Escolar Documentos
Profissional Documentos
Cultura Documentos
PANEL IDENTIFICATION ___________________ 2 RADIATOR SUPPORT ASSEMBLY ____________ 4 FRONT WHEELHOUSE ASSEMBLY __________ 6 FRONT LOWER RAIL ASSEMBLY ____________ 8 FRONT SUSPENSION SUPPORT (#1 BAR) __ 11 DOOR FRAME OPENING ___________________14 DOOR SERVICE ___________________________ 20 ROOF PANEL _____________________________ 21 QUARTER PANEL _________________________ 22 OUTER REAR WHEELHOUSE ______________ 26 REAR RAIL _______________________________ 28 REAR FLOOR ASSEMBLY __________________ 31 REAR END PANEL ________________________ 36 BODY DIMENSIONS _______________________ 37
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
1. PANEL IDENTIFICATION
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
1. PANEL IDENTIFICATION
KEY TO COMPONENTS:
Reinforced injected molded (RIM) plastic or thermoplastic olefin (TPO) High-strength low-alloy (HSLA) steel parts
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
4
1995 General Motors Corporation. All Rights Reserved.
Install or Connect
1. Prepare mating surfaces and check for proper fit of the service panels. 2. On the service panels, drill 8mm (5/16") plug weld holes as necessary in the locations noted from the original assembly. 3. Position the service panels, check fit using body dimensions, and plug weld accordingly with frequent measurements to ensure proper fit. 4. Clean and prepare welded surfaces. Prime with two-part catalyzed primer. Apply sealers and corrosion protection materials, as necessary. Do not combine paint systems. Refer to paint manufacturers recommendations. Reinstall all related panels and components.
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
J11943.2
6
CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
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. Remove sealers, sound deadeners and corrosion materials as necessary. 4. Locate, mark and drill out all factory welds. Note the number of welds for installation of the service assembly. Notice There are five welds that secure the strut cap to the cowl plenum. Drill through only one layer of metal. Any holes drilled through the cowl plenum must be filled before installation of the new wheelhouse assembly. 5. Remove the damaged front wheelhouse assembly. Caution When servicing the wheelhouse assembly at the cowl plenum, it is advised you use a fire resistant welding blanket (such as part #J41156 available from Kent-Moore) to help avoid damage to the interior of the vehicle. Install the blanket between the cowl and the foam pad underneath the carpet where the assembly is attached.
Install or Connect
1. Prepare mating surfaces and check for proper fit of the wheelhouse service assembly. 2. On the service assembly, drill 8mm (5/16") plug weld holes as necessary in the locations noted from the original assembly. 3. Position the service assembly, check fit using body dimensions, and plug and stitch weld accordingly with frequent measurements of the strut cap and fender mounting locations to ensure proper fit (Figure 3-3). 4. Clean and prepare welded surfaces. Prime with two-part catalyzed primer. Apply sealers and corrosion protection materials, as necessary. Do not combine paint systems. Refer to paint manufacturers recommendations. Reinstall all related panels and components.
8
CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
FIGURE 4-2 DRILL OUT FACTORY WELDS SECURING THE FRONT SUSPENSION SUPPORT TO THE L OWER R AIL
Install or Connect
1. Prepare mating surfaces and check for proper fit of the lower rail service assembly. 2. On the service assembly, drill 8mm (5/16") plug weld holes as necessary in the locations noted from the original parts. 3. Position the service assembly and check fit using body dimensions. Make sure the suspension support properly mates over the lower rail bracket. Plug weld accordingly with frequent measurements to ensure proper fit. 4. Clean and prepare welded surfaces. Prime with two-part catalyzed primer. Apply corrosion protection materials and sealers, as necessary. 5. Apply Dominion Sure Seal paintable sound deadening pads (part #110900) to the floor as necessary to match original sound deadening. 6. Do not combine paint systems. Refer to paint manufacturers recommendations. Reinstall all related panels and components. 7. When reinstalling the suspension crossmember, torque all six fasteners to 130 Nm (96 lbs. ft.).
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F IGURE 4-3 SEPARATE THE L OWER RAIL FROM THE COWL AND FLOOR E XTENSIONS ( UNDERBODY VIEW )
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Install or Connect
1. Prepare mating surfaces and check for proper fit of the suspension support service assembly. 2. On the service assembly, drill 8mm (5/16") plug weld holes as necessary in the locations noted from the original parts. 3. Position the service assembly over the lower rail brackets and check fit using body dimensions (refer to Figure 4-2 on page 9). Plug weld accordingly. 4. Clean and prepare welded surfaces. Prime with two-part catalyzed primer. Apply sealers and corrosion protection materials, as necessary. Do not combine paint systems. Refer to paint manufacturers recommendations. Reinstall all related panels and components.
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1995 General Motors Corporation. All Rights Reserved.
Remove or Disconnect
1. Remove all related panels and components, including the carpeting and center console if necessary. 2. Visually inspect and restore as much of the damage as possible to factory specifications. 3. From the underside of the vehicle, run a centerpunch through the cagenut mounting bracket and strike with a hammer. This will mark the center of the window to be cut in the floor pan. 4. With a heat gun and gasket scraper, remove the sound deadener material from the floor pan within a 200mm (8") radius of the dimple created in the previous step. 5. Measure and mark a 100mm (4") square centered around the dimple created in step #4. This will be the window used to access the cagenut brackets. 6. Cut three sides of the square marked in the previous step and pry the window toward the center of the vehicle (Figure 5-2). Caution When servicing the cagenut brackets, it is advised you use a fire resistant welding blanket (such as part #J41156 available from Kent-Moore) to help avoid damage to the interior of the vehicle. 7. Locate, centerpunch and drill out the two resistance welds that secure the bracket to the front suspension support. Be careful to only drill through one layer of metal. Notice It is important to leave a layer of metal for installation of the new cagenut bracket. If more than one layer is drilled, fill the hole with a plug weld before installing the new bracket.
Install or Connect
1. Prepare mating surfaces and check for proper fit of the new cagenut bracket. Position the bracket using body dimensions and secure it to the suspension support panel by temporarily installing and tightening the crossmember bolt. 2. Plug weld the new cagenut bracket and then remove the crossmember bolt. 3. Clean and prepare welded surfaces. Prime with two-part catalyzed primer. 4. Bend the access window back to its original position and stitch weld the entire perimeter. 5. Clean and prepare welded surfaces. Prime with two-part catalyzed primer. Apply sealers and corrosion protection materials, as necessary. 6. Apply Dominion Sure Seal paintable sound deadening pads (part #110900) to the floor as necessary to match original sound deadening. 7. Do not combine paint systems. Refer to paint manufacturers recommendations. Reinstall all related panels and components. 8. When reinstalling the suspension crossmember, torque all six fasteners to 130 Nm (96 lbs. ft.).
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
FIGURE 6-1 COUPE DOOR FRAME O PENING (SECTIONING SHOULD NOT T AKE PLACE IN THE SHADED AREAS)
FIGURE 6-2 SEDAN DOOR FRAME O PENING (SECTIONING SHOULD NOT T AKE PLACE IN THE SHADED AREAS)
Notice Four welds must be added on the lower hinge pillar when installing the service assembly. These welds are essential to ensure the structural integrity of the vehicle. Use the door frame opening weld template provided with the service assembly to properly locate the position of these welds.
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
Install or Connect
F IGURE 6-3 INJECT E XPANDABLE FOAM I NTO THE A P ILLAR AND APPLY SEAM SEALER
TO THE JOINT AT THE ROOF LINE
1. Prepare mating surfaces and check for proper fit of the door frame opening service assembly. 2. On the service assembly, drill 8mm (5/16") plug weld holes as necessary in the locations noted from the original assembly. 3. Position the service assembly, check fit using body dimensions, and plug weld accordingly with frequent measurements to ensure proper fit. 4. Inject expandable foam into the A pillar through the bottom interior trim mounting hole (Figure 6-3). This helps reduce noise in the passenger compartment. 5. Clean and prepare welded surfaces. Prime with two-part catalyzed primer. Apply sealers and corrosion protection materials, as necessary. 6. Apply a full-bodied caulk along the surface of the baffle to ensure a proper seal with the inner cowl plenum (Figure 6-4). 7. Apply seam sealer, such as 3M Ultra Pro 08361, along the top edge of the A pillar joint at the roof line (Figure 6-3). 8. Do not combine paint systems. Refer to paint manufacturers recommendations. Reinstall all related panels and components.
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
Remove or Disconnect
1. 2. 3. 4. Remove all related panels and components. Visually inspect and restore as much of the damage as possible to factory specifications. Remove sealers, sound deadeners and corrosion materials as necessary. Drill out and remove the access panel located on the upper outer rail reinforcement (Figure 6-5). Cut and pry the outer reinforcement away from the hinge pillar as necessary to provide room for the sectioning template (Figure 6-6). Align the template provided with the service part and mark a line where indicated. Cut the hinge pillar and inner reinforcement along this line. Perform additional sectioning procedures as necessary to remove damaged areas of the door frame opening. Locate, mark and drill out all necessary factory welds. Note the number of welds for installation of the service part. Remove the damaged section of the door frame opening and the hinge pillar inner reinforcement.
5. 6. 7. 8.
FIGURE 6-5 REMOVE THE ACCESS PANEL ON THE FRONT LOWER RAIL O UTER REINFORCEMENT
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
Install or Connect
1. Align the template on the service part and mark a cut line where indicated. 2. Cut the service part along the marked line. Do not damage the hinge pillar inner reinforcement. Notice Only cut the outer surface of the hinge pillar service part. The inner reinforcement is used as a backing plate when installing the new section.
F IGURE 6-7 REMOVE THE REMAINING SECTION OF THE INNER R EINFORCEMENT
3. Drill out the 4 welds attaching the hinge pillar to the inner reinforcement above the cut line. Do not drill through the inner reinforcement. 4. Perform additional sectioning procedures as necessary to remove the unused areas of the service part. Drill 8mm (5/16") plug weld holes as necessary in the locations noted from the original section. Prepare all mating surfaces for welding. 5. Position the door frame opening service part. Make sure the inner reinforcement extending from the top of the hinge pillar service part is properly positioned within the existing hinge pillar section (Figure 6-8). Check fit using body dimensions and plug weld accordingly with frequent measurements to ensure proper fit. Notice To ensure a secure weld, the hinge pillar sectioning joint should have a gap of approximately one-and-a-half times the thickness of the metal. Trim the parts as necessary to achieve this.
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
Install or Connect
1. Cut the service part to match the damaged section of the door frame opening and remove the unused portion of the service part. 2. Cut a 100mm (4") backing plate from the unused portion of the service part or damaged section of the door frame opening. Modify the backing plate as necessary so that it will fit behind the sectioning joint (Figure 6-10). 3. On the service part, drill 8mm (5/16") plug weld holes as necessary in the locations noted from the original section. Also, drill plug weld holes along the sectioning cut on both the service part and the remaining original part. These will be used to weld the panel to the backing plate. 4. Prepare mating surfaces and slide the backing plates 50mm (2") beneath the sectioning cuts on the vehicle and plug weld in place. Notice To ensure a secure weld, the sectioning joints should have a gap of approximately one-and-a-half times the thickness of the metal. Trim the parts as necessary to achieve this. 5. Position the service part, allowing it to overlap the exposed 50mm (2") of the backing plates. Check fit using body dimensions and plug weld accordingly with frequent measurements to ensure proper fit (Figure 6-10). 6. Stitch weld along the sectioning joints. Make 25mm (1") welds along the seam with 25mm (1") gaps between. Then go back and complete the stitch weld. This will create a solid joint with minimal heat distortion. 7. Complete all other welds as necessary. 8. Clean and prepare welded surfaces. Prime with two-part catalyzed primer. Apply sealers and corrosion protection materials, as necessary. Do not combine paint systems. Refer to paint manufacturers recommendations. Reinstall all related panels and components.
FIGURE 6-10 INSTALL A B ACKING PLATE AND PLUG WELD THE N EW PANEL
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
7. DOOR SERVICE
The doors are available as complete assemblies (Figures 7-1 and 7-2). Additionally, the outer door panels are available separately. Use conventional service procedures when repairing damage to the doors. All doors feature bolt-on hinges and an HSLA door beam for added strength and occupant protection in the event of a side collision.
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
8. ROOF PANEL
The roof is made of steel and welded to the steel roof structure. The roof panel is supplied as part of an assembly that includes the center roof support. The roof assemblies are unique to coupe and sedan models. Notice The headliner, windshield and backglass must be removed prior to removal of the roof assembly. Protect the interior of the vehicle by covering it with blankets and use care when working near adjacent panels, glass, weatherstrips and moldings.
Remove or Disconnect
1. Remove all related panels and components to gain proper access to the welds attaching the roof assembly to the vehicle. 2. Remove sealers, sound deadeners and corrosion materials as necessary. 3. Locate, mark and drill out all factory welds. 4. Remove the roof panel and center roof support.
Install or Connect
1. Prepare mating surfaces and check for proper fit of the roof assembly. 2. Apply urethane memory tape to front and rear roof bows before installing roof panel. 3. Position the roof panel, check fit using body dimensions, and plug weld accordingly with frequent measurements to ensure proper fit. 4. Clean and prepare welded surfaces. Prime with two-part catalyzed primer. Apply sealers and corrosion protection materials, as necessary. Do not combine paint systems. Refer to paint manufacturers recommendations. Reinstall all related panels and components.
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1995 General Motors Corporation. All Rights Reserved.
9. QUARTER PANEL
To simplify repairs, the quarter panels are only available as sub-assemblies including filler panels and taillight mounting panels (Figures 9-1 and 9-2). There are unique replacement procedures for the coupe and sedan models. A key difference is that the rear window can be left in place when performing quarter panel service on the coupe model, but must be removed on the sedan model. Also, the sedan quarter panel service procedure incorporates sectioning to simplify replacement.
Gutter extension
Gutter extension
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
9. QUARTER PANEL
6. Cut a hole in the damaged quarter panel to gain access to the inside surface of the drip rail at the back glass to simplify removal (Figure 9-3). 7. Locate and drill out all factory welds along the quarter panel drip rail at the backglass. 8. Remove the damaged quarter panel assembly. Note how the quarter panel assembly mates with the rear gutter for installation of the new assembly. Caution Take care not to damage the rear window when removing the quarter panel.
Install or Connect
1. Prepare mating surfaces and check for proper fit of the quarter panel service assembly. 2. On the service assembly, drill 8mm (5/16") plug weld holes as necessary in the locations noted from the original assembly. 3. Position the service assembly. Allow the quarter panel to wrap over the rear gutter and then slide the entire assembly forward so that the gutter extension slips beneath the rear gutter. Check fit using body dimensions, and plug weld accordingly with frequent measurements to ensure proper fit. 4. Clean and prepare welded surfaces. Prime with two-part catalyzed primer. Apply sealers and corrosion protection materials, as necessary. Do not combine paint systems. Refer to paint manufacturers recommendations. Reinstall all related panels and components.
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9. QUARTER PANEL
SEDAN QUARTER PANEL REPLACEMENT
When replacing the quarter panel assemblies on the sedan models, a tab is created from the original quarter panel at the joint with the roof. The service part is then modified to fit over this tab, which is used as a backing plate for welding the new panel in place.
Remove or Disconnect
1. Remove all related panels and components including the rear window. Also pry up and remove the reveal molding at the roof line. It is held in place with two-sided tape. 2. Visually inspect and restore as much of the damage as possible to factory specifications. 3. Remove sealers, sound deadeners and corrosion materials as necessary. 4. Locate, mark and drill out all factory welds around the perimeter of the quarter panel assembly, except for those under the reveal molding. Note the number of welds for installation of the service assembly. 5. Cut a hole in the damaged quarter panel to gain access to the inside surface of the drip rail at the back glass to simplify removal (Figure 9-4). 6. Apply a strip of 25mm (1") masking tape along the top edge of the quarter panel where it meets the roof. 7. Cut along the bottom edge of the masking tape and remove the damaged quarter panel assembly, leaving a 25mm (1") tab attached to the roof (Figure 9-5).
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
9. QUARTER PANEL
Install or Connect
1. Trim and discard the upper mounting flange on the service assembly so that it can fit over the 25mm (1") tab left from the original panel (Figure 9-6). 2. On the service assembly, drill 8mm (5/16") plug weld holes as necessary in the locations noted from the original assembly. Also drill four plug weld holes along the top edge of the new quarter panel for attachment to the one-inch tab (Figure 9-7) 3. Position the service assembly from the top down. Check fit using body dimensions. Notice Verify fit of the pinch-flange molding. If the gap is unsatisfactory, adjust the one-inch tab until correct alignment is achieved. 4. When the assembly is correctly positioned, plug weld accordingly with frequent measurements to ensure proper fit. Begin with the welds over the 25mm (1") tab and then continue around the perimeter of the assembly. 5. Clean and prepare welded surfaces. Prime with two-part catalyzed primer. Apply fillers, sealers and corrosion protection materials, as necessary. Do not combine paint systems. Refer to paint manufacturers recommendations. Reinstall all related panels and components. Notice Apply seam sealer, such as 3M Ultra Pro 08361, along the top edge of the A pillar joint at the roof line (Figure 9-8).
FIGURE 9-8 APPLY SEAM SEALER TO THE J OINT WITH THE ROOF
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
Beltline reinforcement
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. Remove sealers, sound deadeners and corrosion materials as necessary. 4. Drill out the factory welds at the forward lower portion of the wheelhouse at the rocker panel. On coupe models, also drill out the four factory welds along the outboard edge of the beltline reinforcement.
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
20mm(34") tab
FIGURE 10-4 APPLY TAPE, CUT AND REMOVE DAMAGED PORTION OF WHEELHOUSE
Install or Connect
1. Temporarily install the wheelhouse service part and check fit. On coupe models, first fit the forward lower portion then slide the weld flange over the tab on the original section and under the beltline reinforcement. 2. On the service part, mark plug weld holes every 40mm (1-1/2") along the weld flange, alternating between the vertical and horizontal surfaces to ensure uniform strength (Figure 10-5). 3. Remove the service part and drill 8mm (5/16") plug welds where marked in the previous step. 4. Prepare mating surfaces and position the service part. Check fit using body dimensions and plug weld accordingly with frequent measurements to ensure proper fit. Take care not to warp or distort the metal. 5. Plug weld the factory welds at the forward lower portion of the wheelhouse at the rocker panel (see step #4 of Remove or Disconnect). On coupe models, also plug weld the four factory welds along the outboard edge of the beltline reinforcement. 6. Clean and prepare welded surfaces. Prime with twopart catalyzed primer. Apply sealers and corrosion protection materials, as necessary. Do not combine paint systems. Refer to paint manufacturers recommendations. Reinstall all related panels and components.
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
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1995 General Motors Corporation. All Rights Reserved.
F IGURE 11-2 CUT AND REMOVE THE DAMAGED SECTION OF THE REAR RAIL
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
FIGURE 12-2 CUT AND REMOVE THE DAMAGED SECTION OF THE REAR FLOOR PAN AND RAILS
Remove or Disconnect
1. 2. 3. 4. Remove all related panels and components. Visually inspect and restore as much of the damage as possible to factory specifications. Remove sealers, sound deadeners and corrosion materials as necessary. Align the templates in the appropriate locations. Use a center punch or an awl to mark the assembly by punching through the templates. Remove the templates, connect the dots with a straight edge and scribe the cut lines. Notice The cut lines for the left and right sides are in different positions. Make sure to use the appropriate templates. Do not damage the templates since they must also be used to mark the service assembly. Attach them with a non-permanent spray adhesive such as 3Ms Repositionable Adhesive (part #6091). 5. Locate mark and drill out all related factory welds rearward of the cut lines. 6. From the underside of the vehicle, cut the rails and floor pan along the rough cut line. Continue this cut around the radius of the spare tire tub. Remove the damaged section of the rear floor and rails (Figure 12-2).
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
FIGURE 12-3 SEPARATE THE SIDERAILS OF THE REAR RAIL INNER REINFORCEMENT FROM THE OUTER PANEL
8. Locate, mark and drill out the factory welds securing the rear rail inner reinforcements to the outer panels between the rough cut and final cut lines. Do not drill through the inner reinforcements. 9. Separate the side walls of the inner reinforcement from the outer panel of the rail by slightly prying the reinforcements inwards (Figure 12-3). 10. Cut the sides of the rail outer panel along the final cut lines, taking care not to damage the inner reinforcement. Cut along the bottom of the outer panel approximately 3/4 of the metal thickness deep. 11. Bend the rail up and down until the outer panel breaks along the partial cut. Remove the damaged section of the rear rail, leaving the reinforcement extending from inside the remaining rail section (Figure 12-4).
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
Overlap
Install or Connect
1. Prepare mating surfaces and check for proper fit of the rear floor service assembly section, allowing it to overlap the original floor. Notice To ensure a secure weld, the rear rail sectioning joints should have a gap of approximately oneand-a-half times the thickness of the metal. Trim the parts as necessary to achieve this. Make sure to plug weld the inner reinforcement to the new rail section. This may require drawing the reinforcement flat against the rail using a screw. It may also be necessary to install backing plates on either side of the original rails above the reinforcements. These can be cut from the unused inner reinforcements of the service part. Drill holes in the rail and plug weld the backing plates in place. 2. With the service assembly positioned, plug weld the inner reinforcements to the rail service parts. 3. Verify position of the service assembly using body dimensions and plug weld accordingly with frequent measurements to ensure proper fit (Figure 12-6). 4. Clean and prepare welded surfaces. Prime with two-part catalyzed primer. Apply sealers and corrosion protection materials, as necessary. Caulk both sides of the floor pan seam. Notice Use a full-bodied caulk, such as 3Ms Ultra Pro Seam Sealer (part #08360-1), to seal both sides of the floor pan seam. 5. Refinish as necessary. Do not combine paint systems. Refer to paint manufacturers recommendations. Reinstall all related panels and components.
35
Sunfire Coupe
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. Remove sealers, sound deadeners and corrosion materials as necessary. 4. Locate, mark and drill out all factory welds. Note the number of welds for installation of the service assembly. 5. Remove the damaged assembly.
Install or Connect
1. Prepare mating surfaces and check for proper fit of the service assembly. 2. On the service assembly drill 8mm (5/ 16") plug weld holes as necessary in the locations noted from the original assembly. 3. Position the service assembly, check fit using body dimensions, and plug weld accordingly with frequent measurements to ensure proper fit. 4. Clean and prepare welded surfaces. Prime with two-part catalyzed primer. Apply sealers and corrosion protection materials, as necessary. Do not combine paint systems. Refer to paint manufacturers recommendations. Reinstall all related panels and components.
36
CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
37
CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
38
CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
CAVALIER/SUNFIRE FRONT
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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
40
CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
41
CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
42
CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.
REMOVE OR DISCONNECT
1. Remove all related panels and components including the suspension crossmember 2. Locate the two factory welds that secure the cagenut to the lower rail surface. Insert a pry bar between the torque box closeout panel and the lower rail and bend the metal outward to expose the two factory welds (Figure 2). 3. Center punch and drill through the welds with a 10mm (3/8") drill bit. 4. Wrap a wire through the cagenut to keep it from sliding down into the rail. 5. Rotate the damaged cagenut bracket and remove it through the rail slot.
1
1995 General Motors Corporation. All Rights Reserved.
INSTALL OR CONNECT
1. Prep weld areas for installation as noted from the original part. 2. Wrap a wire through the new cagnut and install the cagenut bracket through the rail slot. 3. Position the new cagenut bracket and check fit using body dimensions.
Hidden welds
Notice It may be necessary to temporarily secure the new cagenut bracket to the rail using the crossmember mounting bolt.
FIGURE 2 PRY THE TORQUE BOX CLOSEOUT PANEL O UTWARDS TO EXPOSE FACTORY W ELDS
4. Plug weld the cagenut bracket in place at original locations. 5. Clean and prepare welded surfaces. Prime plug welds using two-part catalyzed primer. 6. Straighten the torque box closeout panel bent outward in step #2 of Remove and Disconnect. 7. Clean and prepare the lower rail surface. Do not combine paint systems. Refer to paint manufacturers recommendations. Apply corrosion protection materials, as necessary. 8. Reinstall all related panels and components. When reinstalling the suspension crossmember, torque all six fasteners to 130 Nm (96 lbs. ft.).