Escolar Documentos
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Pontiac Grand Am
and Oldsmobile Alero
Panel Identification ..................................................... 2-1
white
Two-Sided Galvanized Steel
High-Strength Low-Alloy Steel
Thermoplastic Olefin
Panel Identification
2-2
white
Two-Sided Galvanized Steel
Panel Identification
,,,
Riv-nuts
— INSTALL OR CONNECT —
1 Clean and prepare surfaces to be welded.
2 Trim and discard tab off service part which is
normally welded to the cowl panel (Fig.␣ 2.6)
3 Drill 8mm (5/16-inch) holes for plug welding
in the locations noted from the original
assembly.
4 Drill six holes for plug welding every 40mm
(1-1/2 inches) along the overlap which
attaches service part to flange remaining
from original assembly. (Fig.␣ 2.7)
5 Check the position of the wheelhouse
assembly using three-dimensional measuring
Fig.␣ 2.6 — Trim weld flange equipment and plug weld accordingly. Install
from service assembly one weld in the tab from cowl to strut cap.
(Fig.␣ 2.8)
Notice: The welds which attach the strut
cap to the cowl can be installed from the
cowl plenum side of the joint (Fig.␣ 2.8).
6 Clean and prepare all welded surfaces.
Important: Prior to refinishing, refer to
GM P/N 4901 M-D Refinish Manual for
recommended products.
7 Locate and drill 2 fender-mounting holes in
new wheelhouse using three-dimensional
measuring equipment.
8 Apply approved anti-corrosion primer.
9 Apply sealers and sound deadeners and
refinish as necessary. Do not combine paint
systems. Refer to paint manufacturer’s
recommendations.
10 Install threaded inserts at fender mounting
locations. (Kent-Moore tools: Riv-nut Kit
P/N J␣ 42151-MS). Reuse original fasteners
Fig.␣ 2.7 — Drill 8mm (5/15 inch) holes or equivalent.
along overlap
11 Install all related panels and components.
Cowl
plenum Wheelhouse
PREPARING SERVICE PART 3 On the left inner rail service part, mark a line
FOR INSTALLATION around the panel 30mm (1-1/4 inch) rearward
— INSTALL OR CONNECT — of the 16 x 35 hole on the inner rail. Using the
1 Locate and drill out factory welds attaching hole as a guide, mark a line around the rail
the outer panel to the inner panel on the (Fig.␣ 2.14).
service part. Drill through one layer ONLY at 4 Cut the service part along the marked line
the front half of the rail. and discard the unused section.
Notice: Welds on engine cradle mounting 5 On the sectioned service part, cut a 2mm (1/8
bracket must also be drilled out to remove inch) gap approximately 30mm (1-1/4 inch)
outer panel. deep along the corners of the inner rail to
create tabs (Fig.␣ 2.15).
2 Separate inner from outer rail using an air
chisel. Remove the outer panel and set aside. 6 Step the tabs inward to allow the service part
section to fit inside the original rail (Fig.␣ 2.15).
30mm
Fig.␣ 2.14 — Left rail service part, add 30mm for weld tabs
1. Cut Corners
2. Step tabs
inward
Fig.␣ 2.15 — Cut corners and step tabs inward on service part
7 Drill 5 holes for plug welding along the 10 Position the outer panel, check for proper fit
overlap, approximately 13mm (1/2 inch) from and alignment.
the sectioning cut (Fig.␣ 2.16). 11 Stitch weld along the entire joint. Plug weld
8 Position the modified service part inside the all holes drilled during the removal process
original rail align using three-dimensional including holes drilled along overlapped
measuring equipment. areas (Fig.␣ 2.17).
9 On rail outer panel, trim off tab that attaches 12 Clean and prepare welded surfaces.
to cowl panel. Drill three 8mm (5/16 inch) Important: Prior to refinishing, refer to
plug weld holes along overlap. GM P/N 4901 M-D Refinish Manual for
Notice: Be certain the engine cradle recommended products.
mounting location is in the proper 13 Apply approved anti-corrosion primer.
position. Align and hand tighten bolt.
14 Apply sealers and refinish as necessary. Do
Important: When stitch welding, make not combine paint systems. Refer to paint
25mm (1 inch) welds along the seam with manufacturer’s recommendations.
25mm (1 inch) gaps between. Then go 15 Install all related panels and components.
back and complete the stitch weld along
the seam.
Fig.␣ 2.16 — Drill 8mm (5/16 inch) holes for plug welding
RIGHT - FRONT LOWER RAIL SECTIONING 5 Drill out all the factory welds attaching the
— REMOVE OR DISCONNECT — outer panel to the rail inner panel, be sure
1 Remove all related panels and components. not to drill through the inner panel. Remove
the rail outer panel.
2 Visually inspect and restore as much of the
damage as possible to factory specifications. 6 Measure 75mm (3 inches) forward of the
engine mount brace located inside the rail
3 Remove all sealers and anti-corrosion
and mark a line (Fig.␣ 2.18). Drill a 1/8 inch
materials as necessary.
hole on the line. Using the hole as a guide,
4 Apply 25mm (1 inch) wide tape on the lower mark a line around the outside of the rail.
rail outer panel following the contour of the
7 Cut the rail along the marked line and
cowl. Cut the outer panel along the forward
remove the damaged portion of the rail.
edge of the tape (refer to Fig.␣ 2.12). This will
provide an overlap for welding the service
part to the original rail, without welding
directly to the cowl panel.
75mm
Fig.␣ 2.18 — Remove outer panel and measure damaged inner rail
45mm FRT
Fig.␣ 2.19 — Remove outer panel to measure inner rail on service part
1. Cut Corners
FRT
2. Step tabs
inward
Fig.␣ 2.20 — Cut corners and step tabs inward on service part
7 Drill 5 holes for plug welding along the 10 Position the outer panel, check for proper fit
overlap, approximately 13mm (1/2 inch) and alignment.
from the sectioning cut (Fig. 2.21) 11 Stitch weld along the entire joint. Plug weld
8 Position the modified service part inside the all holes drilled during the removal process
original rail using three-dimensional (Fig.␣ 2.22).
measuring equipment. 12 Clean and prepare welded surfaces.
Notice: Be certain the engine cradle Important: Prior to refinishing, refer to
mounting location is in the proper GM P/N 4901 M-D Refinish Manual for
position. Align and hand tighten bolt. recommended products.
Important: When stitch welding, make 13 Apply approved anti-corrosion primer.
25mm (1 inch) welds along the seam with 14 Apply sealers and refinish as necessary. Do
25mm (1 inch) gaps between. Then go not combine paint systems. Refer to paint
back and complete the stitch weld. manufacturer’s recommendations.
9 Drill 3 holes in the rail outer panel in front of 15 Install all related panels and components.
the cowl.
Fig.␣ 2.21 — Drill 8mm (5/16 inch) holes for plug welding
FRONT LOWER RAIL REPLACEMENT 1/8-inch drill bit, drill through floor to mark
— REMOVE OR DISCONNECT — welds for removal.
1 Remove all related panels and components. 7 Separate the floor pan reinforcement vertical
2 Visually inspect and restore as much of the flange from inside the lower rail. Care must
damage as possible to factory specifications. be taken to not damage the flange.
3 Remove sealers, sound deadeners and 8 Drill out factory welds along the lower flange
anti-corrosion materials as necessary. on the floor pan reinforcement and at the
wheelhouse. Note that the flanges overlap
4 Using an air chisel, remove the rear engine the rails.
mount.
9 From inside the vehicle, use an 8mm (5/16
5 Locate and drill out resistance welds in
inch) drill bit to drill through the floor pan
torque box panel (Fig.␣ 2.23). Drill through
and the reinforcement inside the vehicle
one layer of metal ONLY.
(Fig␣ 2.24).
6 From underside of vehicle, locate welds that
10 Remove the damaged rail.
secure the rail to the floorpan. Using a
Fig.␣ 2.23 — Drill through rail in torque box to locate welds inside vehicle
Fig.␣ 2.24 — Drill from inside vehicle at pilot hole locations using an 8mm (5/16 inch) drill bit
Door Frame Opening 3 Position the service assembly, check fit using
Full Replacement body dimension and plug weld accordingly
— REMOVE OR DISCONNECT —
with frequent measurements to ensure
proper fit.
1 Remove all related panels and components
including the roof panel, upper outer rail 4 Inject expandable foam into the “A” Pillar
reinforcement and, on coupe models only, through the bottom interior trim-mounting
the quarter panel. hole. This helps reduce noise in the pas-
senger compartment.
2 Visually inspect and restore as much of the
damage as possible to factory specifications. 5 Clean and prepare welded surfaces.
3 Remove sealers, sound deadeners and anti- Important: Prior to refinishing, refer to
corrosion materials as necessary. GM P/N 4901 M-D Refinish Manual for
recommended products.
4 Locate, mark and drill out all factory welds.
Note the number of welds for installation of 6 Apply approved anti-corrosion primer.
the service assembly. 7 Apply a full-bodied caulk along the surface of
5 Remove the damaged doorframe opening. the baffle to ensure a proper seal with the
inner cowl plenum (Fig.␣ 2.27).
8 Apply sealers and refinish as necessary. Do
— INSTALL OR CONNECT —
not combine paint systems. Refer to paint
1 Prepare mating surfaces and check for manufacturer’s recommendations
proper fit of the door frame opening service
9 Reinstall all related panels and components.
assembly.
2 On the service assembly, drill 8mm
(5/16-inch) plug weld holes as necessary in
the locations noted from the original
assembly.
Notice: In any area damaged beyond
recognition, space plug weld holes every
40mm (1-1/2 inches) apart.
When sectioning areas other than the hinge 1 Remove all related panels and components.
pillar, a 100mm (4 inch) backing plate must be 2 Visually inspect and restore as much of the
used behind the joint to ensure a solid and damage as possible to factory specification.
secure weld in areas where there is no inner 3 Remove sealers, sound deadeners and anti-
reinforcement. Backing plates can usually be cut corrosion materials as necessary.
from the unused portion of the service part or an
4 Cut the doorframe opening where it is to be
undamaged section of the doorframe opening.
sectioned. Do not damage any inner panels
Notice: There are some key reinforcements or reinforcements.
that are to be replaced at factory seams only 5 Locate, mark and drill out all necessary
(Fig. 2.28). Sectioning these panels may factory welds. Note the number of welds for
compromise the structural integrity of the installation of the service part.
vehicle. 6 Remove the damaged section of the
The rocker panel can also be replaced in its doorframe opening.
entirety when the quarter panel has been
removed.
Fig.␣ 2.28 — Door frame reinforcements are part of the service assemblies
— INSTALL OR CONNECT —
1 Cut the service part to match the undamaged
section of the door frame opening and
remove unused portion of the service part.
2 Cut an appropriate-sized backing plate from
the unused portion of the service part or
undamaged section of the doorframe
opening. Modify the backing plate as
necessary so that it will fit behind the
sectioning joint (Fig.␣ 2.29).
100mm
50mm
100mm
100mm
50mm
100mm
3 Windshield pillar sectioning requires a 50mm 7 Position the service part, allowing it to
(2 inch) backing plate. Section within the overlap the exposed portion of the backing
recommended areas (Fig. 2.29). plates. Check fit using body dimensions and
Notice: The striker plate is mounted in a plug weld accordingly with frequent
cage that allows some degree of measurements to ensure proper fit.
adjustment independent of the outer 8 Stitch weld along the sectioning joints. Make
panel’s. Use body dimensions to ensure 25mm (1 inch) welds along the seam with
the striker mounting location falls within 25mm (1 inch) gaps between. Then go back
the plate’s range of adjustment and complete the stitch weld. This will create
4 Sectioning the rocker panel requires a a solid joint with minimal heat distortion.
100mm (4 inch) backing plate for 9 Complete all other welds as necessary.
reinforcement (Fig. 2.29). Section within the 10 Clean and prepare welded surfaces.
recommended area. Important: Prior to refinishing, refer to
5 On the service part, drill 8mm (5/16-inch) GM P/N 4901 M-D Refinish Manual for
plug weld holes as necessary in the locations recommended products.
noted from the original section. Also, drill 11 Apply approved anti-corrosion primer
plug weld holes along the sectioning cut on
both the service part and the remaining 12 Apply sealers and refinish as necessary. Do
not combine paint systems. Refer to paint
original part. These will be used to weld the
manufacturer’s recommendations.
panel to the backing plate.
13 Reinstall all related panels and components.
6 Prepare mating surfaces and slide the
backing plates halfway under the sectioning
cuts on the vehicle and plug weld in place.
T
FR
Pre-installed
sound-soak panel
— REMOVE OR DISCONNECT —
Silicon Bronze
Joint 1 Remove all related panels and components
necessary to access the welds attaching the
roof assembly to the vehicle.
2 Visually inspect and restore as much of the
damage as possible.
3 Remove sealers and anti-corrosion materials
as necessary.
4 Locate silicon-bronze joints which attach roof
panel to quarter panels (Fig.␣ 2.31).
5 Cut through the roof panel just above the left
and right silicon-bronze joints using a
die-grinder or equivalent tool (Fig.␣ 2.32).
6 Locate, mark and drill out all factory welds.
Note the number and location of welds for
installation of the service assembly.
7 Remove the damaged roof panel assembly.
8 Grind off silicon-bronze weld and remove
remaining roof panel tabs.
— INSTALL OR CONNECT —
1 Clean and prepare the mating surfaces as
Fig.␣ 2.31 — Locate roof seam at quarter panel necessary.
2 Position the roof panel on the vehicle. Check
fit and alignment.
3 When the service assembly is correctly
positioned, plug weld accordingly.
4 MIG stitch weld the quarter panel to roof
joints at factory seams.
DO NOT CUT SAIL PANEL REINFORCEMENT. Important: Make 25mm (1 inch) welds
CUT ROOF PANEL ONLY along the seam with 25mm (1 inch) gaps
between. Then go back and complete the
stitch weld. This will create a solid joint
with minimal heat distortion.
5 Clean and prepare all welded surfaces.
Important: Prior to refinishing, refer to
GM P/N 4901 M-D Refinish Manual for
recommended products.
6 Apply approved anti-corrosion primer.
Notice: The windshield and bonding area
should be a primer surface ONLY and not
an aftermarket, top-coated (paint or
color-coated) surface. Refer to Bulletin
#43-10-48 for more detailed information.
7 Apply sealers and refinish as necessary. Do
not combine paint systems. Refer to paint
manufacturer’s recommendations.
8 Install all related panels and components.
SEDAN
Taillamp pockets
serviced separately
COUPE
100mm
Fig.␣ 2.39 — Drill 8mm (5/16 inch) holes for plug welding
Fig.␣ 2.40 — Use 100mm (4 inch) backing plate
Sedan
— REMOVE OR DISCONNECT —
1 Remove all related panels and components
including the back glass.
2 From inside of vehicle, pull back and protect
wiring along inner wheelhouse.
3 Locate and drill out six welds securing Fig.␣ 2.41 — Replacement wheelhouse (coupe/sedan)
beltline reinforcement to quarter inner
assembly (Fig.␣ 2.42)
Notice: Drill through one layer only.
4 Locate and drill out welds at factory seams
along perimeter of wheelhouse flange.
5 Remove damaged wheelhouse panel.
— INSTALL OR CONNECT —
1 On service part, drill 8mm (5/16-inch) holes
every 40mm (1-1/2 inches).
2 Prepare mating surfaces.
3 Apply suitable weld-through primer.
4 Position service part. Check for proper fit.
Notice: Outer wheelhouse positioning may
require dry-fitting of quarter outer panel.
5 Clean and prepare welded surfaces.
Important: Prior to refinishing, refer to
GM P/N 4901 M-D Refinish Manual for
recommended products.
6 Apply approved anti-corrosion primer.
7 Apply sealers and sound deadener materials
and refinish as necessary. Do not combine Fig.␣ 2.42 — Remove beltline reinforcement
paint systems. Refer to paint manufacturer’s (SEDAN ONLY)
recommendations.
8 Install related panels and components.
Beltline Reinforcement
— INSTALL OR CONNECT —
1 Remove weld flange on remaining portion of
original wheelhouse (at rocker panel) to
ensure proper fit of service part.
2 Temporarily install service part over beltline
reinforcement flange and inside of original
wheelhouse (Fig. 2.46).
3 On the service part, drill 8mm (5/16 inch)
plug weld holes every 40mm (1-1/2 inches
along perimeter of entire service part.
(Fig.␣ 2.47) Drill 4 holes on edge where
service part mates to rocker panel.
4 Prepare the mating surfaces and position the
service part. Apply suitable weld-through
primer.
5 Check for proper fit and plug weld
accordingly. Use care to not warp or distort
the metal.
Notice: Outer wheelhouse positioning may
require dry-fitting of quarter outer panel.
6 Clean and prepare welded surfaces.
Fig.␣ 2.45 — Separate wheelhouse from quarter
inner assembly (leave weld flange in place) Important: Prior to refinishing, refer to
GM P/N 4901 M-D Refinish Manual for
recommended products.
7 Apply approved anti-corrosion primer.
8 Apply sealers and sound deadeners as
necessary. Do not combine paint systems.
Refer to paint manufacturer’s
recommendations.
9 Install all related panels and components.
Over
Inside
Rail
extensions
Fig.␣ 2.48 — Floor pan “skin” and rail extensions are serviced
Rear Floor Panel Partial factory welds which secure floor to rails.
Replacement Note the number and location of welds for
— REMOVE OR DISCONNECT —
installation of the floor service panel (Fig.
2.49).
1 Remove all related panels and components,
including fuel tank. 5 Drill completely through welds that attach
the floorpan to the inner wheelhouse.
2 Visually inspect and restore as much of the
damage as possible. 6 Remove both inner wheelhouse braces.
Identify weld locations and drill through
3 Remove sealers, sound deadeners and
one layer of metal only.
anti-corrosion materials as necessary.
7 Remove the damaged floor section.
4 Locate factory seam at front edge of
crossbar, rearward of seat back. Locate,
mark and drill through one layer only, all
The floor pan assembly comes complete 1 Prepare mating surfaces with suitable
including lower rails, crossbar, rear floor weld-through primer.
extension and various other components. Notice: In any area damaged beyond
(Fig.␣ 2.51) recognition, space plug weld holes every
— REMOVE OR DISCONNECT — 40mm (1-1/2 inches) apart.
Notice: One side inner and outer wheelhouses 2 Drill 8mm (5/16-inch) plug weld holes along
must be removed when replacing entire all mating surfaces except where the floor
sub-assembly. mates to each wheelhouse.
1 Remove all related panels and components. 3 Position the service floorpan. Check for
2 Visually inspect and restore as much of the proper fit using three-dimensional
damage as possible. measurements.
3 Remove sealers, sound deadeners and 4 Clean and prepare all welded surfaces.
anti-corrosion materials as necessary. Important: Prior to refinishing, refer to
4 Remove 4 inner reinforcements ( 2-dynamic GM P/N 4901 M-D Refinish Manual for
side impact braces-front; 2- floor pan recommended products.
braces-rear) to access spot welds (Fig 2.52). 5 Apply approved anti-corrosion primer to all
Notice: If these parts are damaged they bare metal surfaces.
must be ordered separately. 6 Apply body sealers and refinish as necessary.
Do not combine paint systems. Refer to paint
manufacturer’s recommendations.
7 Reinstall all related components.
Fig.␣ 2.53 — Modify weld flange if ordering and installing entire rear rail only
Fig.␣ 2.54 —
K
L: 2733
W: 440
Body Dimensions
H: 364
C CL
L: 1215 B N L
W: 442 L: 292 L: 2111 M L: 2466
H: 326 W: 356 O W: 430 L: 2321 W: 440
H: 243 L: 1650 H: 369 W: 433 H: 375
W: 563 H: 369
H: 400
2-37
Body Dimensions
FRONT VIEW
P Q
W: 508 W: 517
H: 416 CL H: 474
L: 1364
L: 1364
R S
W: 517 W: 517
H: 376 H: 376
L: 1364 L: 1364
REAR VIEW
T U
W: 374 W: 508
H: 346 CL H: 416
L:3013 L:3013
V W
W: 374 W: 374
H: 346 H: 346
L:3013 L:3013
ALL DIMENSIONS ARE MEASURED FROM A ZERO LINE, CENTER LINE, AND A
COMMON DATUM. ALL DIMENSIONS ARE SYMMETRICAL UNLESS OTHERWISE SPECIFIED.