1999

Pontiac Grand Am
and Oldsmobile Alero
Panel Identification ..................................................... 2-1

Front End Assembly ..................................................... 2-3

Front Wheelhouse Assembly ....................................... 2-4

Front Lower Rail Assembly ......................................... 2-7

Door Frame Opening ..................................................2-17

Roof Panel ................................................................... 2-22

Quarter Panel ..............................................................2-24

Rear Wheelhouse ........................................................2-28

Rear Floor Assembly ..................................................2-31

Rear Rails ..................................................................... 2-35

Rear End Panel Assembly ........................................... 2-36

Body Dimensions ........................................................2-37

 Coupe

white
Two-Sided Galvanized Steel
High-Strength Low-Alloy Steel
Thermoplastic Olefin
Panel Identification

1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair

2-1
 Sedan

2-2
white
Two-Sided Galvanized Steel
Panel Identification

High-Strength Low-Alloy Steel

Thermoplastic Olefin

1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair

Front End Assembly
The front-end structure consists of six
resistance-welded components. The upper tie
bar and upper reinforcement panel are serviced
as individual components. The brace, (front-end
lower structure) includes rail reinforcement
gussets, which provide cross-car alignment of
the service assembly. Left and right impact bar
brackets are serviced separately and must be
installed using three-dimensional coordinates
(Fig.␣ 2.1).
— REMOVE OR DISCONNECT —
1 Remove all related panels and components.
2 Visually inspect and restore as much of the
damage as possible to factory specifications.
3 Remove sealers and anti-corrosion materials
as necessary.
4 Locate, mark and drill out all factory welds as
necessary. Note the number of welds for
installation of the service panels.
5 Remove the damaged panels in the upper tie
bar assembly and the front end lower brace,
as necessary.
Fig.␣ 2.1 — Front end structure
1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
— INSTALL OR CONNECT —
1 Prepare mating surfaces and check for
proper fit of the service panels.
2 On the service panels, drill 8mm (5/16) plug
weld holes as necessary in the locations
noted from the original assembly.
Notice: If original components are
damaged beyond recognition, place plug
weld holes every 40mm (1-1/2) inches
apart.
3 Position the service panels, check fit using
body dimensions, and plug weld accordingly
with frequent measurements to ensure
proper fit.
4 Clean and prepare welded surfaces.
Important: Prior to refinishing, refer to
GM P/N 4901 M-D Refinish Manual for
recommended products.
5 Apply approved anti-corrosion primer
6 Apply sealers and refinish as necessary. Do
not combine paint systems. Refer to paint
manufacturer’s recommendations.
Notice: Upper tie-bar service parts do
not have mounting locations for (3) center
latch-support holes. Use threaded inserts
such as Riv-nuts, available through Kent-
Moore tools (Riv-nut Kit P/N J␣ 42151-8MS).
7 Reinstall all related panels and components.
2-3
Front Wheelhouse Assembly
The left and right front wheelhousings are
available as complete assemblies (Fig.␣ 2.2).
Additionally, the front portion of the aprons
and upper rail can be ordered and serviced as a
partial assembly (Fig.␣ 2.3). Strut mounting holes
are pre-drilled in the service assemblies. The
front wheelhouse assembly is serviced without
the form and pierced fender mounting locations.
When replacing as an assembly, technicians must
three-dimensionally locate fender-mounting
holes and use threaded inserts for fender bolts
and body shims to achieve correct height
(Fig.␣ 2.4). (Riv-nuts with crimping tool are
available from Kent-Moore tools: Riv-nut Kit,
Fig.␣ 2.2 — Wheelhouse service assembly
P/N J42151-8MS).
Sectioning procedures have been developed to
simplify wheelhouse repairs. Use the following
guidelines to determine whether wheelhouse can
be sectioned or should be replaced at factory
seams.

Fig.␣ 2.3 — Front assembly also available

,,,
Riv-nuts

Fig.␣ 2.4 — Use threaded inserts at fender

mounting locations

2-4 1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair


Wheelhouse Sectioning
Notice: Inspect the cowl panel for damage
where the wheelhouse is attached. If the
panels have been separated, it will be
necessary to repair the cowl panel and
replace the wheelhouse at factory seams. If
panels have not been separated and there is
no damage in this location, the wheelhouse
can be serviced as follows.
— REMOVE OR DISCONNECT —
1 Remove all related panels and components.
2 Visually inspect and restore as much of the
damage as possible to factory specifications.
3 Remove all sealers and anti-corrosion
materials as necessary.
Fig.␣ 2.5 — Create weld flange from original panel
1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
Front Wheelhouse Assembly
4 At wheelhouse to cowl panel joint, measure
forward 75mm (3 inches). Mark a vertical line
from strut cap to frame rail (do not cut into
strut cap). Cut the wheelhouse along this
line, from rail up to strut cap (Fig.␣ 2.5). This
will provide an overlap flange for welding the
service part to the original wheelhouse,
without welding directly to the cowl panel.
Notice: Drill through strut cap welds to
locate areas to be re-welded at cowl
panel.
5 Locate, mark and drill out the factory welds,
which attach the wheelhouse assembly to the
cowl panel, radiator support and lower front
rails.
6 Remove the damaged wheelhouse assembly.
2-5
Front Wheelhouse Assembly

— INSTALL OR CONNECT —
1 Clean and prepare surfaces to be welded.
2 Trim and discard tab off service part which is
normally welded to the cowl panel (Fig.␣ 2.6)
3 Drill 8mm (5/16-inch) holes for plug welding
in the locations noted from the original
assembly.
4 Drill six holes for plug welding every 40mm
(1-1/2 inches) along the overlap which
attaches service part to flange remaining
from original assembly. (Fig.␣ 2.7)
5 Check the position of the wheelhouse
assembly using three-dimensional measuring
Fig.␣ 2.6 — Trim weld flange equipment and plug weld accordingly. Install
from service assembly one weld in the tab from cowl to strut cap.
(Fig.␣ 2.8)
Notice: The welds which attach the strut
cap to the cowl can be installed from the
cowl plenum side of the joint (Fig.␣ 2.8).
6 Clean and prepare all welded surfaces.
Important: Prior to refinishing, refer to
GM P/N 4901 M-D Refinish Manual for
recommended products.
7 Locate and drill 2 fender-mounting holes in
new wheelhouse using three-dimensional
measuring equipment.
8 Apply approved anti-corrosion primer.
9 Apply sealers and sound deadeners and
refinish as necessary. Do not combine paint
systems. Refer to paint manufacturer’s
recommendations.
10 Install threaded inserts at fender mounting
locations. (Kent-Moore tools: Riv-nut Kit
P/N J␣ 42151-MS). Reuse original fasteners
Fig.␣ 2.7 — Drill 8mm (5/15 inch) holes or equivalent.
along overlap
11 Install all related panels and components.

Cowl
plenum Wheelhouse

Fig.␣ 2.8 — Weld plenum to strut cap from plenum side

2-6 1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair

Front Lower Rail Assembly
Replacement of the engine compartment lower rail
assemblies has been improved on the Grand
Am/Alero through the use of a sub-assembly service
part. The lower rail service part comes complete
with all brackets and reinforcements (Fig.␣ 2.9). When
sectioning, order the entire assembly and extract
the necessary parts (Fig.␣ 2.10).

Fig.␣ 2.9 — Left side service assembly

Fig.␣ 2.10 — Extract parts for sectioning

1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair 2-7

Front Lower Rail Assembly

Lower Rail Sectioning Important: Damage to the front lower rails

Sectioning procedures have been developed to
help simplify repair of the lower rails, provided the
majority of damage can be returned to factory
specifications. This allows technicians to repair the
damaged front section without having to make a
complete rail replacement. Sectioning of the lower
rail does not require removal of the powertrain.
must be limited to the portion of the rail
forward of the sectioning joint, if damage
exceeds the forward portion, complete
replacement of the rail is recommended.
(See complete rail replacement procedures.)
Notice: The lower rail sectioning cut lines
vary from left to right. Be sure to use the
correct procedure. (Fig.␣ 2.11)

Left rail, inner

Right rail, inner

Right rail, outer

Fig.␣ 2.11 — Unique rails, unique repair procedures left to right

2-8 1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair

 Front Lower Rail Assembly

LEFT - FRONT LOWER RAIL SECTIONING

— REMOVE OR DISCONNECT —
1 Remove all related panels and components
including left front cradle bolt.
2 Visually inspect and restore as much of the
damage as possible to factory specifications.
3 Remove all sealers and anti-corrosion
materials as necessary.
4 Apply 25mm (1 inch) wide tape on the lower
rail outer panel following the contour of the
cowl (Fig.␣ 2.12). Cut the outer panel along
the forward edge of the tape. This will
provide an overlap tab for welding the
service part to the original rail without
welding directly to the cowl panel.
5 Drill out all factory welds attaching the outer
panel to the rail inner panel, be sure not to
drill through the inner panel.
Notice: Welds on engine cradle mounting
bracket must also be drilled out to remove
outer panel.
6 Remove the rail outer panel.
7 Locate the 16 x 35 slot on the in-board side Fig.␣ 2.12 — Cut the outer panel
of the rail (Fig.␣ 2.13). Using the hole as a along forward edge of tape
guide, mark a line on all three sides of the
rail.
8 Cut the rail along the marked line and
remove the damaged portion of the rail.

Fig.␣ 2.13 — Mark a line on the damaged rail

1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair 2-9

Front Lower Rail Assembly

PREPARING SERVICE PART
FOR INSTALLATION
— INSTALL OR CONNECT —
1 Locate and drill out factory welds attaching
the outer panel to the inner panel on the
service part. Drill through one layer ONLY at
the front half of the rail.
Notice: Welds on engine cradle mounting
bracket must also be drilled out to remove
outer panel.
2 Separate inner from outer rail using an air
chisel. Remove the outer panel and set aside.
3 On the left inner rail service part, mark a line
around the panel 30mm (1-1/4 inch) rearward
of the 16 x 35 hole on the inner rail. Using the
hole as a guide, mark a line around the rail
(Fig.␣ 2.14).
4 Cut the service part along the marked line
and discard the unused section.
5 On the sectioned service part, cut a 2mm (1/8
inch) gap approximately 30mm (1-1/4 inch)
deep along the corners of the inner rail to
create tabs (Fig.␣ 2.15).
6 Step the tabs inward to allow the service part
section to fit inside the original rail (Fig.␣ 2.15).

30mm

Fig.␣ 2.14 — Left rail service part, add 30mm for weld tabs

1. Cut Corners

2. Step tabs
inward

Fig.␣ 2.15 — Cut corners and step tabs inward on service part

2-10 1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair

 Front Lower Rail Assembly

7 Drill 5 holes for plug welding along the
overlap, approximately 13mm (1/2 inch) from
the sectioning cut (Fig.␣ 2.16).
8 Position the modified service part inside the
original rail align using three-dimensional
measuring equipment.
9 On rail outer panel, trim off tab that attaches
to cowl panel. Drill three 8mm (5/16 inch)
plug weld holes along overlap.
Notice: Be certain the engine cradle
mounting location is in the proper
position. Align and hand tighten bolt.
Important: When stitch welding, make
25mm (1 inch) welds along the seam with
25mm (1 inch) gaps between. Then go
back and complete the stitch weld along
the seam.
10 Position the outer panel, check for proper fit
and alignment.
11 Stitch weld along the entire joint. Plug weld
all holes drilled during the removal process
including holes drilled along overlapped
areas (Fig.␣ 2.17).
12 Clean and prepare welded surfaces.
Important: Prior to refinishing, refer to
GM P/N 4901 M-D Refinish Manual for
recommended products.
13 Apply approved anti-corrosion primer.
14 Apply sealers and refinish as necessary. Do
not combine paint systems. Refer to paint
manufacturer’s recommendations.
15 Install all related panels and components.

Fig.␣ 2.16 — Drill 8mm (5/16 inch) holes for plug welding

Fig.␣ 2.17 — Plug welds and stitch welds completed

1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair 2-11

Front Lower Rail Assembly

RIGHT - FRONT LOWER RAIL SECTIONING 5 Drill out all the factory welds attaching the
— REMOVE OR DISCONNECT — outer panel to the rail inner panel, be sure
1 Remove all related panels and components. not to drill through the inner panel. Remove
the rail outer panel.
2 Visually inspect and restore as much of the
damage as possible to factory specifications. 6 Measure 75mm (3 inches) forward of the
engine mount brace located inside the rail
3 Remove all sealers and anti-corrosion
and mark a line (Fig.␣ 2.18). Drill a 1/8 inch
materials as necessary.
hole on the line. Using the hole as a guide,
4 Apply 25mm (1 inch) wide tape on the lower mark a line around the outside of the rail.
rail outer panel following the contour of the
7 Cut the rail along the marked line and
cowl. Cut the outer panel along the forward
remove the damaged portion of the rail.
edge of the tape (refer to Fig.␣ 2.12). This will
provide an overlap for welding the service
part to the original rail, without welding
directly to the cowl panel.

75mm

Right rail, inner

Right rail, outer

Fig.␣ 2.18 — Remove outer panel and measure damaged inner rail

2-12 1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair

 Front Lower Rail Assembly

PREPARING SERVICE PART 3 On the right side rail, measure 45mm

FOR INSTALLATION
— INSTALL OR CONNECT —
1 Locate and drill out factory welds attaching
the outer panel to the inner panel on the
service part. Drill through one layer ONLY at
the front half of the rail.
Notice: Welds on engine cradle mounting
bracket must also be drilled out to remove
outer panel.
2 Separate inner from outer rail using an air
chisel. Remove the outer panel and trim off
the rear edge that welds to the cowl panel.
(1-3/4␣ inches) forward of the engine mount
brace (Fig.␣ 2.19), notice this is 30mm (1-1/4
inches) less than the original sectioning cut.
Drill a 1/8- inch hole on the line. Using the
hole as a guide, mark a line around the rail.
4 Cut the service part along the marked line
and discard the unused section.
5 On the sectioned service part, cut a 2mm (1/8
inch) gap approximately 30mm (1-1/4 inch)
deep along the corners of the inner rail to
create tabs (Fig.␣ 2.20).
6 Step the tabs inward to allow the service part
section to fit inside the original rail (Fig.␣ 2.20).

Right rail, inner

45mm FRT

Right rail, outer

Fig.␣ 2.19 — Remove outer panel to measure inner rail on service part

1. Cut Corners

FRT

2. Step tabs
inward

Fig.␣ 2.20 — Cut corners and step tabs inward on service part

1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair 2-13

Front Lower Rail Assembly

7 Drill 5 holes for plug welding along the
overlap, approximately 13mm (1/2 inch)
from the sectioning cut (Fig. 2.21)
8 Position the modified service part inside the
original rail using three-dimensional
measuring equipment.
Notice: Be certain the engine cradle
mounting location is in the proper
position. Align and hand tighten bolt.
Important: When stitch welding, make
25mm (1 inch) welds along the seam with
25mm (1 inch) gaps between. Then go
back and complete the stitch weld.
9 Drill 3 holes in the rail outer panel in front of
the cowl.
10 Position the outer panel, check for proper fit
and alignment.
11 Stitch weld along the entire joint. Plug weld
all holes drilled during the removal process
(Fig.␣ 2.22).
12 Clean and prepare welded surfaces.
Important: Prior to refinishing, refer to
GM P/N 4901 M-D Refinish Manual for
recommended products.
13 Apply approved anti-corrosion primer.
14 Apply sealers and refinish as necessary. Do
not combine paint systems. Refer to paint
manufacturer’s recommendations.
15 Install all related panels and components.

Fig.␣ 2.21 — Drill 8mm (5/16 inch) holes for plug welding

Fig.␣ 2.22 — Plug welds and stitch weld completed

2-14 1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair


FRONT LOWER RAIL REPLACEMENT
— REMOVE OR DISCONNECT —
1 Remove all related panels and components.
2 Visually inspect and restore as much of the
damage as possible to factory specifications.
3 Remove sealers, sound deadeners and
anti-corrosion materials as necessary.
4 Using an air chisel, remove the rear engine
mount.
5 Locate and drill out resistance welds in
torque box panel (Fig.␣ 2.23). Drill through
one layer of metal ONLY.
6 From underside of vehicle, locate welds that
secure the rail to the floorpan. Using a
Fig.␣ 2.23 — Drill through rail in torque box to locate welds inside vehicle
1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
Front Lower Rail Assembly
1/8-inch drill bit, drill through floor to mark
welds for removal.
7 Separate the floor pan reinforcement vertical
flange from inside the lower rail. Care must
be taken to not damage the flange.
8 Drill out factory welds along the lower flange
on the floor pan reinforcement and at the
wheelhouse. Note that the flanges overlap
the rails.
9 From inside the vehicle, use an 8mm (5/16
inch) drill bit to drill through the floor pan
and the reinforcement inside the vehicle
(Fig␣ 2.24).
10 Remove the damaged rail.
2-15
Front Lower Rail Assembly

— INSTALL OR CONNECT — hammer to flatten inner panel against floor

1 Prepare mating surfaces and check for
proper fit of the new rail. Apply suitable
weld-through primer.
2 Position the new rail in place and check for
proper alignment using three-dimensional
measuring equipment.
3 With the new rail in place, plug weld all the
holes created from the removal process. In
the areas the floor inner panel does not
contact the floor pan, use a ball- peen
pan. Plug weld floor to new rail in remaining
areas.
4 Clean and prepare welded surfaces.
Important: Prior to refinishing, refer to
GM P/N 4901 M-D Refinish Manual for
recommended products.
5 Apply approved anti-corrosion primer.
6 Apply sealers and refinish as necessary. Do
not combine paint systems. Refer to paint
manufacturer’s recommendations.
7 Install all related panels and components.

Fig.␣ 2.24 — Drill from inside vehicle at pilot hole locations using an 8mm (5/16 inch) drill bit

2-16 1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair

Door Frame Opening
The side door frame openings feature a unique
modular build sub-assembly design to improve
manufacturing quality. They are composed of
numerous individual components that are
pre-assembled and then attached to the vehicle
as a single unit.
The door frame can be replaced as a complete
assembly or various segments of it can be
sectioned, which is usually much faster and more
cost effective. However, there are some key
structural areas where sectioning should not take
place (Fig.␣ 2.25). Since left and right door frame
openings are available as complete assemblies,
service parts for sectioning must be cut from the
complete assembly and modified as necessary.

SECTIONING SHOULD NOT

TAKE PLACE IN SHADED AREAS

Fig.␣ 2.25 — Coupe and Sedan side door frames

1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair 2-17

 Door Frame Opening

Door Frame Opening 3 Position the service assembly, check fit using
Full Replacement body dimension and plug weld accordingly
— REMOVE OR DISCONNECT —
with frequent measurements to ensure
proper fit.
1 Remove all related panels and components
including the roof panel, upper outer rail 4 Inject expandable foam into the “A” Pillar
reinforcement and, on coupe models only, through the bottom interior trim-mounting
the quarter panel. hole. This helps reduce noise in the pas-
senger compartment.
2 Visually inspect and restore as much of the
damage as possible to factory specifications. 5 Clean and prepare welded surfaces.
3 Remove sealers, sound deadeners and anti- Important: Prior to refinishing, refer to
corrosion materials as necessary. GM P/N 4901 M-D Refinish Manual for
recommended products.
4 Locate, mark and drill out all factory welds.
Note the number of welds for installation of 6 Apply approved anti-corrosion primer.
the service assembly. 7 Apply a full-bodied caulk along the surface of
5 Remove the damaged doorframe opening. the baffle to ensure a proper seal with the
inner cowl plenum (Fig.␣ 2.27).
8 Apply sealers and refinish as necessary. Do
— INSTALL OR CONNECT —
not combine paint systems. Refer to paint
1 Prepare mating surfaces and check for manufacturer’s recommendations
proper fit of the door frame opening service
9 Reinstall all related panels and components.
assembly.
2 On the service assembly, drill 8mm
(5/16-inch) plug weld holes as necessary in
the locations noted from the original
assembly.
Notice: In any area damaged beyond
recognition, space plug weld holes every
40mm (1-1/2 inches) apart.

Do not plug drain slot

Fig.␣ 2.27 — Apply sealer along inner cowl plenum

Fig.␣ 2.26 — Remove upper outer rail reinforcement

2-18 1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair

 Door Frame Opening

General Sectioning Procedures — REMOVE OR DISCONNECT —

When sectioning areas other than the hinge
pillar, a 100mm (4 inch) backing plate must be
used behind the joint to ensure a solid and
secure weld in areas where there is no inner
reinforcement. Backing plates can usually be cut
from the unused portion of the service part or an
undamaged section of the doorframe opening.
Notice: There are some key reinforcements
that are to be replaced at factory seams only
(Fig. 2.28). Sectioning these panels may
compromise the structural integrity of the
vehicle.
The rocker panel can also be replaced in its
entirety when the quarter panel has been
removed.
1 Remove all related panels and components.
2 Visually inspect and restore as much of the
damage as possible to factory specification.
3 Remove sealers, sound deadeners and anti-
corrosion materials as necessary.
4 Cut the doorframe opening where it is to be
sectioned. Do not damage any inner panels
or reinforcements.
5 Locate, mark and drill out all necessary
factory welds. Note the number of welds for
installation of the service part.
6 Remove the damaged section of the
doorframe opening.

Reinforcements are replaced at factory seams only

Fig.␣ 2.28 — Door frame reinforcements are part of the service assemblies

1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair 2-19

Door Frame Opening

— INSTALL OR CONNECT —
1 Cut the service part to match the undamaged
section of the door frame opening and
remove unused portion of the service part.
2 Cut an appropriate-sized backing plate from
the unused portion of the service part or
undamaged section of the doorframe
opening. Modify the backing plate as
necessary so that it will fit behind the
sectioning joint (Fig.␣ 2.29).

Gap = one and

one-half times 100mm
the thickness (4 in)
of the metal Backing
Plate

100mm

50mm

100mm
100mm

50mm

100mm

Fig.␣ 2.29 — Door frame sectioning specifications

2-20 1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair


3 Windshield pillar sectioning requires a 50mm
(2 inch) backing plate. Section within the
recommended areas (Fig. 2.29).
Notice: The striker plate is mounted in a
cage that allows some degree of
adjustment independent of the outer
panel’s. Use body dimensions to ensure
the striker mounting location falls within
the plate’s range of adjustment
4 Sectioning the rocker panel requires a
100mm (4 inch) backing plate for
reinforcement (Fig. 2.29). Section within the
recommended area.
5 On the service part, drill 8mm (5/16-inch)
plug weld holes as necessary in the locations
noted from the original section. Also, drill
plug weld holes along the sectioning cut on
both the service part and the remaining
original part. These will be used to weld the
panel to the backing plate.
6 Prepare mating surfaces and slide the
backing plates halfway under the sectioning
cuts on the vehicle and plug weld in place.
1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
Door Frame Opening
7 Position the service part, allowing it to
overlap the exposed portion of the backing
plates. Check fit using body dimensions and
plug weld accordingly with frequent
measurements to ensure proper fit.
8 Stitch weld along the sectioning joints. Make
25mm (1 inch) welds along the seam with
25mm (1 inch) gaps between. Then go back
and complete the stitch weld. This will create
a solid joint with minimal heat distortion.
9 Complete all other welds as necessary.
10 Clean and prepare welded surfaces.
Important: Prior to refinishing, refer to
GM P/N 4901 M-D Refinish Manual for
recommended products.
11 Apply approved anti-corrosion primer
12 Apply sealers and refinish as necessary. Do
not combine paint systems. Refer to paint
manufacturer’s recommendations.
13 Reinstall all related panels and components.
2-21
Roof Panel
The roof panel is made of mild steel and welded
to the steel roof structure, including the outer
panel and the inner reinforcements. The roof
panel is serviced as a “skin” with no
reinforcements, only sound-soak patches
pre-installed for efficient installation.(Fig.␣ 2.30)
The roof panel must be drilled to remove the
outer panel and inner reinforcements for
servicing.
Notice: The headliner, windshield and
backglass must be removed prior to the
removal of the roof assembly. Protect the
interior of the vehicle. Use care when working
near adjacent panels, glass, weatherstrips and
moldings.
Important: On vehicles equipped with a
sunroof, take care not to damage the drain
tubes. The drain tubes are located between
the inner and outer windshield pillar.

T
FR
Pre-installed
sound-soak panel

Fig.␣ 2.30 — Coupe roof panel with sunroof opening

2-22 1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair

 Roof Panel

— REMOVE OR DISCONNECT —
Silicon Bronze
Joint 1 Remove all related panels and components
necessary to access the welds attaching the
roof assembly to the vehicle.
2 Visually inspect and restore as much of the
damage as possible.
3 Remove sealers and anti-corrosion materials
as necessary.
4 Locate silicon-bronze joints which attach roof
panel to quarter panels (Fig.␣ 2.31).
5 Cut through the roof panel just above the left
and right silicon-bronze joints using a
die-grinder or equivalent tool (Fig.␣ 2.32).
6 Locate, mark and drill out all factory welds.
Note the number and location of welds for
installation of the service assembly.
7 Remove the damaged roof panel assembly.
8 Grind off silicon-bronze weld and remove
remaining roof panel tabs.

— INSTALL OR CONNECT —
1 Clean and prepare the mating surfaces as
Fig.␣ 2.31 — Locate roof seam at quarter panel necessary.
2 Position the roof panel on the vehicle. Check
fit and alignment.
3 When the service assembly is correctly
positioned, plug weld accordingly.
4 MIG stitch weld the quarter panel to roof
joints at factory seams.
DO NOT CUT SAIL PANEL REINFORCEMENT. Important: Make 25mm (1 inch) welds
CUT ROOF PANEL ONLY along the seam with 25mm (1 inch) gaps
between. Then go back and complete the
stitch weld. This will create a solid joint
with minimal heat distortion.
5 Clean and prepare all welded surfaces.
Important: Prior to refinishing, refer to
GM P/N 4901 M-D Refinish Manual for
recommended products.
6 Apply approved anti-corrosion primer.
Notice: The windshield and bonding area
should be a primer surface ONLY and not
an aftermarket, top-coated (paint or
color-coated) surface. Refer to Bulletin
#43-10-48 for more detailed information.
7 Apply sealers and refinish as necessary. Do
not combine paint systems. Refer to paint
manufacturer’s recommendations.
8 Install all related panels and components.

Fig.␣ 2.32 — Rough cut roof panel above factory seam

1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair 2-23

Quarter Panel
The quarter panel is a service assembly that
includes the gutter, lock-striker cagenut and an
extension panel for the taillamp pocket (tail lamp
pocket is serviced separately). Replacement of
the quarter panel requires removal of the back
light and quarter glass on coupe models. On
both the coupe and sedan models, the quarter
panel is attached to the roof panel by a
silicon-bronze welded joint. To maintain the
integrity of this joint, sectioning of the quarter
panel at sail panel will be performed 100mm
(4␣ inches) below this joint where roof overlaps
quarter panel (Fig. 2.33).

SEDAN

Taillamp pockets
serviced separately

COUPE

Fig.␣ 2.33 — Quarter panel service assemblies

2-24 1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair

 Quarter Panel

Coupe Quarter Panel 5 At B-Pillar location on outer panel only,

Service Procedure measure distance between lower 2 trim
— REMOVE OR DISCONNECT —
holes. Scribe a line at half the distance
between the 2 holes. This is the
1 Visually inspect and restore as much of the
recommended sectioning point (Fig.␣ 2.34).
damage as possible to factory specifications.
Notice: Do not cut into inner
2 Remove all related panels and components,
reinforcement.
including the side and back glass.
6 At scribed line, cut quarter panel ONLY.
3 Remove sealers, sound deadeners and
Locate, mark and drill out the factory welds.
anti-corrosion materials as necessary.
Note the location and number of welds.
4 Locate silicone-bronze seam at roof/quarter-
7 Remove damaged quarter panel.
panel overlap. Measure down 100mm from
pinch weld flange at side and rear window 8 Remove majority of baffle material in sail
(door frame) locations (Fig.␣ 2.34). Mark cut panel and along rocker panel.
line.

Measure equal distance

100mm
between trim holes

Fig.␣ 2.34 — Locating coupe quarter panel

sectioning locations

100mm

Fig.␣ 2.35 — Measure and mark 100mm down

from silicon bronze joint

1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair 2-25

Quarter Panel

PREPARING SERVICE PANEL

FOR INSTALLATION
— INSTALL OR CONNECT —
1 At the sail panel, measure and mark a line
100mm from step at top edge of service part
(Fig.␣ 2.35).
2 At B-Pillar location on outer panel only, measure
distance between lower 2 trim holes. Scribe a
line at half the distance between the 2 holes.
This is the recommended sectioning point (see
Fig. 2.34).
3 Cut along line to trim service part and create a
100mm backing plate. Remove the flange on
Fig.␣ 2.36 — Drill 8mm 5/16 plug weld holes
each side of backing plate so that it will fit along overlap
behind the sectioning joint.
4 Drill 8mm (5/16) plug weld holes as necessary in
the locations noted from the original panel. Drill
plug weld holes along the sectioning areas of
the service part and original panel. These holes
should be located approximately 13mm
(1/2␣ inch) from the edge of the cuts (Fig.␣ 2.36).
5 Prepare the mating surfaces. Position and
secure both backing plates with half of the Important: Care must be taken to ensure that the
backing plate exposed at each joint. Position the fuel filler neck is properly sealed when replacing
service part to overlap the backing plates and the right side quarter panel. Use SPO Sealing
butt up to the original panel (Fig. 2.37). Check strip (P/N 12399117) between the quarter panel
and the fuel filler neck. Install according to
for proper fit and alignment. provided instruction sheet.
Notice: Leave a gap of one and one half
times the thickness of the metal at the
sectioning joint.
6 Plug weld accordingly. Stitch weld along the
entire sectioning joint. Make 25mm (1 inch)
welds along the seam with 25mm gaps between
them. Go back and complete the stitch weld.
100mm
This will create a solid joint with minimal heat
distortion.
7 Plug weld all other areas as noted from the
original panel.
50mm
8 Clean and prepare all welded surfaces.
Important: Prior to refinishing, refer to GM
P/N 4901 Refinish Manual for recommended
products.
9 Apply approved anti-corrosion primer.
10 Apply body sealers and refinish as necessary. Do
not combine paint systems. Refer to paint Fig.␣ 2.37 — Use the correct size backing plates
manufacturer’s recommendations. when installing new panel
11 Install all related panels and components.

2-26 1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair


Sedan Quarter Panel Service
Procedure
— REMOVE OR DISCONNECT —
1 Remove all related panels and components,
including the back glass.
2 Visually inspect and restore as much of the
damage as possible to factory specifications.
3 Remove sealers and corrosion protection
materials as necessary.
4 Note the size of the service part and locate
the sectioning joint at the “sail panel.” Mark
a line 100mm below the silicon bronze joint
and cut (Fig.␣ 2.39).
5 Locate, mark and drill out all factory welds.
Note the number and location of welds for
installation of the service assembly.
6 Remove the damaged quarter panel.
100mm
Fig.␣ 2.38 — Measure 100mm below silicon
bronze joint
Fig.␣ 2.39 — Drill 8mm (5/16 inch) holes for plug welding
1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
Quarter Panel
— INSTALL OR CONNECT —
1 Prepare the mating surfaces as necessary.
2 Temporarily position the service panel on
vehicle. Trim the original panel to leave a gap
of one and one half times the thickness of the
metal at the sectioning joint
3 Cut 100mm (4-inch) piece from the original
quarter panel for backing plates. Remove the
flange on each side of the backing plates so
that they will fit behind the sectioning joints.
4 Drill 8mm (5/16-inch) plug weld holes as
necessary in the locations noted from the
original panel. Also drill plug weld holes
along the sectioned area of the service part.
These should be located approximately
25mm (1 inch) from the edge of the cuts
(Fig.␣ 2.39).
5 Prepare the mating surfaces. Position the
service part to overlap the backing plate and
butt up to the original panel (Fig. 2.40).
Notice: Leave a gap of one and one half
times the thickness of the metal at the
sectioning joint.
6 Plug weld all other areas as noted from the
original panel.
7 Clean and prepare all welded surfaces.
Important: Prior to refinishing, refer to
GM P/N 4901 M-D Refinish Manual for
recommended products.
8 Apply approved anti-corrosion primer
9 Apply sealers, sound deadeners and
corrosion protection materials.
10 Refinish as necessary. Do not combine paint
systems. Refer to paint manufacturer’s
recommendation.
11 Install all related panels and components.
Fig.␣ 2.40 — Use 100mm (4 inch) backing plate
2-27
Rear Wheelhouse
The sedan outer rear wheelhouse (Figs. 2.41) can
be replaced at factory seams. Both models have
a beltline reinforcement that overlaps a portion
of the wheelhouses. Remove the reinforcement
on sedan models according to recommended
procedures. On coupe models, templates have
been developed to ensure proper wheelhouse
installation on coupe models.

Sedan
— REMOVE OR DISCONNECT —
1 Remove all related panels and components
including the back glass.
2 From inside of vehicle, pull back and protect
wiring along inner wheelhouse.
3 Locate and drill out six welds securing Fig.␣ 2.41 — Replacement wheelhouse (coupe/sedan)
beltline reinforcement to quarter inner
assembly (Fig.␣ 2.42)
Notice: Drill through one layer only.
4 Locate and drill out welds at factory seams
along perimeter of wheelhouse flange.
5 Remove damaged wheelhouse panel.

— INSTALL OR CONNECT —
1 On service part, drill 8mm (5/16-inch) holes
every 40mm (1-1/2 inches).
2 Prepare mating surfaces.
3 Apply suitable weld-through primer.
4 Position service part. Check for proper fit.
Notice: Outer wheelhouse positioning may
require dry-fitting of quarter outer panel.
5 Clean and prepare welded surfaces.
Important: Prior to refinishing, refer to
GM P/N 4901 M-D Refinish Manual for
recommended products.
6 Apply approved anti-corrosion primer.
7 Apply sealers and sound deadener materials
and refinish as necessary. Do not combine Fig.␣ 2.42 — Remove beltline reinforcement
paint systems. Refer to paint manufacturer’s (SEDAN ONLY)
recommendations.
8 Install related panels and components.

2-28 1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair


Outer Rear Wheelhouse
Notice: It is recommended that the service
part be prepared before removing the
damaged panel from the vehicle.
Coupe
PREPARING THE SERVICE PART
FOR INSTALLATION
1 Align the appropriate template along the
service part contour lines, per template
instructions.
2 Cut service part as indicated on template to
ensure proper fit of service part.
3 Trim leading edge of service part to allow
flush fit with rocker panel (Fig.␣ 2.44).
4 Remove the excess portion of the
wheelhouse.
Fig.␣ 2.43 — Modify wheelhouse service
part (COUPE ONLY)
1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
Rear Wheelhouse
— REMOVE OR DISCONNECT —
1 Remove all related panels and components
2 Visually inspect and restore as much of the
damage as possible to factory specifications.
3 Remove sealers and sound deadeners as
necessary.
4 Apply 25mm (1 inch) tape along perimeter of
beltline reinforcement where it contacts
outer wheelhouse.
5 Cut along outer (Fig. 2.44) edge of tape to
form mating flange.
6 Apply tape to lower front portion of
wheelhouse, parallel to rocker panel edge,
cut along top edge of tape from outer lip of
wheelhouse to valley (see Fig.␣ 2.44), creating
a flange for reattachment of wheelhouse part
at rocker panel.
7 Cut along radius of wheelhouse (Fig. 2.45).
8 Remove the damaged wheelhouse.
Beltline Reinforcement
Fig.␣ 2.44 — Apply tape as indicated to leave a
portion of the original wheelhouse
for efficient installation of the service panel
2-29
Rear Wheelhouse

— INSTALL OR CONNECT —
1 Remove weld flange on remaining portion of
original wheelhouse (at rocker panel) to
ensure proper fit of service part.
2 Temporarily install service part over beltline
reinforcement flange and inside of original
wheelhouse (Fig. 2.46).
3 On the service part, drill 8mm (5/16 inch)
plug weld holes every 40mm (1-1/2 inches
along perimeter of entire service part.
(Fig.␣ 2.47) Drill 4 holes on edge where
service part mates to rocker panel.
4 Prepare the mating surfaces and position the
service part. Apply suitable weld-through
primer.
5 Check for proper fit and plug weld
accordingly. Use care to not warp or distort
the metal.
Notice: Outer wheelhouse positioning may
require dry-fitting of quarter outer panel.
6 Clean and prepare welded surfaces.
Fig.␣ 2.45 — Separate wheelhouse from quarter
inner assembly (leave weld flange in place) Important: Prior to refinishing, refer to
GM P/N 4901 M-D Refinish Manual for
recommended products.
7 Apply approved anti-corrosion primer.
8 Apply sealers and sound deadeners as
necessary. Do not combine paint systems.
Refer to paint manufacturer’s
recommendations.
9 Install all related panels and components.

Over

Inside

Fig.␣ 2.46 — Install modified wheelhouse

Fig.␣ 2.47 — Service part modified (COUPE ONLY)

2-30 1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair

Rear Floor Assembly
The rear floor is sold as a complete assembly
including rear rails, crossmembers and rear
extension; or sold separately as floor pan “skin”
with exhaust heat shield only. (Fig.␣ 2.48)

Rail
extensions

With the floor pan removed,

drill out and replace rear frame
rail extensions at factory
seams. Use 8mm (5/16 inch)
plug welds to reinstall the
replacement rail extensions.

Fig.␣ 2.48 — Floor pan “skin” and rail extensions are serviced

1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair 2-31

 Rear Floor Assembly

Rear Floor Panel Partial factory welds which secure floor to rails.
Replacement Note the number and location of welds for
— REMOVE OR DISCONNECT —
installation of the floor service panel (Fig.
2.49).
1 Remove all related panels and components,
including fuel tank. 5 Drill completely through welds that attach
the floorpan to the inner wheelhouse.
2 Visually inspect and restore as much of the
damage as possible. 6 Remove both inner wheelhouse braces.
Identify weld locations and drill through
3 Remove sealers, sound deadeners and
one layer of metal only.
anti-corrosion materials as necessary.
7 Remove the damaged floor section.
4 Locate factory seam at front edge of
crossbar, rearward of seat back. Locate,
mark and drill through one layer only, all

Important: On pan only

re-install, wheelhouse
flange must be bent up
on service part to
accommodate welds.

Fig.␣ 2.49 — Floor pan weld joint on vehicle

2-32 1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair

 Rear Floor Assembly

— INSTALL OR CONNECT — 4 Re-install both wheelhouse braces (Fig. 2.50).

1 Prepare mating surfaces with suitable
weld-through primer.
2 Drill 8mm (5/16-inch) plug weld holes as
necessary in the locations noted from the
original floor.
Notice: In any area damaged beyond
recognition, space plug weld holes every
40mm (1-1/2 inches) apart.
Important: Sound deadeners along the
inner wheelhouse must be removed prior
to welding new panels in place
3 Position the service floor pan, check for
proper fit using three-dimensional measuring
and plug weld accordingly.
5 Clean and prepare all welded surfaces.
Important: Prior to refinishing, refer to
GM P/N 4901 M-D Refinish Manual for
recommended products.
6 Apply approved anti-corrosion primer.
7 Apply body sealers and refinish as necessary.
Do not combine paint systems. Refer to paint
manufacturer’s recommendations.
8 Install all related panels and components.

Fig.␣ 2.50 — Reinstall internal floor braces (2 per side)

1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair 2-33

Rear Floor Assembly
FLOOR PAN ASSEMBLY
The floor pan assembly comes complete
including lower rails, crossbar, rear floor
extension and various other components.
(Fig.␣ 2.51)
— REMOVE OR DISCONNECT —
Notice: One side inner and outer wheelhouses
must be removed when replacing entire
sub-assembly.
1 Remove all related panels and components.
2 Visually inspect and restore as much of the
damage as possible.
3 Remove sealers, sound deadeners and
anti-corrosion materials as necessary.
4 Remove 4 inner reinforcements ( 2-dynamic
side impact braces-front; 2- floor pan
braces-rear) to access spot welds (Fig 2.52).
Notice: If these parts are damaged they
must be ordered separately.
Fig.␣ 2.51 — Floor pan assembly
2-34 1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
— INSTALL OR CONNECT —
1 Prepare mating surfaces with suitable
weld-through primer.
Notice: In any area damaged beyond
recognition, space plug weld holes every
40mm (1-1/2 inches) apart.
2 Drill 8mm (5/16-inch) plug weld holes along
all mating surfaces except where the floor
mates to each wheelhouse.
3 Position the service floorpan. Check for
proper fit using three-dimensional
measurements.
4 Clean and prepare all welded surfaces.
Important: Prior to refinishing, refer to
GM P/N 4901 M-D Refinish Manual for
recommended products.
5 Apply approved anti-corrosion primer to all
bare metal surfaces.
6 Apply body sealers and refinish as necessary.
Do not combine paint systems. Refer to paint
manufacturer’s recommendations.
7 Reinstall all related components.
Fig.␣ 2.52 — Remove all four internal braces to
locate hidden welds
Rear Rails
The left and right rear rails are available as
complete sub-assemblies and can be replaced in
their entirety similar to past model vehicles. Each
consists of an outer panel, two inner
reinforcements and all necessary component
mounting brackets. The outer panel and rear
mounting brackets are also available separately.
When replacing a rail in its entirety, the weld
flange that mates with the wheelhouse must be
bent upwards. The service assembly is supplied
with this flange in a horizontal position. (Fig.
2.53)
The rear rail can be removed by drilling out all
factory welds at the floor pan. When doing so,
the outboard flange at the forward end of the rail
overlapping the rocker interior panel must be
bent upward. The bottom flange of the crossbar
must be bent downward.
Notice: Remove the floor and wheelhouse
braces at factory seams to access additional
lower rail welds. Reinstall upon completion
(see Fig. 2.52).
The rear rail can then be separated from the
vehicle.

Service assembly supplied with horizontal

wheelhouse flange

Service assembly with wheelhouse flange

bent upwards for installation

Fig.␣ 2.53 — Modify weld flange if ordering and installing entire rear rail only

1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair 2-35

Rear End Panel Assembly
The rear end panel is supplied as a complete
assembly consisting of three inner reinforce-
ments and one outer panel. The rear end panel
on the coupe has a single inner reinforcement.
Taillight mounting panels, which attach to the
outside corners of the rear end panel assembly,
are available separately. Service for all of these
panels is performed at factory seams (Fig.␣ 2.54).
— REMOVE OR DISCONNECT —
1 Remove all related panels and components.
2 Visually inspect and restore as much of the
damage as possible to factory specifications.
3 Remove sealers, sound deadeners and
corrosion materials as necessary.
4 Locate, mark and drill out all factory welds.
Note the number of welds for installation of
the service assembly.
5 Remove the damaged assembly.
Fig.␣ 2.54 —
2-36 1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair
— INSTALL OR CONNECT —
1 Prepare mating surfaces and check for
proper fit o the service assembly.
2 On the service assembly, drill 8mm
(5/16-inch) plug weld holes as necessary in
the locations noted from the original
assembly. Apply suitable weld-through
primer.
3 Position the service assembly, check fit using
body dimensions and plug weld accordingly
with frequent measurements to ensure
proper fit.
4 Clean and prepare welded surfaces.
Important: Prior to refinishing, refer to
GM P/N 4901 M-D Refinish Manual for
recommended products.
5 Apply approved anti-corrosion primer.
6 Apply sealers and refinish as necessary. Do
not combine paint systems. Refer to paint
manufacturer’s recommendations.
7 Reinstall all related panels and components.
 E H
L: 506 F L: 2226
W: 561 W: 430
L: 2126 G
H: 810 A H: 371 I
W: 430 L: 2163
L: 0 H: 360 W: 560 L: 2391
D W: 435 H: 834 W: 440
L: 1250 H: 133 H: 400
W: 465
H: 326
J
L: 2850
W: 440
H: 400

K
L: 2733
W: 440
Body Dimensions

H: 364

C CL
L: 1215 B N L
W: 442 L: 292 L: 2111 M L: 2466
H: 326 W: 356 O W: 430 L: 2321 W: 440
H: 243 L: 1650 H: 369 W: 433 H: 375
W: 563 H: 369
H: 400

1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair

ALL DIMENSIONS ARE MEASURED FROM A ZERO LINE, CENTER LINE, AND A
COMMON DATUM. ALL DIMENSIONS ARE SYMMETRICAL UNLESS OTHERWISE SPECIFIED.

2-37
Body Dimensions

FRONT VIEW
P Q
W: 508 W: 517
H: 416 CL H: 474
L: 1364
L: 1364

R S
W: 517 W: 517
H: 376 H: 376
L: 1364 L: 1364

REAR VIEW
T U
W: 374 W: 508
H: 346 CL H: 416
L:3013 L:3013

V W
W: 374 W: 374
H: 346 H: 346
L:3013 L:3013

ALL DIMENSIONS ARE MEASURED FROM A ZERO LINE, CENTER LINE, AND A
COMMON DATUM. ALL DIMENSIONS ARE SYMMETRICAL UNLESS OTHERWISE SPECIFIED.

2-38 1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair

 Body Dimensions

1999 Grand Am/Alero

Underbody Dimension Hole Size Chart

Letter Feature Size Usage

A 19mm gage hole

B 20mm cradle attach
C 13mm x 19mm gage slot
D 20mm cradle attach
E 76mm center strut cap
F 15mm rear suspension attach
G 83mm center strut cap
H 15mm rear suspension attach
I 19mm gage hole
J 19mm x 26mm slot
K 19mm x 26mm slot
L 19mm gage hole
M 15mm rear suspension attach
N 15mm rear suspension attach
O 19mm gage hole
P 14mm x19mm slot front impact bar
Q 14mm front impact bar
R 14mm x 19mm slot front impact bar
S 14mm front impact bar
T 10mm rear impact bar
U 10mm rear impact bar
V 10mm rear impact bar
W 10mm x 18mm slot rear impact bar

1999 Pontiac Grand Am/Oldsmobile Alero Collision Repair 2-39