2001 Oldsmobile Aurora 2000 Pontiac Bonneville 2000 Buick Lesabre Collision Repair Manual

Outer Front Pillar

Sectioning 3-5

Outer Center Pillar

Sectioning 3-7Quarter Panel

Sectioning 3-9

Inner Front PillarSectioning 3-12

Floor Replacement -Rear 3-16

Rear Rail

Sectioning 3-14

Full Outer

Wheelhouse

Sectioning 3-15

Inner/Outer Door Frame Sectioning

2001 Oldsmobile Aurora

2000 Pontiac Bonneville

2000 Buick LeSabre

(note: all procedures apply to all models,unless otherwise noted)

Front Wheelhouse

Replacement 3-1

Front Lower Rail

Sectioning 3-2

Inner Center Pillar

Sectioning (With OuterPanel Removed) 3-13

Rail Replacement -

Rear 3-18

Roof PanelReplacement 3-20

2001 aurora / 2000 bonneville / 2000 lesabre 3-1

Front WheelhouseReplacement

Removal Procedure1. Remove panels and components as necessary

for access.2. Restore as much of the damage as possible to

the factory specifications.3. Remove all sealers and anti-corrosion

materials as necessary.4. Place a piece of 25␣ mm (1␣ in) wide masking

tape (Fig. 3-1), on the forward contour of thewheelhouse at the flange where it attaches tothe cowl panel.

5. Cut the wheelhouse along the forward edgeof the masking tape to leave a 25␣ mm (1␣ in)tab extending forward from the cowl panel.(This will provide an overlap for welding theservice part to the original wheelhouse,without welding directly to the cowl panel.)

6. Locate, mark, and drill out the factory weldswhich attach the wheelhouse assembly at the:• Upper rail inner panel• Cowl panel• Radiator support• Lower front rails

7. Remove the damaged wheelhouse assembly.

Installation Procedure1. Clean and prepare surfaces to be welded.2. Cut the flange off the service part that is

normally welded to the cowl panel (Fig. 3-2).3. Drill 8␣ mm (5/16␣ in) holes for plug welding in

the locations noted from the originalassembly. Also drill holes for plug weldingevery 40␣ mm (1-1/2 inches) along the cutedge to be attached to the tab remainingfrom the original assembly.CAUTION: Watch for flammable materialswhen welding to the interior panels of thevehicle.

4. Position the wheelhouse assembly usingthree-dimensional measuring equipment.

5. Plug weld the wheelhouse as necessary.6. Clean and prepare all bare metal surfaces.

Apply as necessary:• Sealers and anti-corrosion materials• Sound deadeners• Two-part catalyzed primer• Top-coat

MAKE 25 MM (1 IN) TABAS SHOWN

FRTON NEW

SERVICE PANEL,CUT TAB OFF

DRILL 8 MM (5/16 IN) HOLESEVERY 40 MM (1-1/2 IN) ALONG

CUT EDGE

Fig. 3-1 — Cut wheelhouse 25␣ mm (1␣ in)Forward of the Cowl Panel

Fig. 3-2 — Cut Tab and Drill Holes

3-2 2001 aurora / 2000 bonneville / 2000 lesabre

Fig. 3-4 — Create Tabs in the Lower Rail

Fig. 3-3 — Align Templates and Cut the Lower Rail

Fig. 3-5 — Step the Tabs Inwardand Weld Edges Together

Front Lower RailSectioningSectioning procedures have been developed tohelp simplify repair of the lower rails provided themajority of damage can be returned to factoryspecifications. This allows technicians to repair thedamaged front section without the need for acomplete rail replacement.Sectioning of the lower rail does not require theremoval of the power train, though the frontcradle must be lowered. To begin, remove allrelated components and panels. Visually inspectand restore as much of the damage as possible tofactory specifications. Also, for right side repair itmay be necessary to remove the alternator and airconditioning compressor.

NOTICE: Inner and outer sectioning templatesare available for the following parts: Left lowerrail original part; Right lower rail original part;Left lower rail service part; Right lower railservice part. IT IS VERY IMPORTANT TO USETHE CORRECT TEMPLATE WHEN MARKINGLINES FOR CUTTING.

Remove or Disconnect1. Align the appropriate inner and outer

templates on the damaged lower rail and marklines as indicated. There are two templates forthe left rail and two templates for the right rail(Fig. 3-3).

2. Cut the rail along the marked lines and removethe damaged portion of the rail(Fig. 3-3).

3. Cut and remove approximately 20␣ mm(3/4␣ in) of the outboard and downwardturned flanges of the lower rail. Cut a 5␣ mmgap approximately 20␣ mm (3/16␣ in) along thecorners of the lower rail to create tabs.(Fig.␣ 3-4)

4. Step the tabs inward to allow the replacementlower rail section to fit over the original rail(Fig. 3-5). Weld all four edges together.


Fig. 3-7 — Plug and Stitch Weld the New Rail Section

Fig. 3-6 — Mark the New Rail

Install or Connect1. Align the inner and outer templates on the

service part and mark lines as indicated(Fig. 3-6). There are two templates for thenew left rail and two templates for the newright rail.

2. Cut the service part along the marked linesand discard the unused section. Drill plug weldholes according to the template.

3. Position the modified service part over thestepped tabs of the original rail, allowing20␣ mm (3/4␣ in) of overlap. Plug weld eachhole and stitch weld along the entire joint(Fig.␣ 3-7). When stitch welding, make 1-inchwelds along the seam with 1-inch gapsbetween. Then go back and complete thestitch weld along the seam.

4. Clean and prepare welded surfaces. Applysealers and corrosion protection materials, asnecessary.

5. Prime with two-part catalyzed primer.IMPORTANT: Prior to refinishing, refer tothe publication GM4901M-D-2000 “GMApproved Refinish Materials” forrecommended products. Do not combinepaint systems. Refer to paint manufacturer’srecommendations.

6. Re-install all related components.


Outer Door Frame SectioningThe full body side outer panel comes as a one-piece assembly and can be replaced at factory seams.Any one of these procedures can be performed separately, or in any combination, dependent uponthe extent of damage to the vehicle. Sectioning must take place in specified areas only (Fig. 3-8).Left and right service parts are structurally identical but have varied service slot placement in midrocker areas. Remove front and rear glass when sectioning front pillar and quarter panel.

IMPORTANT: When replacing panels that involve servicing stationary glass, refer to GM ServiceBulletin 43-10-48 before performing any priming or refinishing.

Fig.␣ 3-8 — Outer Door Frames

Aurora

LeSabre

Bonneville


Outer Front PillarSectioningRemoval Procedure

IMPORTANT: Sectioning should be performedonly in the recommended areas. Failure to do somay compromise the structural integrity of thevehicle.

1. Visually inspect and restore as much of thedamage as possible to factory specifications.

2. Remove fender, windshield and door.3. Drill out factory spot welds of upper-outer

rail (Fig. 3-9). Remove upper rail and save forreinstallation.

4. Determine sectioning locations. Section inapproved areas only (see Fig. 3-8).

5. Mark locations and cut part through outerpanel only.

6. Locate factory welds and drill out, notingnumber and locations of welds (Fig. 3-9).

7. Remove outer panel.8. Note placement and number of foam baffles

for new installation. If baffles are damaged,replacement service parts are available.IMPORTANT: Hinge pillar blocks must bereplaced if damaged (Fig. 3-10)

Fig.␣ 3-9 — Upper Outer Rail Removal

Fig.␣ 3-10 — Hinge Pillar Block


50 MM (2 IN)BACKING PLATE

GAP = ONE-AND-ONE-HALFTIMES THE THICKNESSOF THE METAL

Fig.␣ 3-12 — Backing Plate Windshield Pillar

Installation Procedure1. Cut service part in corresponding locations to

fit original cut lines. Leave a gap of one-and-one-half times the metal thickness ofsectioning joint.

2. Create 100␣ mm (4 in) backing plate on rockerpanel from unused portion of service part (Fig.3-11).

3. In windshield pillar area, create 50␣ mm (2 in)backing plate from unused portion of servicepart (Fig. 3-12). Remove flange from backingplates for proper fit behind sectioning joint.

4. Drill 8␣ mm (5/16 in) plug weld holes in servicepart according to original locations as noted,and in original panel where parts overlapbacking plate (Fig. 3-12).

5. Apply weld-through primer to mating surfacesprior to assembly.

6. Weld backing plates into position on body.IMPORTANT: Replace hinge pillar blocksprior to welding outer panel.

7. Position service part on vehicle. Clamp inplace. Check for proper fit.

8. Plug weld accordingly. Stitch weld alongthe entire sectioning joint. Make 25␣ mm (1 in)welds along the seam with 25␣ mm (1 in) gapsbetween (Fig. 3-13), then go back andcomplete the stitch weld to ensure structuralintegrity of the vehicle.

9. Install upper rail assembly.10. Clean and prepare all welded surfaces.11. Install insulating foam as necessary in areas

noted from original baffle locations.IMPORTANT: Prior to refinishing, refer tothe publication GM4901M-D-2000 “GMApproved Refinish Materials” forrecommended products. Do not combinepaint systems. Refer to paint manufacturer’srecommendations.

12. Refinish as necessary.

Fig.␣ 3-13 — Plug Weld Service Panel


GAP = ONE AND ONE-HALF TIMESMETAL THICKNESS

Fig.␣ 3-11 — Rocker Sectioning


Outer Center PillarSectioningRemoval Procedure

IMPORTANT: Sectioning should be performedonly in the recommended areas. Failure to do somay compromise the structural integrity of thevehicle.

1. Measure 130␣ mm (7-11/16 in) down from topedge of center pillar top crease. Mark andscribe a line. This is the cut location (Fig. 3-14).

2. Cut center pillar at cut line. Use cautionnot to cut inner reinforcement (Fig. 3-15); theinner reinforcement will be used for a backingplate.

3. Drill out factory welds (Fig. 3-14).4. Create cut lines on rocker within approved

sectioning locations (Fig. 3-15). Cut the rockervertically along the sectioning lines.NOTICE: Center pillar is welded and bondedabove hinges.

5. Use caution to not damage inner reinforcementwhen removing outer panel. Remove damagedpart.

6. Note placement and number of foam bafflesfor new installation. If baffles are damaged,replacement service parts are available.

Preparation Of Service Part1. On the service part, mark a horizontal line

in corresponding locations to the originalsectioning cut, to leave a gap of one andone-half times the thickness of the metal at thesectioning joint (Fig. 3-16).

2. Cut the outer door frame opening service partalong this line.

3. Make vertical cut lines in rocker areasto correspond with original section lines.Leave a gap one-and-one-half times themetal thickness.

4. Cut two 100␣ mm (4 in) pieces from the unusedportion of the service part for backing plates onrockers (Fig. 3-17). Remove the flange on eachside of the backing plates so that they will fitbehind the sectioning joint.

5. Drill 8␣ mm (5/16 in) holes for plug welding inthe service part in the locations noted from theoriginal panel.

6. Drill holes for plug welding along thesectioning cuts on both the service partand the original panel. Locate these holesapproximately 25␣ mm (1 in) from the edgeof the sectioning cuts, spaced 40␣ mm (1-5/8in) apart.

7. Apply weld-through primer to mating surfacesprior to assembly.

Fig.␣ 3-14 — Outer Center Pillar

130 MM

Fig.␣ 3-15 — Outer Center pillar SectioningLocations

INNERREINFORCEMENT

Fig.␣ 3-16 — Inner Reinforcement

Fig.␣ 3-17 — Backing Plate

100 MM (4 IN.)BACKING PLATE

GAP = ONE-AND-ONE-HALF TIMESTHE THICKNESS OF THE METAL


Installation Procedure1. Install sleeves on vehicle at rocker areas. Inner

reinforcement will be used as a backing plateon center pillar.

2. Position part on vehicle. Clamp in place andcheck for proper fit (Fig. 3-18).

3. Remove service part. Apply urethane tocenter pillar reinforcement in areascorresponding to original locations.CAUTION: Leave a one-inch gap betweenurethane adhesive and any weld areas.

4. Replace hinge blocks.5. Align part and clamp in place. Check fit.6. Make 25␣ mm (1␣ in) stitch welds along the

seam with 25␣ mm (1␣ in) gaps between them,then go back and complete the stitch weld.This will create a solid joint with minimal heatdistortion.

7. Clean and prepare welded surfaces.IMPORTANT: Prior to refinishing, refer tothe publication GM4901M-D-2000 “GMApproved Refinish Materials” forrecommended products. Do not combinepaint systems. Refer to paint manufacturer’srecommendations.

8. Prime with two-part catalyzed primer.9. Refinish as necessary.

Fig.␣ 3-18 — Inner Reinforcement




GAP = ONE AND ONE-HALF TIMES THE THICKNESS OF THE METALGAP = ONE AND ONE-HALF TIMES THE THICKNESS OF THE METAL

Fig.␣ 3-20 — Quarter Panel Backing Plates

Quarter Panel SectioningRemoval Procedure

IMPORTANT: When replacing panels thatinvolve servicing stationary glass, refer to GMService Bulletin 43-10-48 before performing anypriming or refinishing.

IMPORTANT: Sectioning must take place inspecified areas only. Failure to do so maycompromise the structural integrity of thevehicle.

1. Visually inspect and restore as muchof the damage as possible to thefactory specifications.

2. Remove all related panels and components.3. Remove all sealers, sound deadeners and anti-

corrosion materials as necessary. Noteplacement and number of foam baffles for newinstallation. If baffles are damaged,replacement service parts are available.

4. Determine sectioning locations (Fig. 3-19).5. Mark a line and cut in approved

sectioning areas.6. Locate, mark and drill out all factory welds.

Note the number and location of welds forinstallation of the service assembly.

7. Remove damaged panel.

Preparation Of Service Part1. Cut service part in corresponding locations to

fit original cut lines.2. Create 100␣ mm (4 in) backing plate on rocker

panel from unused portion of service part.3. Create a 50␣ mm (2 in) backing plate on upper

quarter panel from unused portion of servicepart (Fig. 3-20).

Fig.␣ 3-19 — Quarter Panel Cut Locations


Installation Procedure1. Position service part on vehicle. Check fit

using body dimensions.2. Temporarily remove service part to install GM

P/N 12399117 Sealing Strip between outerwheelhouse and gas door pocket.

3. Weld backing plates into position.4. Drill 8␣ mm (5/16 in) plug weld holes as noted

from original locations. Also drill plug weldholes along the sectioned areas of the servicepart. These should be located 25␣ mm (1␣ in)from the edge of the cuts (Fig. 3-21).

5. Position service part and clamp in place.6. Stitch weld along entire sectioning joint. Make

25␣ mm (1 in) welds along the seam with25␣ mm (1 in) gaps between them, then goback and complete the stitch weld. This willcreate a solid joint with minimal heatdistortion.

7. Plug weld in original locations (Fig. 3-22).8. Clean and prepare all welded surfaces.9. Install all sealers, sound deadeners and

anti-corrosion materials as necessary.Install acoustic foam baffles as notedfrom original part.IMPORTANT: Prior to refinishing, refer tothe publication GM4901M-D-2000 “GMApproved Refinish Materials” forrecommended products. Do not combinepaint systems. Refer to paint manufacturer’srecommendations.

10. Apply two-part catalyzed primer.11. Refinish as necessary.12. Install all related panels and components.

Fig.␣ 3-21 — Prepare Quarter Panel

Fig.␣ 3-22 — Install Quarter Panel


Inner Door Frame SectioningCAUTION: Sectioning should take place in the specified areasonly.

The full body-side inner panel (Fig. 3-23) comes as a one-pieceassembly and can be replaced at factory seams after removal ofouter panel, roof and glass. Any one of these procedures can beperformed separately, or in any combination, dependent upon theextent of damage to the vehicle. Left and right service parts arestructurally identical but have varied service slot placement in mid-rocker areas. Remove front and rear glass when sectioning frontpillar and quarter panel.

IMPORTANT: When replacing panels that involve servicingstationary glass, refer to GM Service Bulletin 43-10-48 beforeperforming any priming or refinishing.

Fig.␣ 3-23 — Sectioning Locations


Inner Front Pillar SectioningRemoval Procedure

IMPORTANT: Sectioning should be performedonly in the recommended areas (see Fig. 3-23).Failure to do so may compromise the structuralintegrity of the vehicle.

1. Visually inspect and restore as much of thedamage as possible to factory specifications.

2. Remove outer panel according to specifieddirections in removal process.

3. Remove dash, instrument panel, seat andall necessary components to allow accessto repair.

4. Locate and follow laser-weld line (1) acrossFront pillar at lower windshield area(Fig. 3-24).

5. Measure down 50␣ mm (2 in) and scribe a lineparallel to the laser-weld line (2). This is yourcut location.

6. At rocker panel, locate sectioning location (3).Scribe a line. Cut through one layer of metalonly.NOTICE: Left and right service parts arestructurally identical but have varied serviceslot placement in mid rocker areas. On rightside rocker, section at rear of access hole onoriginal panel. Overlap service part 50␣ mm(2 in) and use access holes as alignmentguides.

7. Drill out factory spot welds.8. Remove damaged panel.

Create Service Flange1. On windshield pillar lower edge, measure

forward 25␣ mm (1 in) from door opening(Fig. 3-16). Scribe a vertical line.

2. Measure forward 190␣ mm (7-1/2 in) fromfirst scribed line and scribe a second verticalline (2).

3. Cut along vertical markings to laser-weldline (1), to create a flange for weldingservice part.

4. Cut along laser-weld, outboard of vertical cuts,remove tabs. This creates a 50␣ mm x 190␣ mm(2 in x 7-1/2 in) tab (2) for attaching servicepart to front pillar (Fig. 3-24).

Preparation of Service Part1. Locate laser-weld at bottom of windshield

pillar area of the service part. This will bethe same laser-weld location as the originalpanel (1).

2. Cut along laser-weld.

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190 MM(7-1/2 IN)

25 MM(1 IN)

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Fig.␣ 3-24 — Front Pillar Detail

3. Create a vertical line for sectioning rocker(3). Allow space for a 50␣ mm (2 in) overlapfor welding.

4. Notch upper and lower edges of service part to fitbehind existing rocker panel, remove tabs.

5. Drill plug weld holes in locations noted from originalpanel.

Installation Procedure1. Drill plug weld holes in front pillar flange, spaced

40␣ mm (1-1/2 in) apart.2. Drill plug weld holes at rocker overlap.3. Prepare mating surfaces.

IMPORTANT: Prior to refinishing, refer to thepublication GM4901M-D-2000 “GM ApprovedRefinish Materials” for recommended products. Donot combine paint systems. Refer to paintmanufacturer’s recommendations.

4. Prime with two-part catalyzed primer.5. Position part on vehicle and clamp in place. Check fit.6. Plug weld accordingly.7. Stitch weld at front pillar, at rocker-inner and at

sectioning locations.8. Clean and prepare all welded surfaces.9. Refinish as necessary.10. Install all related panels and components.


Inner Center PillarSectioning (With OuterPanel Removed)Removal Procedure1. Remove seats, carpet and related panels

and components.2. Secure wiring from repair area.3. Remove inner reinforcement by drilling

approximately 8 spot-welds (see Fig. 3-24).4. Measure down 135␣ mm (5-5/16␣ in) from

upper-inner reinforcement. Scribe a horizontalcut line.

5. At front door rocker area, scribe a verticalcut line at the specified sectioning location.

6. At rear door rocker area, scribe a vertical cutline at the rear edge of the 50 x 100␣ mm(2␣ in␣ x␣ 4␣ in) oval hole.NOTICE: This may be performed at any ofthe similar sized holes in the inner panel.

7. Cut on the three scribed lines.8. Drill out factory spot welds, noting their

location for installation of service part.9. Remove the damaged panel.

Preparing the Service Part1. Remove inner reinforcement on

center pillar (Fig. 3-25).2. Cut service part at top of 24␣ mm (1␣ in) round

hole (1) located midway down the center pillar(Fig. 3-26).

3. Cut down 40␣ mm of the outturnedweatherstrip flanges on the center pillar (2).

4. Trim inside corners for flush fit.5. At front door rocker area, cut service part,

allowing for a 50␣ mm (2␣ in) overlap to originalcut line on inner rocker (Fig. 3-27).

6. Trim a 20␣ mm x 50␣ mm (4/5␣ in x 2␣ in) tab attop and bottom (1) of sectioned area onservice part to allow for a flush fit at pinchwelds (Fig. 3-27).

7. In rear door, inner rocker area, trim tabsand use the front edge of the next 50␣ mmx␣ 100␣ mm (2␣ in␣ x␣ 4␣ in) oval hole as analignment guide to create a 50␣ mm (2␣ in)overlap (2).

8. Drill plug weld holes in sectioning areas, 25␣ mm(1 in) back from cut line on rocker and pillararea.

9. Drill 8␣ mm (5/16 in) plug weld holes as notedfrom original locations.

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Fig.␣ 3-26 — Center Pillar Detail

INNERREINFORCEMENT

135MM(5 5/16 IN)

Fig.␣ 3-25 — Center PillarReinforcement


Installation Procedure1. Apply two-part catalyzed primer to center

pillar area and service part.2. Clamp part in position. Check for fit.3. Spot-blast plug weld areas.4. Plug weld as necessary.5. Complete stitch welds at section areas.6. Clean and prepare all welded surfaces.7. Reinstall inner reinforcement (3) (Fig. 3-27).

IMPORTANT: Prior to refinishing, refer tothe publication GM4901M-D-2000 “GMApproved Refinish Materials” forrecommended products. Do not combinepaint systems. Refer to paint manufacturer’srecommendations.

8. Refinish as necessary.9. Install all related panels and components.

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Fig.␣ 3-27 — Center Pillar Installation


50 MM(2 IN)

LASER-WELD LINE

50 MM(2 IN)

Fig.␣ 3-28 — Outer Wheelhouse Removal



LASER WELD

TRIM TABS

CUT LINE

Fig.␣ 3-29 — Outer Wheelhouse Service Panel

Full Outer WheelhouseSectioningRemoval Procedure1. Locate horizontal laser-weld line in upper

quarter area (Fig. 3-28).2. Measure down 50␣ mm and scribe a cut line.3. On vehicle rocker area, cut 50␣ mm (2␣ in) and

scribe a cut line.4. On vehicle rocker area, cut 50␣ mm (2␣ in)

rearward of 50␣ mm x 100␣ mm (2 in x 4␣ in)access hole, allowing for a 50␣ mm (2␣ in)overlap.

5. Cut panel at marked locations.6. Drill out factory welds. Note the number and

location of welds.7. Remove damaged panel.

Installation Procedure1. Locate laser-weld line on service part

(Fig. 3-29).2. Cut along laser-weld line.3. In specified sectioning location of rocker area,

create a vertical cut line. Allow for a 50␣ mm(2␣ in) overlap of service part to rocker area.

4. Cut service part along marked locations.5. Trim a 20␣ mm x 50␣ mm (4/5␣ in x 2␣ in) tab at

top and bottom of section area of service partto allow for a flush fit at pinch welds.

6. Drill plug weld holes as noted from originalpanel.

7. Install new part and clamp in place. Checkfor fit.IMPORTANT: Prior to refinishing, refer tothe publication GM4901M-D-2000 “GMApproved Refinish Materials” forrecommended products. Do not combinepaint systems. Refer to paint manufacturer’srecommendations.

8. Apply two-part catalyzed primer.9. Make 25␣ mm (1␣ in) stitch welds along the

seam with 25␣ mm (1␣ in) gaps between them,then go back and complete the stitch weld.This will create a solid weld with minimal heatdistortion.

10. Clean and prepare all welded surfaces.11. Use a brushable seam sealer on inside seam.12. Install all related panels and components.


Floor Replacement - Rear

Removal Procedure

IMPORTANT: The rear floor service part comes pre-cut tothe appropriate size for sectioning. It does not need to bemodified.

1. Remove all panels and components as necessary foraccess.

2. Restore as much of the damage as possible to factoryspecifications.

3. Locate, mark, and drill out all factory welds rearward ofthe crossbar connecting the rear rails to the floor panel.

4. Locate and drill out the welds attaching the rear floorpanel to the wheelhouse.

5. Cut the rear floor along the rearward edge of thecrossbar (Fig. 3-30).

6. Take care not to cut the crossbar or the rear rails.7. Remove the damaged section of the rear floor panel.

CUT AT REAR EDGE OF CROSSBAR

Fig.␣ 3-30 — Rear Floor


Installation Procedure1. Position the service floor section and clamp in place. Allow

the floor service assembly to overlap the original floor ontop of the rear crossbar.

2. Drill 8␣ mm (5/16␣ in) holes for plug welding in the servicepanels necessary in the locations noted from the originalfloor panel.

3. Drill holes approximately 40␣ mm (1-5/8␣ in) apart wherethe new floor section attaches to the rear rail and crossbarflanges.

4. Plug weld as necessary (Fig. 3-31).5. Clean and prepare all bare metal surfaces.

IMPORTANT: Prior to refinishing, refer to the publicationGM4901M-D-2000 “GM Approved Refinish Materials”for recommended products. Do not combine paintsystems. Refer to paint manufacturer’s recommendations.

6. Apply as necessary:• Sealers• Anti-corrosion materials• Two-part catalyzed primer• Top coat

7. Install the panels and components previously removed foraccess.

Fig.␣ 3-31 — Rear Floor


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

Removal ProcedureSectioning procedures can be used to repair the rearrail if just the portion rearward of the crossbar isdamaged. When sectioning, use the rear rail outerpanel P/N 25552778 or 25552779.1. Visually inspect and restore as much of the

damage as possible to factory specifications.2. Remove all related panels and components.3. Cut the rear rail along the rearward flange of the

crossbar and continue this cut around the rear rail(Fig. 3-33).

4. Drill out the factory welds on the end of the rearrail inner reinforcement.

5. Remove the damaged portion of the rear rail.6. Either move the end of the rear rail inner

reinforcement forward or cut this part andremove it from the rear rail.

REAR CROSSBAR

FRT

Fig.␣ 3-32 — Rear Rails

Fig.␣ 3-33 — Cut Rear Rail


Installation Procedure1. Use the original part as a guide to mark a line

on the new rail 35␣ mm (1-3/8␣ in) forward ofthe cut made to the original part. This willprovide an overlap for welding the newsection.

2. Cut the new rail along the marked lines anddiscard the unused section.

3. Cut and remove approximately 35␣ mm(1-3/8␣ in) of the flanges on the new rail(Fig. 3-34).

4. Cut a 5␣ mm gap approximately 35␣ mm(1-3/8␣ in) along the corners of the new rail tocreate tabs.

5. Step the tabs inward to allow the new rail tofit inside the original rail (Fig. 3-35).

6. Position the modified new rail inside theoriginal rail, allowing 35␣ mm (1-3/8␣ in)of overlap.

7. Check the position of the new rear rail sectionusing body dimensions and plug weld in threelocations long all three sides of the rail.

8. Stitch weld along the entire seam and replacefactory welds, as appropriate (Fig. 3-36).IMPORTANT: Prior to refinishing, refer tothe publication GM4901M-D-2000 “GMApproved Refinish Materials” forrecommended products. Do not combinepaint systems. Refer to paint manufacturer’srecommendations.

9. Clean and prepare welded surfaces.10. Apply sealers and corrosion protection

materials, as necessary.11. Prime with two-part catalyzed primer.12. Install all related components.

FRT

Fig.␣ 3-34 — Cut and Remove Flanges

Fig.␣ 3-35 — Step Tabs Inward

Fig.␣ 3-36 — Stitch Weld Seams


Roof PanelReplacement

Removal ProcedureThe roof panel is attached to the steel roof structurewith beads of adhesive on the sides and spot-welds onthe windshield and back-glass flanges. Replacement ofthe roof panel can be performed using conventionalprocedures, however, the windshield and back glassmust be removed (Fig. 3-37).

IMPORTANT: Use care when cutting to protectadjacent panels. Cut inboard of the roof structure.

1. Visually inspect and restore as much of the damageas possible to the factory specifications.

2. Remove all related panels and components.3. Remove the following:

• Sealers• Sound deadeners• Anti-corrosion materials

4. Locate and mark all factory welds.5. Drill all factory welds. Note the number and

location of welds for installation of the serviceassembly.

6. Cut the adhesive with an appropriate tool afterremoving the panel.

7. Remove the remaining portion of the originalpanel.

Installation Procedure1. Clean and prepare the attaching surfaces for

welding.2. Drill 8␣ mm (5/16␣ in) for plug welding along the

windshield and back glass edges of the servicepanel as noted from the original panel (Fig. 3-38).Drill the holes for plug welding along the front andrear flanges every 40␣ mm (1-1/2␣ in).

3. Position the service panel.4. Check the fit.

IMPORTANT: Prior to refinishing, refer to thepublication GM4901M-D-2000 “GM ApprovedRefinish Materials” for recommended products.Do not combine paint systems. Refer to paintmanufacturer’s recommendations.

5. Install the panel using one-part windshieldurethane to side flanges.

6. Plug weld accordingly.7. Clean and prepare all welded surfaces.8. Prime with two-part catalyzed primer.

IMPORTANT: When replacing panels thatinvolve servicing stationary glass, refer to GMService Bulletin 43-10-48 before performing anypriming or refinishing.

9. Install all related panels and components.

Fig. 3-37 — Spot-Welded Front and Rear Edge

Fig. 3-38 — Adhesively Bonded Sides


Ø

WIDTH

HEIGHT

LENGTH

CA

B

D

E

F

G

540

469

552

427

925

888

1673

2457

3257

1092

348

358

577

577

504

526

430

496

553

492

Underbody Dimensions

Aurora/Bonneville/LeSabre

Description Location Length Width Height

28␣ mm gage nut A 1092 540 46916 mm x 22␣ mm slot B 925 504 55210.5␣ mm x 12.5␣ mm hole C 0 526 42716␣ mm gage hole D 888 430 34823␣ mm gage hole E 1673 496 35810␣ mm gage hole F 2457 553 57719␣ mm x 25␣ mm gage hole G 3257 492 577

All dimensions are measured in millimeters, from a zero line, center line, and a common datum. All dimensions are symmetrical, unless otherwise specified.


ø

A

B

C

D

E

F

DATUM LINEHEIGHT

WIDTH

LENGTH

810 806822

357

824

1062

0

1084

2090

824

1101

809

931970 993 795 653 946


13␣ mm gage hole A 357 824 97019␣ mm gage hole B 0 822 931Upper hinge hole C 1084 810 993Striker lock attachment D 1062 809 795Lower hinge bolt hole E 1101 824 653Clinch nut lock strike attachment F 2090 806 946


Body Side Dimensions – 2001 Aurora


Body Side Dimensions – 2000 Bonneville

ø

A

B

C

D

E

F

DATUM LINEHEIGHT

WIDTH

LENGTH

810 806

822

357

824

1062

0

1084

2087

824

1101

809

931970 993 795 653 978





ø

A

B

C

D

E

F

DATUM LINEHEIGHT

WIDTH

LENGTH

810 806822

357

824

1062

0

1084

2087

824

1101

809

931970 993 795 653 978




Body Side Dimensions – 2000 LeSabre

Documents

2001 Oldsmobile Aurora 2000 Pontiac Bonneville 2000 Buick Lesabre Collision Repair Manual