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Inner/Outer Door Frame Sectioning Quarter Panel Sectioning 3-9 Full Outer Wheelhouse Sectioning 3-15 Outer Center Pillar Sectioning 3-7 Inner Center Pillar Sectioning (With Outer Panel Removed) 3-13 Outer Front Pillar Sectioning 3-5 Inner Front Pillar Sectioning 3-12
Installation Procedure
1. Clean and prepare surfaces to be welded. 2. Cut the flange off the service part that is normally welded to the cowl panel (Fig. 3-2). 3. Drill 8 mm (5/16 in) holes for plug welding in the locations noted from the original assembly. Also drill holes for plug welding every 40 mm (1-1/2 inches) along the cut edge to be attached to the tab remaining from the original assembly. CAUTION: Watch for flammable materials when welding to the interior panels of the vehicle. 4. Position the wheelhouse assembly using three-dimensional measuring equipment. 5. Plug weld the wheelhouse as necessary. 6. Clean and prepare all bare metal surfaces. Apply as necessary: Sealers and anti-corrosion materials Sound deadeners Two-part catalyzed primer Top-coat
RT
DRILL 8 MM (5/16 IN) HOLES EVERY 40 MM (1-1/2 IN) ALONG CUT EDGE
3-1
Remove or Disconnect
1. Align the appropriate inner and outer templates on the damaged lower rail and mark lines as indicated. There are two templates for the left rail and two templates for the right rail (Fig. 3-3). 2. Cut the rail along the marked lines and remove the damaged portion of the rail (Fig. 3-3). 3. Cut and remove approximately 20 mm (3/4 in) of the outboard and downward turned flanges of the lower rail. Cut a 5 mm gap approximately 20 mm (3/16 in) along the corners of the lower rail to create tabs. (Fig. 3-4) 4. Step the tabs inward to allow the replacement lower rail section to fit over the original rail (Fig. 3-5). Weld all four edges together.
Fig. 3-5 Step the Tabs Inward and Weld Edges Together
3-2
Install or Connect
1. Align the inner and outer templates on the service part and mark lines as indicated (Fig. 3-6). There are two templates for the new left rail and two templates for the new right rail. 2. Cut the service part along the marked lines and discard the unused section. Drill plug weld holes according to the template. 3. Position the modified service part over the stepped tabs of the original rail, allowing 20 mm (3/4 in) of overlap. Plug weld each hole and stitch weld along the entire joint (Fig. 3-7). When stitch welding, make 1-inch welds along the seam with 1-inch gaps between. Then go back and complete the stitch weld along the seam. 4. Clean and prepare welded surfaces. Apply sealers and corrosion protection materials, as necessary. 5. Prime with two-part catalyzed primer. IMPORTANT: Prior to refinishing, refer to the publication GM4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturers recommendations. 6. Re-install all related components.
Fig. 3-7 Plug and Stitch Weld the New Rail Section
3-3
Aurora
Bonneville
LeSabre
3-4
3-5
Installation Procedure
1. Cut service part in corresponding locations to fit original cut lines. Leave a gap of one-andone-half times the metal thickness of sectioning joint. 2. Create 100 mm (4 in) backing plate on rocker panel from unused portion of service part (Fig. 3-11). 3. In windshield pillar area, create 50 mm (2 in) backing plate from unused portion of service part (Fig. 3-12). Remove flange from backing plates for proper fit behind sectioning joint. 4. Drill 8 mm (5/16 in) plug weld holes in service part according to original locations as noted, and in original panel where parts overlap backing plate (Fig. 3-12). 5. Apply weld-through primer to mating surfaces prior to assembly. 6. Weld backing plates into position on body. IMPORTANT: Replace hinge pillar blocks prior to welding outer panel. 7. Position service part on vehicle. Clamp in place. Check for proper fit. 8. Plug weld accordingly. Stitch weld along the entire sectioning joint. Make 25 mm (1 in) welds along the seam with 25 mm (1 in) gaps between (Fig. 3-13), then go back and complete the stitch weld to ensure structural integrity of the vehicle. 9. Install upper rail assembly. 10. Clean and prepare all welded surfaces. 11. Install insulating foam as necessary in areas noted from original baffle locations. IMPORTANT: Prior to refinishing, refer to the publication GM4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturers recommendations. 12. Refinish as necessary.
GAP = ONE AND ONE-HALF TIMES METAL THICKNESS Fig. 3-11 Rocker Sectioning
3-6
Removal Procedure
IMPORTANT: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle. 1. Measure 130 mm (7-11/16 in) down from top edge of center pillar top crease. Mark and scribe a line. This is the cut location (Fig. 3-14). 2. Cut center pillar at cut line. Use caution not to cut inner reinforcement (Fig. 3-15); the inner reinforcement will be used for a backing plate. 3. Drill out factory welds (Fig. 3-14). 4. Create cut lines on rocker within approved sectioning locations (Fig. 3-15). Cut the rocker vertically along the sectioning lines. NOTICE: Center pillar is welded and bonded above hinges. 5. Use caution to not damage inner reinforcement when removing outer panel. Remove damaged part. 6. Note placement and number of foam baffles for new installation. If baffles are damaged, replacement service parts are available.
INNER REINFORCEMENT
Installation Procedure
1. Install sleeves on vehicle at rocker areas. Inner reinforcement will be used as a backing plate on center pillar. 2. Position part on vehicle. Clamp in place and check for proper fit (Fig. 3-18). 3. Remove service part. Apply urethane to center pillar reinforcement in areas corresponding to original locations. CAUTION: Leave a one-inch gap between urethane adhesive and any weld areas. 4. Replace hinge blocks. 5. Align part and clamp in place. Check fit. 6. Make 25 mm (1 in) stitch welds along the seam with 25 mm (1 in) gaps between them, then go back and complete the stitch weld. This will create a solid joint with minimal heat distortion. 7. Clean and prepare welded surfaces. IMPORTANT: Prior to refinishing, refer to the publication GM4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturers recommendations. 8. Prime with two-part catalyzed primer. 9. Refinish as necessary.
3-8
Fig. 3-20 Quarter Panel Backing Plates 2001 aurora / 2000 bonneville / 2000 lesabre
3-9
Installation Procedure
1. Position service part on vehicle. Check fit using body dimensions. 2. Temporarily remove service part to install GM P/N 12399117 Sealing Strip between outer wheelhouse and gas door pocket. 3. Weld backing plates into position. 4. Drill 8 mm (5/16 in) plug weld holes as noted from original locations. Also drill plug weld holes along the sectioned areas of the service part. These should be located 25 mm (1 in) from the edge of the cuts (Fig. 3-21). 5. Position service part and clamp in place. 6. Stitch weld along entire sectioning joint. Make 25 mm (1 in) welds along the seam with 25 mm (1 in) gaps between them, then go back and complete the stitch weld. This will create a solid joint with minimal heat distortion. 7. Plug weld in original locations (Fig. 3-22). 8. Clean and prepare all welded surfaces. 9. Install all sealers, sound deadeners and anti-corrosion materials as necessary. Install acoustic foam baffles as noted from original part. IMPORTANT: Prior to refinishing, refer to the publication GM4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturers recommendations. 10. Apply two-part catalyzed primer. 11. Refinish as necessary. 12. Install all related panels and components.
3-10
3-11
Installation Procedure
1. Drill plug weld holes in front pillar flange, spaced 40 mm (1-1/2 in) apart. 2. Drill plug weld holes at rocker overlap. 3. Prepare mating surfaces. IMPORTANT: Prior to refinishing, refer to the publication GM4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturers recommendations. 4. 5. 6. 7. Prime with two-part catalyzed primer. Position part on vehicle and clamp in place. Check fit. Plug weld accordingly. Stitch weld at front pillar, at rocker-inner and at sectioning locations. 8. Clean and prepare all welded surfaces. 9. Refinish as necessary. 10. Install all related panels and components.
3-12
INNER REINFORCEMENT
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2 1
3-13
Installation Procedure
1. Apply two-part catalyzed primer to center pillar area and service part. 2. Clamp part in position. Check for fit. 3. Spot-blast plug weld areas. 4. Plug weld as necessary. 5. Complete stitch welds at section areas. 6. Clean and prepare all welded surfaces. 7. Reinstall inner reinforcement (3) (Fig. 3-27). IMPORTANT: Prior to refinishing, refer to the publication GM4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturers recommendations. 8. Refinish as necessary. 9. Install all related panels and components.
3-14
50 MM (2 IN)
50 MM (2 IN)
1. Locate horizontal laser-weld line in upper quarter area (Fig. 3-28). 2. Measure down 50 mm and scribe a cut line. 3. On vehicle rocker area, cut 50 mm (2 in) and scribe a cut line. 4. On vehicle rocker area, cut 50 mm (2 in) rearward of 50 mm x 100 mm (2 in x 4 in) access hole, allowing for a 50 mm (2 in) overlap. 5. Cut panel at marked locations. 6. Drill out factory welds. Note the number and location of welds. 7. Remove damaged panel.
Installation Procedure
Fig. 3-28 Outer Wheelhouse Removal
LASER WELD
TRIM TABS
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Fig. 3-29 Outer Wheelhouse Service Panel
1. Locate laser-weld line on service part (Fig. 3-29). 2. Cut along laser-weld line. 3. In specified sectioning location of rocker area, create a vertical cut line. Allow for a 50 mm (2 in) overlap of service part to rocker area. 4. Cut service part along marked locations. 5. Trim a 20 mm x 50 mm (4/5 in x 2 in) tab at top and bottom of section area of service part to allow for a flush fit at pinch welds. 6. Drill plug weld holes as noted from original panel. 7. Install new part and clamp in place. Check for fit. IMPORTANT: Prior to refinishing, refer to the publication GM4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturers recommendations. 8. Apply two-part catalyzed primer. 9. Make 25 mm (1 in) stitch welds along the seam with 25 mm (1 in) gaps between them, then go back and complete the stitch weld. This will create a solid weld with minimal heat distortion. 10. Clean and prepare all welded surfaces. 11. Use a brushable seam sealer on inside seam. 12. Install all related panels and components.
CUT LINE
3-15
3-16
Installation Procedure
1. Position the service floor section and clamp in place. Allow the floor service assembly to overlap the original floor on top of the rear crossbar. 2. Drill 8 mm (5/16 in) holes for plug welding in the service panels necessary in the locations noted from the original floor panel. 3. Drill holes approximately 40 mm (1-5/8 in) apart where the new floor section attaches to the rear rail and crossbar flanges. 4. Plug weld as necessary (Fig. 3-31). 5. Clean and prepare all bare metal surfaces. IMPORTANT: Prior to refinishing, refer to the publication GM4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturers recommendations. 6. Apply as necessary: Sealers Anti-corrosion materials Two-part catalyzed primer Top coat 7. Install the panels and components previously removed for access.
3-17
REAR CROSSBAR
Removal Procedure
Sectioning procedures can be used to repair the rear rail if just the portion rearward of the crossbar is damaged. When sectioning, use the rear rail outer panel P/N 25552778 or 25552779. 1. Visually inspect and restore as much of the damage as possible to factory specifications. 2. Remove all related panels and components. 3. Cut the rear rail along the rearward flange of the crossbar and continue this cut around the rear rail (Fig. 3-33). 4. Drill out the factory welds on the end of the rear rail inner reinforcement. 5. Remove the damaged portion of the rear rail. 6. Either move the end of the rear rail inner reinforcement forward or cut this part and remove it from the rear rail.
FR
3-18
Installation Procedure
1. Use the original part as a guide to mark a line on the new rail 35 mm (1-3/8 in) forward of the cut made to the original part. This will provide an overlap for welding the new section. 2. Cut the new rail along the marked lines and discard the unused section. 3. Cut and remove approximately 35 mm (1-3/8 in) of the flanges on the new rail (Fig. 3-34). 4. Cut a 5 mm gap approximately 35 mm (1-3/8 in) along the corners of the new rail to create tabs. 5. Step the tabs inward to allow the new rail to fit inside the original rail (Fig. 3-35). 6. Position the modified new rail inside the original rail, allowing 35 mm (1-3/8 in) of overlap. 7. Check the position of the new rear rail section using body dimensions and plug weld in three locations long all three sides of the rail. 8. Stitch weld along the entire seam and replace factory welds, as appropriate (Fig. 3-36). IMPORTANT: Prior to refinishing, refer to the publication GM4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturers recommendations. 9. Clean and prepare welded surfaces. 10. Apply sealers and corrosion protection materials, as necessary. 11. Prime with two-part catalyzed primer. 12. Install all related components.
FR
3-19
Installation Procedure
1. Clean and prepare the attaching surfaces for welding. 2. Drill 8 mm (5/16 in) for plug welding along the windshield and back glass edges of the service panel as noted from the original panel (Fig. 3-38). Drill the holes for plug welding along the front and rear flanges every 40 mm (1-1/2 in). 3. Position the service panel. 4. Check the fit. IMPORTANT: Prior to refinishing, refer to the publication GM4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturers recommendations. 5. Install the panel using one-part windshield urethane to side flanges. 6. Plug weld accordingly. 7. Clean and prepare all welded surfaces. 8. Prime with two-part catalyzed primer. IMPORTANT: When replacing panels that involve servicing stationary glass, refer to GM Service Bulletin 43-10-48 before performing any priming or refinishing. 9. Install all related panels and components.
Fig. 3-38 Adhesively Bonded Sides
3-20
Underbody Dimensions
Aurora/Bonneville/LeSabre
504
526
430
496
553
540
348
358
577
469
552
HEIGHT
B A LENGTH
Description 28 mm gage nut 16 mm x 22 mm slot 10.5 mm x 12.5 mm hole 16 mm gage hole 23 mm gage hole 10 mm gage hole 19 mm x 25 mm gage hole
427
Location A B C D E F G
All dimensions are measured in millimeters, from a zero line, center line, and a common datum. All dimensions are symmetrical, unless otherwise specified.
577
492
WIDTH
3-21
824 WIDTH
822
806
HEIGHT 970
653
LENGTH
Description 13 mm gage hole 19 mm gage hole Upper hinge hole Striker lock attachment Lower hinge bolt hole Clinch nut lock strike attachment
Location A B C D E F
All dimensions are measured in millimeters, from a zero line, center line, and a common datum. All dimensions are symmetrical, unless otherwise specified.
3-22
806
HEIGHT
970
LENGTH
Description 13 mm gage hole 19 mm gage hole Upper hinge hole Striker lock attachment Lower hinge bolt hole Clinch nut lock strike attachment
Location A B C D E F
All dimensions are measured in millimeters, from a zero line, center line, and a common datum. All dimensions are symmetrical, unless otherwise specified.
3-23
824 WIDTH
806
HEIGHT 970
653
LENGTH
Description 13 mm gage hole 19 mm gage hole Upper hinge hole Striker lock attachment Lower hinge bolt hole Clinch nut lock strike attachment
Location A B C D E F
All dimensions are measured in millimeters, from a zero line, center line, and a common datum. All dimensions are symmetrical, unless otherwise specified.
3-24