Collision Repair Gm Genuine Parts-Books Pdf

Collision Repair GM Genuine Parts
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Body Side Dimensions Regular Cab, Visual Identification. Structure Identification, Structure Identification. Number Description Material Procedure, 1 Roof Panel Mild Steel Roof Outer Panel Replacement. 2 Front Door Panel Mild Steel Front Side Door Outer Panel Replacement Belt. 3 Rear Door Panel Mild Steel Rear Side Door Outer Panel Replacement Belt. 4 Box Front Panel Mild Steel Pickup Box Front End Panel Replacement. 5 Box Side Panel Mild Steel, Pickup Box Replacement Side. Pickup Box Outer Side Panel Replacement, Bond On Pickup Box Outer Side Panel.
Replacement Weld On, 6 Body Side Outer Mild Steel, Rocker Outer Panel Sectioning. Front Hinge Pillar Sectioning, Center Pillar Sectioning. Rear Pillar Sectioning, 7 Body Side Inner Ultra High Strength Steel. Center Pillar Outer Panel Reinforcement, Replacement. Rocker Inner Panel Replacement, Repair Instructions.
Front Full Frame Sectioning Light Duty, Removal Procedure. If damage permits a pre sleeved replacement front frame service section has been developed as a cost effective alternative to complete frame replacement. This procedure is for the light duty pick up front frame section the utility front frame section is similar. Warning Refer to Approved Equipment for Collision Repair Warning. Warning Refer to Collision Sectioning Warning, Note Perform all of the steps on both of the rails for complete module replacement. 1 Disable the SIR system Refer to SIR Disabling and Enabling. 2 Disconnect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection Single Battery Battery Negative Cable. Disconnection and Connection Dual Battery, 3 Remove all of the related panels and components. 4 Locate and mark the sectioning location by using at least 2 of the measurements below for each frame rail. Top of the frame rail edge rearward 420 mm 16 1 2 in with bumper bracket removed. Bottom of the frame rail edge rearward 387 mm 15 3 16 in with bumper bracket removed. Front edge of the gauge hole forward 22 mm 7 8 in, Center of the gauge hole forward 33 mm 1 1 4 in. Rear edge of the gauge hole forward 47 mm 1 7 8 in. Note Line up the masking tape with the tape edge facing the front of the vehicle on the sectioning location. 5 Apply masking tape completely around the frame rail next to the sectioning location as shown. Note The tape edge facing the front of the vehicle is the proper cut location. 6 Cut each frame rail at the front edge of the tape line using a reciprocating saw or equivalent as shown. 7 Remove the damaged frame section, Installation Procedure.
1 Grind the existing frame rail seam to taper seam at a 45 degree angle. 2 Prepare all of the attaching surfaces as necessary. 3 Apply the weld thru primer to all of the welded surfaces. 4 Position the service frame section to the existing frame and clamp in place. Note Verify the frame measurements 3 dimensionally to ensure proper position of the service frame. 5 Continuous weld the upper and lower horizontal joints through each corner. 6 Continuous weld the inner and outer vertical joints from corner to corner. 7 Clean and prepare all of the welded surfaces, 8 Install all of the related panels and components. 9 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection Single Battery Battery Negative Cable. Disconnection and Connection Dual Battery, 10 Enable the SIR system Refer to SIR Disabling and Enabling. Front Full Frame Sectioning Heavy Duty, Removal Procedure. If damage permits a pre sleeved replacement front frame service section has been developed as a cost effective alternative to complete frame replacement. This procedure is for the heavy duty pick up front frame service section. Warning Refer to Approved Equipment for Collision Repair Warning. Warning Refer to Collision Sectioning Warning, Note Perform all of the steps on both of the rails for complete module replacement. 1 Disable the SIR system Refer to SIR Disabling and Enabling. 2 Disconnect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection Single Battery Battery Negative Cable. Disconnection and Connection Dual Battery, 3 Remove all of the related panels and components.
Note Perform the following steps on both of the rails for complete module replacement. 4 Locate and mark the sectioning location by using at least 2 of the measurements below for each frame rail. Top of the frame rail edge rearward approximately 550 mm with bumper bracket removed. Front edge of the gauge hole rearward approximately 5 mm. Back edge of the lower control arm crossmember rearward approximately 20 mm. Approximately 50 mm rearward of shock tower bracket. Approximately 55 mm rearward of shock tower bracket inboard side rail. Note Line up the masking tape with the tape edge facing the front of the vehicle on the sectioning location. 5 Apply masking tape completely around the frame rail next to the sectioning location as shown. Note The tape edge facing the front of the vehicle is the proper cut location. 6 Using a reciprocating saw or equivalent cut each frame rail approximately 5 mm forward of the front edge of the tape line This will allow for final trimming. of each rail rearward to the proper sectioning location. 7 Remove the damaged frame section, Installation Procedure. 1 Grind the existing frame rail at the proper sectioning location at a 45 degree angle a as shown. 2 Prepare all of the attaching surfaces as necessary. 3 Apply the weld thru primer to all of the welded surfaces. 4 Position the service frame section to the existing frame and clamp in place. Note Verify the frame measurements 3 dimensionally to ensure proper position of the service frame. 5 Continuous weld the upper and lower horizontal joints through each corner. 6 Continuous weld the inner and outer vertical joints from corner to corner. 7 Clean and prepare all of the welded surfaces, 8 Apply 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 of the related panels and components. 11 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection Single Battery Battery Negative Cable. Disconnection and Connection Dual Battery, 12 Enable the SIR system Refer to SIR Disabling and Enabling. Roof Outer Panel Replacement, Removal Procedure, Warning Refer to Approved Equipment for Collision Repair Warning. Warning Refer to Glass and Sheet Metal Handling Warning. Note This procedure shows the crew cab pickup the extended cab and the regular cab are similar. 1 Disable the SIR system Refer to SIR Disabling and Enabling. 2 Disconnect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection Single Battery Battery Negative Cable. Disconnection and Connection Dual Battery, 3 Remove all related panels and components.
4 Repair as much of the damage as possible to factory specifications. Warning Refer to Foam Sound Deadeners Warning, 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. Note Do not damage any inner panels or reinforcements. 6 Locate and drill out all factory welds Note the number and location of the welds for installation of the roof panel. 7 Remove the damaged roof panel, Installation Procedure. 1 Prepare all attachment surfaces as necessary for welding. Apply GM approved Weld Thru Coating or equivalent to all mating surfaces Refer to Anti Corrosion Treatment and Repair. 2 Position the roof panel, 3 Weld accordingly, 4 Clean and prepare all welded surfaces. 5 Apply the sealers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair. 6 Paint the repair area Refer to Basecoat Clearcoat Paint Systems. 7 Install all related panels and components, 8 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection Single Battery Battery Negative Cable. Disconnection and Connection Dual Battery, 9 Enable the SIR system Refer to SIR Disabling and Enabling.
Apply GM approved Weld Thru Coating or equivalent to all mating surfaces Refer to Anti Corrosion Treatment and Repair 3 Position the inner rocker reinforcement assembly to the vehicle using 3 dimensional measuring equipment Clamp in place 4 Prior to installing outer body side replace all necessary welds that are covered by the outer body side weld accordingly at those original weld

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