Cavalier Sunfire Despiece Chasis PDF

TABLE OF CONTENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
PANEL IDENTIFICATION ___________________ 2

RADIATOR SUPPORT ASSEMBLY ____________ 4
FRONT WHEELHOUSE ASSEMBLY __________ 6
FRONT LOWER RAIL ASSEMBLY ____________ 8
FRONT SUSPENSION SUPPORT (#1 BAR) __ 11
DOOR FRAME OPENING ___________________ 14
DOOR SERVICE ___________________________ 20
ROOF PANEL _____________________________ 21
QUARTER PANEL _________________________ 22
OUTER REAR WHEELHOUSE ______________ 26
REAR RAIL _______________________________ 28
REAR FLOOR ASSEMBLY __________________ 31
REAR END PANEL ________________________ 36
BODY DIMENSIONS _______________________ 37
CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

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

1. PANEL IDENTIFICATION
TPO on Cavalier and Sunfire Sedan;

RIM on Sunfire Coupe
KEY TO COMPONENTS:
Reinforced injected molded (RIM) plastic

or thermoplastic olefin (TPO)
High-strength low-alloy (HSLA)
steel parts
2. RADIATOR SUPPORT ASSEMBLY

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

Remove or Disconnect
1. Remove all related panels and components.

2. Visually inspect and restore as much of the damage as possible to
factory specifications.
3. Remove sealers, sound deadeners and corrosion materials as
necessary.
4. Locate, mark and drill out all factory welds. Note the number of
welds for installation of the service panels.
5. Remove the damaged panels in the radiator support assembly
Install or Connect
1. Prepare mating surfaces and check for proper fit of the service
panels.
2. On the service panels, drill 8mm (5/16") plug weld holes as
necessary in the locations noted from the original assembly.
3. Position the service panels, check fit using body dimensions, and
plug weld accordingly with frequent measurements to ensure proper
fit.
4. Clean and prepare welded surfaces. Prime with two-part catalyzed
primer. Apply sealers and corrosion protection materials, as
necessary. Do not combine paint systems. Refer to paint
manufacturers recommendations. Reinstall all related panels and
components.

3. FRONT WHEELHOUSE ASSEMBLY

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

Visually inspect and restore as much of the damage as possible to factory specifications.
Remove sealers, sound deadeners and corrosion materials as necessary.
Locate, mark and drill out all factory welds. Note the number of welds for installation of the service
assembly.
Notice
There are five welds that secure the strut cap to the cowl plenum. Drill through only one layer of
metal. Any holes drilled through the cowl plenum must be filled before installation of the new
wheelhouse assembly.
5. Remove the damaged front wheelhouse assembly.
Caution
When servicing the wheelhouse assembly at the cowl plenum, it is advised you use a fire resistant
welding blanket (such as part #J41156 available from Kent-Moore) to help avoid damage to the
interior of the vehicle. Install the blanket between the cowl and the foam pad underneath the carpet
where the assembly is attached.
Install or Connect
1. Prepare mating surfaces and check for proper fit of the wheelhouse service assembly.
2. On the service assembly, drill 8mm (5/16") plug weld holes as necessary in the locations noted from
the original assembly.
3. Position the service assembly, check fit using body dimensions, and plug and stitch weld accordingly
with frequent measurements of the strut cap and fender mounting locations to ensure proper fit (Figure
3-3).
4. Clean and prepare welded surfaces. Prime with two-part catalyzed primer. Apply sealers and
corrosion protection materials, as necessary. Do not combine paint systems. Refer to paint
manufacturers recommendations. Reinstall all related panels and components.

4. FRONT LOWER RAIL ASSEMBLY

Lower Rail Sub-Assembly
Replacement of the engine compartment lower rail assemblies has been

improved on the Cavalier and Sunfire through the use of a sub-assembly service
part. This helps to simplify ordering, stocking and replacement procedures.
The lower rail service part comes as a complete assembly, including all
brackets and reinforcements (Figure 4-1). Bumper mounting brackets can be
replaced separately.
Bumper mounting brackets

can be ordered separately
FIGURE 4-1
LOWER RAIL SUB-ASSEMBLY

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


Caution
When servicing the lower rail, it is advised you use a fire resistant welding
blanket (such as part #J41156 available from Kent-Moore) to help avoid
damage to the interior of the vehicle. Install the blanket between the floor
pan and the foam pad underneath the carpet.
Install or Connect
1. Prepare mating surfaces and check for proper fit of the lower rail service
assembly.
2. On the service assembly, drill 8mm (5/16") plug weld holes as necessary in
the locations noted from the original parts.
3. Position the service assembly and check fit using body dimensions. Make sure
the suspension support properly mates over the lower rail bracket. Plug weld
accordingly with frequent measurements to ensure proper fit.
4. Clean and prepare welded surfaces. Prime with two-part catalyzed primer.
Apply corrosion protection materials and sealers, as necessary.
5. Apply Dominion Sure Seal paintable sound deadening pads (part #110900)
to the floor as necessary to match original sound deadening.
6. Do not combine paint systems. Refer to paint manufacturers recommendations.
Reinstall all related panels and components.
7. When reinstalling the suspension crossmember, torque all six fasteners to 130
Nm (96 lbs. ft.).
10
FIGURE 4-3
SEPARATE THE LOWER RAIL FROM THE COWL AND
FLOOR EXTENSIONS (UNDERBODY VIEW )
5. FRONT SUSPENSION SUPPORT ASSEMBLY (#1 BAR)

The front suspension support ties the lower rails together across the lower portion of the cowl. Located on
this panel assembly are two of the six mounting locations for the suspension crossmember (Figure 5-1). The
panel assembly comes complete with the cagenut brackets installed. The cagenut brackets can also be
ordered and replaced separately.
When the front lower rails are repaired or replaced, the front suspension support should be inspected for the
following:
Surface deformation in the suspension crossmember mounting areas
Any separation in the welds securing the cagenut brackets to the support
If either of these conditions exist, the cagenut brackets or front suspension support assembly must be replaced.
FIGURE 5-1
FRONT SUSPENSION SUPPORT ASSEMBLY (#1 B AR)
11

5. FRONT SUSPENSION SUPPORT (#1 BAR)

FULL REPLACEMENT OF THE FRONT SUSPENSION SUPPORT ASSEMBLY
1. Remove all related panels and components, including the linkage that passes through the front
suspension support panel.
4. Locate, mark and drill out factory welds on the damaged assembly. Note the number of welds for
installation of the service assembly.
5. Remove the damaged suspension support assembly.
Install or Connect
1. Prepare mating surfaces and check for proper fit of the suspension support service assembly.
the original parts.
3. Position the service assembly over the lower rail brackets and check fit using body dimensions (refer to
Figure 4-2 on page 9). Plug weld accordingly.
12
FIGURE 5-2
CUT A WINDOW IN THE FLOOR
5. FRONT SUSPENSION SUPPORT (#1 BAR)

REPLACEMENT OF THE FRONT SUSPENSION SUPPORT CAGENUT
BRACKETS
If damage permits, it is possible to replace just the cagenut brackets. The replacement procedure is similar
to that used to replace bodymount cagenut assemblies on full-frame vehicles. This is done by cutting a window
in the floor pan to access the cagenut bracket.
1. Remove all related panels and components, including the carpeting and center console if necessary.
3. From the underside of the vehicle, run a centerpunch through the cagenut mounting bracket and strike
with a hammer. This will mark the center of the window to be cut in the floor pan.
4. With a heat gun and gasket scraper, remove the sound deadener material from the floor pan within a
200mm (8") radius of the dimple created in the previous step.
5. Measure and mark a 100mm (4") square centered around the dimple created in step #4. This will be
the window used to access the cagenut brackets.
6. Cut three sides of the square marked in the previous step and pry the window toward the center of the
vehicle (Figure 5-2).
Caution
When servicing the cagenut brackets, it is advised you use a fire resistant welding blanket (such as
part #J41156 available from Kent-Moore) to help avoid damage to the interior of the vehicle.
7. Locate, centerpunch and drill out the two resistance welds that secure the bracket to the front
suspension support. Be careful to only drill through one layer of metal.
Notice
It is important to leave a layer of metal for installation of the new cagenut bracket. If more than one
layer is drilled, fill the hole with a plug weld before installing the new bracket.
Install or Connect
1. Prepare mating surfaces and check for proper fit of the new cagenut bracket. Position the bracket
using body dimensions and secure it to the suspension support panel by temporarily installing and
tightening the crossmember bolt.
2. Plug weld the new cagenut bracket and then remove the crossmember bolt.
4. Bend the access window back to its original position and stitch weld the entire perimeter.
corrosion protection materials, as necessary.
6. Apply Dominion Sure Seal paintable sound deadening pads (part #110900) to the floor as necessary
to match original sound deadening.
7. Do not combine paint systems. Refer to paint manufacturers recommendations. Reinstall all related
panels and components.
8. When reinstalling the suspension crossmember, torque all six fasteners to 130 Nm (96 lbs. ft.).
13

6. DOOR FRAME OPENING

The side door frame openings feature a unique modular build sub-assembly design
to improve manufacturing quality. They are composed of numerous individual
components that are pre-assembled and then attached to the vehicle as a single
unit.
The door frame can be replaced as a complete unit or various segments of it can
be sectioned, which is usually much faster and more cost effective. However,
there are some key structural areas where sectioning should not take place (Figures
6-1 and 6-2). Since left and right door frame openings are only available as
complete assemblies, service parts for sectioning must be cut from the complete
assembly and modified as necessary.
FIGURE 6-1
COUPE DOOR FRAME OPENING
(SECTIONING SHOULD NOT TAKE PLACE
IN THE SHADED AREAS)
Notice
Four welds must be added on the lower hinge pillar when installing the
service assembly. These welds are essential to ensure the structural
integrity of the vehicle. Use the door frame opening weld template
provided with the service assembly to properly locate the position of these
welds.
14
FIGURE 6-2
SEDAN DOOR FRAME OPENING
(SECTIONING SHOULD NOT TAKE PLACE
IN THE SHADED AREAS)

DOOR FRAME OPENING FULL
REPLACEMENT PROCEDURE
1. Remove all related panels and components

including the roof panel and upper outer rail
reinforcement.
2. Visually inspect and restore as much of the
damage as possible to factory specifications.
3. Remove sealers, sound deadeners and corrosion
materials as necessary.
4. Locate, mark and drill out all factory welds. Note
the number of welds for installation of the service
assembly.
5. Remove the damaged door frame opening.
Install or Connect
FIGURE 6-3
INJECT EXPANDABLE FOAM INTO THE
A PILLAR AND APPLY SEAM SEALER
TO THE JOINT AT THE ROOF LINE
FIGURE 6-4
APPLY SEALER TO THE INNER COWL PLENUM
1. Prepare mating surfaces and check for proper fit of

the door frame opening service assembly.
2. On the service assembly, drill 8mm (5/16") plug
weld holes as necessary in the locations noted from
3. Position the service assembly, check fit using body
dimensions, and plug weld accordingly with
frequent measurements to ensure proper fit.
4. Inject expandable foam into the A pillar through
the bottom interior trim mounting hole (Figure 6-3).
This helps reduce noise in the passenger
compartment.
5. Clean and prepare welded surfaces. Prime with
two-part catalyzed primer. Apply sealers and
6. Apply a full-bodied caulk along the surface of the
baffle to ensure a proper seal with the inner cowl
plenum (Figure 6-4).
7. Apply seam sealer, such as 3M Ultra Pro 08361,
along the top edge of the A pillar joint at the
roof line (Figure 6-3).
8. Do not combine paint systems. Refer to paint
manufacturers recommendations. Reinstall all
related panels and components.
15


LOWER FRONT HINGE PILLAR SECTIONING PROCEDURE
Sectioning is performed on the lower front hinge pillar between the two hinge mounting locations. The hinge
pillar inner reinforcement on the service part is used as a backing plate when welding the new section in
place.
1.
2.
3.
4.
5.
6.
7.
8.

Drill out and remove the access panel located on the upper outer rail reinforcement (Figure 6-5). Cut
and pry the outer reinforcement away from the hinge pillar as necessary to provide room for the
sectioning template (Figure 6-6).
Align the template provided with the service part and mark a line where indicated. Cut the hinge
pillar and inner reinforcement along this line.
Perform additional sectioning procedures as necessary to remove damaged areas of the door frame
opening.
Locate, mark and drill out all necessary factory welds. Note the number of welds for installation of
the service part.
Remove the damaged section of the door frame opening and the hinge pillar inner reinforcement.
FIGURE 6-5
REMOVE THE ACCESS PANEL ON THE FRONT LOWER
RAIL OUTER REINFORCEMENT
FIGURE 6-6
CUT AND PRY OUTER REINFORCEMENT
16

9. Drill out the 4 welds attaching the hinge
pillar to the inner reinforcement above
the cut line. Remove the remaining
section of the inner reinforcement.
(Figure 6-7)
Install or Connect
1. Align the template on the service part

and mark a cut line where indicated.
2. Cut the service part along the marked
line. Do not damage the hinge pillar
inner reinforcement.
Notice
Only cut the outer surface of the hinge
pillar service part. The inner
reinforcement is used as a backing plate
when installing the new section.
FIGURE 6-7
REMOVE THE REMAINING SECTION OF THE
INNER R EINFORCEMENT
3. Drill out the 4 welds attaching the hinge

pillar to the inner reinforcement above
the cut line. Do not drill through the
inner reinforcement.
4. Perform additional sectioning
procedures as necessary to remove the
unused areas of the service part. Drill
8mm (5/16") plug weld holes as
necessary in the locations noted from
the original section. Prepare all mating
surfaces for welding.
5. Position the door frame opening service
part. Make sure the inner reinforcement
extending from the top of the hinge
pillar service part is properly positioned
within the existing hinge pillar section
(Figure 6-8). Check fit using body
dimensions and plug weld accordingly
with frequent measurements to ensure
proper fit.
Notice
To ensure a secure weld, the hinge
pillar sectioning joint should have a gap
of approximately one-and-a-half times
the thickness of the metal. Trim the
parts as necessary to achieve this.
FIGURE 6-8
POSITION THE NEW DOOR FRAME SECTION
17


6. Stitch weld along the entire hinge pillar sectioning
joint. Make 25mm (1") welds along the seam with
25mm (1") gaps between. Then go back and
complete the stitch weld. This will create a solid
joint with minimal heat distortion.
7. Straighten the upper outer rail reinforcement and
weld seam.
Notice
Leave a gap at the forward edge of the baffle to
allow for proper water drainage.
8. Apply a full-bodied caulk along the surface of the
baffle to ensure a proper seal with the inner cowl
plenum (Figure 6-9).
9. Complete all other welds and sectioning
procedures as necessary.
corrosion protection materials, as necessary. Do
not combine paint systems. Refer to paint
FIGURE 6-9
APPLY SEALER TO THE INNER COWL
PLENUM
DOOR FRAME OPENING GENERAL SECTIONING

PROCEDURES
When sectioning areas other than the hinge pillar, a 100mm (4") backing plate must be
used behind the joint to ensure a solid and secure weld in areas where there is no inner
reinforcement. Backing plates can usually be cut from the unused portion of the service
part or the damaged section of the door frame opening.
Notice
There are some key areas where sectioning should not take place (Figures 6-1
and 6-2 on page 14). Sectioning in these areas may compromise the structural
integrity of the vehicle.
Also, the rocker panel can be replaced in its entirety when the quarter panel has been
removed.
18

1.
2.
3.
4.

Cut the door frame opening where it is to be sectioned. Do not damage any inner panels or
reinforcements.
5. Locate, mark and drill out all necessary factory welds. Note the number of welds for installation of
the service part.
6. Remove the damaged section of the door frame opening.
Install or Connect
1. Cut the service part to match the damaged section of the door frame opening and remove the unused
portion of the service part.
2. Cut a 100mm (4") backing plate from the unused portion of the service part or damaged section of
the door frame opening. Modify the backing plate as necessary so that it will fit behind the
sectioning joint (Figure 6-10).
3. On the service part, drill 8mm (5/16") plug weld holes as necessary in the locations noted from the
original section. Also, drill plug weld holes along the sectioning cut on both the service part and the
remaining original part. These will be used to weld the panel to the backing plate.
4. Prepare mating surfaces and slide the backing plates 50mm (2") beneath the sectioning cuts on the
vehicle and plug weld in place.
Notice
To ensure a secure weld, the sectioning joints should have a gap of approximately one-and-a-half
times the thickness of the metal. Trim the parts as necessary to achieve this.
FIGURE 6-10
INSTALL A BACKING PLATE
AND PLUG WELD THE NEW PANEL
5. Position the service part, allowing it to overlap the

exposed 50mm (2") of the backing plates. Check
fit using body dimensions and plug weld
accordingly with frequent measurements to ensure
proper fit (Figure 6-10).
6. Stitch weld along the sectioning joints. Make
25mm (1") welds along the seam with 25mm (1")
gaps between. Then go back and complete the
stitch weld. This will create a solid joint with
minimal heat distortion.
7. Complete all other welds as necessary.
corrosion protection materials, as necessary. Do
19

7. DOOR SERVICE
The doors are available as complete
assemblies (Figures 7-1 and 7-2).
Additionally, the outer door panels are
available separately. Use conventional
service procedures when repairing
damage to the doors. All doors feature
bolt-on hinges and an HSLA door beam
for added strength and occupant
protection in the event of a side collision.
FIGURE 7-1
SEDAN DOOR A SSEMBLY
FIGURE 7-2
COUPE DOOR ASSEMBLY
20
8. ROOF PANEL
The roof is made of steel and welded to the steel roof structure. The roof panel is supplied
as part of an assembly that includes the center roof support. The roof assemblies are
unique to coupe and sedan models.
Notice
The headliner, windshield and backglass must be removed prior to removal of
the roof assembly. Protect the interior of the vehicle by covering it with blankets
and use care when working near adjacent panels, glass, weatherstrips and
moldings.
1. Remove all related panels and components to gain proper access to the welds
attaching the roof assembly to the vehicle.
3. Locate, mark and drill out all factory welds.
4. Remove the roof panel and center roof support.
Install or Connect
1. Prepare mating surfaces and check for proper fit of the roof assembly.
2. Apply urethane memory tape to front and rear roof bows before installing roof
panel.
3. Position the roof panel, check fit using body dimensions, and plug weld
accordingly with frequent measurements to ensure proper fit.
Apply sealers and corrosion protection materials, as necessary. Do not combine
paint systems. Refer to paint manufacturers recommendations. Reinstall all
Center roof support
FIGURE 8-1
ROOF A SSEMBLY
21

9. QUARTER PANEL
To simplify repairs, the quarter panels are only available as sub-assemblies including filler panels and taillight
mounting panels (Figures 9-1 and 9-2). There are unique replacement procedures for the coupe and sedan
models. A key difference is that the rear window can be left in place when performing quarter panel service
on the coupe model, but must be removed on the sedan model. Also, the sedan quarter panel service
procedure incorporates sectioning to simplify replacement.
COUPE QUARTER PANEL REPLACEMENT

1. Remove all related panels and components including the modular side glass and close-out molding.
Notice
The quarter window close-out molding is retained with two-sided tape and urethane. Use the E-Z
Strip Molding Tool (part # 217-80003) to remove this molding (call 1-800-GM-TOOLS).
2.
3.
4.
5.
Mask the rear window lace and glass to protect them from possible damage.
Locate, mark and drill out all accessible factory welds on the quarter panel assembly. Note the
number of welds for installation of the service assembly.
Gutter extension
FIGURE 9-1
COUPE QUARTER PANEL A SSEMBLY
22
Gutter extension
FIGURE 9-2
SEDAN QUARTER PANEL ASSEMBLY
9. QUARTER PANEL
6. Cut a hole in the damaged quarter panel to gain access to the inside surface of the drip rail at the
back glass to simplify removal (Figure 9-3).
7. Locate and drill out all factory welds along the quarter panel drip rail at the backglass.
8. Remove the damaged quarter panel assembly. Note how the quarter panel assembly mates with the
rear gutter for installation of the new assembly.
Caution
Take care not to damage the rear window when removing the quarter panel.
Install or Connect
1. Prepare mating surfaces and check for proper fit of the quarter panel service assembly.
3. Position the service assembly. Allow the quarter panel to wrap over the rear gutter and then slide the
entire assembly forward so that the gutter extension slips beneath the rear gutter. Check fit using
body dimensions, and plug weld accordingly with frequent measurements to ensure proper fit.
FUEL FILLER NECK
Care must be taken to ensure that the fuel filler neck is properly sealed when replacing the right quarter panel.
Use SPO Sealing Strip (Part #12395952) between the quarter panel and fuel filler neck. Install using the
provided instructions.
FIGURE 9-3
CUT ACCESS HOLE TO THE DRIP RAIL
23

9. QUARTER PANEL
SEDAN QUARTER PANEL
REPLACEMENT
When replacing the quarter panel assemblies

on the sedan models, a tab is created from the
original quarter panel at the joint with the roof.
The service part is then modified to fit over this
tab, which is used as a backing plate for
welding the new panel in place.
1. Remove all related panels and

components including the rear window.
Also pry up and remove the reveal
molding at the roof line. It is held in
place with two-sided tape.
2. Visually inspect and restore as much of
the damage as possible to factory
specifications.
3. Remove sealers, sound deadeners and
corrosion materials as necessary.
4. Locate, mark and drill out all factory
welds around the perimeter of the
quarter panel assembly, except for those
under the reveal molding. Note the
number of welds for installation of the
service assembly.
5. Cut a hole in the damaged quarter
panel to gain access to the inside
surface of the drip rail at the back glass
to simplify removal (Figure 9-4).
6. Apply a strip of 25mm (1") masking
tape along the top edge of the quarter
panel where it meets the roof.
7. Cut along the bottom edge of the
masking tape and remove the damaged
quarter panel assembly, leaving a
25mm (1") tab attached to the roof
(Figure 9-5).
24
FIGURE 9-4
CUT ACCESS HOLE TO THE DRIP RAIL
25mm (1") tab
FIGURE 9-5
CREATE A 25MM (1") T AB FROM THE ORIGINAL
QUARTER PANEL
9. QUARTER PANEL
Install or Connect
FIGURE 9-6
TRIM THE SERVICE PART
FIGURE 9-7
DRILL PLUG WELD HOLES IN THE SERVICE
ASSEMBLY
1. Trim and discard the upper mounting flange

on the service assembly so that it can fit over
the 25mm (1") tab left from the original panel
(Figure 9-6).
2. On the service assembly, drill 8mm (5/16")
plug weld holes as necessary in the locations
noted from the original assembly. Also drill
four plug weld holes along the top edge of
the new quarter panel for attachment to the
one-inch tab (Figure 9-7)
3. Position the service assembly from the top
down. Check fit using body dimensions.
Notice
Verify fit of the pinch-flange molding. If the
gap is unsatisfactory, adjust the one-inch tab
until correct alignment is achieved.
4. When the assembly is correctly positioned,
plug weld accordingly with frequent
measurements to ensure proper fit. Begin with
the welds over the 25mm (1") tab and then
continue around the perimeter of the
assembly.
5. Clean and prepare welded surfaces. Prime
with two-part catalyzed primer. Apply fillers,
sealers and corrosion protection materials, as
necessary. Do not combine paint systems.
Refer to paint manufacturers
recommendations. Reinstall all related panels
and components.
Notice
Apply seam sealer, such as 3M Ultra Pro
08361, along the top edge of the A pillar
joint at the roof line (Figure 9-8).
FUEL FILLER NECK
Care must be taken to ensure that the fuel filler neck

is properly sealed when replacing the right quarter
panel. Use GM Part #12399117 between the
quarter panel and fuel filler neck. Install using the
provided instructions.
FIGURE 9-8
APPLY SEAM SEALER TO THE JOINT WITH THE ROOF
25

10. OUTER REAR WHEELHOUSE

REAR WHEELHOUSE
SECTIONING PROCEDURE
The outer rear wheelhouse (Figures 10-1 and

10-2) is repaired by sectioning when damage to
the rest of the panel is minimal. Coupe models
have a beltline reinforcement that creates unique
service concerns. Therefore, templates have been
developed to ensure proper wheelhouse
sectioning on coupe models.
It is recommended that the service part be
prepared before removing the damaged section of
the panel from the vehicle. This will help you
become familiar with the procedure and know
exactly where to cut the damaged panel for a
better fit of the new section.
Prepare the Service Part
1. Apply a strip of 20mm (3/4") masking tape

along the vertical surface of the wheelhouse
radius to form a welding flange.
2. On coupe models, align the appropriate
template over the gage holes according to
the template instructions.
3. On sedan models, cut along the top edge
of the tape. On coupe models, cut along
the top edge of the tape and at the radius
of the wheelhouse as indicated on the
template (Figure 10-3).
4. Remove the excess portion of the
wheelhouse.
Beltline reinforcement
FIGURE 10-1
OUTER REAR WHEELHOUSE (COUPE)
FIGURE 10-2
OUTER REAR WHEELHOUSE (SEDAN)
1. Remove all related panels and components.

damage as possible to factory
specifications.
4. Drill out the factory welds at the forward
lower portion of the wheelhouse at the
rocker panel. On coupe models, also drill
out the four factory welds along the
outboard edge of the beltline reinforcement.
26
Trimmed according
to template
Cut along top edge of tape
FIGURE 10-3
APPLY TAPE AND CUT THE SERVICE PART
10. OUTER REAR WHEELHOUSE
20mm(34") tab
FIGURE 10-4
APPLY TAPE, CUT AND REMOVE DAMAGED
PORTION OF WHEELHOUSE
FIGURE 10-5
WELD THE NEW WHEELHOUSE
SECTION
5. Apply a strip of 20mm (3/4") masking

tape along the horizontal surface of the
wheelhouse radius.
6. Cut along the outboard side of the
masking tape to create a tab for the
weld flange on the new wheelhouse
section (Figure 10-4). On coupe
models, cut the portion of the
wheelhouse under the beltline
reinforcement from inside the
wheelhouse. Simply connect the two cut
lines on either side of the reinforcement.
7. Remove the damaged section of the
wheelhouse.
Install or Connect
1. Temporarily install the wheelhouse service part and

check fit. On coupe models, first fit the forward lower
portion then slide the weld flange over the tab on the
original section and under the beltline reinforcement.
2. On the service part, mark plug weld holes every
40mm (1-1/2") along the weld flange, alternating
between the vertical and horizontal surfaces to ensure
uniform strength (Figure 10-5).
3. Remove the service part and drill 8mm (5/16") plug
welds where marked in the previous step.
4. Prepare mating surfaces and position the service part.
Check fit using body dimensions and plug weld
accordingly with frequent measurements to ensure
proper fit. Take care not to warp or distort the metal.
5. Plug weld the factory welds at the forward lower
portion of the wheelhouse at the rocker panel (see step
#4 of Remove or Disconnect). On coupe models, also
plug weld the four factory welds along the outboard
edge of the beltline reinforcement.
6. Clean and prepare welded surfaces. Prime with twopart catalyzed primer. Apply sealers and corrosion
protection materials, as necessary. Do not combine
paint systems. Refer to paint manufacturers
recommendations. Reinstall all related panels and
components.
27

11. REAR RAIL

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

Prepare the Service Part
1. Invert the service part and secure it to a bench for cutting.

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

bent upwards for installation
28
FIGURE 11-1
REAR RAIL ASSEMBLY
11. REAR RAIL

"Final" cut line
FIGURE 11-2
CUT AND REMOVE THE DAMAGED SECTION OF
THE REAR RAIL
1. Remove all related panels and components

including the fuel tank, fuel filler neck and
exhaust system.
damage as possible to factory specifications.
4. Align the appropriate template on the
underside of the rail. Use a center punch or
an awl to mark the rail by punching through
the template. Remove the template and
connect the dots with a straight edge and
scribe the cut line.
5. Locate, mark and drill out the factory welds
rearward of the marked cut line, including
those securing the rear rail inner reinforcement
to the outer panel. Do not drill through the
inner reinforcement (Figure 11-2).
6. Cut the rail along the rough cut line. Remove
the damaged section of the rear rail.
7. Separate the side walls of the inner
reinforcement from the outer panel of the rail
by slightly prying the reinforcement inwards.
8. Cut the sides of the rail outer panel along the
final cut line, taking care not to damage the
inner reinforcement. Cut along the bottom of
the outer panel approximately 3/4 of the
metal thickness deep.
Notice
Be careful not to cut the inner reinforcement.
This reinforcement will act as a backing plate
when welding the new rail section in place.
9. Bend the rail down and up until the outer
panel breaks along the partial cut. Remove
the damaged section of the rear rail, leaving
the reinforcement extending from inside the
remaining rail section (Figure 11-3)
FIGURE 11-3
LEAVE INNER REINFORCEMENT
EXTENDING FROM ORIGINAL RAIL
29

11. REAR RAIL

Install or Connect
1. Prepare mating surfaces and position the service part, allowing it to slide over
the inner reinforcement extending from the original rail section. Check fit using
body dimensions and plug weld accordingly with frequent measurements to
ensure proper fit.
Notice
Make sure to plug weld the inner reinforcement to the new rail section. This
may require drawing the reinforcement flat against the rail using a screw.
It may be necessary to install backing plates on either side of the original rail
above the inner reinforcement. These can be cut from the unused inner
reinforcement of the service part. Drill holes and plug weld the backing plates
in place (Figure 11-4).
5. Stitch weld along the entire joint. Make 25mm (1") welds along the seam with
25mm (1") gaps between. Then go back and complete the stitch weld. This will
create a solid joint with minimal heat distortion.
Notice
To ensure a secure weld, the sectioning joints should have a gap of
approximately one-and-a-half times the thickness of the metal. Trim the parts as
necessary to achieve this.
Apply sealers and corrosion protection materials, as necessary. Do not combine
paint systems. Refer to paint manufacturers recommendations. Reinstall all
FIGURE 11-4
INSTALL BACKING PLATES AND WELD NEW SECTION
30
12. REAR FLOOR ASSEMBLY

REAR FLOOR ASSEMBLY SECTIONING PROCEDURE
Sectioning procedures are used to repair the rear floor. The rear floor is sold as an assembly that includes
the lower rear rails and crossmember. The damaged rails must be cut so that the new rail sections will properly
mate with the original rails and inner reinforcement. Templates and procedures are included with the rear
floor service assembly. Keep the following guidelines in mind when performing this procedure:
Overlap the original floor pan a minimum of 25mm (1") with the service assembly floor pan.
Create a butt joint when mating the lower rails.
Use the original rail inner reinforcements as backing plates when welding the service assembly.
The rear rail inner reinforcements are at different lengths in the left and right rails (Figure 12-1).
There are 4 templates to facilitate the sectioning procedure: left rail, right rail, left floor and right
floor.
FIGURE 12-1
REAR RAIL INNER REINFORCEMENTS
31

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

Align the templates in the appropriate locations. Use a center punch or an awl to mark the assembly
by punching through the templates. Remove the templates, connect the dots with a straight edge and
scribe the cut lines.
Notice
The cut lines for the left and right sides are in different positions. Make sure to use the appropriate
templates. Do not damage the templates since they must also be used to mark the service assembly.
Attach them with a non-permanent spray adhesive such as 3Ms Repositionable Adhesive (part
#6091).
5. Locate mark and drill out all related factory welds rearward of the cut lines.
6. From the underside of the vehicle, cut the rails and floor pan along the rough cut line. Continue this
cut around the radius of the spare tire tub. Remove the damaged section of the rear floor and rails
(Figure 12-2).
32

7. Trim the floor pan to expose the rear
rail inner reinforcements by cutting
along the final cut line, taking care
not to damage the rails or
reinforcements.
Notice
Only cut the floor pan. Do not cut
through the rear rails or inner
reinforcements. These reinforcements
will act as backing plates when
welding the new rail section in place.
Rear rail "rough" cut line
FIGURE 12-3
SEPARATE THE SIDERAILS OF THE REAR RAIL INNER
REINFORCEMENT FROM THE OUTER PANEL
8. Locate, mark and drill out the factory

welds securing the rear rail inner
reinforcements to the outer panels
between the rough cut and final
cut lines. Do not drill through the
inner reinforcements.
9. Separate the side walls of the inner
reinforcement from the outer panel of
the rail by slightly prying the
reinforcements inwards (Figure 12-3).
10. Cut the sides of the rail outer panel
along the final cut lines, taking care
not to damage the inner
reinforcement. Cut along the bottom
of the outer panel approximately 3/4
of the metal thickness deep.
11. Bend the rail up and down until the
outer panel breaks along the partial
cut. Remove the damaged section of
the rear rail, leaving the reinforcement
extending from inside the remaining
rail section (Figure 12-4).
Rear rail "final" cut line
FIGURE 12-4
LEAVE THE INNER REINFORCEMENT EXTENDING
33

FIGURE 12-5
PREPARE THE SERVICE ASSEMBLY
Prepare the Service Assembly
1. Align the templates in the appropriate locations on the service assembly. Use a center punch or an
awl to mark the assembly by punching through the template along the service cut line on the floor
pan and the final cut line on the rails. Remove the templates, connect the dots with a straight edge
and scribe the cut lines.
2. Connect the left and right floor pan service cut lines around the forward radius of the spare tire tub.
This will ensure the correct overlap for service assembly installation (Figure 12-5).
3. Drill out the welds at the front edge of the spare tire radius. Cut through both the floor pan and rails
along the floor pan service cut line. Discard the front portion of the assembly.
4. Cut through the rails along the final cut line and remove the excess portions. Do not cut through the
floor pan.
5. On the remaining rail sections, drill out the welds attaching the inner reinforcements to the outer
panels (typically three welds). Remove the inner reinforcements.
6. Drill 8mm (5/16") plug weld holes as necessary in the locations noted from the original floor. Also
drill weld holes along the overlap joint of the floor pan. These should be placed approximately
40mm (1-1/2") apart.
34
Overlap
Install or Connect
FIGURE 12-6
WELD THE NEW SECTION
1. Prepare mating surfaces and check for proper fit of the rear floor service assembly section, allowing it
to overlap the original floor.
Notice
To ensure a secure weld, the rear rail sectioning joints should have a gap of approximately oneand-a-half times the thickness of the metal. Trim the parts as necessary to achieve this. Make sure
to plug weld the inner reinforcement to the new rail section. This may require drawing the
reinforcement flat against the rail using a screw.
It may also be necessary to install backing plates on either side of the original rails above the
reinforcements. These can be cut from the unused inner reinforcements of the service part. Drill
holes in the rail and plug weld the backing plates in place.
2. With the service assembly positioned, plug weld the inner reinforcements to the rail service parts.
3. Verify position of the service assembly using body dimensions and plug weld accordingly with
frequent measurements to ensure proper fit (Figure 12-6).
corrosion protection materials, as necessary. Caulk both sides of the floor pan seam.
Notice
Use a full-bodied caulk, such as 3Ms Ultra Pro Seam Sealer (part #08360-1), to seal both sides of
the floor pan seam.
5. Refinish as necessary. Do not combine paint systems. Refer to paint manufacturers
recommendations. Reinstall all related panels and components.
35

13. REAR END PANEL

The rear end panel is supplied as a complete
assembly consisting of three inner
reinforcements and one outer panel on
Cavalier coupe and sedan and Sunfire sedan.
The rear end panel on Sunfire coupe has a
single inner reinforcement. Taillight mounting
panels, which attach to the outside corners of
the rear end panel assembly, are available
separately. Service for all of these panels is
performed at factory seams (Figure 13-1).
Sunfire Coupe
1. Remove all related panels and

components.
2. Visually inspect and restore as much of
the damage as possible to factory
specifications.
4. Locate, mark and drill out all factory
welds. Note the number of welds for
installation of the service assembly.
5. Remove the damaged assembly.
Drill dimples for

latch mounting
Install or Connect
1. Prepare mating surfaces and check for

proper fit of the service assembly.
2. On the service assembly drill 8mm (5/
16") plug weld holes as necessary in the
locations noted from the original
assembly.
3. Position the service assembly, check fit
using body dimensions, and plug weld
accordingly with frequent measurements
to ensure proper fit.
4. Clean and prepare welded surfaces.
Prime with two-part catalyzed primer.
Apply sealers and corrosion protection
materials, as necessary. Do not
combine paint systems. Refer to paint
manufacturers recommendations.
Reinstall all related panels and
components.
36
Cavalier and Sunfire Sedan

Drill dimples for
latch mounting
FIGURE 13-1
REAR END PANEL ASSEMBLY
14. BODY DIMENSIONS

CAVALIER/SUNFIRE UNDERBODY
37

CAVALIER/SUNFIRE ENGINE COMPARTMENT
14. BODY DIMENSIONS
38
CAVALIER/SUNFIRE FRONT
14. BODY DIMENSIONS
39

CAVALIER/SUNFIRE SEDAN SIDE
14. BODY DIMENSIONS
40
CAVALIER/SUNFIRE COUPE SIDE
14. BODY DIMENSIONS
41

14. BODY DIMENSIONS

CAVALIER/SUNFIRE REAR
42
SLOTTED RAIL CAGENUT REPLACEMENT

The following procedure has been developed to repair stripped or damaged cagenuts when full lower rail
replacement is not necessary. It allows the cagenuts to be serviced from the underside of the vehicle. This
is done by gaining access to and drilling out the hidden welds holding the cagenut bracket in place. The
damaged cagenut and bracket can then be removed through the rail slot (Figure 1).
REMOVE OR DISCONNECT
1. Remove all related panels and components including the suspension crossmember
2. Locate the two factory welds that secure the cagenut to the lower rail surface. Insert a pry bar
between the torque box closeout panel and the lower rail and bend the metal outward to expose the
two factory welds (Figure 2).
3. Center punch and drill through the welds with a 10mm (3/8") drill bit.
4. Wrap a wire through the cagenut to keep it from sliding down into the rail.
5. Rotate the damaged cagenut bracket and remove it through the rail slot.
Slotted rail viewed from

underneath the vehicle
FIGURE 1
SLOTTED LOWER RAIL

SLOTTED RAIL CAGENUT REPLACEMENT

Notice
If the rail slot is too narrow to remove the
cagenut bracket, make it wider by slightly
grinding the edges of the gap. Do not
remove more than 2mm of metal (Figure 3).
INSTALL OR CONNECT
1. Prep weld areas for installation as noted from

the original part.
2. Wrap a wire through the new cagnut and
install the cagenut bracket through the rail
slot.
3. Position the new cagenut bracket and check
fit using body dimensions.
Hidden
welds
FIGURE 2
PRY THE TORQUE BOX CLOSEOUT PANEL OUTWARDS
TO EXPOSE FACTORY WELDS
Do not remove more than 2mm
FIGURE 3
WIDEN THE RAIL SLOT (IF NECESSARY)
Notice
It may be necessary to temporarily secure the
new cagenut bracket to the rail using the
crossmember mounting bolt.
4. Plug weld the cagenut bracket in place at
original locations.
5. Clean and prepare welded surfaces. Prime
plug welds using two-part catalyzed primer.
6. Straighten the torque box closeout panel bent
outward in step #2 of Remove and
Disconnect.
7. Clean and prepare the lower rail surface. Do
manufacturers recommendations. Apply
8. Reinstall all related panels and components.
When reinstalling the suspension
crossmember, torque all six fasteners to 130
Nm (96 lbs. ft.).

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TABLE OF CONTENTS

PANEL IDENTIFICATION ___________________ 2

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

TPO on Cavalier and Sunfire Sedan;

Reinforced injected molded (RIM) plastic

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

1995 General Motors Corporation. All Rights Reserved.

2. RADIATOR SUPPORT ASSEMBLY

Pre-assembled service part

Bolt-on lower support

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

1995 General Motors Corporation. All Rights Reserved.

2. RADIATOR SUPPORT ASSEMBLY

1. Remove all related panels and components.

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

3. FRONT WHEELHOUSE ASSEMBLY

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

1995 General Motors Corporation. All Rights Reserved.

3. FRONT WHEELHOUSE ASSEMBLY

Remove all related panels and components.

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

4. FRONT LOWER RAIL ASSEMBLY

Replacement of the engine compartment lower rail assemblies has been

Bumper mounting brackets

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

1995 General Motors Corporation. All Rights Reserved.

4. FRONT LOWER RAIL ASSEMBLY

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

4. FRONT LOWER RAIL ASSEMBLY

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

1995 General Motors Corporation. All Rights Reserved.

5. FRONT SUSPENSION SUPPORT ASSEMBLY (#1 BAR)

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

5. FRONT SUSPENSION SUPPORT (#1 BAR)

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

1995 General Motors Corporation. All Rights Reserved.

5. FRONT SUSPENSION SUPPORT (#1 BAR)

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

6. DOOR FRAME OPENING

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

1995 General Motors Corporation. All Rights Reserved.

6. DOOR FRAME OPENING

1. Remove all related panels and components

1. Prepare mating surfaces and check for proper fit of

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

6. DOOR FRAME OPENING

Remove all related panels and components.

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

1995 General Motors Corporation. All Rights Reserved.

6. DOOR FRAME OPENING

1. Align the template on the service part

3. Drill out the 4 welds attaching the hinge

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

6. DOOR FRAME OPENING

DOOR FRAME OPENING GENERAL SECTIONING

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

1995 General Motors Corporation. All Rights Reserved.

6. DOOR FRAME OPENING

Remove all related panels and components.

5. Position the service part, allowing it to overlap the

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES