Chevrolet 1997 Corvette User manual

1997/98
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 ....................................................... 3-24
Rear Compartment Panel ..........................................3-25
Rear Compartment Panel Frame ..............................3-30
Rear Bumper Impact Bar ........................................... 3-33
SMC Repair Procedures ..............................................3-37
Body Dimensions ........................................................ 3-38

1997/98 Chevrolet Corvette Collision Repair 3-1
Panel Identification
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POLYCARBONATE = TRANSLUCENT TARGA TOP
1 RRIM = REINFORCED REACTION INJECTION MOLDED 2 TSGS = TWO SIDED GALVANIZED STEEL 3 UHSS = ULTRA HIGH STRENGTH STEEL 4 SMC = SHEET MOLDED COMPOUND 5 AL = ALUMINUM
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1
1
2
1
3
3
2
4
44
4
4
4
4
5
5
4

3-2 1997/98 Chevrolet Corvette Collision Repair
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Fig.␣ 3.1 — Ultra High Strength Steel Beam
Fig.␣ 3.2 — Adapter Clamp
for Conventional Anchoring System
Fig.␣ 3.3 — Note Location of Welds for
Reinstallation
Frame Adapter
Clamp
Front Bumper Impact Bar
The front impact bar (bumper beam) is made of
Ultra-High Strength steel. The impact bar is MIG
welded to the mild steel frame rails. The impact
bar can be repaired if damage excludes kinks, or
damage which would require the use of heat to
straighten.
Replacing the bumper bar requires special
procedures to access the welds attaching the
bumper bar to the frame rails. This procedure
was developed to facilitate this repair while
maintaining the integrity of the bumper system.
The front bumper impact bar as supplied for
service includes riv-nuts pre-installed (Fig.␣ 3.1)
for component mounting: (SIR sensors,
fog-lamps, energy absorber, etc.) Replacement
riv-nuts are available from Kent Moore Tools
(Riv-Nut Kit: P/N J42151-8MS), if needed.
— REMOVE OR DISCONNECT —
1Remove all panels and components to gain
access to the impact bar. This includes the
bumper cover, impact absorbers, and fog
lamps.
Notice: To increase accessibility to the
front impact bar, rotate the front brake
ducts and manually raise the headlamps.
2Visually inspect and restore as much of the
damage as possible to specifications using
three-dimensional measuring procedures.
Notice: Use Kent Moore Tools Frame
Adapter Clamp (P/N J42058) to secure the
vehicle if pulling and straightening
is required (Fig. 3.2).
Notice: Be sure to protect vehicle
components before cutting or grinding on
the bumper impact bar or frame rails.
3Remove or reposition wiring as necessary to
avoid damage.
4Cut the welds around the perimeter of the
frame rail (fishmouth) ends (Fig.␣ 3.3). Cut
welds favoring the impact bar side of the
joint. DO NOT cut into the frame rails.
5Remove the damaged impact bar.
6Extract 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.

1997/98 Chevrolet Corvette Collision Repair 3-3
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C of
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Fig.␣ 3.5 — Weld Perimeter of Joint, as Indicated
Fig.␣ 3.4 — Remove Remaining Portion
of Impact Bar in Frame Rail
Front Bumper Impact Bar
— INSTALL OR CONNECT —
1Straighten and deburr the rail ends as
necessary to allow the service impact bar to
fit properly.
2Temporarily position the impact bar and
scribe lines into the primer indicating where
the welds will be made. Remove the primer
from the areas to be MIG welded by sanding
with 80-grit paper on a ‘Dual-Action’ sander
(DA). Do Not use a grinder to remove the
primer.
3Prepare all bare metal surfaces and apply
weld-through primer as necessary. Be sure to
apply primer to the inside of the ‘fishmouth’
area also.
Notice: When installing the replacement
bumper bar, weld the sides first in order
to ensure uniform contact with the frame
rails.
4Position the bumper impact bar using
three-dimensional measuring equipment and
install per the original weld locations. Stitch
weld around the ‘fishmouth’ joint. If no trace
of the original welds are present, use Fig.␣ 3.5
as a guide for welding the side rails to the
impact bar. This weld pattern will create a
solid weld joint with minimal heat distortion.
5Clean and prepare all welded surfaces, use
3M’s Scotch-Brite Clean-N-Strip Discs (disc
PN 07460, mandrel P/N 07491) or equivalent.
IMPORTANT: Prior to refinishing, refer to
GM P/N 4901 M-D Refinish Manual for
recommended products.
6Apply approved anti-corrosion primer. Do
not combine paint systems. Refer to paint
manufacturer’s recommendations.
7Install all related panels and components.

3-4 1997/98 Chevrolet Corvette Collision Repair
Fig.␣ 3.6 — Front Wheelhouse Service Assembly
Fig.␣ 3.7 — Service Assembly Can Be Separated
for Outer Wheelhouse Panel Replacement
Fig.␣ 3.8 — Adapter Clamp for Anchoring System
Frame Adapter
Clamp
Front wheelhouse
The wheelhouse consists of two pieces, an outer
portion that rivets and bonds to a larger inner
portion (Fig.␣ 3.6). The wheelhouse is the inner
mounting structure for the front fender.
The wheelhouse mounting surfaces vary from left
to right. The left side (driver’s side) has more
bonded surface area than the right side, and is
bonded to the cowl. Also, both sides bond and
bolt to the front hinge pillar. The outer
wheelhouse can be separated for partial
installation (Fig.␣ 3.7).
Notice: Do not replace any SMC body panels
until the frame rails have been replaced or
repaired, mounting SMC panels requires the
rails to be positioned accurately.
— REMOVE OR DISCONNECT —
1Remove all panels and components to gain
access to the front wheelhouse. This may
include removing front wheel, fender, fender
splash panel, bumper cover, battery, and
headlamp mounting brackets.
2Visually inspect, if any damage to the frame
rails or wheelhouse mounting areas exist,
then restore as much of the damage as
possible to specifications using
three-dimensional measuring procedures.
Notice: Use Kent Moore Tools Frame
Adapter Clamp (P/N J42058) to secure the
vehicle if pulling and straightening is
required (Fig.␣ 3.8).
3Relocate wiring as necessary to avoid
damage.
4Remove the four bracket bolts attaching the
wheelhouse to the front hinge pillar (Fig.␣ 3.9).
Heat and pry to remove or dislodge adhesive
beads attaching the wheelhouse to the
vehicle, see Fig.␣ 3.10. Remove the damaged
wheelhouse.