00 Complete Manual

General Motors.
The Collision Repair

Industry Leader.
This booklet provides you with detailed repair information.
It is important to note that serviceability has been an integral part of the development of these
vehicles. General Motors has made every effort to take the technician’s concerns into
consideration and to make sure we are providing quality information for quality technical
repairs.
General Motors recognizes the important role that each of you plays in keeping customers
happy and satisfied with our vehicles. That is why we have dedicated all our service resources
to giving you the knowledge, information and tools you need to accurately and efficiently
service these vehicles. We feel confident that working together with you, we have what it takes
to achieve total customer satisfaction.
Service information is also available on the web.

• This website includes service repair information for the total vehicle and is a
subscription based site. (www.acdelcotechconnect.com)
• This website includes select collision repair information only and is downloadable
and free to the user. (www.techinfo.gmgoodwrench.com)
TABLE OF CONTENTS
General Information ....................................... 1-1 Rail Replacement - Rear (Z06) .....................
General Information
2-43
Actions to Take When Working with Rail Replacement - Rear Section (Z06) ......... 2-46
Fuel Caution ............................................... 1-1 Floor Panel Replacement (Z06) ..................... 2-53
Approved Equipment for Collision Compartment Panel Replacement -
Repair Caution ............................................ 1-1 Rear (Corvette) ......................................... 2-56
Battery Disconnect Caution ............................. 1-1 Compartment Panel Frame Replacement -
Collision Sectioning Caution ............................ 1-1 Rear (Corvette) ......................................... 2-59
Foam Sound Deadeners Caution .................... 1-1 Sheet Molded Compound (SMC) Panel
Glass and Sheet Metal Handling Caution ........ 1-1 Bonding .................................................... 2-62
Safety Glasses Caution ................................... 1-1 2006 Pontiac Solstice/
SIR Caution .................................................... 1-1 2007 Saturn SKY ........................... 3-1
Sound Deadener Foam in the Lock Striker Pillars Dimensions - Body (Door Openings) ............... 3-1
Caution ....................................................... 1-1 Dimensions - Body (Motor Compartment) ........ 3-2
Fastener Notice .............................................. 1-1 Hinge Pillar Body Reinforcement
2006 Chevrolet Corvette Z06 ........................ 2-1 Replacement - Front .................................... 3-3
Structure Identification ..................................... 2-1 Hinge Pillar Body Replacement - Front ............ 3-5
Windshield Frame Header Panel
2006 Chevrolet Corvette Z06

Dimensions - Body (Motor Compartment -
Corvette) ..................................................... 2-3 Replacement - Front .................................... 3-7
Dimensions - Body (Z06) ................................ 2-4 Pillar Lock Front Door Replacement -
Impact Bar Replacement - Front Outer ........................................................ 3-10
Bumper (Z06) ............................................. 2-5 Pillar Lock Front Door Replacement -
Hood Plate Stud Replacement (Z06) ............... 2-7 Inner ........................................................ 3-12
Wheelhouse Replacement - Front (Z06) ........ 2-10 Quarter Panel Replacement - Outer ............... 3-15
Pillar Lock Front Door Replacement - Impact Bar Replacement - Rear Bumper ....... 3-18
Outer (Z06) ............................................... 2-11 Rail Replacement - Front Section .................. 3-21
Impact Bar Replacement - Rear Sleeved Butt Joint Repair .............................. 3-25
Bumper (Z06) ............................................ 2-14 Windshield Panel Replacement - Lower ......... 3-26
Rail Replacement - Front (Z06) ..................... 2-20 Door Opening Frame Replacement - Side ...... 3-29
Rail Replacement - Front Section (Z06) ........ 2-22 Rail Replacement - Rear Section .................. 3-31
Rail End Replacement - Front (Z06) .............. 2-30 Floor Panel Replacement .............................. 3-35
Rail End Replacement - Rear (Z06) .............. 2-34 Compartment Panel Replacement - Rear ....... 3-38
Sleeved Butt Joint Repair (Z06) .................... 2-36 Panel Replacement - Rear End ..................... 3-40
Windshield Frame Replacement .................... 2-38 Sheet Molded Compound (SMC) Panel
2006 Pontiac Solstice/2007 Saturn SKY

Door Opening Frame Replacement - Side ...... 2-41 Bonding .................................................... 3-43
1
General Information
Actions to Take When Working with Fuel Foam Sound Deadeners Caution
Caution
General Information
Caution: Foam sound deadeners must be removed
Caution: Fuel Vapors can collect while servicing from areas within 152.4 mm (6 in) of where flame
fuel system parts in enclosed areas such as a is to be used for body repairs. When reinstalling
trunk. To reduce the risk of fire and increased foam sound deadeners, avoid inhaling fumes
exposure to vapors: as bodily injury may result.
• Use forced air ventilation such as a fan set
outside of the trunk. Glass and Sheet Metal Handling Caution
• Plug or cap any fuel system openings in order Caution: When working with any type of glass
to reduce fuel vapor formation. or sheet metal with exposed or rough edges, wear
• Clean up any spilled fuel immediately. approved safety glasses and gloves in order to
reduce the chance of personal injury.
• Avoid sparks and any source of ignition.
• Use signs to alert others in the work area that Safety Glasses Caution
fuel system work is in process.
Caution: Wear safety glasses in order to avoid eye
Approved Equipment for Collision Repair damage.
Caution SIR Caution
Caution: To avoid personal injury when exposed
to welding flashes or to galvanized (Zinc Oxide) Caution: When performing service on or near the
metal toxic fumes while grinding/cutting on SIR components or the SIR wiring, the SIR
any type of metal or sheet molded compound, you system must be disabled. Refer to SIR Disabling
and Enabling Zones. Failure to observe the correct
must work in a properly ventilated area, wearing
an approved respirator, eye protection, earplugs, procedure could cause deployment of the SIR
welding gloves, and protective clothing. components, personal injury, or unnecessary SIR
system repairs.
Battery Disconnect Caution
Sound Deadener Foam in the Lock Striker
Caution: Before servicing any electrical Pillars Caution
component, the ignition key must be in the OFF or
LOCK position and all electrical loads must be Caution: Sound deadener foam in the lock striker
OFF, unless instructed otherwise in these pillars can be a fire hazard. Create a weld flange
procedures. If a tool or equipment could easily to avoid welding directly to the lock striker pillars
come in contact with a live exposed electrical as damage to the vehicle and serious bodily
terminal, also disconnect the negative battery injury may result.
cable. Failure to follow these precautions
may cause personal injury and/or damage to the Fastener Notice
vehicle or its components.
Notice: Use the correct fastener in the correct
location. Replacement fasteners must be the correct
Collision Sectioning Caution part number for that application. Fasteners requiring
Caution: Sectioning should be performed only in replacement or fasteners requiring the use of
the recommended areas. Failure to do so may thread locking compound or sealant are identified in
compromise the structural integrity of the vehicle the service procedure. Do not use paints, lubricants, or
and cause personal injury if the vehicle is in a corrosion inhibitors on fasteners or fastener joint
collision. surfaces unless specified. These coatings affect
fastener torque and joint clamping force and may
damage the fastener. Use the correct tightening
sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
General Information 1-1

Specifications
Dimensions - Body (Door Openings)
1613519
2006 Pontiac Solstice/2007 Saturn SKY 3-1

Dimensions - Body (Motor Compartment)
1613522
3-2 2006 Pontiac Solstice/2007 Saturn SKY

Repair Instructions
Hinge Pillar Body Reinforcement
Replacement - Front
Removal Procedure
Caution: Refer to Approved Equipment for
Collision Repair Caution on page 1-1.
1. Disable the SIR system. Refer to SIR Disabling
and Enabling Zones.
2. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnect/Connect
Procedure.
3. Remove all related panels and components.
4. Repair as much of the damage as possible to
factory specifications.
5. Remove the side door frame and quarter panel.
Refer to Door Opening Frame Replacement -
Side on page 3-29.
Caution: Refer to Foam Sound Deadeners Caution 1616264
on page 1-1.
6. Note the location and remove the sealers and
anti–corrosion materials from the repair area,
as necessary. Refer to Anti-Corrosion Treatment
and Repair.
Important: Do not damage any inner panels or
reinforcements.
7. Locate and drill out all factory rivets. Note the
number and location of rivets for installation of
the hinge pillar body reinforcement.

1616261

8. Remove the damaged hinge pillar body
reinforcement.
1616262
Installation Procedure
1. Position the hinge pillar body reinforcement.
1616262
2. Install rivets accordingly.

3. Clean and prepare all surfaces.
4. Apply the sealers and anti-corrosion materials to
the repair area, as necessary. Refer to
Anti-Corrosion Treatment and Repair.
5. Paint the repair area. Refer to Basecoat/Clearcoat
Paint Systems.
6. Install the side door frame and quarter panel.
Refer to Door Opening Frame Replacement -
Side on page 3-29.
7. Install all related panels and components.
8. Connect the negative battery cable. Refer to
Procedure.
9. Enable the SIR system. Refer to SIR Disabling
and Enabling Zones.
1616265

Hinge Pillar Body Replacement - Front
Removal Procedure
The front hinge pillar panel is bolted and welded to the
side structure and frame rail. The replacement front
hinge pillar panel is serviced as an assembly.
You must remove and replace the side door opening
panel in order to replace the front hinge pillar.
1508861

and Enabling Zones.
Procedure.
factory specifications. Refer to Dimensions -
Body (Door Openings) on page 3-1 or Dimensions
- Body (Motor Compartment) on page 3-2.
5. Note the location of the sealers and the
anti-corrosion materials and remove these
components from the repair area as necessary.
Refer to Anti-Corrosion Treatment and Repair.
6. Remove the bolts (1) attaching the front hinge
pillar to the windshield frame.
986434
Important: Do NOT damage the inner panels or the

reinforcements.
7. Locate and remove all factory welds (1) from the
outer hinge pillar. Note the number and location of
the welds for installation of the new hinge pillar.
1508874

8. Locate and remove all factory welds (1) from the
inner hinge pillar. Note the number and location of
the welds for installation of the new hinge pillar.
1508869
9. Remove the damaged hinge pillar.

10. Note the location of the adhesive and remove all
remaining loose adhesive.
1508864
1. Prepare all welding attachment surfaces as
necessary.
2. Apply 3M® Weld-Thru Coating P/N 05916 or
equivalent to all mating surfaces.
3. Position the hinge pillar to the vehicle using
3-dimensional measuring equipment.
Notice: Refer to Fastener Notice on page 1-1.
4. Install the bolts.
1508865

5. Using a metal inert gas (MIG) welder, stitch weld
the inner hinge pillar to the vehicle in the locations
noted on the original panel.
1508869
6. Using a MIG welder, stitch weld the outer hinge

pillar to the vehicle in the locations noted on the
original panel.
7. Apply the sealers and the anti-corrosion materials
to the repair area, as necessary. Refer to
Paint Systems.
Procedure.
and Enabling Zones.
1508874
Windshield Frame Header Panel

Replacement - Front
Removal Procedure
and Enabling Zones.
Procedure.
Caution: Refer to Foam Sound Deadeners Caution
on page 1-1.
and Repair.
1583429

reinforcements.
5. Locate and drill out all factory welds. Note the
number and location of welds for installation of
the header panel.
1583431
6. Using a grinder or an equivalent tool, remove the

silicon bronze welds on each end of the header.
1583432
7. Remove the damaged header panel.
1583430

1. Drill 8 mm (5/16 in) plug weld holes in the service
part as necessary at the locations noted from the
original header panel.
2. Prepare all mating surfaces as necessary.
3. Apply 3M® Weld-Thru coating P/N 05916 or
1237857
4. Position the header panel.
1583430
5. Plug weld accordingly.

6. Continuous weld each side of the outer
header panel.
7. Clean and prepare all welded surfaces.
Paint Systems.
Procedure.
and Enabling Zones.
1583433

Pillar Lock Front Door
Replacement - Outer
Removal Procedure
The replacement inner lock panel is serviced as an
assembly. You must remove and replace the
outer body side panel in order to replace the outer
lock pillar.
1274768

and Enabling Zones.
Procedure.
3. Remove all related panels and components
including the outer body side panel. Refer to Door
Opening Frame Replacement - Side on
page 3-29.
on page 1-1.
anti-corrosion materials from the repair area, as
necessary. Refer to Anti-Corrosion Treatment and
Repair.
1276023
reinforcements.
number and location of the welds for installation
of the replacement part.

6. Remove the damaged inner lock pillar.
1276028
part as necessary in the locations noted on the
original panel.
2. Prepare all attachment surfaces as necessary.
1276033
4. Position the inner lock pillar.
1276034

6. Install all related panels.
Paint Systems.
10. Install all related components.
Procedure.
and Enabling Zones.
1276037
Pillar Lock Front Door Replacement - Inner
Removal Procedure
The replacement inner lock panel is serviced as an
assembly. You must remove and replace the
outer body side panel and the roof mounting bracket
in order to replace the inner lock pillar. The outer body
side panel and the roof mounting bracket must be
ordered separately.
1274768

and Enabling Zones.
Procedure.
factory specifications. Refer to Door Opening
and Roof Stowage Dimensions in Dimensions -
Body (Door Openings) on page 3-1 or Dimensions
- Body (Motor Compartment) on page 3-2.
on page 1-1.
anti-corrosion materials from the repair area, as
necessary. Refer to Anti-Corrosion Treatment and
Repair.
1274765

reinforcements.
number and location of the welds for installation
of the replacement part.
1276023
7. Verify the existence of structural weld-through

adhesive. Refer to Structure Adhesive -
Identification. If necessary use a chisel to separate
the inner rocker from the adjacent panels.
1276025
8. Remove the damaged inner lock pillar.
1276028

original panel.
2. Replace the structural adhesive with an additional
plug weld between the existing plug welds if
necessary.
3. Prepare all attachment surfaces as necessary.
1276033
5. Position the inner lock pillar. Refer to Door

Opening section of Dimensions - Body (Door
Openings) on page 3-1 or Dimensions - Body
(Motor Compartment) on page 3-2.
1276034
1276037

Important: Proper alignment of the roof mounting
bracket is critical for proper folding top operation and
alignment.
7. Position the roof mounting bracket.
9. Install all related panels.
Paint Systems.
13. Install all related components.
Procedure.
and Enabling Zones. 1276020
Quarter Panel Replacement - Outer
Tools Required
J 42058 Frame Adapter Clamp
Removal Procedure
The side door frame and the quarter panel are made
of stamped sheet metal, and are bonded to the
side structure and the frame rails with the combination
of structural adhesive dollops and urethane.
and Enabling Zones.
Procedure.
1615684
Caution: Refer to Actions to Take When Working

with Fuel Caution on page 1-1.
4. Make sure the fuel inlet is sealed before
proceeding with repair procedure.

5. Apply heat and pry to detach the adhesives along
the bonding surfaces.
1616251

reinforcements.
6. Locate and drill out all factory welds that attach
the quarter outer panel to the trunk gutter.
1616254
7. Remove the door frame and quarter panel from

the vehicle.
8. Note the location of the adhesives. Remove all
9. Inspect the side structure and frame rails for
damage.
10. Restore as much of the damage as possible to
the factory specifications.
11. Use J 42058 to secure the vehicle if pulling and
straightening is required.
1616248

1. Before applying adhesives, use shims to dry fit
the door frame and quarter panel for proper fit
and alignment.
2. Clean and prepare all bonding mating surfaces
according to adhesive manufacturer’s
recommendations.
Important: DO NOT top coat any bonding surface.
Use primer only on bonding surfaces. Refer to
adhesive manufacturer’s recommendations.
3. Apply a consistent bead of urethane 20 mm
(13/16 in) in diameter to the inner surface of
the door frame and the quarter panel to mate with
the side structure and frame rail and to all
areas originally bonded. Refer to Sheet Molded
Compound (SMC) Panel Bonding on page 3-43.
1616259
4. Apply structural adhesive dollops 20 mm (3/4 in)

in diameter to the inner surface of the door frame
and the quarter panel in areas originally bonded.
1616255
5. Position the door frame and the quarter panel to

the vehicle.
6. Apply pressure to the door frame and the quarter
panel to set the adhesive.
7. Clamp or tape the door frame and the quarter
panel in place as necessary.
8. Remove any excess adhesive.
Procedure.
and Enabling Zones.
1616248

Impact Bar Replacement - Rear Bumper
Tools Required
Removal Procedure
and Enabling Zones.
Procedure.
4. Remove or reposition the wiring to avoid damage.
1583428 straightening are required.
7. Locate the area inside the rear tub (1) over the
top welds of the rear bar.
1233792
8. Cut out an access hole (1) over the top welds of

the rear bar.
9. Save the cut-out piece to patch the hole.
anti-corrosion materials from the repair area.
1233790

Important: Do not cut into the frame rails.
11. Cut the welds around the perimeter of the frame
rail ends. Cut the welds favoring the impact bar
side of the joint.
12. Remove the damaged impact bar.
1205122
13. Extract pieces of the impact bar which are left

attached to the rail ends.
14. Straighten and deburr the rail ends. Keep the
perimeter and shape of the rail ends as original
as possible.
181153

1. Temporarily position the impact bar for proper fit
and alignment.
2. Clean and prepare all of the welded surfaces.
3. Apply 3M® weld-thru coating P/N 05916 or
equivalent as necessary and to the inside of
the rail ends.
4. Position the bumper impact bar to the vehicle
using three-dimensional measuring equipment.
181153

Important: If no trace of the original welds are
present, follow the pattern specified for welding the
side rails to the impact bar.
5. Using a metal inset gas (MIG) welder, stitch weld
the rear bar to the frame rail ends.
the repair area. Refer to Anti-Corrosion Treatment
and Repair.
7. Use the original cut-out piece to patch the
access hole.
1205122
8. Apply adhesive bonding material as necessary to

the repair area of the floor and the patch. Refer to
Sheet Molded Compound (SMC) Panel Bonding
on page 3-43.
9. Position the patch and press firmly into place.
Important: A leak proof seal is necessary so
that exhaust and fuel fumes cannot enter the vehicle.
10. Smooth out the adhesive around the
repaired area.
11. Verify that no voids or gaps occur in the adhesive.
Paint Systems.
Procedure.
15. Enable SIR system. Refer to SIR Disabling and
Enabling Zones.
1233797

Rail Replacement - Front Section
Removal Procedure
Caution: Sectioning should be performed only in
the recommended areas. Failure to do so may
compromise the structural integrity of the vehicle
and cause personal injury if the vehicle is in a
collision.
and Enabling Zones.
Procedure.
4. Repair as much of the damage as possible. Refer
to Dimensions - Body (Door Openings) on
1616267
page 3-1 or Dimensions - Body (Motor
Compartment) on page 3-2.
5. Remove the sealers and anti-corrosion materials
from the repair area, as necessary. Refer to
6. Locate the area on the rail where the
recommended sectioning repair will be performed.
Important: Note the number and location of the

factory welds for installation of the service rail.
7. Locate all necessary factory welds. Using a die
grinder with a cut-off wheel or similar tool,
remove the factory welds.

1619978

8. Using a sliding square and scribe tool, scribe a
line on the outer side surface of the rail.
9. Using the mark made in the previous step as a
starting point, use a sliding square to transfer a
line on the top, side, and bottom of the rail.
1619989
10. Cut the rail at the marked location.
1619992
11. Remove the damaged section of the rail.
1619993

1. On the service rail, determine the sectioning
location.
starting point, use a sliding square and scribing
tool to transfer a line on all of the way around the
rail. This is the same process as in the Removal
Procedure.
3. Cut the service part at the marked location.
1645014
4. Make a 50–mm (2–in) weld backer sleeve. Refer

to Sleeved Butt Joint Repair on page 3-25.
1617523
5. Grind the existing frame rail sectioning location

and the service rail sectioning location to a
45–degree angle.
748652

6. Install the backing plate.
1619997
7. Position the rail to the vehicle, using 3-dimensional

measuring equipment. Clamp the rail in place.
1620000
8. Stitch and plug weld accordingly.

10. Install all of the related panels and components.
11. Apply the sealers and anti-corrosion materials
12. Paint the repaired area. Refer to
Basecoat/Clearcoat Paint Systems.
Procedure.
and Enabling Zones.
1620004

Sleeved Butt Joint Repair
Caution: Refer to Collision Sectioning Caution on
page 1-1.
Important: When determining the area to perform the
sectioning near a riv-nut within the recommended
areas, choose a location that centers the sleeve
through the hole. This will ensure that riv-nut fasteners
remain straight during installation.
1. From the new unused portion of the service frame
rail, measure, mark, and cut 50 mm (2 in) of
frame rail to be used as a sleeve (backing plate)
for the sectioning joint.
2. Cut through each side of the sleeve to create
four individual L-shaped pieces that can be
installed in the new frame rail section.
3. Install the four pieces, one at a time.
857910
4. Trim the pieces as necessary, to provide a flush
fit along the inner surface of the new frame rail
section.
5. Tac weld all four L-shaped pieces together.
6. Remove the sleeve from the rail.
7. Drill 8 mm (5/16 in) holes 13 mm (1/2 in) from the
sectioning edge on the rail on the vehicle and the
service rail.
9. Apply 3M weld-thru coating P/N 05916 or
equivalent as necessary.
10. Using a metal inert gas (MIG) welder, tack weld
the four pieces to the inner surface of the new
frame rail section.
11. Grind the sleeve as necessary to allow for
accurate alignment of the existing frame rail.

1617523

12. Install the new frame rail section to the existing
frame rail to create the butt joint while maintaining
a gap of one and one half frame rail metal
thickness at the sleeve butt-joint.
13. Inspect the new frame rail section using
three-dimensional measurements.
1617524
Important: Use a 25 mm (1 in) stitch weld to avoid

minimal heat distortion.
14. Using a MIG welder, weld completely around the
sleeve joint.
1620007
Windshield Panel Replacement - Lower

Removal Procedure
and Enabling Zones.
Procedure.
on page 1-1.
and Repair.
1588007

reinforcements.
number and location of welds for installation of
the windshield frame side panel.
1588010
7. Using a grinder or an equivalent tool, remove the

silicon bronze welds at the upper windshield
frame side panel and header location.
1615418
8. Remove the damaged windshield frame

side panel.
1588005

part as necessary at the locations noted from the
original windshield frame side panel.
3. Apply 3M® Weld-Thru coating P/N 05916 or
1615421
4. Position the windshield frame side panel.
1588005

6. Continuous weld the upper windshield frame side
panel to the header joint.
Paint Systems.
Procedure.
and Enabling Zones.
1615425

Door Opening Frame Replacement - Side
Tools Required
Removal Procedure
The side door frame and the quarter panel are made
of stamped sheet metal, and are bonded to the
side structure and the frame rails with the combination
of structural adhesive dollops and urethane.
and Enabling Zones.
Procedure.
1615684
Caution: Refer to Actions to Take When Working
4. Make sure the fuel inlet is sealed before
proceeding with repair procedure.
5. Apply heat and pry to detach the adhesives along
the bonding surfaces.

1616251

reinforcements.
6. Locate and drill out all factory welds that attach
the quarter outer panel to the trunk gutter.
1616254
7. Remove the door frame and quarter panel from

the vehicle.
8. Note the location of the adhesives. Remove all
9. Inspect the side structure and frame rails for
damage.
10. Restore as much of the damage as possible to
1616248
1. Before applying adhesives, use shims to dry fit
the door frame and quarter panel for proper fit
and alignment.
recommendations.
3. Apply a consistent bead of urethane 20 mm
(13/16 in) in diameter to the inner surface of
the door frame and the quarter panel to mate with
the side structure and frame rail and to all
areas originally bonded. Refer to Sheet Molded
1616259

4. Apply structural adhesive dollops 20 mm (3/4 in)
in diameter to the inner surface of the door frame
and the quarter panel in areas originally bonded.
1616255
5. Position the door frame and the quarter panel to

the vehicle.
6. Apply pressure to the door frame and the quarter
panel to set the adhesive.
7. Clamp or tape the door frame and the quarter
panel in place as necessary.
Procedure.
and Enabling Zones.
1616248
Rail Replacement - Rear Section

Removal Procedure
and Enabling Zones.
Procedure.
4. Remove the rear impact bar. Refer to Impact Bar
Replacement - Rear Bumper on page 3-18.
5. Remove the quarter panel. Refer to Quarter Panel
Replacement - Outer on page 3-15.
1620008

6. Remove the rear compartment. Refer to
Compartment Panel Replacement - Rear
on page 3-38.
anti-corrosion materials from the repair area.
8. Repair as much of the damage as possible to the
Caution: Refer to Collision Sectioning Caution on
page 1-1.
9. Detrmine the sectioning joint location.
10. Locate 5 mm (5/32 in) hole on the outboard
surface, rearward of the rear suspension
mounting.
11. Measure 25 mm (1 in) (a) rearward from the
hole (a).
12. Mark the top of the frame rail at the sectioning
location.
13. At the mark align a sliding square or similar tool
square to surface to the vertical walls of the
frame rail.
14. Scribe a line to both sides of the frame rail.
1617509
15. Apply masking tape (1) to the scribe line

completely around the frame rail.
16. Cut the frame rail at the rear edge of the tape line
using a reciprocating saw or equivalent tool (1).
1617511

17. Remove the damaged frame rail end section (1).
1617513
1. Locate the 5 mm (5/32 in) hole on the outboard
surface of the service rail.
2. Measure rearward from the hole 25 mm (1 in).
Mark the location (a) in the same manner as in
the Removal Procedure.
1587986

starting point, use a sliding square and a scribing
tool to transfer a line all of the way around the
service rail.
4. Cut the service rail at the marked location.
1617495

5. Grind the existing frame rail and the new service
part seam to taper the seam at a 45-degree angle.
6. Clean and prepare all of the welded mating
surfaces.
7. Apply 3M weld-thru coating P/N 05916 or
equivalent as necessary to all bare metal surfaces.
748652
8. Make a 50 mm weld-backer sleeve. Refer ti

Sleeved Butt Joint Repair on page 3-25.
1617523
9. Position the service frame section to the

existing frame.
10. Maintain a gap of one and one half frame rail
metal thickness at the sectioning joint (1) and
clamp in place.
11. Inspect the frame measurements
three-dimensional to ensure proper position of the
service frame.
1617500

Important: Use a 25-mm (1-in) stitch weld to avoid
minimal heat distortion.
12. Using a MIG welder, weld completely around the
sleeve joint.
13. Install the rear impact bar. Refer to Impact Bar
Replacement - Rear Bumper on page 3-18.
14. Install the quarter panel. Refer to Quarter Panel
Replacement - Outer on page 3-15.
15. Install the rear compartment. Refer to
Compartment Panel Replacement - Rear on
page 3-38.
the repair area. Refer to Anti-Corrosion Treatment
and Repair.
17. Paint the repair area. Refer to Basecoat/Clearcoat 1620007
Paint Systems. in Paint and Coating.
Procedure.
and Enabling Zones.
Floor Panel Replacement
Tools Required
Removal Procedure
1. Use the J 42058 to secure the vehicle if pulling
and straightening is required.
and Enabling Zones.

Procedure.
5. Remove or reposition electrical components and
wiring harness as necessary to avoid damage. 1497179
6. Remove wiring harness clips for transfer to new
floor panel.

8. Remove the outer reinforcements that attach to
the floor panel and the frame rail.
966581
9. Locate and drill out all necessary factory welds.
1587987
10. Remove the floor panel from the vehicle.

11. Save all brackets, mounting studs, and
accessories for transfer to the new floor.
966590

Important: If the location of the original plug weld
holes can not be determined, space the plug
weld holes every 40 mm (1 1/2 in).
original panel.
1647028
4. Install the floor panel to the vehicle.
966590

6. Install the floor panel reinforcements.
8. Install all of the related panels and components.
Paint Systems.
Procedure.
and Enabling Zones.
1587985

Compartment Panel Replacement - Rear
Tools Required
Removal Procedure
The rear compartment panel is made of sheet molded
compound (SMC), and is bonded to the rear
structure and frame rails with structural adhesive.
and Enabling Zones.
Procedure.
1587989 Caution: Refer to Actions to Take When Working
4. Ensure that the fuel inlet is sealed before
proceeding with the repair procedure.
5. Remove the right and left quarter panels. Refer to
Quarter Panel Replacement - Outer on page 3-15.
6. Remove bolts attaching the rear compartment

panel to the frame rails.
1587992

Important: The front edge of the rear compartment
panel is also bonded across the seatback area and
along the top of the rear right and left rails.
7. Remove the rear compartment panel by applying
heat to the inside of the rear compartment along
the bonding surface (1) as indicated.
8. Pry to detach adhesive along the bonding surface.
1587993
9. Remove the rear compartment panel.

10. Save any and all brackets, mounting studs, and
accessories for transfer to the new rear
compartment panel.
12. Inspect the rear structure and frame rails for
damage.
1587994

1. Before applying adhesive dry fit the rear
compartment panel for proper fit and alignment.
adhesive manufacturer’s recommendations. The
recommended adhesive is windshield urethane. Refer
to Adhesive Service Kit Description.
recommendations.
3. Apply a consistent bead of windshield urethane
12 mm (1/2 in) in diameter to the top surface of
the rear frame rails (1), to the attaching surface of
the seat back, and to the original bonding
surfaces (2). Refer to Sheet Molded
4. Apply windshield urethane 20 mm (3/4 in) in
diameter in spots to the fuel tank support bar (3).
1587995

5. Install the rear compartment panel to the vehicle.
6. Apply pressure to the rear compartment panel to
set the adhesive.
1587994
7. Install the screws attaching the rear compartment

panel to the frame rails.
8. Clamp or mechanically fasten the rear
compartment panel into place as necessary.
10. Install the right and left quarter panels. Refer to
Quarter Panel Replacement - Outer on page 3-15.
Procedure.
and Enabling Zones.
1587992
Panel Replacement - Rear End

Tools Required
Removal Procedure
and Enabling Zones.
Procedure.
1620009

4. Remove the bolts holding the rear end panel to
the rear end compartment.
5. Remove the rear end panel by applying heat, and
prying to detach the adhesive along the bonding
surface (a).
1617501
6. Remove the rear end panel.

8. Inspect the rear structure and frame rails for
damage.
1647016

Important: Shims may be necessary to achieve
proper panel alignment.
1. Before applying the adhesive, dry fit the rear end
panel for proper fit and alignment.
according to the adhesive manufacturer’s
recommendations.
3. Apply a consistent bead of structural adhesive
10 mm (3/8 in) in diameter to the rear
compartment panel in order to mate with the rear
end panel.
4. Apply a consistent bead of structural adhesive
10 mm (3/8 in) in diameter to both the right and
the left tail lamp pocket locations.
Install the rear compartment frame (1).
1647020
5. Clamp or mechanically fasten the rear

compartment frame into place.
Procedure.
and Enabling Zones.
1620009

Description and Operation
Sheet Molded Compound (SMC) Panel Important: DO NOT top coat any adhesive bonding
Bonding mating surface. Use primer only on bonding surfaces.
Refer to adhesive manufacturer’s recommendations
This is intended to provide general guidelines for for priming applications.
sheet molded compound (SMC) adhesive bonding of
full panel replacement in regards to collision repair Adhesives currently meeting the performance
procedures: requirements include General Motors materials and
Sectioning, partial panel of full panels, is not supported products manufactured by Ashland and Lord Fusor. At
by General Motors unless specifically documented this time, ONLY the adhesive products listed below
in a Service Bulletin or Manual: meet this guideline:
Important: Prepare the surfaces to be bonded

recommendations. Many adhesive manufacturers have
different preparation methods. Do not intermix
adhesive manufacturers systems. Mixing materials
from different manufacturers can produce
unsatisfactory results.
Sheet Molded Compound (SMC) Panel Bonding
Ashland Pliogrip Lord Fusor Structural
GM Goodwrench® GMSPO of Canada Structure Adhesive Adhesive Product Type
89020330 8902332 7770B 127 EZ Medium Set
N/A N/A 7779B N/A Fast Set
Canadian applications may use U.S. part numbers. Refer to your GM Dealer Parts Department for the correct part number
applications.
Special Tools and Equipment

Illustration Tool Number/ Description
J 42058Adapter Clamp for

Conv. Anchoring System
181147

NOTES

NOTES

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General Motors.

The Collision Repair

Service information is also available on the web.

2006 Chevrolet Corvette Z06

2006 Pontiac Solstice/2007 Saturn SKY

General Information 1-1

Dimensions - Body (Door Openings)

2006 Pontiac Solstice/2007 Saturn SKY

2006 Pontiac Solstice/2007 Saturn SKY 3-1

3-2 2006 Pontiac Solstice/2007 Saturn SKY

2006 Pontiac Solstice/2007 Saturn SKY

2006 Pontiac Solstice/2007 Saturn SKY 3-3

2. Install rivets accordingly.

3-4 2006 Pontiac Solstice/2007 Saturn SKY

Caution: Refer to Approved Equipment for

Important: Do NOT damage the inner panels or the

2006 Pontiac Solstice/2007 Saturn SKY

2006 Pontiac Solstice/2007 Saturn SKY 3-5

9. Remove the damaged hinge pillar.

3-6 2006 Pontiac Solstice/2007 Saturn SKY

6. Using a MIG welder, stitch weld the outer hinge

Windshield Frame Header Panel

2006 Pontiac Solstice/2007 Saturn SKY

2006 Pontiac Solstice/2007 Saturn SKY 3-7

6. Using a grinder or an equivalent tool, remove the

7. Remove the damaged header panel.

3-8 2006 Pontiac Solstice/2007 Saturn SKY

4. Position the header panel.

5. Plug weld accordingly.

2006 Pontiac Solstice/2007 Saturn SKY

2006 Pontiac Solstice/2007 Saturn SKY 3-9

Caution: Refer to Approved Equipment for

3-10 2006 Pontiac Solstice/2007 Saturn SKY

4. Position the inner lock pillar.

2006 Pontiac Solstice/2007 Saturn SKY

2006 Pontiac Solstice/2007 Saturn SKY 3-11

Pillar Lock Front Door Replacement - Inner

Caution: Refer to Approved Equipment for

3-12 2006 Pontiac Solstice/2007 Saturn SKY

7. Verify the existence of structural weld-through

8. Remove the damaged inner lock pillar.

2006 Pontiac Solstice/2007 Saturn SKY

2006 Pontiac Solstice/2007 Saturn SKY 3-13

5. Position the inner lock pillar. Refer to Door

6. Plug weld accordingly.

3-14 2006 Pontiac Solstice/2007 Saturn SKY

Quarter Panel Replacement - Outer

2006 Pontiac Solstice/2007 Saturn SKY

2006 Pontiac Solstice/2007 Saturn SKY 3-15

Important: Do not damage any inner panels or

7. Remove the door frame and quarter panel from

3-16 2006 Pontiac Solstice/2007 Saturn SKY

4. Apply structural adhesive dollops 20 mm (3/4 in)

5. Position the door frame and the quarter panel to

2006 Pontiac Solstice/2007 Saturn SKY

2006 Pontiac Solstice/2007 Saturn SKY 3-17

8. Cut out an access hole (1) over the top welds of

3-18 2006 Pontiac Solstice/2007 Saturn SKY

13. Extract pieces of the impact bar which are left

2006 Pontiac Solstice/2007 Saturn SKY

2006 Pontiac Solstice/2007 Saturn SKY 3-19

8. Apply adhesive bonding material as necessary to

3-20 2006 Pontiac Solstice/2007 Saturn SKY