Chevrolet Corvette 2016 Service Manual
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Chevrolet Corvette 2016 Service Manual

Collision repair
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Body Repair

Collision Repair

Specifications

Fastener Specifications
Fastener Specifications
Cross-Car Brace Mounting Bolts
Windshield Frame Mounting Bolts
Application
Application
Specification
Metric
English
25  Y
18   lb   ft
25  Y
18   lb   ft

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Summary of Contents for Chevrolet Corvette 2016

  • Page 1: Body Repair

    Body Repair Collision Repair Specifications Fastener Specifications Fastener Specifications Application Application Specification Metric English Cross-Car Brace Mounting Bolts 25  Y 18   lb   ft Windshield Frame Mounting Bolts 25  Y 18   lb   ft...

  • Page 2: Dimensions - Body

    Dimensions - Body Point-to-point measurements are for reference only. All measurements are given in millimeters. Use these measurements for diagnosing and estimating. Point-to- point measurements are duplicated with tram bar pointers set at equal lengths. All die marks, holes, slots, and fasteners are measured to the center. All dimensions are symmetrical unless otherwise specified Point to Point Measurements...

  • Page 3: Dimensions - Body (Motor Compartment - Corvette)

    Dimensions - Body (Motor Compartment - Corvette) Point-to-point measurements are for reference only. All measurements are given in millimeters. Use these measurements for diagnosing and estimating. Point-to- point measurements are duplicated with tram bar pointers set at equal lengths. All die marks, holes, slots, and fasteners are measured to the center. All dimensions are symmetrical unless otherwise specified Point to Point Measurements...

  • Page 4: Visual Identification

    Visual Identification Structure Identification Structure Identification Number Description Material Procedure Rear Compartment Panel Frame Sheet Molded Compound (SMC) Rear Compartment Panel Frame Panel Bonding Replacement Windshield Frame Aluminum Windshield Frame Replacement Front Wheelhouse Sheet Molded Compound (SMC) Front Wheelhouse Panel Panel Bonding Replacement Side Door Frame Opening Sheet Molded Compound (SMC)
  • Page 5 Structure Identification Number Description Material Procedure Hood Plate Stud Aluminum Hood Plate Stud Replacement Front Bumper Impact Bar Aluminum Front Bumper Impact Bar Replacement Front Rail (Front Section) Aluminum Front Rail Replacement (Rear Section)Front Rail Replacement (Front Section) Front Rail Section (Rear Section) Aluminum Front Rail Replacement (Rear Section)Front Rail Replacement...
  • Page 6 Rear Rail Replacement (Front Aluminum Rear Rail Replacement (Front Section) Section)Rear Rail Replacement (Rear Section) Rear Rail Replacement (Rear Aluminum Rear Rail Replacement (Front Section) Section)Rear Rail Replacement (Rear Section) Rear Bumper Impact Bar Aluminum Rear Bumper Impact Bar Replacement...

  • Page 7: Repair Instructions

    Repair Instructions Front Bumper Impact Bar Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning. Disable the SIR system. Refer to SIR Disabling and Enabling. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Remove all related panels and components.
  • Page 8 Dry fit the bumper bar for proper fit and alignment before welding. Note: Use a stainless steel brush to remove the oxide layer prior to welding. Clean and prepare all of the welded mating surfaces. Install the front bumper bar   (1). Position the bumper bar to the vehicle using 3-dimensional measuring equipment.
  • Page 9 Note: Recommend wire alloy is 5554 and wire size is 0.035. The shielding gas is 100 percent Argon. A two minute cooling down period is recommend for every 2 minutes or 100   mm (4   in) of welding. Using a MIG welder, equipped with PULSE technology (P-MIG), weld   (1) the bumper bar to the frame rail ends duplicating the factory welds. Apply the sealers and anti-corrosion materials to the repair area.

  • Page 10: Hood Plate Stud Replacement

    Hood Plate Stud Replacement Removal Procedure The hood anchor plate assembly is riveted to the inside of the front frame rail. Access to the hood plate assembly will require the removal of the welded front bumper bar. Warning: Refer to Approved Equipment for Collision Repair Warning.

  • Page 11: Front Wheelhouse Panel Replacement

    Front Wheelhouse Panel Replacement Special Tools J 42058 Frame Adapter Clamp Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning. The front wheelhouse is comprised of 2 types of materials. These include sheet molded compound (SMC) for the inner panel and carbon fiber for the outer panel. The wheelhouse is bonded to the front structure and frame rail with structural adhesive.
  • Page 12 Remove the wheelhouse   (1) from the vehicle. Save any and all brackets, mounting studs, and accessories for transfer to the new front wheelhouse. Note the location of the adhesive and remove all remaining loose adhesive. Inspect the front structure and frame rails for damage. Repair as much of the damage as possible to the factory specifications.
  • Page 13 Install the wheelhouse   (1) to the vehicle. Apply pressure to the wheelhouse to set the adhesive. Clamp or mechanically fasten the wheelhouse into place as necessary. Remove any excess adhesive and let dry to manufactures specifications. Install all related panels and components. Connect the negative battery cable.

  • Page 14: Front Hinge Pillar Body Replacement

    Front Hinge Pillar Body Replacement Removal Procedure Note: When welding cast aluminum recommend wire alloy is 4043 and the recommend wire size is 0.035. The shielding gas is 100 percent Argon. The front hinge pillar panel is bolted, welded, and bonded with structural adhesive to the side structure and frame rail. The replacement front hinge pillar panel is comprised of two types of materials.
  • Page 15 Note: Do NOT damage the inner panels or the reinforcements. Note: Hand tools, saw blades and abrasives used for aluminum repairs should be dedicated for aluminum only to prevent contamination. Locate and remove all factory welds   (1) from the front outer hinge pillar. Note the number and location of the welds for installation of the new hinge pillar. Locate and remove all factory welds  ...
  • Page 16 10. Remove the damaged hinge pillar. 11. Note the location of the adhesive and remove all remaining loose adhesive. Installation Procedure Before applying the adhesive, dry fit the hinge pillar for proper fit and alignment. Note: Use primer only on bonding surfaces. Do NOT top coat any bonding surfaces. Refer to the adhesive manufacture's recommendation. Clean and prepare all bonding mating surfaces according to the adhesive manufacturer's recommendations.
  • Page 17 Using a PULED-MIG welder, stitch weld the front outer hinge pillar to the vehicle in the locations noted on the original panel. Using a PULED-MIG welder, stitch weld the rear outer hinge pillar to the vehicle in the locations noted on the original panel   (1). Using a PULED-MIG welder, stitch weld the inner hinge pillar to the vehicle in the locations noted on the original panel.
  • Page 18 13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 14. Enable the SIR system. Refer to SIR Disabling and Enabling.

  • Page 19: Body Lock Pillar Outer Panel Replacement

    Body Lock Pillar Outer Panel Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning. Disable the SIR system. Refer to SIR Disabling and Enabling. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Remove all related panels and components.
  • Page 20 Remove the damaged outer lock pillar. Installation Procedure Position the outer lock pillar. Clean and prepare all mating surfaces, as necessary for welding. Drill 8   mm (5/16   in) for plug welding around the perimeter of the outer lock pillar (1) as noted from the original panel.
  • Page 21 Verify the fit of the outer lock pillar reinforcement. Clamp the outer lock pillar into position Note: Recommended wire alloy is 5554 and wire size is 0.035. The shielding gas is 100 percent Argon. Using a PULSED-MIG (P-MIG) or Resistance Welder, weld the lock pillar to the structure duplicating the factory welds   (1). Apply the sealers and the anti-corrosion materials to the repair area, as necessary.

  • Page 22: Rear Bumper Impact Bar Replacement

    Rear Bumper Impact Bar Replacement Special Tools J 42058 Frame Adapter Clamp Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning. Disable the SIR system. Refer to SIR Disabling and Enabling. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  • Page 23 10. To gain access to the inner rail welds, modify the rear wall of the SMC rear compartment panel in the following manner: • From inside the vehicle locate, mark, and cut out windows in the rear compartment panel. • Save the cutouts for re-installation.
  • Page 24 Note: If no trace of the original welds are present, follow the pattern specified for welding the side rails to the impact bar. Using a metal inert gas (MIG) welder, stitch weld the rear bar to the frame rail ends. Note: Recommend wire alloy is 5554 and wire size is 0.035.

  • Page 25: Front Rail Replacement (Rear Section)

    Front Rail Replacement (Rear Section) Special Tools J-42058 Frame Adapter Clamp For equivalent regional tools, refer to Special Tools. Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning. Disable the SIR system. Refer to SIR Disabling and Enabling. Disconnect the negative battery cable.
  • Page 26 13. Remove the screws from the front floor panel upper support   (1). 14. Remove the screws from the lower frame rail extensions   (1). Note: The adhesive material will release from the structure by applying heat to approximately 200°C (400°F). A noticeable popping sound can normally be heard when the adhesive releases.
  • Page 27 17. Remove the screws from the floor panel bracket   (1). 18. Remove the bolts from the frame rail   (1). 19. Favoring the center rail cut the weld from the cast rail section using a cut off wheel or equivalent tool.
  • Page 28 20. Favoring the center rail cut the weld from the top and side of the cast rail section using a cut off wheel or equivalent tool. Note: The adhesive material will release from the structure by applying heat to approximately 200°C (400°F). A noticeable popping sound can normally be heard when the adhesive releases 21.
  • Page 29 Note: Pre-Drill holes with 7/32 or 5.6   mm drill before installation of service screw. As noted from original part. Install the service screws in the front floor panel upper support   (1). Note: Pre-Drill holes with 7/32 or 5.6   mm drill before installation of service screw. As noted from original part. Install the service screws in the lower frame rail extensions  ...
  • Page 30 Note: Recommended wire alloy is 5554 and wire size is 1   mm (0.035   in). The shielding gas is 100 percent Argon. Using a P-MIG welder, stitch weld the outer and lower rail duplicating the factory welds   (1). Using a P-MIG welder, stitch weld the rail on the inside duplicating the factory welds  ...
  • Page 31 Note: Avoid applying structural adhesive in the location of plug weld locations. Apply structural adhesive to the front floor panel. Plug weld the front floor panel in place. 10. Apply structural adhesive and install the front floor panel extension   (1). 11.

  • Page 32: Front Rail Replacement (Front Section)

    Front Rail Replacement (Front Section) Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning. Disable the SIR system. Refer to SIR Disabling and Enabling. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Remove all related panels and components. Remove the front impact bar.
  • Page 33 Note: If no trace of the original welds is present, follow the pattern specified for welding the rail to the cast rail section. Measurement shown are in millimeters. Install the front impact bar. Refer to Front Bumper Impact Bar Replacement. Note: Recommend wire alloy is 5554 and wire size is .035.

  • Page 34: Windshield Frame Replacement

    Windshield Frame Replacement Special Tools J 42058 Frame Adapter Clamp Removal Procedure The windshield frame is made of cast aluminum components. The windshield frame is bonded and bolted to the front hinge pillars with structural adhesive. It is also braced to the tunnel assembly by a bolted and bonded cross car beam. Warning: Refer to Approved Equipment for Collision Repair...
  • Page 35 Remove the bolts attaching the lower plenum and dash panel (1). Apply heat and pry to detach the adhesive along the bonding surfaces. 10. Remove the bolts   (1) attaching the windshield frame to the front hinge pillars. 11. Remove the windshield frame   (1) by applying heat and pry to detach the adhesive along the bonding surface. 12.
  • Page 36 15. Repair as much of the damage as possible to the factory specifications. 16. Use J 42058 frame adapter clamp to secure the vehicle if pulling and straightening is required. Installation Procedure Before applying adhesive, dry fit the windshield frame for proper fit and alignment. Note: DO NOT top coat any bonding surface.
  • Page 37 Caution: Refer to Fastener Caution. Install the bolts   (1) that attach the windshield frame to the front hinge pillar and tighten to 25  Y (18   lb   ft). Clamp or mechanically fasten the windshield frame into place. Apply structural adhesive to bond the lower dash panel and lower plenum to the windshield frame. Refer to Sheet Molded Compound (SMC) Panel Bonding.
  • Page 38 14. Install the upper plenum   (1) to the windshield frame. 15. Install the close-end rivets, in the factory locations, securing the upper plenum to the windshield frame. 16. Remove any excess adhesive. 17. Install all related panels and components. 18.

  • Page 39: Side Door Opening Frame Replacement

    Side Door Opening Frame Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning. The side door opening frame is made of sheet molded compound (SMC), and is bonded to the side structure and frame rail with structural adhesive. Disable the SIR system.
  • Page 40 Apply a bead of High Viscosity Urethane to the side structure and frame rail and to all areas originally bonded. Apply dollops of structural adhesive (1) to the original locations on the body side. Refer to Sheet Molded Compound (SMC) Panel Bonding.

  • Page 41: Rear Rail Replacement (Front Section)

    Rear Rail Replacement (Front Section) Special Tools J-42058 Frame Adapter Clamp For equivalent regional tools, refer to Special Tools. Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning. Disable the SIR system. Refer to SIR Disabling and Enabling. Disconnect the negative battery cable.
  • Page 42 11. Locate and remove all factory welds   (1) attaching the outer body extension panel to the structure. Note the location of the welds for installation of the new extension panel 12. Remove the screws from the extension panel bracket   (1). 13.

  • Page 43: Installation Procedure

    Installation Procedure Note: Pre-Drill holes with 7/32 or 5.6   mm drill before installation of service screw. As noted from original part. Install the screws for the extension panel bracket   (1). Refer to Sheet Molded Compound (SMC) Panel Bonding. Install the screws for the floor panel bracket  ...
  • Page 44 Apply structural adhesive to the inboard side of the upper extension panel. (1). Refer to Sheet Molded Compound (SMC) Panel Bonding. Note: Recommended wire alloy is 5554 and wire size is 1   mm (0.035   in). The shielding gas is 100 percent Argon. Using a P-MIG welder, plug weld the upper extension panel  ...

  • Page 45: Rear Rail Replacement (Rear Section)

    Rear Rail Replacement (Rear Section) Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning. Disable the SIR system. Refer to SIR Disabling and Enabling. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Remove all related panels and components. Remove the rear impact bar.
  • Page 46 Note: If no trace of the original welds is present, follow the pattern specified for welding the rear rail to the cast rail section. Numbers represent measurement in millimeters. Install the rear impact bar. Refer to Rear Bumper Impact Bar Replacement.

  • Page 47: Floor Panel Replacement

    Floor Panel Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning. The floor panel is an LCM (Liquid Compression Mold) Composite and is bonded to the structure using panel bonding adhesive. Disable the SIR system. Refer to SIR Disabling and Enabling.
  • Page 48 Remove the floor panel from the vehicle. Save any and all brackets, mounting studs, and accessories for transfer to the new floor. 10. Note the location and remove all remaining loose adhesive. 11. Inspect the structure and frame rails for damage. Installation Procedure Before applying adhesive dry fit the floor panel for proper fit and alignment.
  • Page 49 Install the floor panel to the vehicle. Apply weight to the floor panel to set the adhesive. Install the seat mounting nuts to set the adhesive at the cross brace. Note: Ensure that no adhesive is on the threads before installing nuts. Smooth adhesive around perimeter of floor panel from underside of vehicle to form a consistent, leak-proof seal.

  • Page 50: Rear Compartment Panel Replacement

    Rear Compartment Panel Replacement Special Tools J 42058 Frame Adapter Clamp Removal Procedure The rear compartment panel is made of sheet molded compound (SMC), and is bonded to the rear structure and frame rails with structural adhesive. Warning: Refer to Approved Equipment for Collision Repair Warning.
  • Page 51 Note: The front edge of the rear compartment panel is also bonded across the seatback area and along the top of the rear impact bar. Note: The adhesive material will release from the structure by applying heat to approximately 200°C (400°F). A noticeable popping sound can normally be heard when the adhesive releases.
  • Page 52 Apply a consistent bead of structural adhesive   (1) 12   mm (1/2   in) in diameter to the following locations. Refer to Sheet Molded Compound (SMC) Panel Bonding. • The top of the frame rails • The backside of the lock pillars •...
  • Page 53 Install the rear compartment panel to the vehicle. Apply pressure to the rear compartment panel to set the adhesive. Install the screws attaching the rear compartment panel to the frame rails. Clamp or mechanically fasten the rear compartment panel in place as necessary. Remove any excess adhesive.

  • Page 54: Rear Compartment Panel Frame Replacement

    Rear Compartment Panel Frame Replacement Removal Procedure The rear compartment frame is made of sheet molded compound (SMC), and is bonded to the rear structure with structural adhesive. Warning: Refer to Approved Equipment for Collision Repair Warning. Disable the SIR system. Refer to SIR Disabling and Enabling.
  • Page 55 Remove the rear compartment frame   (1). Note the location of the adhesive and remove all remaining loose adhesive. Inspect the rear structure and frame rails for damage. Installation Procedure Note: Shims may be necessary to achieve proper panel alignment. Use care to keep shims out of adhesive path. Before applying the adhesive, dry fit the rear compartment frame for proper fit and alignment.
  • Page 56 Install the rear compartment frame   (1). Apply pressure to the rear compartment frame to set the adhesive. Clamp or mechanically fasten the rear compartment frame into place. Remove any excess adhesive. Install all related panels and components. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.

  • Page 57: Description And Operation

    Description and Operation Aluminum Panel Bonding (Non-Structural) This information is intended to provide general guidelines for non-structural adhesive bonding of aluminum panels. Panel bonding of aluminum is only recommended when the panel is originally bonded to the vehicle. The adhesives listed in this document are known to meet the General Motors specifications and requirements for non-structural bonding of aluminum body panels.
  • Page 58 Aluminum Panel Bonding (Structural) This information is intended to provide general guidelines for adhesive bonding of aluminum panels. Panel bonding of aluminum is only recommended when the panel is originally bonded to the vehicle. The adhesives listed in this document are known to meet the General Motors specifications and requirements for bonding of aluminum body panels. Bonding procedures in general are applicable only at factory joints.

  • Page 59: Sheet Molded Compound (Smc) Panel Bonding

    Sheet Molded Compound (SMC) Panel Bonding This is intended to provide general guidelines for sheet molded compound (SMC) and carbon fiber 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: •...

  • Page 60: Special Tools And Equipment

    Special Tools and Equipment Special Tools Illustration Tool Number/ Description J   42058 Frame Adapter Clamp...

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