2001 Oldsmobile Aurora 2000 Pontiac Bonneville 2000 Buick LeSabre
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
Floor Replacement Rear 3-16
Rail Replacement Rear 3-18
Rear Rail Sectioning 3-14
Roof Panel Replacement 3-20 Front Wheelhouse Replacement 3-1
Front Lower Rail Sectioning 3-2
(note: all procedures apply to all models, unless otherwise noted)
Front Wheelhouse Replacement

Removal Procedure

1. Remove panels and components as necessary for access. 2. Restore as much of the damage as possible to the factory specifications. 3. Remove all sealers and anti-corrosion materials as necessary. 4. Place a piece of 25 mm (1 in) wide masking tape (Fig. 3-1), on the forward contour of the wheelhouse at the flange where it attaches to the cowl panel. 5. Cut the wheelhouse along the forward edge of the masking tape to leave a 25 mm (1 in) tab extending forward from the cowl panel. (This will provide an overlap for welding the service part to the original wheelhouse, without welding directly to the cowl panel.) 6. Locate, mark, and drill out the factory welds which attach the wheelhouse assembly at the: Upper rail inner panel Cowl panel Radiator support Lower front rails 7. Remove the damaged wheelhouse assembly.

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
ON NEW SERVICE PANEL, CUT TAB OFF
MAKE 25 MM (1 IN) TAB AS SHOWN
DRILL 8 MM (5/16 IN) HOLES EVERY 40 MM (1-1/2 IN) ALONG CUT EDGE
Fig. 3-2 Cut Tab and Drill Holes
Fig. 3-1 Cut wheelhouse 25 mm (1 in) Forward of the Cowl Panel
2001 aurora / 2000 bonneville / 2000 lesabre
Front Lower Rail Sectioning
Sectioning procedures have been developed to help simplify repair of the lower rails provided the majority of damage can be returned to factory specifications. This allows technicians to repair the damaged front section without the need for a complete rail replacement. Sectioning of the lower rail does not require the removal of the power train, though the front cradle must be lowered. To begin, remove all related components and panels. Visually inspect and restore as much of the damage as possible to factory specifications. Also, for right side repair it may be necessary to remove the alternator and air conditioning compressor. NOTICE: Inner and outer sectioning templates are available for the following parts: Left lower rail original part; Right lower rail original part; Left lower rail service part; Right lower rail service part. IT IS VERY IMPORTANT TO USE THE CORRECT TEMPLATE WHEN MARKING LINES FOR CUTTING.
Fig. 3-3 Align Templates and Cut the Lower Rail

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. 3-4 Create Tabs in the Lower Rail
Fig. 3-5 Step the Tabs Inward and Weld Edges Together

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. 3-6 Mark the New Rail
Fig. 3-7 Plug and Stitch Weld the New Rail Section
Outer Door Frame Sectioning
The full body side outer panel comes as a one-piece assembly and can be replaced at factory seams. Any one of these procedures can be performed separately, or in any combination, dependent upon the extent of damage to the vehicle. Sectioning must take place in specified areas only (Fig. 3-8). Left and right service parts are structurally identical but have varied service slot placement in mid rocker areas. Remove front and rear glass when sectioning front pillar and quarter panel. IMPORTANT: When replacing panels that involve servicing stationary glass, refer to GM Service Bulletin 43-10-48 before performing any priming or refinishing.

Aurora

Bonneville

LeSabre

Fig. 3-8 Outer Door Frames
Outer Front Pillar Sectioning
IMPORTANT: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle. 1. Visually inspect and restore as much of the damage as possible to factory specifications. 2. Remove fender, windshield and door. 3. Drill out factory spot welds of upper-outer rail (Fig. 3-9). Remove upper rail and save for reinstallation. 4. Determine sectioning locations. Section in approved areas only (see Fig. 3-8). 5. Mark locations and cut part through outer panel only. 6. Locate factory welds and drill out, noting number and locations of welds (Fig. 3-9). 7. Remove outer panel. 8. Note placement and number of foam baffles for new installation. If baffles are damaged, replacement service parts are available. IMPORTANT: Hinge pillar blocks must be replaced if damaged (Fig. 3-10)

Fig. 3-9 Upper Outer Rail Removal
Fig. 3-10 Hinge Pillar Block
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.
100 MM (4 IN) BACKING PLATE
GAP = ONE AND ONE-HALF TIMES METAL THICKNESS Fig. 3-11 Rocker Sectioning
50 MM (2 IN) BACKING PLATE
GAP = ONE-AND-ONE-HALF TIMES THE THICKNESS OF THE METAL
Fig. 3-12 Backing Plate Windshield Pillar
Fig. 3-13 Plug Weld Service Panel
Outer Center Pillar Sectioning

130 MM

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.

Fig. 3-14 Outer Center Pillar
Fig. 3-15 Outer Center pillar Sectioning Locations
Preparation Of Service Part
1. On the service part, mark a horizontal line in corresponding locations to the original sectioning cut, to leave a gap of one and one-half times the thickness of the metal at the sectioning joint (Fig. 3-16). 2. Cut the outer door frame opening service part along this line. 3. Make vertical cut lines in rocker areas to correspond with original section lines. Leave a gap one-and-one-half times the metal thickness. 4. Cut two 100 mm (4 in) pieces from the unused portion of the service part for backing plates on rockers (Fig. 3-17). Remove the flange on each side of the backing plates so that they will fit behind the sectioning joint. 5. Drill 8 mm (5/16 in) holes for plug welding in the service part in the locations noted from the original panel. 6. Drill holes for plug welding along the sectioning cuts on both the service part and the original panel. Locate these holes approximately 25 mm (1 in) from the edge of the sectioning cuts, spaced 40 mm (1-5/8 in) apart. 7. Apply weld-through primer to mating surfaces prior to assembly.
2001 aurora / 2000 bonneville / 2000 lesabre 3-7

INNER REINFORCEMENT

Fig. 3-16 Inner Reinforcement
100 MM (4 IN.) BACKING PLATE

Fig. 3-17 Backing Plate

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.

Fig. 3-18 Inner Reinforcement

Quarter Panel Sectioning

IMPORTANT: When replacing panels that involve servicing stationary glass, refer to GM Service Bulletin 43-10-48 before performing any priming or refinishing. IMPORTANT: Sectioning must take place in specified areas only. Failure to do so may compromise the structural integrity of the vehicle. 1. Visually inspect and restore as much of the damage as possible to the factory specifications. 2. Remove all related panels and components. 3. Remove all sealers, sound deadeners and anticorrosion materials as necessary. Note placement and number of foam baffles for new installation. If baffles are damaged, replacement service parts are available. 4. Determine sectioning locations (Fig. 3-19). 5. Mark a line and cut in approved sectioning areas. 6. Locate, mark and drill out all factory welds. Note the number and location of welds for installation of the service assembly. 7. Remove damaged panel.
Fig. 3-19 Quarter Panel Cut Locations
1. Cut service part in corresponding locations to fit original cut lines. 2. Create 100 mm (4 in) backing plate on rocker panel from unused portion of service part. 3. Create a 50 mm (2 in) backing plate on upper quarter panel from unused portion of service part (Fig. 3-20).
GAP = ONE AND ONE-HALF TIMES THE THICKNESS OF THE METAL
Fig. 3-20 Quarter Panel Backing Plates 2001 aurora / 2000 bonneville / 2000 lesabre
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.
Fig. 3-21 Prepare Quarter Panel

Fig. 3-22 Install Quarter Panel
Inner Door Frame Sectioning
CAUTION: Sectioning should take place in the specified areas only. The full body-side inner panel (Fig. 3-23) comes as a one-piece assembly and can be replaced at factory seams after removal of outer panel, roof and glass. Any one of these procedures can be performed separately, or in any combination, dependent upon the extent of damage to the vehicle. Left and right service parts are structurally identical but have varied service slot placement in midrocker areas. Remove front and rear glass when sectioning front pillar and quarter panel. IMPORTANT: When replacing panels that involve servicing stationary glass, refer to GM Service Bulletin 43-10-48 before performing any priming or refinishing.
Fig. 3-23 Sectioning Locations
Inner Front Pillar Sectioning
IMPORTANT: Sectioning should be performed only in the recommended areas (see Fig. 3-23). Failure to do so may compromise the structural integrity of the vehicle. 1. Visually inspect and restore as much of the damage as possible to factory specifications. 2. Remove outer panel according to specified directions in removal process. 3. Remove dash, instrument panel, seat and all necessary components to allow access to repair. 4. Locate and follow laser-weld line (1) across Front pillar at lower windshield area (Fig. 3-24). 5. Measure down 50 mm (2 in) and scribe a line parallel to the laser-weld line (2). This is your cut location. 6. At rocker panel, locate sectioning location (3). Scribe a line. Cut through one layer of metal only. NOTICE: Left and right service parts are structurally identical but have varied service slot placement in mid rocker areas. On right side rocker, section at rear of access hole on original panel. Overlap service part 50 mm (2 in) and use access holes as alignment guides. 7. Drill out factory spot welds. 8. Remove damaged panel. 3. Create a vertical line for sectioning rocker (3). Allow space for a 50 mm (2 in) overlap for welding. 4. Notch upper and lower edges of service part to fit behind existing rocker panel, remove tabs. 5. Drill plug weld holes in locations noted from original panel.
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.

Create Service Flange

1. On windshield pillar lower edge, measure forward 25 mm (1 in) from door opening (Fig. 3-16). Scribe a vertical line. 2. Measure forward 190 mm (7-1/2 in) from first scribed line and scribe a second vertical line (2). 3. Cut along vertical markings to laser-weld line (1), to create a flange for welding service part. 4. Cut along laser-weld, outboard of vertical cuts, remove tabs. This creates a 50 mm x 190 mm (2 in x 7-1/2 in) tab (2) for attaching service part to front pillar (Fig. 3-24).
yyy PPP @@@ ,,, y y P P @ @ , , yyy PPP @@@ ,,,

25 MM (1 IN) 1

190 MM (7-1/2 IN)
Preparation of Service Part
1. Locate laser-weld at bottom of windshield pillar area of the service part. This will be the same laser-weld location as the original panel (1). 2. Cut along laser-weld.
Fig. 3-24 Front Pillar Detail
Inner Center Pillar Sectioning (With Outer Panel Removed)
1. Remove seats, carpet and related panels and components. 2. Secure wiring from repair area. 3. Remove inner reinforcement by drilling approximately 8 spot-welds (see Fig. 3-24). 4. Measure down 135 mm (5-5/16 in) from upper-inner reinforcement. Scribe a horizontal cut line. 5. At front door rocker area, scribe a vertical cut line at the specified sectioning location. 6. At rear door rocker area, scribe a vertical cut line at the rear edge of the 50 x 100 mm (2 in x 4 in) oval hole. NOTICE: This may be performed at any of the similar sized holes in the inner panel. 7. Cut on the three scribed lines. 8. Drill out factory spot welds, noting their location for installation of service part. 9. Remove the damaged panel.

135MM (5 5/16 IN)

Fig. 3-25 Center Pillar Reinforcement
Preparing the Service Part
1. Remove inner reinforcement on center pillar (Fig. 3-25). 2. Cut service part at top of 24 mm (1 in) round hole (1) located midway down the center pillar (Fig. 3-26). 3. Cut down 40 mm of the outturned weatherstrip flanges on the center pillar (2). 4. Trim inside corners for flush fit. 5. At front door rocker area, cut service part, allowing for a 50 mm (2 in) overlap to original cut line on inner rocker (Fig. 3-27). 6. Trim a 20 mm x 50 mm (4/5 in x 2 in) tab at top and bottom (1) of sectioned area on service part to allow for a flush fit at pinch welds (Fig. 3-27). 7. In rear door, inner rocker area, trim tabs and use the front edge of the next 50 mm x 100 mm (2 in x 4 in) oval hole as an alignment guide to create a 50 mm (2 in) overlap (2). 8. Drill plug weld holes in sectioning areas, 25 mm (1 in) back from cut line on rocker and pillar area. 9. Drill 8 mm (5/16 in) plug weld holes as noted from original locations.

yy PP @@ ,, y P @ , yy PP @@ ,, yyyyy PPPPP @@@@@ ,,,,, yyyy PPPP @@@@ ,,,, yyyy PPPP @@@@ ,,,, yyyy PPPP @@@@ ,,,,
Fig. 3-26 Center Pillar Detail
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.
Fig. 3-27 Center Pillar Installation
Full Outer Wheelhouse Sectioning

LASER-WELD LINE

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.
Fig. 3-28 Outer Wheelhouse Removal

LASER WELD

TRIM TABS

yy PP @@ ,, yy PP @@ ,,

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

Floor Replacement - Rear
IMPORTANT: The rear floor service part comes pre-cut to the appropriate size for sectioning. It does not need to be modified. 1. Remove all panels and components as necessary for access. 2. Restore as much of the damage as possible to factory specifications. 3. Locate, mark, and drill out all factory welds rearward of the crossbar connecting the rear rails to the floor panel. 4. Locate and drill out the welds attaching the rear floor panel to the wheelhouse. 5. Cut the rear floor along the rearward edge of the crossbar (Fig. 3-30). 6. Take care not to cut the crossbar or the rear rails. 7. Remove the damaged section of the rear floor panel.

CUT AT REAR EDGE OF CROSSBAR

Fig. 3-30 Rear Floor

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.

Fig. 3-31 Rear Floor

Rail Replacement Rear
The rear rails are available as a complete assembly. Each assembly consists of an outer panel, two inner reinforcements and all necessary component mounting brackets (Fig. 3-32). The outer panel and rear mounting brackets are also available separately to facilitate sectioning. Additionally, there is a crossbar that connects the two rear rails for added strength and rigidity. The rear rail can be removed by drilling out all factory welds and letting it drop down. When doing so, the outboard flange at the forward end of the rail must be cut in one location or bent upward. The bottom flange of the crossbar must be bent downward. The rear rail can then be lowered from the vehicle.

REAR CROSSBAR

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.

Fig. 3-32 Rear Rails

Fig. 3-33 Cut Rear Rail
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.
Fig. 3-34 Cut and Remove Flanges
Fig. 3-35 Step Tabs Inward
Fig. 3-36 Stitch Weld Seams

Roof Panel Replacement

The roof panel is attached to the steel roof structure with beads of adhesive on the sides and spot-welds on the windshield and back-glass flanges. Replacement of the roof panel can be performed using conventional procedures, however, the windshield and back glass must be removed (Fig. 3-37). IMPORTANT: Use care when cutting to protect adjacent panels. Cut inboard of the roof structure. 1. Visually inspect and restore as much of the damage as possible to the factory specifications. 2. Remove all related panels and components. 3. Remove the following: Sealers Sound deadeners Anti-corrosion materials 4. Locate and mark all factory welds. 5. Drill all factory welds. Note the number and location of welds for installation of the service assembly. 6. Cut the adhesive with an appropriate tool after removing the panel. 7. Remove the remaining portion of the original panel.
Fig. 3-37 Spot-Welded Front and Rear Edge
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

Underbody Dimensions

Aurora/Bonneville/LeSabre

HEIGHT

B A LENGTH

C 888 D 3257 E F G

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

Location A B C D E F G

Length 3257

Width 492

Height 577
All dimensions are measured in millimeters, from a zero line, center line, and a common datum. All dimensions are symmetrical, unless otherwise specified.
Body Side Dimensions 2001 Aurora

824 WIDTH

HEIGHT 970

946 DATUM LINE

B C D E F

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

Length 1101 2090

Width 824 806

Height 653 946
Body Side Dimensions 2000 Bonneville

WIDTH 822

DATUM LINE

Length 1101 2087

Height 653 978
Body Side Dimensions 2000 LeSabre

809 824

978 DATUM LINE