Chevrolet Corvette 1997 Complete Manual

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Owner's manual (357 pages)

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Page 1: Table Of Contents
1 997/98 Corvette Panel Identification ............. 3-1 Front Bumper Impact Bar ........... 3-2 Front Wheelhouse ............3-4 Rail - Underbody Side Assembly ......... 3-6 Front Side Door Opening Assembly ......3-17 Windshield Frame Assembly ........3-19 Front Floor Panel ............3-22 Roof Bow Service ............
Page 2: Panel Identification
Panel Identification 1997/98 Chevrolet Corvette Collision Repair...
Page 3: Front Bumper Impact Bar
Extract pieces of the impact bar left attached to the rail ends (Fig. 3.4). Keep the perimeter and shape of the rail end (fishmouth) as original as possible. Fig. 3.3 — Note Location of Welds for Reinstallation 1997/98 Chevrolet Corvette Collision Repair...
Page 4 Refer to paint 30mm manufacturer’s recommendations. 50mm Install all related panels and components. C of vehicle 30mm 15mm 50mm 40mm View A Fig. 3.5 — Weld Perimeter of Joint, as Indicated 1997/98 Chevrolet Corvette Collision Repair...
Page 5: Front Wheelhouse
Fig. 3.7 — Service Assembly Can Be Separated vehicle, see Fig. 3.10. Remove the damaged for Outer Wheelhouse Panel Replacement wheelhouse. Frame Adapter Clamp Fig. 3.8 — Adapter Clamp for Anchoring System 1997/98 Chevrolet Corvette Collision Repair...
Page 6 Install headlamp mounting bracket. Trowel around perimeter of bonding area to remove excess adhesive and restore original appearance. Install all related panels and components. Fig. 3.11 — Apply Adhesive to Service Part 1997/98 Chevrolet Corvette Collision Repair...
Page 7: Rail - Underbody Side Assembly
Fig. 3.12 — One-Piece Mild Steel Frame Rails Frame Adapter Clamp Fig. 3.13 — Adapter Clamp for Conventional Anchoring System 1997/98 Chevrolet Corvette Collision Repair...
Page 8 2 Offset Lap Joint Sleeve Overlap Sleeve Overlap Min. 50 mm (2 in) Min. 25 mm (1 in) Max. 100 mm (4 in) Max. 50 mm (2 in) Fig. 3.15 — Use the Appropriate Sectioning Technique, as Indicated 1997/98 Chevrolet Corvette Collision Repair...
Page 9 Notice: Retain a gap of one and one half rail accordingly. times the metal thickness at the butt-joint Cut any additional welds as necessary and when attaching the service part to the remove the damaged portion of the frame vehicle. rail. 1997/98 Chevrolet Corvette Collision Repair...
Page 10 Notice: DO NOT top-coat any bonding Overlap surface. 11 Clean and prepare all bonding surfaces as Min. 50 mm (2 in) necessary. (Refer to SMC Repair Procedures.) (4 in) Max. 100 mm Fig. 3.20 — 1997/98 Chevrolet Corvette Collision Repair...
Page 11 Do not combine paint side rail assembly. systems. Refer to paint manufacturer’s recommendations. After sectioning repairs are completed, attach panels and components as necessary. Rear Rail Front Rail Center Rail Fig. 3.21 — Frame Rail Service Parts 1997/98 Chevrolet Corvette Collision Repair 3-10...
Page 12 (where SMC floor panel stops and floorpan extension begins) . Fig. 3.22 — Check Front of Dash Bonding Areas for Cracks Fig. 3.23 — Pry Up Extension Panel to Expose Rail for Sectioning 1997/98 Chevrolet Corvette Collision Repair 3-11...
Page 13 10 Perform offset lap-joint sectioning as required. ( Refer to Offset Lap-Joint Sectioning Procedures. ) 2" Flange SMC Floor Pan Fig. 3.24 — Remove Majority of Lower Extension Panel to Access the Rail 1997/98 Chevrolet Corvette Collision Repair 3-12...
Page 14 Do not combine paint systems. Refer to paint manufacturer’s recommendations. Stitch weld to rail Plug weld at tunnel brace. SMC Floor Pan Fig. 3.25 — Positioning and Replacement of Floor Extension 1997/98 Chevrolet Corvette Collision Repair 3-13...
Page 15 SMC for cracks or areas that may need to be repaired or resealed. (Refer to SMC Repair Procedures.) Notice: Use the Offset Lap-Joint method to perform rear rail repairs. Fig. 3.26 — Shaded Areas Are High-Strength Steel 1997/98 Chevrolet Corvette Collision Repair 3-14...
Page 16 Clean and prepare all surfaces for assembly as necessary. Perform offset lap-joint sectioning as required. ( Refer to Offset Lap-Joint Sectioning Procedures .) Access rail under panel Fig. 3.29 — Pry Up Extension Panel for Rail Access 1997/98 Chevrolet Corvette Collision Repair 3-15...
Page 17 Refer to paint manufacturer’s • Always follow repair procedures and recommendations. recommendations to ensure that structural After sectioning repairs are completed, integrity and safety are restored to the attach panels and components as necessary. vehicle 1997/98 Chevrolet Corvette Collision Repair 3-16...
Page 18: Front Side Door Opening Assembly
Fig. 3.34. (NOTE: Use caution along the underside of the vehicle when applying heat not to de-bond the floor panels from the frame rail.) Fig. 3.33 — Adapter Clamp for Conventional Anchoring System 1997/98 Chevrolet Corvette Collision Repair 3-17...
Page 19 11 Install all related panels and components. Fig. 3.36 — Install Screws to Secure Panel While Adhesive Cures. Also Apply Adhesive to the Lower Edge of Rocker to Bond at Bottom Side of Rail. 1997/98 Chevrolet Corvette Collision Repair 3-18...
Page 20: Windshield Frame Assembly
SMC repairs are attempted. Remove and relocate wiring as necessary to avoid damage. Fig. 3.39 — Adapter Clamp for Conventional Anchoring System 1997/98 Chevrolet Corvette Collision Repair 3-19...
Page 21 Apply adhesive to attach lower plenum to windshield frame, drill holes and use close-end rivets (GM P/N 9418420 or, equivalent) to hold plenum secure while adhesive cures. Fig. 3.41 — Install Adhesive to Service Part 3-20 1997/98 Chevrolet Corvette Collision Repair...
Page 22 Apply adhesive to the upper plenum and install using close-end rivets in factory locations, to hold in place while adhesive cures (Fig. 3.42). Fig. 3.42 — Install Adhesive to Windshield Frame for Upper Plenum Installation 1997/98 Chevrolet Corvette Collision Repair 3-21...
Page 23: Front Floor Panel
Important: Prior to refinishing, refer to GM P/N 4901 Refinish Manual for recommended products. Apply approved anti-corrosion primer. Notice: DO NOT top-coat any bonding surface. Fig. 3.45 — Reinforcement Bonded to Tunnel and Floor 3-22 1997/98 Chevrolet Corvette Collision Repair...
Page 24 11 Apply top-coat over all primed areas. Refer to paint manufacturer’s recommendations. Do not combine paint systems. ADHESIVE 12 Install all related panels and components. FLOOR Fig. 3.48 — Cross Section of Floor and Rail Brace 1997/98 Chevrolet Corvette Collision Repair 3-23...
Page 25: Roof Bow Service
(Fig. 3.51). Apply heat to the bonded area and break the adhesive to remove the Roof Bow Cover. (Follow SMC Repair Procedures.) Fig. 3.50 — SMC Roof Bow Cover Fig. 3.51 — Adhesive Bead Location 3-24 1997/98 Chevrolet Corvette Collision Repair...
Page 26: Rear Compartment Panel
XMBR along the top of the rear impact bar. BOLT Detach bonds and remove as necessary. Remove damaged rear compartment panel. Fig. 3.54 — Scribed Lines and Text in All Compartment Panels 1997/98 Chevrolet Corvette Collision Repair 3-25...
Page 27 Fit the Rail Remove any excess adhesive squeeze-out as necessary. Let adhesive cure according to adhesive manufacturer recommendations. 10 Install all related panels and components. (Refer to Rear Compartment Panel Frame Installation procedures.) 3-26 1997/98 Chevrolet Corvette Collision Repair...
Page 28 Notice: The frame rails and bumper impact bars must be serviced as required, and returned to three-dimensional coordinates before any SMC repairs are attempted (Fig. 3.57). Fig. 3.57 — Frame-Rear Compartment Panel Sectioning 1997/98 Chevrolet Corvette Collision Repair 3-27...
Page 29 (Refer to SMC Repair Procedures.) XMBR BOLT BOND BOND XMBR BOLT Fig. 3.58 — Top View of Rear Compartment Panel Section Lines Etched in All Parts 3-28 1997/98 Chevrolet Corvette Collision Repair...
Page 30 15 Install all related panels and components. down firmly to wet-out the adhesive. Use two close-end rivets or self-drilling screws in BOND Fig. 3.59 — Install Sectioned Panel to Backing Plates Created From Undamaged SMC 1997/98 Chevrolet Corvette Collision Repair 3-29...
Page 31: Rear Compartment Panel Frame
Fig. 3.61 — Convertible rear panel frame Use backing plate No backing plate necessary Fig. 3.62 — Section coupe rear surround in shaded area Fig. 3.63 — Stagger the rear panel frame to rear compartment panel sectioning joints 3-30 1997/98 Chevrolet Corvette Collision Repair...
Page 32 Conventional Anchoring System removed, clean off most of the adhesive bead. Leave a few small areas (about 25mm (1 inch) in length) of adhesive in place to act as shims for the new ‘rear surround’. 1997/98 Chevrolet Corvette Collision Repair 3-31...
Page 33 ADHESIVE Fig. 3.67 — Apply a Consistent Bead of ADHESIVE Adhesive to the Entire Perimeter to Form a Leak-Proof Seal Fig. 3.66 — Adjust Rear Surround Using Adhesive Bead 1mm≤ 7mm In Thickness 3-32 1997/98 Chevrolet Corvette Collision Repair...
Page 34: Rear Bumper Impact Bar
SMC repairs are attempted. Remove or reposition wiring as necessary to avoid being damaged. Fig. 3.70 — Mig Stitch Welded to Frame Rails 1997/98 Chevrolet Corvette Collision Repair 3-33...
Page 35 Remove any adhesive which is cracked or broken loose from the rails or the rear compartment panel. Fig. 3.73 — Bond Between Beam and Tub 3-34 1997/98 Chevrolet Corvette Collision Repair...
Page 36 82014B System 2000 Structural Adhesive, a PLIOGRIP ® adhesive manufactured by Ashland Chemical Company, or equivalent. Note the 9 minute working time and 1 hour cure time. Fig. 3.75 — Prime Bare Metal Areas Before Installing Window Cutouts 1997/98 Chevrolet Corvette Collision Repair 3-35...
Page 37 10 Clean and prepare all bonding surfaces as Do not combine paint systems. necessary. (Refer to SMC Repair Procedures.) 15 Install all related panels and components. Fig. 3.76 — Bond Rear Compartment Panel to Top Side at Impact Bar 3-36 1997/98 Chevrolet Corvette Collision Repair...
Page 38: Smc Repair Procedures
Allow to cure according to adhesive manufacturer’s recommendations. Apply a thin coat of Goodwrench Structural Bonding Epoxy (P/N 12345726) or equivalent as a final coat to blend in the repair to resemble OEM appearance. 1997/98 Chevrolet Corvette Collision Repair 3-37...
Page 39: Body Dimensions
Body Dimensions 3-38 1997/98 Chevrolet Corvette Collision Repair...
Page 40 Body Dimensions 1997/98 Chevrolet Corvette Collision Repair 3-39...
Page 41 Body Dimensions 3-40 1997/98 Chevrolet Corvette Collision Repair...

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Chevrolet Corvette 1997 Complete Manual

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