Pontiac Grand Am and Oldsmobile Alero by vru17206

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									                                                                            1999
 Pontiac Grand Am
and Oldsmobile Alero
 Panel Identification ..................................................... 2-1

 Front End Assembly ..................................................... 2-3

 Front Wheelhouse Assembly ....................................... 2-4

 Front Lower Rail Assembly ......................................... 2-7

 Door Frame Opening ..................................................2-17

 Roof Panel ................................................................... 2-22

 Quarter Panel ..............................................................2-24

 Rear Wheelhouse ........................................................2-28

 Rear Floor Assembly ..................................................2-31

 Rear Rails ..................................................................... 2-35

 Rear End Panel Assembly ........................................... 2-36

 Body Dimensions ........................................................2-37
                                                          Coupe

                                                                  white
                                                                          Two-Sided Galvanized Steel
                                                                          High-Strength Low-Alloy Steel
                                                                          Thermoplastic Olefin
                                                                                                          Panel Identification




1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
    2-1
                                                                                                  Sedan




 2-2
                                                          white
                                                                  Two-Sided Galvanized Steel
                                                                                                          Panel Identification




                                                                  High-Strength Low-Alloy Steel
                                                                  Thermoplastic Olefin




1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
Front End Assembly
The front-end structure consists of six                 — INSTALL OR CONNECT —
resistance-welded components. The upper tie             1   Prepare mating surfaces and check for
bar and upper reinforcement panel are serviced              proper fit of the service panels.
as individual components. The brace, (front-end         2   On the service panels, drill 8mm (5/16) plug
lower structure) includes rail reinforcement                weld holes as necessary in the locations
gussets, which provide cross-car alignment of               noted from the original assembly.
the service assembly. Left and right impact bar
                                                            Notice: If original components are
brackets are serviced separately and must be
                                                            damaged beyond recognition, place plug
installed using three-dimensional coordinates
                                                            weld holes every 40mm (1-1/2) inches
(Fig. 2.1).
                                                            apart.
— REMOVE OR DISCONNECT —
                                                        3   Position the service panels, check fit using
1   Remove all related panels and components.
                                                            body dimensions, and plug weld accordingly
2   Visually inspect and restore as much of the             with frequent measurements to ensure
    damage as possible to factory specifications.           proper fit.
3   Remove sealers and anti-corrosion materials         4   Clean and prepare welded surfaces.
    as necessary.
                                                            Important: Prior to refinishing, refer to
4   Locate, mark and drill out all factory welds as         GM P/N 4901 M-D Refinish Manual for
    necessary. Note the number of welds for                 recommended products.
    installation of the service panels.
                                                        5    Apply approved anti-corrosion primer
5   Remove the damaged panels in the upper tie
    bar assembly and the front end lower brace,         6   Apply sealers and refinish as necessary. Do
    as necessary.                                           not combine paint systems. Refer to paint
                                                            manufacturer’s recommendations.
                                                            Notice: Upper tie-bar service parts do
                                                            not have mounting locations for (3) center
                                                            latch-support holes. Use threaded inserts
                                                            such as Riv-nuts, available through Kent-
                                                            Moore tools (Riv-nut Kit P/N J 42151-8MS).
                                                        7   Reinstall all related panels and components.




                                      Fig. 2.1 — Front end structure



                                       1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair       2-3
Front Wheelhouse Assembly
                                                      The left and right front wheelhousings are
                                                      available as complete assemblies (Fig. 2.2).
                                                      Additionally, the front portion of the aprons
                                                      and upper rail can be ordered and serviced as a
                                                      partial assembly (Fig. 2.3). Strut mounting holes
                                                      are pre-drilled in the service assemblies. The
                                                      front wheelhouse assembly is serviced without
                                                      the form and pierced fender mounting locations.
                                                      When replacing as an assembly, technicians must
                                                      three-dimensionally locate fender-mounting
                                                      holes and use threaded inserts for fender bolts
                                                      and body shims to achieve correct height
                                                      (Fig. 2.4). (Riv-nuts with crimping tool are
                                                      available from Kent-Moore tools: Riv-nut Kit,
      Fig. 2.2 — Wheelhouse service assembly
                                                      P/N J42151-8MS).
                                                      Sectioning procedures have been developed to
                                                      simplify wheelhouse repairs. Use the following
                                                      guidelines to determine whether wheelhouse can
                                                      be sectioned or should be replaced at factory
                                                      seams.




  Fig. 2.3 — Front assembly also available




                   ,,,
                   Riv-nuts




        Fig. 2.4 — Use threaded inserts at fender
                   mounting locations



2-4       1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
                                                                               Front Wheelhouse Assembly



Wheelhouse Sectioning                                  4   At wheelhouse to cowl panel joint, measure
                                                           forward 75mm (3 inches). Mark a vertical line
Notice: Inspect the cowl panel for damage                  from strut cap to frame rail (do not cut into
where the wheelhouse is attached. If the                   strut cap). Cut the wheelhouse along this
panels have been separated, it will be                     line, from rail up to strut cap (Fig. 2.5). This
necessary to repair the cowl panel and                     will provide an overlap flange for welding the
replace the wheelhouse at factory seams. If                service part to the original wheelhouse,
panels have not been separated and there is                without welding directly to the cowl panel.
no damage in this location, the wheelhouse
                                                           Notice: Drill through strut cap welds to
can be serviced as follows.
                                                           locate areas to be re-welded at cowl
— REMOVE OR DISCONNECT —                                   panel.
1   Remove all related panels and components.          5   Locate, mark and drill out the factory welds,
2   Visually inspect and restore as much of the            which attach the wheelhouse assembly to the
    damage as possible to factory specifications.          cowl panel, radiator support and lower front
3   Remove all sealers and anti-corrosion                  rails.
    materials as necessary.                            6   Remove the damaged wheelhouse assembly.




                           Fig. 2.5 — Create weld flange from original panel




                                      1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair          2-5
Front Wheelhouse Assembly



                                                     — INSTALL OR CONNECT —
                                                     1   Clean and prepare surfaces to be welded.
                                                     2   Trim and discard tab off service part which is
                                                         normally welded to the cowl panel (Fig. 2.6)
                                                     3   Drill 8mm (5/16-inch) holes for plug welding
                                                         in the locations noted from the original
                                                         assembly.
                                                     4    Drill six holes for plug welding every 40mm
                                                         (1-1/2 inches) along the overlap which
                                                         attaches service part to flange remaining
                                                         from original assembly. (Fig. 2.7)
                                                     5   Check the position of the wheelhouse
                                                         assembly using three-dimensional measuring
           Fig. 2.6 — Trim weld flange                   equipment and plug weld accordingly. Install
             from service assembly                       one weld in the tab from cowl to strut cap.
                                                         (Fig. 2.8)
                                                         Notice: The welds which attach the strut
                                                         cap to the cowl can be installed from the
                                                         cowl plenum side of the joint (Fig. 2.8).
                                                     6   Clean and prepare all welded surfaces.
                                                         Important: Prior to refinishing, refer to
                                                         GM P/N 4901 M-D Refinish Manual for
                                                         recommended products.
                                                     7  Locate and drill 2 fender-mounting holes in
                                                        new wheelhouse using three-dimensional
                                                        measuring equipment.
                                                     8 Apply approved anti-corrosion primer.
                                                     9 Apply sealers and sound deadeners and
                                                        refinish as necessary. Do not combine paint
                                                        systems. Refer to paint manufacturer’s
                                                        recommendations.
                                                     10 Install threaded inserts at fender mounting
                                                        locations. (Kent-Moore tools: Riv-nut Kit
                                                        P/N J 42151-MS). Reuse original fasteners
      Fig. 2.7 — Drill 8mm (5/15 inch) holes            or equivalent.
                  along overlap
                                                     11 Install all related panels and components.




                             Cowl
                            plenum                                             Wheelhouse




                        Fig. 2.8 — Weld plenum to strut cap from plenum side



2-6      1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
Front Lower Rail Assembly
Replacement of the engine compartment lower rail
assemblies has been improved on the Grand
Am/Alero through the use of a sub-assembly service
part. The lower rail service part comes complete
with all brackets and reinforcements (Fig. 2.9). When
sectioning, order the entire assembly and extract
the necessary parts (Fig. 2.10).




                                  Fig. 2.9 — Left side service assembly




                                Fig. 2.10 — Extract parts for sectioning




                                      1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair   2-7
Front Lower Rail Assembly



Lower Rail Sectioning                                     Important: Damage to the front lower rails
Sectioning procedures have been developed to              must be limited to the portion of the rail
help simplify repair of the lower rails, provided the     forward of the sectioning joint, if damage
majority of damage can be returned to factory             exceeds the forward portion, complete
specifications. This allows technicians to repair the     replacement of the rail is recommended.
damaged front section without having to make a            (See complete rail replacement procedures.)
complete rail replacement. Sectioning of the lower        Notice: The lower rail sectioning cut lines
rail does not require removal of the powertrain.          vary from left to right. Be sure to use the
                                                          correct procedure. (Fig. 2.11)




 Left rail, inner




   Right rail, inner




   Right rail, outer




                       Fig. 2.11 — Unique rails, unique repair procedures left to right




2-8      1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
                                                                               Front Lower Rail Assembly




LEFT - FRONT LOWER RAIL SECTIONING
— REMOVE OR DISCONNECT —
1   Remove all related panels and components
    including left front cradle bolt.
2   Visually inspect and restore as much of the
    damage as possible to factory specifications.
3   Remove all sealers and anti-corrosion
    materials as necessary.
4   Apply 25mm (1 inch) wide tape on the lower
    rail outer panel following the contour of the
    cowl (Fig. 2.12). Cut the outer panel along
    the forward edge of the tape. This will
    provide an overlap tab for welding the
    service part to the original rail without
    welding directly to the cowl panel.
5   Drill out all factory welds attaching the outer
    panel to the rail inner panel, be sure not to
    drill through the inner panel.
    Notice: Welds on engine cradle mounting
    bracket must also be drilled out to remove
    outer panel.
6   Remove the rail outer panel.
7   Locate the 16 x 35 slot on the in-board side                Fig. 2.12 — Cut the outer panel
    of the rail (Fig. 2.13). Using the hole as a                  along forward edge of tape
    guide, mark a line on all three sides of the
    rail.
8   Cut the rail along the marked line and
    remove the damaged portion of the rail.




                               Fig. 2.13 — Mark a line on the damaged rail




                                       1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair     2-9
Front Lower Rail Assembly



PREPARING SERVICE PART                                 3   On the left inner rail service part, mark a line
FOR INSTALLATION                                           around the panel 30mm (1-1/4 inch) rearward
— INSTALL OR CONNECT —                                     of the 16 x 35 hole on the inner rail. Using the
1   Locate and drill out factory welds attaching           hole as a guide, mark a line around the rail
    the outer panel to the inner panel on the              (Fig. 2.14).
    service part. Drill through one layer ONLY at      4   Cut the service part along the marked line
    the front half of the rail.                            and discard the unused section.
    Notice: Welds on engine cradle mounting            5   On the sectioned service part, cut a 2mm (1/8
    bracket must also be drilled out to remove             inch) gap approximately 30mm (1-1/4 inch)
    outer panel.                                           deep along the corners of the inner rail to
                                                           create tabs (Fig. 2.15).
2   Separate inner from outer rail using an air
    chisel. Remove the outer panel and set aside.      6   Step the tabs inward to allow the service part
                                                           section to fit inside the original rail (Fig. 2.15).




                                                     30mm




                       Fig. 2.14 — Left rail service part, add 30mm for weld tabs




              1. Cut Corners




                  2. Step tabs
                     inward




                      Fig. 2.15 — Cut corners and step tabs inward on service part




2-10    1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
                                                                                Front Lower Rail Assembly



7   Drill 5 holes for plug welding along the            10 Position the outer panel, check for proper fit
    overlap, approximately 13mm (1/2 inch) from            and alignment.
    the sectioning cut (Fig. 2.16).                     11 Stitch weld along the entire joint. Plug weld
8   Position the modified service part inside the          all holes drilled during the removal process
    original rail align using three-dimensional            including holes drilled along overlapped
    measuring equipment.                                   areas (Fig. 2.17).
9   On rail outer panel, trim off tab that attaches     12 Clean and prepare welded surfaces.
    to cowl panel. Drill three 8mm (5/16 inch)             Important: Prior to refinishing, refer to
    plug weld holes along overlap.                         GM P/N 4901 M-D Refinish Manual for
    Notice: Be certain the engine cradle                   recommended products.
    mounting location is in the proper                  13 Apply approved anti-corrosion primer.
    position. Align and hand tighten bolt.
                                                        14 Apply sealers and refinish as necessary. Do
    Important: When stitch welding, make                   not combine paint systems. Refer to paint
    25mm (1 inch) welds along the seam with                manufacturer’s recommendations.
    25mm (1 inch) gaps between. Then go                 15 Install all related panels and components.
    back and complete the stitch weld along
    the seam.




                        Fig. 2.16 — Drill 8mm (5/16 inch) holes for plug welding




                           Fig. 2.17 — Plug welds and stitch welds completed




                                       1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair       2-11
Front Lower Rail Assembly



RIGHT - FRONT LOWER RAIL SECTIONING                    5   Drill out all the factory welds attaching the
— REMOVE OR DISCONNECT —                                   outer panel to the rail inner panel, be sure
1   Remove all related panels and components.              not to drill through the inner panel. Remove
                                                           the rail outer panel.
2   Visually inspect and restore as much of the
    damage as possible to factory specifications.      6   Measure 75mm (3 inches) forward of the
                                                           engine mount brace located inside the rail
3   Remove all sealers and anti-corrosion
                                                           and mark a line (Fig. 2.18). Drill a 1/8 inch
    materials as necessary.
                                                           hole on the line. Using the hole as a guide,
4   Apply 25mm (1 inch) wide tape on the lower             mark a line around the outside of the rail.
    rail outer panel following the contour of the
                                                       7   Cut the rail along the marked line and
    cowl. Cut the outer panel along the forward
                                                           remove the damaged portion of the rail.
    edge of the tape (refer to Fig. 2.12). This will
    provide an overlap for welding the service
    part to the original rail, without welding
    directly to the cowl panel.




                                                            75mm




                Right rail, inner




                Right rail, outer




                    Fig. 2.18 — Remove outer panel and measure damaged inner rail




2-12     1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
                                                                                   Front Lower Rail Assembly



PREPARING SERVICE PART                                  3   On the right side rail, measure 45mm
FOR INSTALLATION                                            (1-3/4 inches) forward of the engine mount
— INSTALL OR CONNECT —                                      brace (Fig. 2.19), notice this is 30mm (1-1/4
1   Locate and drill out factory welds attaching            inches) less than the original sectioning cut.
    the outer panel to the inner panel on the               Drill a 1/8- inch hole on the line. Using the
    service part. Drill through one layer ONLY at           hole as a guide, mark a line around the rail.
    the front half of the rail.                         4   Cut the service part along the marked line
    Notice: Welds on engine cradle mounting                 and discard the unused section.
    bracket must also be drilled out to remove          5   On the sectioned service part, cut a 2mm (1/8
    outer panel.                                            inch) gap approximately 30mm (1-1/4 inch)
                                                            deep along the corners of the inner rail to
2   Separate inner from outer rail using an air
                                                            create tabs (Fig. 2.20).
    chisel. Remove the outer panel and trim off
    the rear edge that welds to the cowl panel.         6   Step the tabs inward to allow the service part
                                                            section to fit inside the original rail (Fig. 2.20).




       Right rail, inner

                                                     45mm                                        FRT




      Right rail, outer



                  Fig. 2.19 — Remove outer panel to measure inner rail on service part




                                                                                 1. Cut Corners




                FRT

                                                                                  2. Step tabs
                                                                                     inward


                       Fig. 2.20 — Cut corners and step tabs inward on service part




                                      1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair             2-13
Front Lower Rail Assembly



7   Drill 5 holes for plug welding along the             10 Position the outer panel, check for proper fit
    overlap, approximately 13mm (1/2 inch)                  and alignment.
    from the sectioning cut (Fig. 2.21)                  11 Stitch weld along the entire joint. Plug weld
8   Position the modified service part inside the           all holes drilled during the removal process
    original rail using three-dimensional                   (Fig. 2.22).
    measuring equipment.                                 12 Clean and prepare welded surfaces.
    Notice: Be certain the engine cradle                    Important: Prior to refinishing, refer to
    mounting location is in the proper                      GM P/N 4901 M-D Refinish Manual for
    position. Align and hand tighten bolt.                  recommended products.
    Important: When stitch welding, make                 13 Apply approved anti-corrosion primer.
    25mm (1 inch) welds along the seam with              14 Apply sealers and refinish as necessary. Do
    25mm (1 inch) gaps between. Then go                     not combine paint systems. Refer to paint
    back and complete the stitch weld.                      manufacturer’s recommendations.
9   Drill 3 holes in the rail outer panel in front of    15 Install all related panels and components.
    the cowl.




                          Fig. 2.21 — Drill 8mm (5/16 inch) holes for plug welding




                             Fig. 2.22 — Plug welds and stitch weld completed




2-14     1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
                                                                                Front Lower Rail Assembly



FRONT LOWER RAIL REPLACEMENT                              1/8-inch drill bit, drill through floor to mark
— REMOVE OR DISCONNECT —                                  welds for removal.
1   Remove all related panels and components.          7 Separate the floor pan reinforcement vertical
2   Visually inspect and restore as much of the           flange from inside the lower rail. Care must
    damage as possible to factory specifications.         be taken to not damage the flange.
3   Remove sealers, sound deadeners and                8 Drill out factory welds along the lower flange
    anti-corrosion materials as necessary.                on the floor pan reinforcement and at the
                                                          wheelhouse. Note that the flanges overlap
4   Using an air chisel, remove the rear engine           the rails.
    mount.
                                                       9 From inside the vehicle, use an 8mm (5/16
5   Locate and drill out resistance welds in
                                                          inch) drill bit to drill through the floor pan
    torque box panel (Fig. 2.23). Drill through
                                                          and the reinforcement inside the vehicle
    one layer of metal ONLY.
                                                          (Fig 2.24).
6   From underside of vehicle, locate welds that
                                                       10 Remove the damaged rail.
    secure the rail to the floorpan. Using a




              Fig. 2.23 — Drill through rail in torque box to locate welds inside vehicle




                                      1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair       2-15
Front Lower Rail Assembly



— INSTALL OR CONNECT —                                     hammer to flatten inner panel against floor
1   Prepare mating surfaces and check for                  pan. Plug weld floor to new rail in remaining
    proper fit of the new rail. Apply suitable             areas.
    weld-through primer.                               4   Clean and prepare welded surfaces.
2   Position the new rail in place and check for           Important: Prior to refinishing, refer to
    proper alignment using three-dimensional               GM P/N 4901 M-D Refinish Manual for
    measuring equipment.                                   recommended products.
3   With the new rail in place, plug weld all the      5   Apply approved anti-corrosion primer.
    holes created from the removal process. In         6   Apply sealers and refinish as necessary. Do
    the areas the floor inner panel does not               not combine paint systems. Refer to paint
    contact the floor pan, use a ball- peen                manufacturer’s recommendations.
                                                       7   Install all related panels and components.




    Fig. 2.24 — Drill from inside vehicle at pilot hole locations using an 8mm (5/16 inch) drill bit




2-16     1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
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
assembly 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 (Fig. 2.25). Since left and right door frame
openings are available as complete assemblies,
service parts for sectioning must be cut from the
complete assembly and modified as necessary.




         SECTIONING SHOULD NOT
       TAKE PLACE IN SHADED AREAS




                             Fig. 2.25 — Coupe and Sedan side door frames




                                      1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair   2-17
 Door Frame Opening



 Door Frame Opening                                  3   Position the service assembly, check fit using
 Full Replacement                                        body dimension and plug weld accordingly
 — REMOVE OR DISCONNECT —
                                                         with frequent measurements to ensure
                                                         proper fit.
 1   Remove all related panels and components
     including the roof panel, upper outer rail      4   Inject expandable foam into the “A” Pillar
     reinforcement and, on coupe models only,            through the bottom interior trim-mounting
     the quarter panel.                                  hole. This helps reduce noise in the pas-
                                                         senger compartment.
 2   Visually inspect and restore as much of the
     damage as possible to factory specifications.   5   Clean and prepare welded surfaces.
 3   Remove sealers, sound deadeners and anti-           Important: Prior to refinishing, refer to
     corrosion materials as necessary.                   GM P/N 4901 M-D Refinish Manual for
                                                         recommended products.
 4   Locate, mark and drill out all factory welds.
     Note the number of welds for installation of    6   Apply approved anti-corrosion primer.
     the service assembly.                           7   Apply a full-bodied caulk along the surface of
 5   Remove the damaged doorframe opening.               the baffle to ensure a proper seal with the
                                                         inner cowl plenum (Fig. 2.27).
                                                     8   Apply sealers and refinish as necessary. Do
 — INSTALL OR CONNECT —
                                                         not combine paint systems. Refer to paint
 1   Prepare mating surfaces and check for               manufacturer’s recommendations
     proper fit of the door frame opening service
                                                     9   Reinstall all related panels and components.
     assembly.
 2   On the service assembly, drill 8mm
     (5/16-inch) plug weld holes as necessary in
     the locations noted from the original
     assembly.
     Notice: In any area damaged beyond
     recognition, space plug weld holes every
     40mm (1-1/2 inches) apart.




                                                            Do not plug drain slot




                                                              Fig. 2.27 — Apply sealer along inner cowl plenum




Fig. 2.26 — Remove upper outer rail reinforcement




 2-18    1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
                                                                                     Door Frame Opening



General Sectioning Procedures                          — REMOVE OR DISCONNECT —

When sectioning areas other than the hinge             1   Remove all related panels and components.
pillar, a 100mm (4 inch) backing plate must be         2   Visually inspect and restore as much of the
used behind the joint to ensure a solid and                damage as possible to factory specification.
secure weld in areas where there is no inner           3   Remove sealers, sound deadeners and anti-
reinforcement. Backing plates can usually be cut           corrosion materials as necessary.
from the unused portion of the service part or an
                                                       4   Cut the doorframe opening where it is to be
undamaged section of the doorframe opening.
                                                           sectioned. Do not damage any inner panels
Notice: There are some key reinforcements                  or reinforcements.
that are to be replaced at factory seams only          5   Locate, mark and drill out all necessary
(Fig. 2.28). Sectioning these panels may                   factory welds. Note the number of welds for
compromise the structural integrity of the                 installation of the service part.
vehicle.                                               6   Remove the damaged section of the
The rocker panel can also be replaced in its               doorframe opening.
entirety when the quarter panel has been
removed.




                                     Reinforcements are replaced at factory seams only




              Fig. 2.28 — Door frame reinforcements are part of the service assemblies




                                      1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair      2-19
Door Frame Opening



— INSTALL OR CONNECT —
1   Cut the service part to match the undamaged
    section of the door frame opening and
    remove unused portion of the service part.
2   Cut an appropriate-sized backing plate from
    the unused portion of the service part or
    undamaged section of the doorframe
    opening. Modify the backing plate as
    necessary so that it will fit behind the
    sectioning joint (Fig. 2.29).

                                                                 Gap = one and
                                                                 one-half times           100mm
                                                                 the thickness            (4 in)
                                                                 of the metal             Backing
                                                                                          Plate




                                                  100mm




                     50mm




                                                                                  100mm
                            100mm



                                                          50mm




                                                                 100mm




                            Fig. 2.29 — Door frame sectioning specifications




2-20    1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
                                                                                     Door Frame Opening



3   Windshield pillar sectioning requires a 50mm       7  Position the service part, allowing it to
    (2 inch) backing plate. Section within the            overlap the exposed portion of the backing
    recommended areas (Fig. 2.29).                        plates. Check fit using body dimensions and
    Notice: The striker plate is mounted in a             plug weld accordingly with frequent
    cage that allows some degree of                       measurements to ensure proper fit.
    adjustment independent of the outer                8 Stitch weld along the sectioning joints. Make
    panel’s. Use body dimensions to ensure                25mm (1 inch) welds along the seam with
    the striker mounting location falls within            25mm (1 inch) gaps between. Then go back
    the plate’s range of adjustment                       and complete the stitch weld. This will create
4   Sectioning the rocker panel requires a                a solid joint with minimal heat distortion.
    100mm (4 inch) backing plate for                   9 Complete all other welds as necessary.
    reinforcement (Fig. 2.29). Section within the      10 Clean and prepare welded surfaces.
    recommended area.                                     Important: Prior to refinishing, refer to
5   On the service part, drill 8mm (5/16-inch)            GM P/N 4901 M-D Refinish Manual for
    plug weld holes as necessary in the locations         recommended products.
    noted from the original section. Also, drill       11 Apply approved anti-corrosion primer
    plug weld holes along the sectioning cut on
    both the service part and the remaining            12 Apply sealers and refinish as necessary. Do
                                                          not combine paint systems. Refer to paint
    original part. These will be used to weld the
                                                          manufacturer’s recommendations.
    panel to the backing plate.
                                                       13 Reinstall all related panels and components.
6   Prepare mating surfaces and slide the
    backing plates halfway under the sectioning
    cuts on the vehicle and plug weld in place.




                                      1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair      2-21
Roof Panel
The roof panel is made of mild steel and welded        Notice: The headliner, windshield and
to the steel roof structure, including the outer       backglass must be removed prior to the
panel and the inner reinforcements. The roof           removal of the roof assembly. Protect the
panel is serviced as a “skin” with no                  interior of the vehicle. Use care when working
reinforcements, only sound-soak patches                near adjacent panels, glass, weatherstrips and
pre-installed for efficient installation.(Fig. 2.30)   moldings.
The roof panel must be drilled to remove the
outer panel and inner reinforcements for               Important: On vehicles equipped with a
servicing.                                             sunroof, take care not to damage the drain
                                                       tubes. The drain tubes are located between
                                                       the inner and outer windshield pillar.




                       T
                     FR
                                                                  Pre-installed
                                                                sound-soak panel




                            Fig. 2.30 — Coupe roof panel with sunroof opening




2-22     1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
                                                                                               Roof Panel



                                                       — REMOVE OR DISCONNECT —
               Silicon Bronze
                    Joint                              1   Remove all related panels and components
                                                           necessary to access the welds attaching the
                                                           roof assembly to the vehicle.
                                                       2   Visually inspect and restore as much of the
                                                           damage as possible.
                                                       3   Remove sealers and anti-corrosion materials
                                                           as necessary.
                                                       4   Locate silicon-bronze joints which attach roof
                                                           panel to quarter panels (Fig. 2.31).
                                                       5   Cut through the roof panel just above the left
                                                           and right silicon-bronze joints using a
                                                           die-grinder or equivalent tool (Fig. 2.32).
                                                       6   Locate, mark and drill out all factory welds.
                                                           Note the number and location of welds for
                                                           installation of the service assembly.
                                                       7   Remove the damaged roof panel assembly.
                                                       8   Grind off silicon-bronze weld and remove
                                                           remaining roof panel tabs.

                                                       — INSTALL OR CONNECT —
                                                       1   Clean and prepare the mating surfaces as
    Fig. 2.31 — Locate roof seam at quarter panel          necessary.
                                                       2   Position the roof panel on the vehicle. Check
                                                           fit and alignment.
                                                       3   When the service assembly is correctly
                                                           positioned, plug weld accordingly.
                                                       4   MIG stitch weld the quarter panel to roof
                                                           joints at factory seams.
   DO NOT CUT SAIL PANEL REINFORCEMENT.                    Important: Make 25mm (1 inch) welds
           CUT ROOF PANEL ONLY                             along the seam with 25mm (1 inch) gaps
                                                           between. Then go back and complete the
                                                           stitch weld. This will create a solid joint
                                                           with minimal heat distortion.
                                                       5   Clean and prepare all welded surfaces.
                                                           Important: Prior to refinishing, refer to
                                                           GM P/N 4901 M-D Refinish Manual for
                                                           recommended products.
                                                       6   Apply approved anti-corrosion primer.
                                                           Notice: The windshield and bonding area
                                                           should be a primer surface ONLY and not
                                                           an aftermarket, top-coated (paint or
                                                           color-coated) surface. Refer to Bulletin
                                                           #43-10-48 for more detailed information.
                                                       7   Apply sealers and refinish as necessary. Do
                                                           not combine paint systems. Refer to paint
                                                           manufacturer’s recommendations.
                                                       8   Install all related panels and components.

Fig. 2.32 — Rough cut roof panel above factory seam




                                      1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair      2-23
Quarter Panel
The quarter panel is a service assembly that           panel is attached to the roof panel by a
includes the gutter, lock-striker cagenut and an       silicon-bronze welded joint. To maintain the
extension panel for the taillamp pocket (tail lamp     integrity of this joint, sectioning of the quarter
pocket is serviced separately). Replacement of         panel at sail panel will be performed 100mm
the quarter panel requires removal of the back         (4 inches) below this joint where roof overlaps
light and quarter glass on coupe models. On            quarter panel (Fig. 2.33).
both the coupe and sedan models, the quarter




                                                     SEDAN




 Taillamp pockets
serviced separately




                                                     COUPE


                              Fig. 2.33 — Quarter panel service assemblies




2-24    1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
                                                                                             Quarter Panel



Coupe Quarter Panel                                    5    At B-Pillar location on outer panel only,
Service Procedure                                           measure distance between lower 2 trim
— REMOVE OR DISCONNECT —
                                                            holes. Scribe a line at half the distance
                                                            between the 2 holes. This is the
1   Visually inspect and restore as much of the
                                                            recommended sectioning point (Fig. 2.34).
    damage as possible to factory specifications.
                                                            Notice: Do not cut into inner
2   Remove all related panels and components,
                                                            reinforcement.
    including the side and back glass.
                                                       6    At scribed line, cut quarter panel ONLY.
3   Remove sealers, sound deadeners and
                                                            Locate, mark and drill out the factory welds.
    anti-corrosion materials as necessary.
                                                            Note the location and number of welds.
4   Locate silicone-bronze seam at roof/quarter-
                                                       7    Remove damaged quarter panel.
    panel overlap. Measure down 100mm from
    pinch weld flange at side and rear window          8    Remove majority of baffle material in sail
    (door frame) locations (Fig. 2.34). Mark cut            panel and along rocker panel.
    line.




                                                                Measure equal distance
                                     100mm
                                                                between trim holes




          Fig. 2.34 — Locating coupe quarter panel
                     sectioning locations




                                                                 100mm




                                                           Fig. 2.35 — Measure and mark 100mm down
                                                                     from silicon bronze joint



                                      1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair       2-25
Quarter Panel



PREPARING SERVICE PANEL
FOR INSTALLATION
— INSTALL OR CONNECT —
1   At the sail panel, measure and mark a line
    100mm from step at top edge of service part
    (Fig. 2.35).
2   At B-Pillar location on outer panel only, measure
    distance between lower 2 trim holes. Scribe a
    line at half the distance between the 2 holes.
    This is the recommended sectioning point (see
    Fig. 2.34).
3   Cut along line to trim service part and create a
    100mm backing plate. Remove the flange on
                                                          Fig. 2.36 — Drill 8mm 5/16 plug weld holes
    each side of backing plate so that it will fit                       along overlap
    behind the sectioning joint.
4   Drill 8mm (5/16) plug weld holes as necessary in
    the locations noted from the original panel. Drill
    plug weld holes along the sectioning areas of
    the service part and original panel. These holes
    should be located approximately 13mm
    (1/2 inch) from the edge of the cuts (Fig. 2.36).
5   Prepare the mating surfaces. Position and
    secure both backing plates with half of the           Important: Care must be taken to ensure that the
    backing plate exposed at each joint. Position the     fuel filler neck is properly sealed when replacing
    service part to overlap the backing plates and          the right side quarter panel. Use SPO Sealing
    butt up to the original panel (Fig. 2.37). Check       strip (P/N 12399117) between the quarter panel
                                                              and the fuel filler neck. Install according to
    for proper fit and alignment.                                      provided instruction sheet.
    Notice: Leave a gap of one and one half
    times the thickness of the metal at the
    sectioning joint.
6   Plug weld accordingly. Stitch weld along the
    entire sectioning joint. Make 25mm (1 inch)
    welds along the seam with 25mm gaps between
    them. Go back and complete the stitch weld.
                                                                        100mm
    This will create a solid joint with minimal heat
    distortion.
7   Plug weld all other areas as noted from the
    original panel.
                                                                                                          50mm
8   Clean and prepare all welded surfaces.
    Important: Prior to refinishing, refer to GM
    P/N 4901 Refinish Manual for recommended
    products.
9 Apply approved anti-corrosion primer.
10 Apply body sealers and refinish as necessary. Do
   not combine paint systems. Refer to paint             Fig. 2.37 — Use the correct size backing plates
   manufacturer’s recommendations.                                  when installing new panel
11 Install all related panels and components.




2-26     1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
                                                                                                   Quarter Panel



    Sedan Quarter Panel Service                              — INSTALL OR CONNECT —
    Procedure                                                1   Prepare the mating surfaces as necessary.
    — REMOVE OR DISCONNECT —                                 2   Temporarily position the service panel on
    1    Remove all related panels and components,               vehicle. Trim the original panel to leave a gap
         including the back glass.                               of one and one half times the thickness of the
    2    Visually inspect and restore as much of the             metal at the sectioning joint
         damage as possible to factory specifications.       3   Cut 100mm (4-inch) piece from the original
    3    Remove sealers and corrosion protection                 quarter panel for backing plates. Remove the
         materials as necessary.                                 flange on each side of the backing plates so
                                                                 that they will fit behind the sectioning joints.
    4    Note the size of the service part and locate
         the sectioning joint at the “sail panel.” Mark      4   Drill 8mm (5/16-inch) plug weld holes as
         a line 100mm below the silicon bronze joint             necessary in the locations noted from the
         and cut (Fig. 2.39).                                    original panel. Also drill plug weld holes
                                                                 along the sectioned area of the service part.
    5    Locate, mark and drill out all factory welds.
                                                                 These should be located approximately
         Note the number and location of welds for
                                                                 25mm (1 inch) from the edge of the cuts
         installation of the service assembly.
                                                                 (Fig. 2.39).
    6    Remove the damaged quarter panel.
                                                             5   Prepare the mating surfaces. Position the
                                                                 service part to overlap the backing plate and
                                                                 butt up to the original panel (Fig. 2.40).
                                                                 Notice: Leave a gap of one and one half
                                                                 times the thickness of the metal at the
                                                                 sectioning joint.
                     100mm
                                                             6   Plug weld all other areas as noted from the
                                                                 original panel.
                                                             7   Clean and prepare all welded surfaces.
                                                                 Important: Prior to refinishing, refer to
                                                                 GM P/N 4901 M-D Refinish Manual for
                                                                 recommended products.
                                                             8  Apply approved anti-corrosion primer
                                                             9  Apply sealers, sound deadeners and
                                                                corrosion protection materials.
                                                             10 Refinish as necessary. Do not combine paint
                                                                systems. Refer to paint manufacturer’s
        Fig. 2.38 — Measure 100mm below silicon                 recommendation.
                      bronze joint
                                                             11 Install all related panels and components.




Fig. 2.39 — Drill 8mm (5/16 inch) holes for plug welding
                                                                   Fig. 2.40 — Use 100mm (4 inch) backing plate




                                            1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair        2-27
Rear Wheelhouse
The sedan outer rear wheelhouse (Figs. 2.41) can
be replaced at factory seams. Both models have
a beltline reinforcement that overlaps a portion
of the wheelhouses. Remove the reinforcement
on sedan models according to recommended
procedures. On coupe models, templates have
been developed to ensure proper wheelhouse
installation on coupe models.

Sedan
— REMOVE OR DISCONNECT —
1   Remove all related panels and components
    including the back glass.
2   From inside of vehicle, pull back and protect
    wiring along inner wheelhouse.
3   Locate and drill out six welds securing          Fig. 2.41 — Replacement wheelhouse (coupe/sedan)
    beltline reinforcement to quarter inner
    assembly (Fig. 2.42)
    Notice: Drill through one layer only.
4   Locate and drill out welds at factory seams
    along perimeter of wheelhouse flange.
5   Remove damaged wheelhouse panel.

— INSTALL OR CONNECT —
1   On service part, drill 8mm (5/16-inch) holes
    every 40mm (1-1/2 inches).
2   Prepare mating surfaces.
3   Apply suitable weld-through primer.
4   Position service part. Check for proper fit.
    Notice: Outer wheelhouse positioning may
    require dry-fitting of quarter outer panel.
5   Clean and prepare welded surfaces.
    Important: Prior to refinishing, refer to
    GM P/N 4901 M-D Refinish Manual for
    recommended products.
6   Apply approved anti-corrosion primer.
7   Apply sealers and sound deadener materials
    and refinish as necessary. Do not combine          Fig. 2.42 — Remove beltline reinforcement
    paint systems. Refer to paint manufacturer’s                     (SEDAN ONLY)
    recommendations.
8   Install related panels and components.




2-28     1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
                                                                                       Rear Wheelhouse



Outer Rear Wheelhouse                                — REMOVE OR DISCONNECT —
                                                     1   Remove all related panels and components
Notice: It is recommended that the service
part be prepared before removing the                 2   Visually inspect and restore as much of the
damaged panel from the vehicle.                          damage as possible to factory specifications.
                                                     3   Remove sealers and sound deadeners as
Coupe                                                    necessary.
PREPARING THE SERVICE PART                           4   Apply 25mm (1 inch) tape along perimeter of
FOR INSTALLATION                                         beltline reinforcement where it contacts
1 Align the appropriate template along the               outer wheelhouse.
   service part contour lines, per template          5   Cut along outer (Fig. 2.44) edge of tape to
   instructions.                                         form mating flange.
2 Cut service part as indicated on template to       6   Apply tape to lower front portion of
   ensure proper fit of service part.                    wheelhouse, parallel to rocker panel edge,
3 Trim leading edge of service part to allow             cut along top edge of tape from outer lip of
   flush fit with rocker panel (Fig. 2.44).              wheelhouse to valley (see Fig. 2.44), creating
4 Remove the excess portion of the                       a flange for reattachment of wheelhouse part
   wheelhouse.                                           at rocker panel.
                                                     7   Cut along radius of wheelhouse (Fig. 2.45).
                                                     8   Remove the damaged wheelhouse.




                                                                                   Beltline Reinforcement




    Fig. 2.43 — Modify wheelhouse service
               part (COUPE ONLY)




                                                      Fig. 2.44 — Apply tape as indicated to leave a
                                                            portion of the original wheelhouse
                                                      for efficient installation of the service panel




                                    1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair      2-29
Rear Wheelhouse



                                                    — INSTALL OR CONNECT —
                                                    1    Remove weld flange on remaining portion of
                                                         original wheelhouse (at rocker panel) to
                                                         ensure proper fit of service part.
                                                    2    Temporarily install service part over beltline
                                                         reinforcement flange and inside of original
                                                         wheelhouse (Fig. 2.46).
                                                    3    On the service part, drill 8mm (5/16 inch)
                                                         plug weld holes every 40mm (1-1/2 inches
                                                         along perimeter of entire service part.
                                                         (Fig. 2.47) Drill 4 holes on edge where
                                                         service part mates to rocker panel.
                                                    4    Prepare the mating surfaces and position the
                                                         service part. Apply suitable weld-through
                                                         primer.
                                                    5    Check for proper fit and plug weld
                                                         accordingly. Use care to not warp or distort
                                                         the metal.
                                                         Notice: Outer wheelhouse positioning may
                                                         require dry-fitting of quarter outer panel.
                                                    6    Clean and prepare welded surfaces.
Fig. 2.45 — Separate wheelhouse from quarter
  inner assembly (leave weld flange in place)            Important: Prior to refinishing, refer to
                                                         GM P/N 4901 M-D Refinish Manual for
                                                         recommended products.
                                                    7    Apply approved anti-corrosion primer.
                                                    8    Apply sealers and sound deadeners as
                                                         necessary. Do not combine paint systems.
                                                         Refer to paint manufacturer’s
                                                         recommendations.
                                                    9    Install all related panels and components.




                    Over




          Inside




Fig. 2.46 — Install modified wheelhouse



                                                        Fig. 2.47 — Service part modified (COUPE ONLY)




2-30    1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
Rear Floor Assembly
The rear floor is sold as a complete assembly
including rear rails, crossmembers and rear
extension; or sold separately as floor pan “skin”
with exhaust heat shield only. (Fig. 2.48)




                                        Rail
                                        extensions


                                                                     With the floor pan removed,
                                                                     drill out and replace rear frame
                                                                     rail extensions at factory
                                                                     seams. Use 8mm (5/16 inch)
                                                                     plug welds to reinstall the
                                                                     replacement rail extensions.




                      Fig. 2.48 — Floor pan “skin” and rail extensions are serviced




                                      1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair           2-31
  Rear Floor Assembly



  Rear Floor Panel Partial                                  factory welds which secure floor to rails.
  Replacement                                               Note the number and location of welds for
  — REMOVE OR DISCONNECT —
                                                            installation of the floor service panel (Fig.
                                                            2.49).
  1   Remove all related panels and components,
      including fuel tank.                              5   Drill completely through welds that attach
                                                            the floorpan to the inner wheelhouse.
  2   Visually inspect and restore as much of the
      damage as possible.                               6   Remove both inner wheelhouse braces.
                                                            Identify weld locations and drill through
  3   Remove sealers, sound deadeners and
                                                            one layer of metal only.
      anti-corrosion materials as necessary.
                                                        7   Remove the damaged floor section.
  4   Locate factory seam at front edge of
      crossbar, rearward of seat back. Locate,
      mark and drill through one layer only, all




Important: On pan only
re-install, wheelhouse
flange must be bent up
on service part to
accommodate welds.




                                Fig. 2.49 — Floor pan weld joint on vehicle




  2-32      1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
                                                                                       Rear Floor Assembly



— INSTALL OR CONNECT —                                  4   Re-install both wheelhouse braces (Fig. 2.50).
1   Prepare mating surfaces with suitable               5   Clean and prepare all welded surfaces.
    weld-through primer.                                    Important: Prior to refinishing, refer to
2   Drill 8mm (5/16-inch) plug weld holes as                GM P/N 4901 M-D Refinish Manual for
    necessary in the locations noted from the               recommended products.
    original floor.                                     6   Apply approved anti-corrosion primer.
    Notice: In any area damaged beyond                  7   Apply body sealers and refinish as necessary.
    recognition, space plug weld holes every                Do not combine paint systems. Refer to paint
    40mm (1-1/2 inches) apart.                              manufacturer’s recommendations.
    Important: Sound deadeners along the                8   Install all related panels and components.
    inner wheelhouse must be removed prior
    to welding new panels in place
3   Position the service floor pan, check for
    proper fit using three-dimensional measuring
    and plug weld accordingly.




                         Fig. 2.50 — Reinstall internal floor braces (2 per side)




                                     1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair        2-33
Rear Floor Assembly



FLOOR PAN ASSEMBLY                                   — INSTALL OR CONNECT —

The floor pan assembly comes complete                1   Prepare mating surfaces with suitable
including lower rails, crossbar, rear floor              weld-through primer.
extension and various other components.                  Notice: In any area damaged beyond
(Fig. 2.51)                                              recognition, space plug weld holes every
— REMOVE OR DISCONNECT —                                 40mm (1-1/2 inches) apart.
Notice: One side inner and outer wheelhouses         2   Drill 8mm (5/16-inch) plug weld holes along
must be removed when replacing entire                    all mating surfaces except where the floor
sub-assembly.                                            mates to each wheelhouse.
1   Remove all related panels and components.        3   Position the service floorpan. Check for
2   Visually inspect and restore as much of the          proper fit using three-dimensional
    damage as possible.                                  measurements.
3   Remove sealers, sound deadeners and              4   Clean and prepare all welded surfaces.
    anti-corrosion materials as necessary.               Important: Prior to refinishing, refer to
4   Remove 4 inner reinforcements ( 2-dynamic            GM P/N 4901 M-D Refinish Manual for
    side impact braces-front; 2- floor pan               recommended products.
    braces-rear) to access spot welds (Fig 2.52).    5   Apply approved anti-corrosion primer to all
    Notice: If these parts are damaged they              bare metal surfaces.
    must be ordered separately.                      6   Apply body sealers and refinish as necessary.
                                                         Do not combine paint systems. Refer to paint
                                                         manufacturer’s recommendations.
                                                     7   Reinstall all related components.




        Fig. 2.51 — Floor pan assembly




                                                     Fig. 2.52 — Remove all four internal braces to
                                                                  locate hidden welds




2-34     1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
Rear Rails
The left and right rear rails are available as           The rear rail can be removed by drilling out all
complete sub-assemblies and can be replaced in           factory welds at the floor pan. When doing so,
their entirety similar to past model vehicles. Each      the outboard flange at the forward end of the rail
consists of an outer panel, two inner                    overlapping the rocker interior panel must be
reinforcements and all necessary component               bent upward. The bottom flange of the crossbar
mounting brackets. The outer panel and rear              must be bent downward.
mounting brackets are also available separately.
                                                         Notice: Remove the floor and wheelhouse
When replacing a rail in its entirety, the weld          braces at factory seams to access additional
flange that mates with the wheelhouse must be            lower rail welds. Reinstall upon completion
bent upwards. The service assembly is supplied           (see Fig. 2.52).
with this flange in a horizontal position. (Fig.
                                                         The rear rail can then be separated from the
2.53)
                                                         vehicle.




                                               Service assembly supplied with horizontal
                                               wheelhouse flange




             Service assembly with wheelhouse flange
             bent upwards for installation




             Fig. 2.53 — Modify weld flange if ordering and installing entire rear rail only




                                       1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair       2-35
Rear End Panel Assembly
The rear end panel is supplied as a complete             — INSTALL OR CONNECT —
assembly consisting of three inner reinforce-            1     Prepare mating surfaces and check for
ments and one outer panel. The rear end panel                  proper fit o the service assembly.
on the coupe has a single inner reinforcement.           2     On the service assembly, drill 8mm
Taillight mounting panels, which attach to the                 (5/16-inch) plug weld holes as necessary in
outside corners of the rear end panel assembly,                the locations noted from the original
are available separately. Service for all of these             assembly. Apply suitable weld-through
panels is performed at factory seams (Fig. 2.54).              primer.
— REMOVE OR DISCONNECT —                                 3     Position the service assembly, check fit using
1   Remove all related panels and components.                  body dimensions and plug weld accordingly
2   Visually inspect and restore as much of the                with frequent measurements to ensure
    damage as possible to factory specifications.              proper fit.
3   Remove sealers, sound deadeners and                  4     Clean and prepare welded surfaces.
    corrosion materials as necessary.                          Important: Prior to refinishing, refer to
4   Locate, mark and drill out all factory welds.              GM P/N 4901 M-D Refinish Manual for
    Note the number of welds for installation of               recommended products.
    the service assembly.                                5     Apply approved anti-corrosion primer.
5   Remove the damaged assembly.                         6     Apply sealers and refinish as necessary. Do
                                                               not combine paint systems. Refer to paint
                                                               manufacturer’s recommendations.
                                                         7     Reinstall all related panels and components.




                                                 Fig. 2.54 —




2-36     1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
                                                                                 E                                                                                      H
                                                                              L: 506                                                            F                    L: 2226
                                                                              W: 561                                                                                 W: 430
                                                                                                                                             L: 2126          G
                                                                              H: 810                    A                                                            H: 371           I
                                                                                                                                             W: 430        L: 2163
                                                                                                     L:   0                                  H: 360        W: 560                 L: 2391
                                                             D                                       W: 435                                                H: 834                 W: 440
                                                          L: 1250                                    H: 133                                                                       H: 400
                                                          W: 465
                                                          H: 326
                                                                                                                                                                                                J
                                                                                                                                                                                             L: 2850
                                                                                                                                                                                             W: 440
                                                                                                                                                                                             H: 400




                                                                                                                                                                                               K
                                                                                                                                                                                            L: 2733
                                                                                                                                                                                            W: 440
                                                                                                                                                                                                       Body Dimensions




                                                                                                                                                                                            H: 364




                                                                       C                         C
                                                                    L: 1215                B
                                                                                                 L                                                  N                             L
                                                                    W: 442              L: 292                                                   L: 2111           M           L: 2466
                                                                    H: 326              W: 356                                        O          W: 430         L: 2321        W: 440
                                                                                        H: 243                                     L: 1650       H: 369         W: 433         H: 375
                                                                                                                                   W: 563                       H: 369
                                                                                                                                   H: 400




1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
                                                                                    ALL DIMENSIONS ARE MEASURED FROM A ZERO LINE, CENTER LINE, AND A
                                                                                COMMON DATUM. ALL DIMENSIONS ARE SYMMETRICAL UNLESS OTHERWISE SPECIFIED.




    2-37
Body Dimensions




                                       FRONT VIEW
               P                                                                    Q
            W: 508                                                               W: 517
            H: 416                            C
                                              L                                  H: 474
                                                                                 L: 1364
            L: 1364




               R                                                                   S
            W: 517                                                              W: 517
            H: 376                                                              H: 376
            L: 1364                                                             L: 1364




                                          REAR VIEW
               T                                                                   U
            W: 374                                                              W: 508
            H: 346                             C
                                               L                                H: 416
            L:3013                                                              L:3013




                            V                                             W
                         W: 374                                        W: 374
                         H: 346                                        H: 346
                         L:3013                                        L:3013




              ALL DIMENSIONS ARE MEASURED FROM A ZERO LINE, CENTER LINE, AND A
          COMMON DATUM. ALL DIMENSIONS ARE SYMMETRICAL UNLESS OTHERWISE SPECIFIED.




2-38    1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
                                                                             Body Dimensions



1999 Grand Am/Alero
Underbody Dimension Hole Size Chart

Letter        Feature Size                     Usage

A             19mm                             gage hole
B             20mm                             cradle attach
C             13mm x 19mm                      gage slot
D             20mm                             cradle attach
E             76mm                             center strut cap
F             15mm                             rear suspension attach
G             83mm                             center strut cap
H             15mm                             rear suspension attach
I             19mm                             gage hole
J             19mm x 26mm                      slot
K             19mm x 26mm                      slot
L             19mm                             gage hole
M             15mm                             rear suspension attach
N             15mm                             rear suspension attach
O             19mm                             gage hole
P             14mm x19mm slot                  front impact bar
Q             14mm                             front impact bar
R             14mm x 19mm slot                 front impact bar
S             14mm                             front impact bar
T             10mm                             rear impact bar
U             10mm                             rear impact bar
V             10mm                             rear impact bar
W             10mm x 18mm slot                 rear impact bar




                             1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair   2-39

								
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