Cavalier Sunfire Despiece Chasis

TABLE OF CONTENTS
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 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
CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

1995 General Motors Corporation. All Rights Reserved.
1. PANEL IDENTIFICATION
TPO on Cavalier; RIM on Sunfire

1. PANEL IDENTIFICATION
TPO on Cavalier and Sunfire Sedan; RIM on Sunfire Coupe
KEY TO COMPONENTS:
Reinforced injected molded (RIM) plastic or thermoplastic olefin (TPO) High-strength low-alloy (HSLA) steel parts
2. RADIATOR SUPPORT ASSEMBLY

The radiator support assembly (Figure 2-1) consists of nine major components: four upper and five lower. The center reinforcement and left and right extensions are preassembled. This helps the technician to properly align the front structure. The upper support is serviced separately for efficient installation. The lower support is held in place with six bolts. It attaches to four brackets that are welded to the lower rails. These brackets are available as part of the lower rail service assembly or they can be ordered separately.
Pre-assembled service part
Bolt-on lower support
FIGURE 2-1 RADIATOR SUPPORT A SSEMBLY
2. RADIATOR SUPPORT ASSEMBLY

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 panels. 5. Remove the damaged panels in the radiator support assembly
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.
Install or Connect

3. FRONT WHEELHOUSE ASSEMBLY

Replacement of the wheelhouse assembly requires the removal of the upper outer rail reinforcement (Figure 3-1). Removal of this panel allows access to the welds that secure the strut cap to the cowl plenum. The left and right front upper rails are part of the wheelhouse service assembly. If damage is limited to these panels, they can be ordered and replaced individually (Figure 3-2). Fender mounting holes are pre-drilled on the upper rails, but lack the formed areas found on the original rails. Spacers can be used to properly position and fit the fender. In addition, the front portion of the aprons and the battery tray can be ordered and replaced separately.
FIGURE 3-1 UPPER OUTER RAIL REINFORCEMENT
J11943.2
FIGURE 3-2 FRONT WHEELHOUSE ASSEMBLY
3. FRONT WHEELHOUSE ASSEMBLY
1. 2. 3. 4.
FIGURE 3-3 INSTALL NEW WHEELHOUSE ASSEMBLY
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. 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.
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.
Install or Connect

4. FRONT LOWER RAIL ASSEMBLY

Lower Rail Sub-Assembly
Replacement of the engine compartment lower rail assemblies has been improved on the Cavalier and Sunfire through the use of a sub-assembly service part. This helps to simplify ordering, stocking and replacement procedures. The lower rail service part comes as a complete assembly, including all brackets and reinforcements (Figure 4-1). Bumper mounting brackets can be replaced separately.
Bumper mounting brackets can be ordered separately
FIGURE 4-1 LOWER RAIL SUB-ASSEMBLY

1. Disconnect and support the engine and transmission with suitable equipment. Note that it is not necessary to entirely remove the powertrain when servicing the lower rails. 2. Remove all other related panels and components, including the suspension and crossmember.
Caution Loosen and protect the fuel and brake lines during rail replacement.
3. Visually inspect and restore as much of the damage as possible to factory specifications. 4. Remove sealers, sound deadeners and corrosion materials as necessary. 5. Locate, mark and drill out factory welds securing the front suspension support to the lower rail (Figure 4-2). Note the number of welds for installation of the service assembly.
Notice Inspect the condition of the front suspension support where the crossmember is mounted. If the cagenut brackets have separated from the front suspension support, that assembly must also be repaired or replaced (refer to page 11)
6. Locate, mark and drill out factory welds along the lower flanges of the rail securing it to the cowl. Then separate the lower rail from the floor extensions in the torque box area (Figure 4-3). 7. Locate, mark and drill out all remaining factory welds. 8. Remove the damaged front lower rail. If the front suspension support is not removed, the damaged rail must be pried out.
FIGURE 4-2 DRILL OUT FACTORY WELDS SECURING THE FRONT SUSPENSION SUPPORT TO THE LOWER RAIL


Caution When servicing the lower rail, 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 floor pan and the foam pad underneath the carpet.
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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FIGURE 4-3 SEPARATE THE LOWER RAIL FROM THE COWL AND FLOOR EXTENSIONS (UNDERBODY VIEW )
5. FRONT SUSPENSION SUPPORT ASSEMBLY (#1 BAR)

The front suspension support ties the lower rails together across the lower portion of the cowl. Located on this panel assembly are two of the six mounting locations for the suspension crossmember (Figure 5-1). The panel assembly comes complete with the cagenut brackets installed. The cagenut brackets can also be ordered and replaced separately. When the front lower rails are repaired or replaced, the front suspension support should be inspected for the following: Surface deformation in the suspension crossmember mounting areas Any separation in the welds securing the cagenut brackets to the support If either of these conditions exist, the cagenut brackets or front suspension support assembly must be replaced.
FIGURE 5-1 FRONT SUSPENSION SUPPORT ASSEMBLY (#1 B AR)

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5. FRONT SUSPENSION SUPPORT (#1 BAR)

FULL REPLACEMENT OF THE FRONT SUSPENSION SUPPORT ASSEMBLY
1. Remove all related panels and components, including the linkage that passes through the front suspension support panel. 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 factory welds on the damaged assembly. Note the number of welds for installation of the service assembly. 5. Remove the damaged suspension support assembly. 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.
Install or Connect
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FIGURE 5-2 CUT A WINDOW IN THE FLOOR
5. FRONT SUSPENSION SUPPORT (#1 BAR)

REPLACEMENT OF THE FRONT SUSPENSION SUPPORT CAGENUT BRACKETS
If damage permits, it is possible to replace just the cagenut brackets. The replacement procedure is similar to that used to replace bodymount cagenut assemblies on full-frame vehicles. This is done by cutting a window in the floor pan to access the cagenut bracket. 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.
Install or Connect
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.
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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6. DOOR FRAME OPENING

The side door frame openings feature a unique modular build sub-assembly design to improve manufacturing quality. They are composed of numerous individual components that are pre-assembled and then attached to the vehicle as a single unit. The door frame can be replaced as a complete unit or various segments of it can be sectioned, which is usually much faster and more cost effective. However, there are some key structural areas where sectioning should not take place (Figures 6-1 and 6-2). Since left and right door frame openings are only available as complete assemblies, service parts for sectioning must be cut from the complete assembly and modified as necessary.
FIGURE 6-1 COUPE DOOR FRAME OPENING (SECTIONING SHOULD NOT TAKE PLACE IN THE SHADED AREAS)
FIGURE 6-2 SEDAN DOOR FRAME OPENING (SECTIONING SHOULD NOT TAKE 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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DOOR FRAME OPENING FULL REPLACEMENT PROCEDURE
1. Remove all related panels and components including the roof panel and upper outer rail reinforcement. 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 door frame opening.
Install or Connect
FIGURE 6-3 INJECT EXPANDABLE FOAM INTO THE A PILLAR AND APPLY SEAM SEALER
TO THE JOINT AT THE ROOF LINE
FIGURE 6-4 APPLY SEALER TO THE INNER COWL PLENUM
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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LOWER FRONT HINGE PILLAR SECTIONING PROCEDURE
1. 2. 3. 4. 5. 6. 7. 8. Sectioning is performed on the lower front hinge pillar between the two hinge mounting locations. The hinge pillar inner reinforcement on the service part is used as a backing plate when welding the new section in place. 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.
FIGURE 6-5 REMOVE THE ACCESS PANEL ON THE FRONT LOWER RAIL OUTER REINFORCEMENT
FIGURE 6-6 CUT AND PRY OUTER REINFORCEMENT
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9. Drill out the 4 welds attaching the hinge pillar to the inner reinforcement above the cut line. Remove the remaining section of the inner reinforcement. (Figure 6-7)
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.
FIGURE 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.
FIGURE 6-8 POSITION THE NEW DOOR FRAME SECTION

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6. Stitch weld along the entire hinge pillar sectioning joint. 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. Straighten the upper outer rail reinforcement and weld seam.
Notice Leave a gap at the forward edge of the baffle to allow for proper water drainage.
8. Apply a full-bodied caulk along the surface of the baffle to ensure a proper seal with the inner cowl plenum (Figure 6-9). 9. Complete all other welds and sectioning procedures as necessary. 10. 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 6-9 APPLY SEALER TO THE INNER COWL PLENUM
DOOR FRAME OPENING GENERAL SECTIONING PROCEDURES
When sectioning areas other than the hinge pillar, a 100mm (4") backing plate must be used behind the joint to ensure a solid and secure weld in areas where there is no inner reinforcement. Backing plates can usually be cut from the unused portion of the service part or the damaged section of the door frame opening.
Notice There are some key areas where sectioning should not take place (Figures 6-1 and 6-2 on page 14). Sectioning in these areas may compromise the structural integrity of the vehicle.
Also, the rocker panel can be replaced in its entirety when the quarter panel has been removed.
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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. Cut the door frame opening where it is to be sectioned. Do not damage any inner panels or reinforcements. 5. Locate, mark and drill out all necessary factory welds. Note the number of welds for installation of the service part. 6. Remove the damaged section of the door frame opening. 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.
1. 2. 3. 4.
Install or Connect
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 BACKING PLATE AND PLUG WELD THE NEW PANEL

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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.
FIGURE 7-1 SEDAN DOOR A SSEMBLY
FIGURE 7-2 COUPE DOOR ASSEMBLY
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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.
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.
Center roof support
FIGURE 8-1 ROOF A SSEMBLY

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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.
COUPE QUARTER PANEL REPLACEMENT

1. Remove all related panels and components including the modular side glass and close-out molding.
Notice The quarter window close-out molding is retained with two-sided tape and urethane. Use the E-Z Strip Molding Tool (part # 217-80003) to remove this molding (call 1-800-GM-TOOLS).
2. 3. 4. 5. Visually inspect and restore as much of the damage as possible to factory specifications. Remove sealers, sound deadeners and corrosion materials as necessary. Mask the rear window lace and glass to protect them from possible damage. Locate, mark and drill out all accessible factory welds on the quarter panel assembly. Note the number of welds for installation of the service assembly.
Gutter extension
FIGURE 9-1 COUPE QUARTER PANEL A SSEMBLY
Gutter extension
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FIGURE 9-2 SEDAN QUARTER PANEL ASSEMBLY
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.
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.
Install or Connect
FUEL FILLER NECK
Care must be taken to ensure that the fuel filler neck is properly sealed when replacing the right quarter panel. Use SPO Sealing Strip (Part #12395952) between the quarter panel and fuel filler neck. Install using the provided instructions.
FIGURE 9-3 CUT ACCESS HOLE TO THE DRIP RAIL

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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.
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).
FIGURE 9-4 CUT ACCESS HOLE TO THE DRIP RAIL

25mm (1") tab
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FIGURE 9-5 CREATE A 25MM (1") T AB FROM THE ORIGINAL QUARTER PANEL
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.
FIGURE 9-6 TRIM THE SERVICE PART
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.
FIGURE 9-7 DRILL PLUG WELD HOLES IN THE SERVICE

ASSEMBLY
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).
FUEL FILLER NECK
Care must be taken to ensure that the fuel filler neck is properly sealed when replacing the right quarter panel. Use GM Part #12399117 between the quarter panel and fuel filler neck. Install using the provided instructions.
FIGURE 9-8 APPLY SEAM SEALER TO THE JOINT WITH THE ROOF

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10. OUTER REAR WHEELHOUSE

REAR WHEELHOUSE SECTIONING PROCEDURE
Beltline reinforcement
The outer rear wheelhouse (Figures 10-1 and 10-2) is repaired by sectioning when damage to the rest of the panel is minimal. Coupe models have a beltline reinforcement that creates unique service concerns. Therefore, templates have been developed to ensure proper wheelhouse sectioning on coupe models. It is recommended that the service part be prepared before removing the damaged section of the panel from the vehicle. This will help you become familiar with the procedure and know exactly where to cut the damaged panel for a better fit of the new section.
Prepare the Service Part
FIGURE 10-1 OUTER REAR WHEELHOUSE (COUPE)
1. Apply a strip of 20mm (3/4") masking tape along the vertical surface of the wheelhouse radius to form a welding flange. 2. On coupe models, align the appropriate template over the gage holes according to the template instructions. 3. On sedan models, cut along the top edge of the tape. On coupe models, cut along the top edge of the tape and at the radius of the wheelhouse as indicated on the template (Figure 10-3). 4. Remove the excess portion of the wheelhouse.
FIGURE 10-2 OUTER REAR WHEELHOUSE (SEDAN)
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.
Trimmed according to template
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Cut along top edge of tape
FIGURE 10-3 APPLY TAPE AND CUT THE SERVICE PART
10. OUTER REAR WHEELHOUSE

5. Apply a strip of 20mm (3/4") masking tape along the horizontal surface of the wheelhouse radius. 6. Cut along the outboard side of the masking tape to create a tab for the weld flange on the new wheelhouse section (Figure 10-4). On coupe models, cut the portion of the wheelhouse under the beltline reinforcement from inside the wheelhouse. Simply connect the two cut lines on either side of the reinforcement. 7. Remove the damaged section of the wheelhouse.
20mm(34") tab
FIGURE 10-4 APPLY TAPE, CUT AND REMOVE DAMAGED PORTION OF WHEELHOUSE
Install or Connect
FIGURE 10-5 WELD THE NEW WHEELHOUSE SECTION
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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11. REAR RAIL

The left and right rear rails are available as complete sub-assemblies and can be replaced in their entirety similar to past model procedures. However, sectioning can be used to simplify repairs if damage is limited to the rear 600mm (24") of the rail. Templates and instruction sheets are packaged with the parts to facilitate service. When replacing a rail in its entirety, the weld flange that mates with the wheelhouse must be bent upwards. The service assembly is supplied with this flange in a horizontal position (Figure 11-1). It is recommended that the service part be prepared before removing the damaged section of the rail from the vehicle. This will help you become familiar with the procedure and know exactly where to cut the damaged rail for a better fit of the new section. It will also help you locate the rear rail inner reinforcement.
REAR RAIL SECTIONING PROCEDURE

Prepare the Service Part
1. Invert the service part and secure it to a bench for cutting. 2. Align the appropriate template on the underside of the rail. Use a center punch or an awl to mark the rail by punching through the template. Remove the template and connect the dots with a straight edge and scribe the cut line.
Notice The cut lines for the left and right sides are in different positions. Make sure to use the appropriate template. Do not damage the template since it must also be used to mark the original rail. Attach it with a non-permanent spray adhesive such as 3Ms Repositionable Adhesive (part #6091).
3. Cut through the outer panel and inner reinforcement along the line and remove the excess portion of the service part. 4. Drill out the welds attaching the inner reinforcement to the outer panel (typically three welds). Remove the inner reinforcement.
Service assembly supplied with horizontal wheelhouse flange
Service assembly with wheelhouse flange bent upwards for installation
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FIGURE 11-1 REAR RAIL ASSEMBLY
11. REAR RAIL

"Final" cut line
FIGURE 11-2 CUT AND REMOVE THE DAMAGED SECTION OF THE REAR RAIL
1. Remove all related panels and components including the fuel tank, fuel filler neck and exhaust system. 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. Align the appropriate template on the underside of the rail. Use a center punch or an awl to mark the rail by punching through the template. Remove the template and connect the dots with a straight edge and scribe the cut line. 5. Locate, mark and drill out the factory welds rearward of the marked cut line, including those securing the rear rail inner reinforcement to the outer panel. Do not drill through the inner reinforcement (Figure 11-2). 6. Cut the rail along the rough cut line. Remove the damaged section of the rear rail. 7. Separate the side walls of the inner reinforcement from the outer panel of the rail by slightly prying the reinforcement inwards. 8. Cut the sides of the rail outer panel along the final cut line, taking care not to damage the inner reinforcement. Cut along the bottom of the outer panel approximately 3/4 of the metal thickness deep.
Notice Be careful not to cut the inner reinforcement. This reinforcement will act as a backing plate when welding the new rail section in place.
9. Bend the rail down and up 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 11-3)
FIGURE 11-3 LEAVE INNER REINFORCEMENT EXTENDING FROM ORIGINAL RAIL

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11. REAR RAIL

Install or Connect
1. Prepare mating surfaces and position the service part, allowing it to slide over the inner reinforcement extending from the original rail section. Check fit using body dimensions and plug weld accordingly with frequent measurements to ensure proper fit.
Notice 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 be necessary to install backing plates on either side of the original rail above the inner reinforcement. These can be cut from the unused inner reinforcement of the service part. Drill holes and plug weld the backing plates in place (Figure 11-4).
5. Stitch weld along the entire joint. 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.
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.
6. 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 11-4 INSTALL BACKING PLATES AND WELD NEW SECTION
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12. REAR FLOOR ASSEMBLY

Sectioning procedures are used to repair the rear floor. The rear floor is sold as an assembly that includes the lower rear rails and crossmember. The damaged rails must be cut so that the new rail sections will properly mate with the original rails and inner reinforcement. Templates and procedures are included with the rear floor service assembly. Keep the following guidelines in mind when performing this procedure: Overlap the original floor pan a minimum of 25mm (1") with the service assembly floor pan. Create a butt joint when mating the lower rails. Use the original rail inner reinforcements as backing plates when welding the service assembly. The rear rail inner reinforcements are at different lengths in the left and right rails (Figure 12-1). There are 4 templates to facilitate the sectioning procedure: left rail, right rail, left floor and right floor.
REAR FLOOR ASSEMBLY SECTIONING PROCEDURE
FIGURE 12-1 REAR RAIL INNER REINFORCEMENTS

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1. 2. 3. 4.
FIGURE 12-2 CUT AND REMOVE THE DAMAGED SECTION OF THE REAR FLOOR PAN AND RAILS
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).
32

7. Trim the floor pan to expose the rear rail inner reinforcements by cutting along the final cut line, taking care not to damage the rails or reinforcements.
Notice Only cut the floor pan. Do not cut through the rear rails or inner reinforcements. These reinforcements will act as backing plates when welding the new rail section in place.
Rear rail "rough" cut line
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).
Rear rail "final" cut line
FIGURE 12-4 LEAVE THE INNER REINFORCEMENT EXTENDING

33
FIGURE 12-5 PREPARE THE SERVICE ASSEMBLY

1. Align the templates in the appropriate locations on the service assembly. Use a center punch or an awl to mark the assembly by punching through the template along the service cut line on the floor pan and the final cut line on the rails. Remove the templates, connect the dots with a straight edge and scribe the cut lines. 2. Connect the left and right floor pan service cut lines around the forward radius of the spare tire tub. This will ensure the correct overlap for service assembly installation (Figure 12-5). 3. Drill out the welds at the front edge of the spare tire radius. Cut through both the floor pan and rails along the floor pan service cut line. Discard the front portion of the assembly. 4. Cut through the rails along the final cut line and remove the excess portions. Do not cut through the floor pan. 5. On the remaining rail sections, drill out the welds attaching the inner reinforcements to the outer panels (typically three welds). Remove the inner reinforcements. 6. Drill 8mm (5/16") plug weld holes as necessary in the locations noted from the original floor. Also drill weld holes along the overlap joint of the floor pan. These should be placed approximately 40mm (1-1/2") apart.
Prepare the Service Assembly
34
Overlap
Install or Connect
FIGURE 12-6 WELD THE NEW SECTION
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
13. REAR END PANEL

The rear end panel is supplied as a complete assembly consisting of three inner reinforcements and one outer panel on Cavalier coupe and sedan and Sunfire sedan. The rear end panel on Sunfire coupe has a single inner reinforcement. Taillight mounting panels, which attach to the outside corners of the rear end panel assembly, are available separately. Service for all of these panels is performed at factory seams (Figure 13-1).
Sunfire Coupe
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.
Drill dimples for latch mounting
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.
Cavalier and Sunfire Sedan Drill dimples for latch mounting
FIGURE 13-1 REAR END PANEL ASSEMBLY
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14. BODY DIMENSIONS

CAVALIER/SUNFIRE UNDERBODY

37
14. BODY DIMENSIONS
CAVALIER/SUNFIRE ENGINE COMPARTMENT
38
14. BODY DIMENSIONS
CAVALIER/SUNFIRE FRONT

39
14. BODY DIMENSIONS
CAVALIER/SUNFIRE SEDAN SIDE
40
14. BODY DIMENSIONS
CAVALIER/SUNFIRE COUPE SIDE

41
14. BODY DIMENSIONS

CAVALIER/SUNFIRE REAR
42
SLOTTED RAIL CAGENUT REPLACEMENT

The following procedure has been developed to repair stripped or damaged cagenuts when full lower rail replacement is not necessary. It allows the cagenuts to be serviced from the underside of the vehicle. This is done by gaining access to and drilling out the hidden welds holding the cagenut bracket in place. The damaged cagenut and bracket can then be removed through the rail slot (Figure 1). 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.
REMOVE OR DISCONNECT
Slotted rail viewed from underneath the vehicle
FIGURE 1 SLOTTED LOWER RAIL

SLOTTED RAIL CAGENUT REPLACEMENT

Notice If the rail slot is too narrow to remove the cagenut bracket, make it wider by slightly grinding the edges of the gap. Do not remove more than 2mm of metal (Figure 3).
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.
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.).
FIGURE 2 PRY THE TORQUE BOX CLOSEOUT PANEL OUTWARDS TO EXPOSE FACTORY WELDS
Do not remove more than 2mm
FIGURE 3 WIDEN THE RAIL SLOT (IF NECESSARY)

Cavalier Sunfire Despiece Chasis

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Cavalier Sunfire Despiece Chasis

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TABLE OF CONTENTS

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

TPO on Cavalier; RIM on Sunfire

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

TPO on Cavalier and Sunfire Sedan; RIM on Sunfire Coupe

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

1995 General Motors Corporation. All Rights Reserved.

2. RADIATOR SUPPORT ASSEMBLY

Pre-assembled service part

Bolt-on lower support

FIGURE 2-1 RADIATOR SUPPORT A SSEMBLY

1995 General Motors Corporation. All Rights Reserved.

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

2. RADIATOR SUPPORT ASSEMBLY

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

3. FRONT WHEELHOUSE ASSEMBLY

FIGURE 3-1 UPPER OUTER RAIL REINFORCEMENT

FIGURE 3-2 FRONT WHEELHOUSE ASSEMBLY

1995 General Motors Corporation. All Rights Reserved.

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

3. FRONT WHEELHOUSE ASSEMBLY

FIGURE 3-3 INSTALL NEW WHEELHOUSE ASSEMBLY

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

4. FRONT LOWER RAIL ASSEMBLY

Bumper mounting brackets can be ordered separately

FIGURE 4-1 LOWER RAIL SUB-ASSEMBLY

1995 General Motors Corporation. All Rights Reserved.

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

4. FRONT LOWER RAIL ASSEMBLY

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

4. FRONT LOWER RAIL ASSEMBLY

1995 General Motors Corporation. All Rights Reserved.

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

5. FRONT SUSPENSION SUPPORT ASSEMBLY (#1 BAR)

FIGURE 5-1 FRONT SUSPENSION SUPPORT ASSEMBLY (#1 B AR)

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

5. FRONT SUSPENSION SUPPORT (#1 BAR)

FIGURE 5-2 CUT A WINDOW IN THE FLOOR

1995 General Motors Corporation. All Rights Reserved.

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

5. FRONT SUSPENSION SUPPORT (#1 BAR)

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

6. DOOR FRAME OPENING

1995 General Motors Corporation. All Rights Reserved.

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

6. DOOR FRAME OPENING

FIGURE 6-4 APPLY SEALER TO THE INNER COWL PLENUM

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

6. DOOR FRAME OPENING

FIGURE 6-6 CUT AND PRY OUTER REINFORCEMENT

1995 General Motors Corporation. All Rights Reserved.

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

6. DOOR FRAME OPENING

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

6. DOOR FRAME OPENING

FIGURE 6-9 APPLY SEALER TO THE INNER COWL PLENUM

DOOR FRAME OPENING GENERAL SECTIONING PROCEDURES

1995 General Motors Corporation. All Rights Reserved.

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

6. DOOR FRAME OPENING

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

FIGURE 7-1 SEDAN DOOR A SSEMBLY

FIGURE 7-2 COUPE DOOR ASSEMBLY