1997-2003 Pontiac Grand Prix Collision Technical Information

1997
G R A N D P R I X
C O L L I S I O N R E P A I R I S S U E S
L E A D E R S I N C O L L I S I O N R E P A I R T E C H N O L O G Y
22303.45-5
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Introduction
Collision Repair Industry Leaders
This booklet provides you with detailed repair information for the 1997 Pontiac
Grand Prix. It is important to note that serviceability has been an integral part of
the development of this vehicle. We’ve 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 and every one 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 this vehicle. We feel
confident that working together with you, we have what it takes to achieve total
customer satisfaction.

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Table of Contents
Panel Identification
2
Radiator Support Assembly
4
Front Upper Rail Assembly
6
Front Wheelhouse Assembly
8
Front Lower Rail Assembly
10
Door Frame Opening
16
Door Service
24
Roof Panel
25
Quarter Panel
26
Rear Outer Wheelhouse
28
Rear Rail Assembly
30
Rear Floor
34
Rear End Panel Assembly
36
Body Dimensions
37
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1. Panel Identification
TSGS
TSGS
W11951.1
Primarily
TSGS
TPO
TSGS
HSLA
TSGS
= Two-Sided Galvanized Steel
HSLA
= High-Strength Low-Alloy Steel
TSGS
TPO
= Thermoplastic Olefin
THE LOWER RAILS ARE MADE OF
HIGH-STRENGTH LOW-ALLOY STEEL.
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P A N E L I D E N T I F I C A T I O N
TSGS
TPO
W11951.2
Primarily
TSGS
TSGS
HSLA
TSGS
TSGS
TSGS
HSLA
TSGS
TSGS
= Two-Sided Galvanized Steel
HSLA
= High-Strength Low-Alloy Steel
TPO
= Thermoplastic Olefin
THE LOWER RAILS ARE MADE OF
HIGH-STRENGTH LOW-ALLOY STEEL.
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2. Radiator Support Assembly
The radiator support assembly can be Radiator Support Assembly
serviced as a complete assembly. The
Replacement
radiator support assembly is made up
Remove or Disconnect
of five major components: four upper and
one lower (figure 2-1).
1. Remove all related panels and components.
2. Visually inspect and restore as much of the
Upper Radiator Support
damage as possible to factory specifications.
The upper radiator support is an assembly
3. Remove sealers and anti-corrosion materials
consisting of four components: a two-piece
as necessary.
upper tie bar, and left and right engine
4. Locate, mark, and drill out all factory welds.
compartment front panels.
Note the number and location of welds for
installation of the service assembly.
Lower Radiator Support
5. Remove the damaged radiator support
The lower radiator support is available as a
assembly.
separate replaceable component if necessary.
Headlight Mounting Brackets
The headlight mounting brackets are
available and serviced separately. Using
three-dimensional measuring equipment,
locate and mark the headlight mounting
holes. Drill the holes as necessary.
W11952.1
Headlight
Mounting Brackets
Figure 2-1:
Radiator Assembly
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R A D I A T O R S U P P O R T A S S E M B L Y
Radiator Support Assembly
Replacement (cont’d)
Install or Connect
1. Prepare the mating surfaces as necessary,
and check for proper fit of the service
panel.
2. Drill 8mm (5⁄16 inch) plug weld holes as
necessary in the locations noted from the
original assembly.
3. Position the service panel using three-
dimensional measuring equipment, plug
weld accordingly with frequent
measurements to ensure proper fit and
alignment.
4. Clean and prepare all welded surfaces.
Prime with two-part catalyzed primer.
Apply sealers and anti-corrosion protection
materials as necessary. Do not combine
paint systems. Refer to paint manufacturer’s
recommendations.
5. Install all related panels and components.
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3. Front Upper Rail Assembly
The front upper rail assembly is
2. Visually inspect and restore as much
serviced as two components: inner
of the damage as possible to factory
and outer panels. The outer panel is
specifications.
serviced as a sub-assembly which includes an
3. Remove sealers and anti-corrosion materials
inner reinforcement (figure 3-1). The inner
as necessary.
rail is completely accessible, after the outer
4. Locate, mark, and drill out all factory welds.
rail has been removed.
Note the number and location
Front Upper Rail Assembly
of welds for installation of the service
assembly.
Service Procedure
5. Remove the damaged front upper rail
Remove or Disconnect
assembly.
1. Remove all related panels and
components.
FRT
Inner Rail
Inner Reinforcement
Outer Rail
W11953.1
Figure 3-1:
Front Upper Rail Assembly
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F R O N T U P P E R R A I L A S S E M B L Y
FRT
W11953.2
Figure 3-2:
Plug Weld the Outer Rail
Front Upper Rail Assembly
Service Procedure (cont’d)
Install or Connect
1. Prepare the mating surfaces as necessary.
4. When the service assembly is correctly
2. Drill 8mm (5⁄
positioned, and with the outer rail
16 inch) plug weld holes as
necessary in the locations noted from the
removed, plug weld the inner rail as
original assembly. NOTE: If original loca-
necessary. Reposition the outer panel with
tions are damaged beyond recognition,
frequent measurements to ensure proper fit
locate holes for plug welding 40mm
and alignment, and plug weld
(11⁄
accordingly(figure 3-2).
2 inches) apart.
3. Temporarily position the inner and outer
5. Clean and prepare all welded surfaces.
rails on the vehicle. Using three-
Prime with two-part catalyzed primer.
dimensional measuring equipment, locate
Apply sealers and anti-corrosion protection
and mark front fender mounting bolt
materials as necessary. Do not combine
holes in the outer rail. Drill 5.5mm holes
paint systems. Refer to paint manufacturer’s
for self-tapping bolts as marked.
recommendations.
6. Install all related panels and components.
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4. Front Wheelhouse Assembly
The front wheelhouse service panel is
available as a complete assembly,
which includes the upper front strut
mounting surface (figure 4-1).
— Notice —
Sectioning of the front wheelhouse assembly
is not recommended.
The upper strut mounting surface is a dimen-
sionally critical area, and three-dimensional
measuring equipment should be used to locate
the front wheelhouse assembly. The front
apron close-out panels are available and
serviced separately.
FRT
Where the wheelhouse is welded to the cowl,
inspect the surface for damage.
W11954.1
Figure 4-1:
Front Apron Panels
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