrecommendations to ensure that structuralintegrity and safety are restored to thevehicle


Fig.␣ 3.31 — Side Door Opening Service Part

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Fig.␣ 3.32 — Service Part Can Be Separatedat the Bonded and Riveted Joint


Front Side Door OpeningAssembly

The Sheet Moulded Compound (SMC) Side DoorOpening assembly is a two panel assembly thatbonds along the frame rail and up the front bodyhinge pillar. The service assembly (Fig.␣ 3.31) canbe disassembled at the riveted and bonded joint(Fig.␣ 3.32) for individual panel replacement. Ifsectioning the side door opening assembly, usebacking plates. (Refer to SMC RepairProcedures.)— REMOVE OR DISCONNECT —


Notice: The frame rails and bumper impactbars must be serviced as required, andreturned to three-dimensional coordinatesbefore any SMC repairs are attempted.

2 Remove all panels and components to gainaccess to door side frame. This may includethe following components: quarter panel andquarter inner splash shield (NOTE: The doorside frame can be removed if the quarterpanel is loosened from it).Notice: Use caution when removing theside door opening assembly in the area ofthe instrument panel. Overlapping interiortrim components must be removed first toprevent damage.

3 Remove latch striker closeout cover andstriker. Also, remove the trim screws thatattach the side door frame panel to the rail.(NOTE: These screws must be re-installed tosecure the service panel in place until theadhesive cures.)Notice: Make sure the fuel inlet is sealedbefore proceeding with repair procedure.

4 Apply heat and pry to break bond along areaindicated in Fig.␣ 3.34. (NOTE: Use cautionalong the underside of the vehicle whenapplying heat not to de-bond the floor panelsfrom the frame rail.)


Front Side Door Opening Assembly

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Fig.␣ 3.36 — Install Screws to Secure Panel WhileAdhesive Cures. Also Apply Adhesive to the Lower

Edge of Rocker to Bond at Bottom Side of Rail.

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A-PILLAR

SI RAIL

ADHESIVE

FOAM

ADHESIVE APPLICATION(BACK OF RH PART SHOWN FOR CLARITY)

Fig.␣ 3.35 —

Fig.␣ 3.34—



2 Clean and prepare all bonding surfaces asnecessary. (Refer to SMC Repair Procedures.) Important: Prior to refinishing, refer toGM P/N 4901 Refinish Manual forrecommended products.


4 Temporarily fit the side door openingassembly to ensure proper fit and alignmentwith adjacent panels.

5 The front body hinge pillar portion of theside door opening panel has a foam seal thatmust make contact with the front hinge pillar(Fig.␣ 3.35).

6 Remove panel assembly and apply aconsistent bead of adhesive, 10mm indiameter to the front body hinge pillar andtop surface of rail and to all areas originallybonded, except for bottom side of rail. (Thisarea is bonded after the side door openingassembly is installed.)Important: Use US Chemical and Plastics82007B System 2000 Structural Adhesive,a PLIOGRIP® adhesive manufactured byAshland Chemical Company, or equivalent.Note the 30 minute working time and 2.5to 3 hour cure time.

7 Install assembly using original screws infactory locations. The screws are necessaryto secure the service part until the adhesivecures (Fig.␣ 3.36).

8 Apply adhesive to inner edge of rocker andclamp in place until adhesive cures. (NOTE:Standoffs in part must fit flush againstbottom surface of rail). See Fig.␣ 3.34.

9 Remove excess adhesive squeeze-out andallow to cure.Important: Prior to refinishing, refer toGM P/N 4901 Refinish Manual forrecommended products.

10 Apply approved anti-corrosion primer. Donot combine paint systems. Always refer topaint manufacturer’s recommendations.



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Fig.␣ 3.37 — Aluminum Windshield Frame Service Part

FRONT VIEW REAR VIEW

Fig.␣ 3.38 — Shaded Area Indicates WindshieldFrame


Windshield Frame Assembly

The windshield frame is an assembly of extrudedaluminum and cast aluminum components(Fig.␣ 3.37). The windshield frame is a structuralassembly, and if damaged, should not berepaired, complete replacement isrecommended. An attempt to repair thewindshield frame may compromise the structuralintegrity of the vehicle, and is NOTrecommended.

The windshield frame assembly is bolted andbonded (with structural adhesive), to the fronthinge pillars (Fig.␣ 3.38). It is also braced to theTunnel assembly by a bolted and bondedcross-car beam.

Replacement of the windshield frame assemblyincludes removal of the windshield, theinstrument panel assembly, and the upperplenum.


1 Remove all panels and components to gainaccess to the windshield assembly. This mayinclude removing front fenders, frontwheelhouses, windshield, and instrumentpanel assembly.Notice: When replacing panels thatinvolve servicing stationary glass, refer toGM Service Bulletin no. 43-10-48 beforeperforming any priming or refinishing.



3 Remove and relocate wiring as necessary toavoid damage.



Fig.␣ 3.40 — Remove Upper Plenum toGain Access to Lower Plenum Bonding Areas

Fig.␣ 3.41 — Install Adhesive to Service Part

4 Drill out the close-end rivets securing theupper plenum to the windshield frame. Applyheat to the upper plenum side of the bondarea and pry up on the panel to remove it(Fig.␣ 3.40).Notice: Use care not to damage theplenums. If they are damaged during theremoval process, they should be replaced.

5 With the upper plenum removed, theadhesive bonds attaching the windshieldframe to the lower plenum can be accessed.Apply heat and pry as necessary to break thewindshield frame loose from the lowerplenum.

6 From inside the vehicle, remove all hardwareattaching the instrument panel supports tothe windshield frame assembly.

7 Remove bolts attaching cross-car brace, heatand break loose adhesive bonds and removebrace from vehicle.

8 Remove bolts attaching windshield frame tothe front hinge pillars (see Fig.␣ 3.38).

9 Heat and break loose adhesive bonds alongfront and rear edges of the front body hingepillars. Remove damaged windshield frame.Notice: Use due care and caution whenremoving the windshield frame not todamage any internal components of thevehicle.





4 Apply adhesive to the bonding surfaces ofthe new windshield frame and install(Fig.␣ 3.41). Bolt the windshield frame servicepart to the front pillars.

5 Apply adhesive to attach lower plenumto windshield frame, drill holes and useclose-end rivets (GM P/N 9418420 or,equivalent) to hold plenum secure whileadhesive cures.



Fig.␣ 3.42 — Install Adhesive to Windshield Framefor Upper Plenum Installation

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Important: Use US Chemical and Plastics82007B System 2000 Structural Adhesive,a PLIOGRIP® adhesive manufactured byAshland Chemical Company, or equivalent.Note the 30 minute working time and 2.5to 3 hour cure time.

6 Apply adhesive to the area that the cross-carbrace bonds to the center tunnel assembly,and install brace and bolt into place.

7 Attach all instrument panel supports to thewindshield frame assembly service part.

8 Apply adhesive to the upper plenum andinstall using close-end rivets in factorylocations, to hold in place while adhesivecures (Fig.␣ 3.42).

Important: Prior to refinishing, refer toGM P/N 4901 Refinish Manual forrecommended products.

9 Apply approved anti-corrosion primer. Donot combine paint systems. Always refer topaint manufacturer’s recommendations.



RAIL

RAIL

ADHESIVE

FLOOR

Fig.␣ 3.44 — Remove Reinforcement

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REINFORCEMENT

Fig.␣ 3.45 — Reinforcement Bonded toTunnel and Floor

Fig.␣ 3.43 — Floor Panel Service Part

Front Floor Panel

The floor panel is serviced as separate left andright side components (Fig.␣ 3.43). The panels arebonded around the outer edges and across theseat mounting braces. For repair other than fullpanel replacement see SMC Repair Procedures.— REMOVE OR DISCONNECT —

1 Remove all panels and components to gainaccess to the floor panel. This will includeremoving seat and carpeting.Notice: When servicing the right frontfloor panel, the bonded and boltedelectrical component mounting bracketsmust be removed. Remove or repositionelectrical components and wiring harnessas necessary to avoid damage.

2 Visually inspect for damage to the frame railand seat mounting brace, restore as much ofthe damage as possible to specificationsusing three-dimensional measuringprocedures.

3 Remove the side reinforcement bonded tothe floor panel and the frame rail (Fig.␣ 3.44).

4 Remove the side reinforcement bonded tothe floor panel and the tunnel area(Fig.␣ 3.45). NOTE: Use care when removingthe reinforcement, if damaged during theremoval process replacement will benecessary.

5 Apply upward force and heat simultaneouslyto the floor panel as necessary to detachadhesive. Remove damaged floor panel.Important: Save wiring harness clips (3 perside), for transfer to service floor panel.


1 Remove all original adhesive using suitabletool. Scuff all bonding surfaces to ensureproper adhesion. (Refer to SMC RepairProcedures.)




Front Floor Panel

RAIL

ADHESIVE

FLOOR

Fig.␣ 3.48 — Cross Section of Floor and Rail Brace

FRONT

Fig.␣ 3.46 — Shaded Area Represents Bond

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F&&H

Fig.␣ 3.47 — Trim Screws May Be Necessaryto Secure Panel While Adhesive Cures

4 Temporarily position the service panel andcheck for proper fit, make sure the perimeterof the floor panel and the seat mountcross-brace fit flush. Remove service panel.

5 After primer is fully cured, apply adhesive tothe mating flanges as necessary, (Keepadhesive away from seat studs to minimizesqueeze out), and install service floor panel.Apply even pressure to all bonding surfacesto ensure the floor panel fits flush and level(Fig.␣ 3.46).Important: Use US Chemical and Plastics82014B System 2000 Structural Adhesive,a PLIOGRIP® adhesive manufactured byAshland Chemical Company, or equivalent.Note the 9 minute working time and 1hour cure time.

6 Apply adhesive to the floor panel supportbracket, and install to attach floor panel totunnel as in Fig.␣ 3.47. Apply adhesive to thefloor panel brace and install as shown inFig.␣ 3.48. Screw the ends of the bracesecurely to the floor panel, apply pressureevenly for uniform adhesive ‘wet-out’(Fig.␣ 3.47). Apply adhesive to wiring harnessclips (3), and install at the etched indicatorson the service panel by pressing firmly intoplace.

7 Temporarily install the seat mounting nuts to‘wet-out’ the adhesive at the cross brace.Smooth adhesive squeeze-out aroundperimeter of floor panel from underside ofvehicle to form a consistent, leak-proof seal.

8 Apply constant firm pressure in the ‘toe-pan’area until the adhesive is fully cured. Afterthe adhesive is fully cured, remove the seatmounting nuts.

9 Finish and feather-edge the repair areas asnecessary to resemble OEM.

10 Prime the body with suitable primer. Applysealers and anti-corrosion materials asnecessary.

11 Apply top-coat over all primed areas. Referto paint manufacturer’s recommendations.Do not combine paint systems.



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Fig.␣ 3.49 — Mild Steel Roof Bow

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Fig.␣ 3.50 — SMC Roof Bow Cover

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Fig.␣ 3.51 — Adhesive Bead Location

Roof Bow Service

The Roof Bow is made from a one piece mildsteel tube that is shaped by hydroforming(Fig.␣ 3.49). The roof bow is located and MIGwelded to the inner and outer lock pillar panels.The roof bow should be three-dimensionallylocated and MIG welded at factory joints whenreplaced. Use 8mm (5/16 in) plug welds toreplace resistance welds at the lock pillar innerpanel.

The Roof Bow Cover is made of Sheet MouldedCompound (SMC), and is bonded to the RoofBow with structural adhesive (Fig.␣ 3.50). The RoofBow Cover overlaps the Rear CompartmentPanel Frame, which should be sectioned if theRoof Bow Cover is not damaged (Refer to RearCompartment Panel Frame Service Procedures).

Important: Use US Chemical and Plastics82014B System 2000 Structural Adhesive, aPLIOGRIP® adhesive manufactured by AshlandChemical Company, or equivalent. Note the 9minute working time and 1 hour cure time.

Notice: Before permanent installation ofeither the Roof Bow or the Roof Bow Coverbe sure to establish location for proper fit andfinish of all adjacent panels.

Removal of the Roof Bow Cover requires theremoval of the screws attaching the front andrear weatherstrips through the cover to thehydroformed roof bow (Fig.␣ 3.51). Apply heat tothe bonded area and break the adhesive toremove the Roof Bow Cover. (Follow SMC RepairProcedures.)


Fig.␣ 3.52 Rear Compartment Panel Service Part

Fig.␣ 3.53 — Adapter Clamp forConventional Anchroing System

Fig.␣ 3.54 — Scribed Lines and Textin All Compartment Panels

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Rear Compartment Panel

The Rear Compartment Panel (tub) is made ofSheet Moulded Compound (SMC). The panel hasmany accessories that secure to it or passthrough it. (The service part contains only thoseholes common to all body styles and options; itmay require modifications to install allaccessories for all models.) The rearcompartment panel is bonded to the rear framerails, the seatback area, and the rear impact bar.Sectioning may be performed if damage islimited to the rear portion of the rearcompartment panel (Fig.␣ 3.52).

Rear Compartment PanelReplacement— REMOVE OR DISCONNECT —

1 Visually inspect and restore as much of thedamage as possible to specifications usingthree-dimensional measuring procedures.Notice: Use Kent Moore Tools FrameAdapter Clamp (P/N J42058) to secure thevehicle if pulling and straightening isrequired (Fig.␣ 3.53).


2 Remove all panels, components, and interiortrim located in the rear compartment. Also,both rear quarter panels, and RearCompartment Frame Panel ‘rear surround’.Caution: Make sure the fuel inlet is sealedbefore proceeding with repair procedure.

Notice: Save any and all brackets,mounting studs, and accessories fortransfer to the new rear compartmentpanel.

3 Remove six screws attaching the tub to therails.

4 Apply heat to inside of tub along “bond”lines indicated by the scribe lines on the floorof the tub. Pry up on the tub at the adhesivejoint until tub bond breaks loose (Fig.␣ 3.54).Notice: The front edge of tub is alsobonded across the seatback area andalong the top of the rear impact bar.Detach bonds and remove as necessary.

5 Remove damaged rear compartment panel.



Fig.␣ 3.55 — Tub Bonding Locationson Frame Rails

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PINLOCATIONS

Fig.␣ 3.56 — Embossed Pins in Tubthat Fit the Rail


1 Remove all original adhesive using suitabletool. Scuff all bonding surfaces to ensureproper adhesion. (Refer to SMC RepairProcedures.)


3 Apply approved anti-corrosion primer.Notice: Do not top-coat any bondingsurface.

4 Temporarily install the tub. The panel must fitflush with the surface of the rails and impactbar.

5 Apply a consistent bead of adhesive, 10mmin diameter to the rail surface as shown inFig.␣ 3.55. Apply adhesive to the backside ofthe lock pillars, as well as over the fuel fillerneck.Important: Use US Chemical and Plastics82007B System 2000 Structural Adhesive,a PLIOGRIP® adhesive manufactured byAshland Chemical Company, or equivalent.Note the 30 minute working time and 2.5to 3 hour cure time.

6 Install the tub orienting the frame locatingpins per Fig.␣ 3.56.Notice: The rear compartment panel ispositioned to the drivers side railassembly using two dimples formed in thebottom surface of the tub (Fig.␣ 3.56).

7 Press down firmly on the entire tub towet-out the adhesive. Use six close-end rivets(GM P/N 9418420, or equivalent), or the sixscrews removed in step 3, in areas indicatedalong the bond line to hold the tub to therails while adhesive cures.Notice: Use fasteners no longer than20mm (3/4 inch) in length.

8 Remove any excess adhesive squeeze-out asnecessary.

9 Let adhesive cure according to adhesivemanufacturer recommendations.

10 Install all related panels and components.(Refer to Rear Compartment Panel FrameInstallation procedures.)



Fig.␣ 3.57 — Frame-Rear Compartment Panel Sectioning

Rear Compartment PanelSectioningThe Rear Compartment Panel is manufacturedwith section lines to indicate the propersectioning location of the service part (seeFig.␣ 3.54). Check all the bonding areas of theRear Compartment Panel (tub), if adhesive iscracked or broken loose from the rails or the‘tub’, complete ‘tub’ replacement isrecommended.— REMOVE OR DISCONNECT —

1 Visually inspect and restore as much of thedamage as possible to specifications usingthree-dimensional measuring procedures.Notice: The frame rails and bumper impactbars must be serviced as required, andreturned to three-dimensional coordinatesbefore any SMC repairs are attempted(Fig.␣ 3.57).

2 Remove all panels, components, and interiortrim located in the rear compartment. Also,remove both rear quarter panels and RearCompartment Panel Frame (rear surround).(Refer to Rear Compartment Panel FrameService Procedures.)Notice: Make sure the fuel inlet is sealedbefore proceeding with repair procedure.

Important: Save any and all brackets,mounting studs, and accessories fortransfer to the new rear compartmentpanel.


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Fig.␣ 3.58 — Top View of Rear Compartment Panel Section Lines Etched in All Parts

3 Identify the SECTION LINE etched in thefloor of the rear compartment panel(Fig.␣ 3.58). NOTE: The etched line is in thefloor only, the line must be continued straightup both side-walls of the tub to complete thecuts. (Scuff area with fine sandpaper tohighlight the line if necessary.)

4 Remove or reposition components on thebottom side of the tub to avoid damagewhere sectioning procedures are beingperformed.Notice: Take care not to damage theframe rails when sectioning the rearcompartment panel.

5 Cut along the SECTION LINE and remove thedamaged panel.





4 Cut the replacement rear compartment panelalong the SECTION LINE to create servicepart (Fig.␣ 3.58).

5 Create 50mm (2 inch) wide backing plates tobe installed along the bottom side of thesection joint. (Refer to SMC RepairProcedures.)



Fig.␣ 3.59 — Install Sectioned Panel to Backing Plates Created From Undamaged SMC

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6 Apply structural adhesive to the backingplate strips and secure along the section jointusing screws. Remove excess adhesive fromthe service part mounting area. (Refer toSMC Repair Procedures.)Important: Use US Chemical and Plastics82006B System 2000 Structural Adhesive,a PLIOGRIP® adhesive manufactured byAshland Chemical Company, or equivalent.Note the 3 minute working time and 15minute cure time.

7 Temporarily install the modified service paneland check for proper fit and alignment.Important: Use Ashland Chemical Pliogrip7779/300B adhesive, or equivalent. Noticethe 10-minute working time, and one hourcure time.

8 Remove service part and apply adhesive tothe extended portion of the mating flangecreated from the backing strips, and to theframe rails, and rear bumper impact bar asnecessary (Fig.␣ 3.59).

9 Install the modified service part and pressdown firmly to wet-out the adhesive. Use twoclose-end rivets or self-drilling screws in

areas indicated along the bond line to holdthe tub to the rails while adhesive cures.Note: Use fasteners no longer than 20mm(3/4 inch) in length.

10 Allow to cure according to adhesivemanufacturer recommendations.

11 After structural adhesive is fully cured, bevelbutt-joint edges to prep for reinforcementand refinishing of the interior joint. (Refer toSMC Repair Procedures.)

12 Apply Goodwrench Structural BondingAdhesive (GM P/N 12345726) to the entire‘joint’ area extending across the cut lines andacross the backer, use tacky mesh tape or anequivalent reinforcement matting. Allow tocure as necessary. (Refer to SMC RepairProcedures.)

13 Prepare the repair areas as necessary toresemble OEM appearance. (Refer to SMCRepair Procedures.)

14 Refinish repair areas. Do not combine paintsystems. Always refer to paint manufacturer’srecommendations.




FRT

FRT

No backing plate necessary

Fig.␣ 3.60 — Coupe rear panel frame

Fig.␣ 3.62 — Section coupe rear surround inshaded area

Fig.␣ 3.63 — Stagger the rear panel frame torear compartment panel sectioning joints

Use backing plate

Rear CompartmentPanel Frame

The Rear Compartment Panel Frame (rearsurround) is made of Sheet Moulded Compound(SMC). This panel, on coupe models, provides amounting surface for the quarter-panels and isthe sealing surface for the rear hatch (Fig. 3.60).Convertible rear compartment panel frameprovides a mounting surface for the stowcompartment and rear compartment lids(Fig.␣ 3.61). Installing this panel is critical to theproper fit-up of the rear end of the vehicle.

Since the Roof Bow Cover overlaps the RearCompartment Panel Frame (rear surround),sectioning is faster and more cost effective thanfull panel replacement, if the Roof Bow Cover isnot damaged. The frame panel may be sectionedanywhere along the quarter panel mountingsurface. Sectioning in the front corners (at thebase of the Roof Bow), does not require the useof a reinforcement, the Rear Compartment Panelflange can act as a backing plate (Fig.␣ 3.62). Ifsectioning is performed in the middle area of the‘rear surround’ a backing plate is required for‘butt-joint’ reinforcement (Fig.␣ 3.63). (Refer toSMC Repair Procedures.)

For shipping onlyremove at assembly

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Fig.␣ 3.61 — Convertible rear panel frame


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Fig.␣ 3.64 — Bolt-On Quarter Panels


Rear Compartment Panel Frame

The SMC roof bow cover must be removed toreplace the ‘rear surround’ at factory seams.Sectioning of this panel is recommended whendamage is limited to the rear portion of the rearsurround, not including the “Roof Bow Cover”.The rear surround is the mounting surface for thequarter panels (Fig.␣ 3.64), and is shimmed withstructural adhesive; it may vary from 1mm ≤ 7mmin thickness.

Always shim and dry-fit the surround andouterbody panels before bonding.— REMOVE OR DISCONNECT —

1 Visually inspect and restore as much of thedamage as possible to specifications usingthree-dimensional measuring procedures.Notice: The frame rails and bumper impactbars must be serviced as required, andreturned to three-dimensional coordinatesbefore any SMC repairs are attempted.

Notice: Use Kent Moore Tools FrameAdapter Clamp (P/N J42058) to secure thevehicle if pulling and straightening isrequired (Fig.␣ 3.65).

2 Remove all interior components related tothe rear of the vehicle.Notice: Save any and all brackets,mounting studs, and accessories fortransfer to the new rear compartmentpanel.

3 Remove quarter panels, rear bumper cover,and the roof bow cover. (Refer to Roof BowCover Service Procedures.)

4 Apply heat to the Rear Compartment FramePanel side of the bond area and pry up on thedamaged panel. Use caution so as not todamage the rear compartment panel.

5 Once the ‘rear surround’ is completelyremoved, clean off most of the adhesivebead. Leave a few small areas (about 25mm(1 inch) in length) of adhesive in place to actas shims for the new ‘rear surround’.


Rear Compartment Panel Frame

ADHESIVE

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Fig.␣ 3.67 — Apply a Consistent Bead ofAdhesive to the Entire Perimeter to Form a

Leak-Proof Seal� ADHESIVE

Fig.␣ 3.66 — Adjust Rear Surround UsingAdhesive Bead 1mm≤ 7mm In Thickness

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1 Scuff the service panel bonding surface toensure good adhesion. (Refer to SMC RepairProcedures.)

2 Temporarily assemble rear end of vehicle tocheck alignment with the doors. This includesinstallation of the quarter-panels, roof bowcover, and rear hatch. Place shims asnecessary to achieve proper panel alignmentand establish adhesive thickness (Fig.␣ 3.66).

3 Remove and disassemble panels forinstallation.

4 Scuff all bonding surfaces to ensure properadhesion. (Refer to SMC Repair Procedures.)



7 Apply a consistent bead of adhesive to theentire perimeter of the rear compartmentpanel mating flange and the tops of speakerhousings. Apply enough adhesive for properwet-out (Fig.␣ 3.67).Important: Use US Chemical and Plastics82007B System 2000 Structural Adhesive,a PLIOGRIP® adhesive manufactured byAshland Chemical Company, or equivalent.Note the 30 minute working time and 2.5to 3 hour cure time.

8 Install shims and ‘rear surround’, clamp inplace. Tool excess adhesive to form aconsistent leak-proof bond.

9 Allow to cure according to the adhesivemanufacturer’s recommendations. Removeclamps and install roof bow panel. (Refer toRoof Bow Cover Service Procedures.)



Fig.␣ 3.68 — Ultra High-Strength Steel Beam

Fig.␣ 3.69 — Adapter Flamp for ConventionalAnchoring System

Fig.␣ 3.70 — Mig Stitch Welded to Frame Rails

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Rear Bumper Impact Bar

The rear bumper (impact bar) is made ofUltra-High Strength steel. The impact bar is MIGwelded to the mild steel frame rails. The impactbar can be repaired if damage excludes kinks, ordamage which would require the use of heat tostraighten.

Replacing the bumper bar requires specialprocedures to access the welds attaching thebumper bar to the frame rails. This procedurewas developed to facilitate this repair whilemaintaining the integrity of the bumper system.The rear bumper impact bar as supplied forservice includes riv-nuts pre-installed (Fig.␣ 3.68)for energy absorber mounting. Replacementriv-nuts are available from Kent Moore Tools(Riv-Nut Kit: P/N J42151), if needed.— REMOVE OR DISCONNECT —

1 Remove all panels and components to gainaccess to the rear impact bar. This includesremoving the rear bumper cover, energyabsorber, and the mufflers if necessary.Notice: Disconnect exhaust at the boltedjoint just forward of the rear axle. Frominside the vehicle remove trim panels andpull back the carpeting inside the rearcompartment area.

Important: Save any and all brackets,mounting studs, and accessories fortransfer to the new rear compartmentpanel.

2 Visually inspect and restore as much of thedamage as possible to specifications usingthree-dimensional measuring procedures.Notice: Use Kent Moore Tools FrameAdapter Clamp (P/N J42058) to secure thevehicle if pulling and straightening isrequired (Fig.␣ 3.69).


3 Remove or reposition wiring as necessary toavoid being damaged.



Fig.␣ 3.71 — Cut and RemoveLeft and Right Corners (Right Corner Shown)

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Fig.␣ 3.72 — Create Windows to Access Welds

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Fig.␣ 3.73 — Bond Between Beam and Tub

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4 Using a die grinder or equivalent, cut theMIG welds attaching the rear impact bar tothe frame rails. Cut the welds around theperimeter of the frame rail (fishmouth) ends.Cut the welds favoring the impact bar side ofthe joint. DO NOT cut into the frame rails.Notice: The top and bottom weldededges, as well as the outer rail welds areaccessible from outside the vehicle(Fig.␣ 3.70).

Caution: DO NOT cut the rails whencutting ‘windows’ in the rear compartmentpanel.

5 Access to the inner rail welds requiremodification to the rear wall of the SMC rearcompartment panel. From inside the vehiclelocate, mark, and cut out ‘windows’ in therear compartment panel as in Fig.␣ 3.71. The‘windows’ provide access to inner MIG weldsattaching the impact bar to the rails(Fig.␣ 3.72).Important: Save the cutouts forre-installation.

6 Cut the remaining welds around theperimeter of the impact bar, favoring theimpact bar side of the joint.Notice: Be sure to protect the interior ofthe vehicle before cutting or grinding theSMC body, or the bumper impact bar.

7 The rear impact bar is also bonded to therear compartment panel, see Fig.␣ 3.73. Ifnecessary, apply heat, then pry apart toseparate impact bar from rear panel. (Referto Rear Compartment Panel ServiceProcedures.)

With the rear bumper impact bar removed, repairany cracks in the SMC from outside the vehicle.(Refer to SMC Repair Procedures.)

Important: Do not install the ‘windows’ in rearcompartment yet; welding access is necessaryfor installing the replacement impact bar.


1 Straighten and deburr the rail ends asnecessary to allow the service bumper impactbar to fit the rail ends properly. Remove anyadhesive which is cracked or broken loosefrom the rails or the rear compartment panel.



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40mm50mm

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Fig.␣ 3.74 — Weld Perimeter of Joint, as Indicated

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Fig.␣ 3.75 — Prime Bare Metal AreasBefore Installing Window Cutouts

2 Temporarily position the impact bar andscribe lines into the primer indicating wherethe welds will be made. Remove the primerfrom the areas to be MIG welded by sandingwith 80-grit paper on a ‘Dual-Action’ sander(DA). Do Not use a grinder to remove theprimer.

3 Prepare all bare metal surfaces and applyweld-through primer as necessary. Be sure toapply primer to the inside of the ‘fishmouth’area also.

4 Position the bumper impact bar usingthree-dimensional measuring equipment andinstall per the original weld locations. Stitchweld around the ‘fishmouth’ joint. If not traceof the original welds are present, useFig.␣ 3.74 as a guide for welding the side railsto the impact bar. This weld pattern willcreate a solid weld joint with minimal heatdistortion.

5 Clean and prepare all welded surfaces,use 3M’s Scotch-Brite Clean-N-Strip Discs(disc P/N 07460, mandrel P/N 07491), orequivalent (Fig.␣ 3.75).Important: Prior to refinishing, refer toGM P/N 4901 Refinish Manual forrecommended products.

6 Apply approved anti-corrosion primer.Notice: DO NOT top-coat any bondingsurfaces.

Notice: Top surface of impact bar (whereit is to be bonded to the rearcompartment panel), must not betop-coated, see Fig.␣ 3.73. The bondingarea must remain a ‘primer only’ surface

7 Apply 50mm (2 inch) wide tape over the‘windows’ cut in the rear compartment panel,from outside the vehicle. Apply adhesive tothe inside of the tape backer, and install thepreviously cut-out pieces in their originallocations (Fig.␣ 3.76). (Refer to SMC repairprocedures.)Important: Use US Chemical and Plastics82014B System 2000 Structural Adhesive,a PLIOGRIP® adhesive manufactured byAshland Chemical Company, or equivalent.Note the 9 minute working time and 1hour cure time.


Fig.␣ 3.76 — Bond Rear Compartment Panel to Top Side at Impact Bar

8 Apply a thin coat of Goodwrench StructuralBonding Epoxy (part no. 1234526), orequivalent, to the entire repair areaextending across the cut lines, use tackymesh tape or an equivalent reinforcementmatting. Apply enough bonding epoxy tofully ‘wet out’ reinforcement matting. Allowto cure as necessary. (Refer to SMC RepairProcedures.)

9 Scuff all bonding surfaces to ensure properadhesion. (Refer to SMC Repair Procedures.)

10 Clean and prepare all bonding surfaces asnecessary. (Refer to SMC Repair Procedures.)

11 Apply a bead of urethane adhesive to bondthe impact bar to the rear compartment asshown in Fig.␣ 3.76. This is a structural bond,and care must be used to ensure that theadhesive fills the gap adequately.

12 Finish and feather-edge the repair areas asnecessary to resemble OEM.

13 Prime the SMC repair areas with a suitableprimer. Apply appropriate sealers .

14 Apply top-coat over all repaired areas. Referto paint manufacturer’s recommendations.Do not combine paint systems.




Some Guidelines for SMC Repair• Clean scuff and solvent wipe all areas to be

repaired.• For added strength and durability, V-groove

and reinforce on at least one side of an SMCjoint using a tacky mesh tape or equivalent.

• When partial panel replacement isperformed, use two inch backing platesmade from SMC or E-coated steel, as areinforcement for all butt joints

Repairing Sheet MoldedCompound Panels1 Scuff area where repair is to be performed.2 Clean bond area with lint-free rag using a

water-based cleaner.3 Cracks should be grooved and reinforced on

at least one side of an SMC joint using atacky mesh tape or equivalent.

4 Sectioning joints require backing strips 50mm(2 inch) wide, cut strips from leftover piecesof SMC.

5 Use US Chemical and Plastics System 2000Structural Adhesive or equivalent (the USChemicals customer service number is1-800-321-0672). Apply ahesive to the entire‘joint’ area extending across the cut lines andacross the backer. Use tacky mesh tape or anequivalent reinforcement matting. Allow tocure according to adhesive manufacturer’srecommendations.

6 Apply a thin coat of Goodwrench StructuralBonding Epoxy (P/N 12345726) or equivalentas a final coat to blend in the repair toresemble OEM appearance.

SMC Repair Procedures

Bonding Undamaged SMC toEpoxy Coated Steel1 Prime all bare metal areas with an

anti-corrosion primer such as PPG’s DP90, orequivalent. Some paint manufacturersrecommend a pre-primer when bonding toepoxy. Always refer to paint manufacturer’srecommendations. Do not combine paintsystems.

2 Clean bond area with a lint-free rag using awater-based cleaner.

3 Scuff both surfaces to be bonded using ascuff pad such as 3M’s Scotch-Brite “Red”scuff pad P/N 07447 or equivalent.

4 Ensure that the surface is clean and dry beforeapplying adhesive. Use compressed air. Donot final wipe surface with hand or rag.

5 Determine whether adhesive is applied to thevehicle or the replacement panel. Refer tospecific procedure of part being replaced.

6 Apply a consistent adhesive bond toprepared surfaces.

7 Mechanically retain panel in place to “wetout” adhesive along entire bonding surface.

8 Allow to cure according to adhesivemanufacturer’s recommendations.


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e: 1

3 m

m

H

ex

L:22

58W

:378

H:

527

Hol

e: 1

5 m

m

L:26

28W

:359

H:

574

Hol

e: 2

0 x

25 m

m

L:26

65W

:359

H:

574

Hol

e: 1

5 m

mL:27

70W

:359

H:

584

Hol

e: 2

0 m

m L:30

66W

:75

H:

572

Hol

e: 1

0 m

m

L:10

00W

:223

H:

723

Hol

e: 1

0 m

m

L:30

66W

:75

H:

572

Hol

e: 1

0 m

m

L:30

80W

:517

H:

572

Hol

e: E

xhau

st

Han

ger

Bra

cket

L:30

80W

:618

H:

572

Hol

e: E

xhau

st

Han

ger

Bra

cket

Zer

oLi

ne

L:29

59W

:359

H:

730

Hol

e: 6

.6 m

m

R

ail T

op

Body Dimensions


Sid

e V

iew

Dim

en

sio

ns

L: 4

95W

:771

H:

805

Hol

e: 7

mm

L:76

W:4

71H

:72

5S

lot:

15 x

10

mm

L:42

2W

:471

H:

764

Hol

e: 1

6 m

m

L:49

5W

:768

H:

864

Hol

e: 7

mm

L:59

5W

:767

H:

905

Hol

e: 7

mm

L:12

80W

:577

H:1

285

Hol

e: 3

.4 m

m(L

atch

Atta

ch)

L:58

0W

:771

H:

762

Slo

t: 50

x 7

0 m

mL:62

0W

:768

H:

870

Hol

e: 7

mm

L:57

9W

:774

H:

547

Hol

e: 7

mm

L: 6

20W

:776

H:

570

Hol

e: 7

mm

L:23

84W

:450

H:

707

Hol

e: 1

3 m

m

L:26

76W

:451

H:

705

Hol

e: 1

3 m

m

L:49

5W

:767

H:

905

Hol

e: 7

mm

L:25

30W

:467

H:

708

Hol

e: 5

5 m

m

Zer

oLi

ne

ALL

DIM

EN

SIO

NS

AR

E M

EA

SUR

ED

FR

OM

A Z

ER

O L

INE

, C

EN

TER

LIN

E,

AN

D A

CO

MM

ON

DA

TUM

. A

LL D

IME

NSI

ON

S A

RE

SY

MM

ETR

ICA

L U

NLE

SS O

THE

RW

ISE

SP

EC

IFIE

D.

Body Dimensions


L:40

5W

:75

0H

: H

ole:

8 m

m

L:20

5W

: 750

H:

Hol

e: 8

mm

L:80

W:

750

H:

Hol

e: 8

mm

L:13

0W

:75

0H

: H

ole:

8 m

m

L:33

0W

:75

0H

: H

ole:

8 m

m

L:29

40W

:66

6H

:110

4H

ole:

3.4

mm

L:27

40W

:68

8H

:110

5H

ole:

3.4

mm

L:25

38W

:70

9H

:110

1H

ole:

3.4

mm

L:23

36W

:72

9H

:109

0H

ole:

3.4

mm

L:21

35W

:74

6H

:107

5H

ole:

3.4

mm

L:19

31W

:76

8H

:102

5H

ole:

20

mm

L:48

0W

: 75

0H

: H

ole:

8 m

m

L:81

0W

:44

4H

:72

6H

ole:

8 m

m S

tud

L:71

7W

:45

0H

:72

5H

ole:

8 m

m S

tud

L:44

8W

:75

2H

:91

5H

ole:

20

mm

Up

pe

rbo

dy

Dim

en

sio

ns

ALL

DIM

EN

SIO

NS

AR

E M

EA

SUR

ED

FR

OM

A Z

ER

O L

INE

, C

EN

TER

LIN

E,

AN

D A

CO

MM

ON

DA

TUM

. A

LL D

IME

NSI

ON

S A

RE

SY

MM

ETR

ICA

L U

NLE

SS O

THE

RW

ISE

SP

EC

IFIE

D.

Body Dimensions

Documents

Corvette - G97119 TOC · 2011. 3. 30. · 1997/98 Chevrolet Corvette Collision Repair 3-3 View A View A 30mm 50mm 15mm 30mm 50mm 40mm C of vehicle L Fig.␣ 3.5 — Weld Perimeter