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)

2006 Chevrolet Corvette Z06 ........................ 2-1 Structure Identification ..................................... 2-1 Dimensions - Body (Motor Compartment Corvette) ..................................................... 2-3 Dimensions - Body (Z06) ................................ 2-4 Impact Bar Replacement - Front Bumper (Z06) ............................................. 2-5 Hood Plate Stud Replacement (Z06) ............... 2-7 Wheelhouse Replacement - Front (Z06) ........ 2-10 Pillar Lock Front Door Replacement Outer (Z06) ............................................... 2-11 Impact Bar Replacement - Rear Bumper (Z06) ............................................ 2-14 Rail Replacement - Front (Z06) ..................... 2-20 Rail Replacement - Front Section (Z06) ........ 2-22 Rail End Replacement - Front (Z06) .............. 2-30 Rail End Replacement - Rear (Z06) .............. 2-34 Sleeved Butt Joint Repair (Z06) .................... 2-36 Windshield Frame Replacement .................... 2-38 Door Opening Frame Replacement - Side ...... 2-41

Rail Replacement - Rear (Z06) ..................... Rail Replacement - Rear Section (Z06) ......... Floor Panel Replacement (Z06) ..................... Compartment Panel Replacement Rear (Corvette) ......................................... Compartment Panel Frame Replacement Rear (Corvette) ......................................... Sheet Molded Compound (SMC) Panel Bonding ....................................................

2-43 2-46 2-53 2-56 2-59 2-62

2006 Pontiac Solstice/ 2007 Saturn SKY ........................... 3-1 Dimensions - Body (Door Openings) ............... 3-1 Dimensions - Body (Motor Compartment) ........ 3-2 Hinge Pillar Body Reinforcement Replacement - Front .................................... 3-3 Hinge Pillar Body Replacement - Front ............ 3-5 Windshield Frame Header Panel Replacement - Front .................................... 3-7 Pillar Lock Front Door Replacement Outer ........................................................ 3-10 Pillar Lock Front Door Replacement Inner ........................................................ 3-12 Quarter Panel Replacement - Outer ............... 3-15 Impact Bar Replacement - Rear Bumper ....... 3-18 Rail Replacement - Front Section .................. 3-21 Sleeved Butt Joint Repair .............................. 3-25 Windshield Panel Replacement - Lower ......... 3-26 Door Opening Frame Replacement - Side ...... 3-29 Rail Replacement - Rear Section .................. 3-31 Floor Panel Replacement .............................. 3-35 Compartment Panel Replacement - Rear ....... 3-38 Panel Replacement - Rear End ..................... 3-40 Sheet Molded Compound (SMC) Panel Bonding .................................................... 3-43

1

2006 Chevrolet Corvette Z06

Actions to Take When Working with Fuel Caution ............................................... 1-1 Approved Equipment for Collision Repair Caution ............................................ 1-1 Battery Disconnect Caution ............................. 1-1 Collision Sectioning Caution ............................ 1-1 Foam Sound Deadeners Caution .................... 1-1 Glass and Sheet Metal Handling Caution ........ 1-1 Safety Glasses Caution ................................... 1-1 SIR Caution .................................................... 1-1 Sound Deadener Foam in the Lock Striker Pillars Caution ....................................................... 1-1 Fastener Notice .............................................. 1-1

2006 Pontiac Solstice/2007 Saturn SKY

General Information ....................................... 1-1

General Information

TABLE OF CONTENTS

General Information

Caution: Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a trunk. To reduce the risk of fire and increased exposure to vapors: • Use forced air ventilation such as a fan set outside of the trunk. • Plug or cap any fuel system openings in order to reduce fuel vapor formation. • Clean up any spilled fuel immediately. • Avoid sparks and any source of ignition. • Use signs to alert others in the work area that fuel system work is in process.

Approved Equipment for Collision Repair Caution Caution: To avoid personal injury when exposed to welding flashes or to galvanized (Zinc Oxide) metal toxic fumes while grinding/cutting on any type of metal or sheet molded compound, you must work in a properly ventilated area, wearing an approved respirator, eye protection, earplugs, welding gloves, and protective clothing.

Battery Disconnect Caution Caution: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

Collision Sectioning Caution 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.

Foam Sound Deadeners Caution Caution: Foam sound deadeners must be removed from areas within 152.4 mm (6 in) of where flame is to be used for body repairs. When reinstalling foam sound deadeners, avoid inhaling fumes as bodily injury may result.

Glass and Sheet Metal Handling Caution Caution: When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and gloves in order to reduce the chance of personal injury.

Safety Glasses Caution Caution: Wear safety glasses in order to avoid eye damage.

SIR Caution Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling and Enabling Zones. Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs.

Sound Deadener Foam in the Lock Striker Pillars Caution Caution: Sound deadener foam in the lock striker pillars can be a fire hazard. Create a weld flange to avoid welding directly to the lock striker pillars as damage to the vehicle and serious bodily injury may result.

Fastener Notice Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint 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

General Information

Actions to Take When Working with Fuel Caution

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

2006 Pontiac Solstice/2007 Saturn SKY

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2006 Pontiac Solstice/2007 Saturn SKY 3-1

Dimensions - Body (Motor Compartment)

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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 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.

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1616261

2006 Pontiac Solstice/2007 Saturn SKY 3-3

2006 Pontiac Solstice/2007 Saturn SKY

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.

8. Remove the damaged hinge pillar body reinforcement.

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Installation Procedure 1. Position the hinge pillar body reinforcement.

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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 Battery Negative Cable Disconnect/Connect Procedure. 9. Enable the SIR system. Refer to SIR Disabling and Enabling Zones.

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3-4

2006 Pontiac Solstice/2007 Saturn SKY

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.

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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. 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

2006 Pontiac Solstice/2007 Saturn SKY

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.

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2006 Pontiac Solstice/2007 Saturn SKY 3-5

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.

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9. Remove the damaged hinge pillar. 10. Note the location of the adhesive and remove all remaining loose adhesive.

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Installation Procedure 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.

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2006 Pontiac Solstice/2007 Saturn SKY

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.

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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 Anti-Corrosion Treatment and Repair. 8. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems. 9. Install all related panels and components. 10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure. 11. Enable the SIR system. Refer to SIR Disabling and Enabling Zones.

1508874

2006 Pontiac Solstice/2007 Saturn SKY

Windshield Frame Header Panel 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. Caution: Refer to Foam Sound Deadeners Caution on page 1-1. 4. Note the location and remove the sealers and anti–corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair. 1583429

2006 Pontiac Solstice/2007 Saturn SKY 3-7

Important: Do not damage any inner panels or reinforcements. 5. Locate and drill out all factory welds. Note the number and location of welds for installation of the header panel.

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6. Using a grinder or an equivalent tool, remove the silicon bronze welds on each end of the header.

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7. Remove the damaged header panel.

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3-8

2006 Pontiac Solstice/2007 Saturn SKY

Installation Procedure 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 equivalent to all mating surfaces.

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4. Position the header panel.

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2006 Pontiac Solstice/2007 Saturn SKY

5. Plug weld accordingly. 6. Continuous weld each side of the outer header panel. 7. Clean and prepare all welded surfaces. 8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair. 9. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems. 10. Install all related panels and components. 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure. 12. Enable the SIR system. Refer to SIR Disabling and Enabling Zones.

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2006 Pontiac Solstice/2007 Saturn SKY 3-9

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.

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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 including the outer body side panel. Refer to Door Opening Frame Replacement - Side on page 3-29. Caution: Refer to Foam Sound Deadeners Caution on page 1-1. 4. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair. 1276023

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2006 Pontiac Solstice/2007 Saturn SKY

Important: Do NOT damage the inner panels or the reinforcements. 5. Locate and drill out all factory welds. Note the number and location of the welds for installation of the replacement part.

6. Remove the damaged inner lock pillar.

1276028

Installation Procedure 1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted on the original panel. 2. Prepare all attachment surfaces as necessary. 3. Apply 3M® Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

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2006 Pontiac Solstice/2007 Saturn SKY

4. Position the inner lock pillar.

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2006 Pontiac Solstice/2007 Saturn SKY 3-11

5. 6. 7. 8.

9. 10. 11.

12.

Plug weld accordingly. Install all related panels. Clean and prepare all welded surfaces. Apply the sealers and the anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems. Install all related components. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure. Enable the SIR system. Refer to SIR Disabling 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

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. 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. Caution: Refer to Foam Sound Deadeners Caution on page 1-1. 5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair. 1274765

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2006 Pontiac Solstice/2007 Saturn SKY

Important: Do NOT damage the inner panels or the reinforcements. 6. Locate and drill out all factory welds. Note the 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.

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2006 Pontiac Solstice/2007 Saturn SKY

8. Remove the damaged inner lock pillar.

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2006 Pontiac Solstice/2007 Saturn SKY 3-13

Installation Procedure 1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted on the 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. 4. Apply 3M® Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

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.

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6. Plug weld accordingly.

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3-14

2006 Pontiac Solstice/2007 Saturn SKY

Important: Proper alignment of the roof mounting bracket is critical for proper folding top operation and alignment. 7. 8. 9. 10. 11.

12. 13. 14.

15.

Position the roof mounting bracket. Plug weld accordingly. Install all related panels. Clean and prepare all welded surfaces. Apply the sealers and the anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems. Install all related components. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure. Enable the SIR system. Refer to SIR Disabling and Enabling Zones.

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Quarter Panel Replacement - Outer Tools Required J 42058 Frame Adapter Clamp

Removal Procedure

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2006 Pontiac Solstice/2007 Saturn SKY

Caution: Refer to Approved Equipment for Collision Repair Caution on page 1-1. 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. 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. 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.

2006 Pontiac Solstice/2007 Saturn SKY 3-15

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

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Important: Do not damage any inner panels or reinforcements. 6. Locate and drill out all factory welds that attach the quarter outer panel to the trunk gutter.

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7. Remove the door frame and quarter panel from the vehicle. 8. Note the location of the adhesives. Remove all remaining loose adhesive. 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.

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3-16

2006 Pontiac Solstice/2007 Saturn SKY

Installation Procedure 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.

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2006 Pontiac Solstice/2007 Saturn SKY

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. 9. Install all related panels and components. 10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure. 11. Enable the SIR system. Refer to SIR Disabling and Enabling Zones.

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2006 Pontiac Solstice/2007 Saturn SKY 3-17

Impact Bar Replacement - Rear Bumper Tools Required J 42058 Frame Adapter Clamp

Removal Procedure

1583428

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. Remove or reposition the wiring to avoid damage. 5. Repair as much of the damage as possible to the factory specifications. 6. Use J 42058 to secure the vehicle if pulling and 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. 10. Note the location and remove the sealers and anti-corrosion materials from the repair area. Refer to Anti-Corrosion Treatment and Repair.

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2006 Pontiac Solstice/2007 Saturn SKY

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.

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2006 Pontiac Solstice/2007 Saturn SKY

Installation Procedure 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

2006 Pontiac Solstice/2007 Saturn SKY 3-19

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. 6. Apply the sealers and anti-corrosion materials to 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.

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3-20

2006 Pontiac Solstice/2007 Saturn SKY

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. 12. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems. 13. Install all related panels and components. 14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure. 15. Enable SIR system. Refer to SIR Disabling and Enabling Zones.

Rail Replacement - Front Section Removal Procedure Caution: Refer to Approved Equipment for Collision Repair Caution on page 1-1. 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. 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. Refer to Dimensions - Body (Door Openings) on 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 Anti-Corrosion Treatment and Repair. 6. Locate the area on the rail where the recommended sectioning repair will be performed.

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2006 Pontiac Solstice/2007 Saturn SKY 3-21

2006 Pontiac Solstice/2007 Saturn SKY

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.

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.

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10. Cut the rail at the marked location.

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11. Remove the damaged section of the rail.

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3-22

2006 Pontiac Solstice/2007 Saturn SKY

Installation Procedure 1. On the service rail, determine the sectioning location. 2. Using the mark made in the previous step as a 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.

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2006 Pontiac Solstice/2007 Saturn SKY

5. Grind the existing frame rail sectioning location and the service rail sectioning location to a 45–degree angle.

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2006 Pontiac Solstice/2007 Saturn SKY 3-23

6. Install the backing plate.

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7. Position the rail to the vehicle, using 3-dimensional measuring equipment. Clamp the rail in place.

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8. 9. 10. 11.

Stitch and plug weld accordingly. Clean and prepare all of the welded surfaces. Install all of the related panels and components. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair. 12. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems. 13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure. 14. Enable the SIR system. Refer to SIR Disabling and Enabling Zones.

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3-24

2006 Pontiac Solstice/2007 Saturn SKY

Sleeved Butt Joint Repair Caution: Refer to Approved Equipment for Collision Repair Caution on page 1-1. Caution: Refer to Collision Sectioning Caution on page 1-1.

857910

1617523

2006 Pontiac Solstice/2007 Saturn SKY 3-25

2006 Pontiac Solstice/2007 Saturn SKY

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. 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. 8. Clean and prepare all of the welded surfaces. 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.

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.

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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.

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Windshield Panel Replacement - Lower 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. Caution: Refer to Foam Sound Deadeners Caution on page 1-1. 5. Note the location and remove the sealers and anti–corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair. 1588007

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2006 Pontiac Solstice/2007 Saturn SKY

Important: Do not damage any inner panels or reinforcements. 6. Locate and drill out all factory welds. Note the number and location of welds for installation of the windshield frame side panel.

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7. Using a grinder or an equivalent tool, remove the silicon bronze welds at the upper windshield frame side panel and header location.

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2006 Pontiac Solstice/2007 Saturn SKY

8. Remove the damaged windshield frame side panel.

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2006 Pontiac Solstice/2007 Saturn SKY 3-27

Installation Procedure 1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary at the locations noted from the original windshield frame side panel. 2. Prepare all mating surfaces as necessary. 3. Apply 3M® Weld-Thru coating P/N 05916 or equivalent to all mating surfaces.

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4. Position the windshield frame side panel.

1588005

5. Plug weld accordingly. 6. Continuous weld the upper windshield frame side panel to the header joint. 7. Clean and prepare all welded surfaces. 8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair. 9. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems. 10. Install all related panels and components. 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure. 12. Enable the SIR system. Refer to SIR Disabling and Enabling Zones.

1615425

3-28

2006 Pontiac Solstice/2007 Saturn SKY

Door Opening Frame Replacement - Side Tools Required J 42058 Frame Adapter Clamp

Removal Procedure

1615684

1616251

2006 Pontiac Solstice/2007 Saturn SKY 3-29

2006 Pontiac Solstice/2007 Saturn SKY

Caution: Refer to Approved Equipment for Collision Repair Caution on page 1-1. 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. 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. 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.

Important: Do not damage any inner panels or 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 remaining loose adhesive. 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

Installation Procedure 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.

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2006 Pontiac Solstice/2007 Saturn SKY

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. 9. Install all related panels and components. 10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure. 11. Enable the SIR system. Refer to SIR Disabling and Enabling Zones.

1616248

2006 Pontiac Solstice/2007 Saturn SKY

Rail Replacement - Rear Section 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. 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

2006 Pontiac Solstice/2007 Saturn SKY 3-31

6. Remove the rear compartment. Refer to Compartment Panel Replacement - Rear on page 3-38. 7. Note the location and remove the sealers and anti-corrosion materials from the repair area. Refer to Anti-Corrosion Treatment and Repair. 8. Repair as much of the damage as possible to the factory specifications. 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).

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2006 Pontiac Solstice/2007 Saturn SKY

17. Remove the damaged frame rail end section (1).

1617513

Installation Procedure 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

2006 Pontiac Solstice/2007 Saturn SKY

3. Using the mark made in the previous step as a 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

2006 Pontiac Solstice/2007 Saturn SKY 3-33

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.

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2006 Pontiac Solstice/2007 Saturn SKY

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. 16. Apply the sealers and anti-corrosion materials to the repair area. Refer to Anti-Corrosion Treatment and Repair. Important: DO NOT top coat any bonding surface. Use primer only on bonding surfaces. Refer to adhesive manufacturer’s recommendations. 17. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems. in Paint and Coating. 18. Install all related panels and components. 19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure. 20. Enable the SIR system. Refer to SIR Disabling and Enabling Zones.

1620007

Floor Panel Replacement Tools Required J 42058 Frame Adapter Clamp

Caution: Refer to Approved Equipment for Collision Repair Caution on page 1-1. 1. Use the J 42058 to secure the vehicle if pulling and straightening is required. 2. Disable the SIR system. Refer to SIR Disabling and Enabling Zones. 3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure. 4. Remove all related panels and components. 5. Remove or reposition electrical components and wiring harness as necessary to avoid damage. 6. Remove wiring harness clips for transfer to new floor panel. 7. Repair as much of the damage as possible to the factory specifications.

1497179

2006 Pontiac Solstice/2007 Saturn SKY 3-35

2006 Pontiac Solstice/2007 Saturn SKY

Removal Procedure

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

3-36

2006 Pontiac Solstice/2007 Saturn SKY

Installation Procedure 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). 1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted on the original panel. 2. Prepare all mating surfaces as necessary. 3. Apply 3M® Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

1647028

4. Install the floor panel to the vehicle.

966590

10. 11. 12.

13.

Plug weld accordingly. Install the floor panel reinforcements. Clean and prepare all welded surfaces. Install all of the related panels and components. Apply the sealers and the anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems. Install all related panels and components. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure. Enable the SIR system. Refer to SIR Disabling and Enabling Zones.

2006 Pontiac Solstice/2007 Saturn SKY

5. 6. 7. 8. 9.

1587985

2006 Pontiac Solstice/2007 Saturn SKY 3-37

Compartment Panel Replacement - Rear Tools Required J 42058 Frame Adapter Clamp

Removal Procedure Caution: Refer to Approved Equipment for Collision Repair Caution on page 1-1. The rear compartment panel is made of sheet molded compound (SMC), and is bonded to the rear structure and frame rails with structural adhesive. 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. 1587989

Caution: Refer to Actions to Take When Working with Fuel Caution on page 1-1. 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.

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2006 Pontiac Solstice/2007 Saturn SKY

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. 11. Note the location of the adhesive and remove all remaining loose adhesive. 12. Inspect the rear structure and frame rails for damage. 13. Repair as much of the damage as possible to the factory specifications.

1587994

2006 Pontiac Solstice/2007 Saturn SKY

Installation Procedure 1. Before applying adhesive dry fit the rear compartment panel for proper fit and alignment. Important: DO NOT top coat any bonding surface. Use primer only on bonding surfaces. Refer to adhesive manufacturer’s recommendations. The recommended adhesive is windshield urethane. Refer to Adhesive Service Kit Description. 2. Clean and prepare all bonding mating surfaces according to adhesive manufacturer’s 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 Compound (SMC) Panel Bonding on page 3-43. 4. Apply windshield urethane 20 mm (3/4 in) in diameter in spots to the fuel tank support bar (3). 1587995

2006 Pontiac Solstice/2007 Saturn SKY 3-39

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. 9. Remove any excess adhesive. 10. Install the right and left quarter panels. Refer to Quarter Panel Replacement - Outer on page 3-15. 11. Install all related panels and components. 12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure. 13. Enable the SIR system. Refer to SIR Disabling and Enabling Zones.

1587992

Panel Replacement - Rear End Tools Required J 42058 Frame Adapter Clamp

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.

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2006 Pontiac Solstice/2007 Saturn SKY

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. 7. Note the location of the adhesive and remove all remaining loose adhesive. 8. Inspect the rear structure and frame rails for damage. 9. Repair as much of the damage as possible to the factory specifications. 10. Use J 42058 to secure the vehicle if pulling and straightening is required.

2006 Pontiac Solstice/2007 Saturn SKY

1647016

2006 Pontiac Solstice/2007 Saturn SKY 3-41

Installation Procedure 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. 2. Clean and prepare all bonding mating surfaces 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. 6. Remove any excess adhesive. 7. Install all related panels and components. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure. 9. Enable the SIR system. Refer to SIR Disabling and Enabling Zones.

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2006 Pontiac Solstice/2007 Saturn SKY

Description and Operation Sheet Molded Compound (SMC) Panel Bonding This is intended to provide general guidelines for sheet molded compound (SMC) adhesive bonding of full panel replacement in regards to collision repair procedures: Sectioning, partial panel of full panels, is not supported by General Motors unless specifically documented in a Service Bulletin or Manual:

Important: DO NOT top coat any adhesive bonding mating surface. Use primer only on bonding surfaces. Refer to adhesive manufacturer’s recommendations for priming applications. Adhesives currently meeting the performance requirements include General Motors materials and products manufactured by Ashland and Lord Fusor. At this time, ONLY the adhesive products listed below meet this guideline:

Important: Prepare the surfaces to be bonded according to adhesive manufacturer’s 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 Structure Adhesive

Lord Fusor Structural Adhesive

Product Type

8902332

7770B

127 EZ

Medium Set

N/A

7779B

N/A

Fast Set

GM Goodwrench®

GMSPO of Canada

89020330 N/A

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

2006 Pontiac Solstice/2007 Saturn SKY

181147

2006 Pontiac Solstice/2007 Saturn SKY 3-43

NOTES

3-44

2006 Pontiac Solstice/2007 Saturn SKY

NOTES