Collision Repair Cadillac STS I

Scheme 17

Dimensions - Body

Scheme 18

Dimensions - Body

Scheme 19

Dimensions - Body

Scheme 20

Scheme 21

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
3. Remove all related panels and components.
4. Restore as much of the damage as possible.
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
6. Locate, mark, and drill out all factory welds attaching the upper tie bar (1) and reinforcements (2) if necessary.
7. Remove the damaged tie bar (1).

Installation Procedure

1. Prepare the mating surfaces as necessary.
2. Apply 3m Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.
3. Drill 8 mm (5/16 in) plug weld holes on the service part as necessary in the locations noted from the original panels. IMPORTANT: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 40 mm (11/2 in).
4. Temporarily position the upper tie bar (1) and reinforcements (2) on the vehicle.
5. Check location using 3-dimensional measuring equipment.
6. Plug weld accordingly.
7. Clean and prepare welded surfaces.
8. Paint the repaired area. Refer to «Basecoat/Clearcoat Paint Systems»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__basecoatclearcoat-paint-systems) in Paint and Coatings.
9. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
10. Install all of the related panels and components.
11. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
12. Enable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.

Removal Procedure

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
3. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
4. Repair as much of the damage as possible.
5. Locate, mark, and drill out all factory welds. Note the number and location of welds for installation of the service assembly.
6. Drill from the outside of the wheelhouse to remove the spot welds that attach the wheelhouse to the frame rail.
7. Remove the wheelhouse from the vehicle.

1. Prepare the mating surfaces as necessary.
2. Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.
3. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original assembly. IMPORTANT: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 40 mm (11/2 in).
4. Position the wheelhouse on the vehicle. Verify proper fit using three-dimensional measuring equipment.
5. When the service assembly is correctly positioned, plug weld accordingly.
6. Measure frequently to ensure proper fit and alignment.
7. Clean and prepare all welded surfaces.
8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
9. Paint the repaired area. Refer to «Basecoat/Clearcoat Paint Systems»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__basecoatclearcoat-paint-systems) in Paint and Coatings.
10. Install all related panels and components.
11. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
12. Enable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
3. Remove all related panels and components.
4. Restore as much of the damage as possible.
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
6. Locate, mark, and drill out all factory welds attaching the outer rail.
7. Remove the damaged outer rail.

1. Prepare the mating surfaces as necessary.
2. Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.
3. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original panels.
4. Temporarily position the outer rail on the vehicle.
5. Verify the location using 3-dimensional measuring equipment.
6. Plug weld accordingly.
7. Clean and prepare welded surfaces.
8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
9. Paint the repaired area. Refer to «Basecoat/Clearcoat Paint Systems»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__basecoatclearcoat-paint-systems) in Paint and Coatings.
10. Install all of the related panels and components.
11. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
12. Enable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
3. Remove all of the related panels and the components, including the left front wheelhouse mounting bracket to the rail.
4. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
5. Repair as much as the damage as possible.
6. Locate the die marks on the inner and outer rail.
7. Locate the die marks on the front rail.
8. Scribe a line 360 degrees around the frame rail at the die marks.
9. Cut at the marked location.
10. Remove the damaged component from the vehicle.

1. Drill 4 plug weld holes; 2 at the inside and 2 at the outside, 13 mm (1/2 in) from the cut line and 50 mm (2 in) apart on the existing frame rail.
2. Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.
3. Install and position the replacement service section using 3-dimensional measuring.
4. Tack weld the part into position at the initial plug weld holes.
5. Inspect the service part for proper dimensions using 3-dimensional measuring equipment.
6. Stitch weld along the entire sectioning joint. Make 25 mm (1 in) welds along the seam with 25 mm (1 in) gaps between.
7. Complete the stitch weld.
8. Clean and prepare the welded surfaces.
9. Position the tie bar mounting bracket. Weld the bracket in place.
10. Install all of the related panels and components.
11. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
12. Paint the repaired area. Refer to «Basecoat/Clearcoat Paint Systems»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__basecoatclearcoat-paint-systems) in Paint and Coatings.
13. Enable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.
14. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.

Scheme 22

The front of the dash panel is formed from laminated steel. This steel is constructed by bonding 2 pieces of cold rolled steel (1) with a viscoelastic layer of adhesive (2). Metal inert gas (MIG) welding laminated steel does not meet GM Corporate standards for structural integrity. As an alternative, all factory welds will be replaced by using the rivet and adhesive bond method described in the installation portion of this procedure. The rivet and adhesive bond method must only be used in the areas as described in this procedure.

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
3. Remove all related panels and components.
4. Repair as much of the damage as possible.
5. Remove the sealers and the anti-corrosion materials from the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint/Coatings.
6. Remove the front wheelhouse assembly. Refer to «Wheelhouse Replacement - Front»(/cadillac/sts/i-2004-2007/remont/exterior-body-panels/#collision-repair) .
7. Using an 8-mm (5/16-in) spot weld remover, locate and drill out the factory welds on the weld flange connecting the lower rail to the dash panel.
8. From the passenger compartment, locate and drill out the remaining factory weld (1) on the dash panel.
9. Locate and drill out the factory welds between the rail inner reinforcement and the rail.
10. Locate and drill out the remaining factory welds on the rail.
11. Remove the full rail.

1. On the full rail service part, locate and drill out the factory welds between the rail inner reinforcement and the service rail.
2. Remove the rail inner reinforcement from the service rail.
3. Position the service rail to the vehicle using three-dimensional measuring equipment.
4. Clamp the rail in place.
5. Using a 7-mm (17/64-in) bit, drill the rivet attachment holes through the service rail and the dash panel in the exact locations as noted from the factory rail.
6. From the passenger compartment side of the vehicle, using a 7-mm (17/64-in) bit, drill the rivet attachment hole through the service rail using the existing 8-mm (5/16-in) hole in the dash panel as an alignment mark.
7. Remove the service rail.
8. Drill 8-mm (5/16-in) plug weld holes in the service rail, as necessary, in the remaining locations noted from the original rail.
9. Prepare the plug weld mating surfaces, as necessary.
10. Apply 3M® Weld-Thru Coating P/N 05913 or equivalent to the plug weld mating surfaces.
11. Prepare the bond mating areas by grinding the body mating and the service part flanges to bare steel. Do NOT damage the corners or thin the metal during the grinding process.
12. Clean the mating surfaces.
13. Apply a 3-6 mm (1/8 to 1/4 in) bead of metal panel bonding adhesive GM P/N 12378567 (Canadian P/N 88901675) or equivalent to both of the mating surfaces.
14. Using a small acid brush, spread a coat of adhesive to both of the mating surfaces. Cover all of the bare metal to ensure corrosion protection.
15. Apply a 3-6 mm (1/8 to 1/4 in) bead of metal panel bonding adhesive GM P/N 12378567 (Canadian P/N 88901675) or equivalent to the mating surface of the service rail.
16. Position the service rail to the vehicle using three-dimensional measuring equipment.
17. Clamp the rail in place.
18. Install the 9 mm (11/32 in) long rivets so that the rivet head contacts the passenger compartment side of the dash.
19. Install the 14 mm (17/32 in) long rivets so that the rivet head contacts the rail.
20. Remove the excess adhesive from the rail area.
21. Plug weld the remaining holes accordingly.
22. Clean and prepare all of the welded surfaces.
23. Install the front wheelhouse assembly. Refer to «Wheelhouse Replacement - Front»(/cadillac/sts/i-2004-2007/remont/exterior-body-panels/#collision-repair) .
24. Apply the sealers and anti-corrosion materials to the repaired area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint/Coatings.
25. Paint the repaired area. Refer to «Basecoat/Clearcoat Paint Systems»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__basecoatclearcoat-paint-systems) in Paint/Coatings.
26. Install all of the related panels and components.
27. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
28. Enable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.

Scheme 23

The full body-side outer panel comes as a complete assembly and can be replaced at factory seams after the removal of the fixed glass and roof. Any one of these service procedures can be performed separately or in any combination, depending upon the extent of damage to the vehicle. Sectioning must take place in specified areas only.

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
3. Remove all related panels and components.
4. Repair as much of the damage as possible.
5. Remove sound deadeners as necessary and note their location.
6. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
7. Cut the panel where sectioning is to be performed.
8. Locate and drill out all factory welds. Note the number and location of welds for installation of the service part.
9. Remove the damaged hinge pillar.

1. Cut the outer front hinge pillar in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of 11/2 times the metal thickness at the sectioning joint.
2. Create a 50 mm (2 in) backing plate from the unused portion of the service part for the windshield area. Create a 100 mm (4 in) backing plate from the unused portion of the service part for the rocker area. Trim the backing plates as necessary to fit behind the sectioning joint.
3. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel and along the sectioning cut.
4. Prepare all mating surfaces as necessary.
5. Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.
6. Fit the backing plates halfway into the sectioning joints, clamp in place and plug weld to the vehicle.
7. Align outer front pillar using 3-dimensional measuring equipment.
8. Plug weld accordingly.
9. To create a solid weld with minimum heat distortion, make a 25 mm (1 in) stitch weld along the seam with 25 mm (1 in) gaps between them. Go back and complete the stitch weld.
10. Clean and prepare all of the welded surfaces.
11. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
12. Paint the repaired area. Refer to «Basecoat/Clearcoat Paint Systems»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__basecoatclearcoat-paint-systems) in Paint and Coatings.
13. Install all of the related panels and components.
14. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
15. Enable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.

The full body side inner panel comes as a one-piece assembly and can be replaced at the factory seams after removal of the outer panels, the roof panel and the front and rear glass, any of these sectioning procedures can be performed separately or in any combination, depending on the extent of the damage to the vehicle.

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
3. Remove all related panels and components.
4. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
5. Restore as much of the damage as possible.
6. On the windshield pillar, measure down 19 mm (3/4 in) from the base of the windshield pillar reinforcement. This is your section location.
7. On the inner rocker panel, use the second triangular opening as your section location as shown.
8. Cut the panel where sectioning is to be performed.
9. Locate and drill out all factory welds. Note the number and location of the welds for installation of the service part.
10. Remove the damaged inner hinge pillar.

1. Cut the replacement service part horizontally at the bottom edge of the outer windshield pillar reinforcement. In the door opening area, notch the flange for a flush fit as shown.
2. Cut the replacement part vertically in the rocker panel area to allow for a full overlap as shown and notch.
3. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary as noted from the original panel.
4. Prepare all mating surfaces as necessary.
5. Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.
6. Align service part using 3 dimensional measuring equipment. Clamp in place.
7. Plug weld accordingly.
8. To create a solid weld with minimum heat distortion, make 25 mm (1 in) stitch welds along the seam with 25 mm (1 in) gaps between them. Then go back and complete the stitch weld.
9. Clean and prepare all of the welded surfaces.
10. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
11. Paint the repaired area. Refer to «Basecoat/Clearcoat Paint Systems»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__basecoatclearcoat-paint-systems) in Paint and Coatings.
12. Install all of the related panels and components.
13. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
14. Enable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
3. Remove all related panels and components.
4. Repair as much of the damage as possible.
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
6. Note structural adhesive locations.
7. Measure down (a) 220 mm (8 5/8 in) from the edge of the door opening. Create a cut line.
8. Cut the panel where sectioning is to be performed.
9. Locate, mark, and drill out all the necessary factory welds.
10. Remove the damaged front pillar.

1. Measure the service part 30 mm (1 3/16 in) longer than the original reinforcement to allow for an overlap.
2. Cut the service part at this sectioning location.
3. Cut the service part in the corners as shown and step the tabs inward to allow the service part to fit under the original reinforcement.
4. Drill 8 mm (5/16 in) plug weld holes along the sectioning cut on the original reinforcement. Locate these holes 13 mm (1/2 in) from the edge and spaced 40 mm (11/2 in) apart.
5. Drill 8 mm (5/16 in) plug weld holes in the service reinforcement, as necessary, in the locations noted from the original panel.
6. Prepare all mating surfaces, as necessary.
7. Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.
8. Apply structural adhesive Lord 108 to locations noted in the removal procedure.
9. Align the service part on the vehicle using 3-dimensional measuring equipment.
10. Plug weld accordingly.
11. To create a solid weld with minimum heat distortion, make 25 mm (1 in) stitch welds along the seam with 25 mm (1 in) gaps between them. Go back and complete the stitch weld.
12. Clean and prepare all of the welded surfaces.
13. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
14. Paint the repaired area. Refer to «Basecoat/Clearcoat Paint Systems»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__basecoatclearcoat-paint-systems) in Paint and Coatings.
15. Install all of the related panels and components.
16. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
17. Enable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.

Note the center pillar reinforcement must be removed from the vehicle to perform this operation.

1. Remove all related panels and components.
2. Disable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.
3. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
4. Restore as much of the damage as possible.
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
6. Note structural adhesive locations.
7. In the inner upper center pillar area, locate the "T" shaped opening on the inside of the pillar. Measure down (a) 100 mm (4 in) from the bottom of the opening. This is your sectioning location.
8. In the inner rocker panel area, select the triangle shaped opening's in the front and rear of the pillar areas to be replaced as shown. These are your lower section locations.
9. Cut the panel where sectioning is to be performed.
10. Locate and drill out all factory welds. Note the number and location of the welds for installation of the service part.
11. Remove the damaged center pillar.

1. Cut the replacement service part in the pillar area (1) to allow for a (a) 25 mm (1 in) overlap of the original section cut.
2. On the pillar area of the service part notch the weld flange areas as shown.
3. Cut the service part in the corners as shown and step the tabs inward to allow the service part to fit under the original reinforcement.
4. Cut the replacement service part vertically in the rocker panel areas to allow for a full overlap and notch as shown.
5. Drill 8 mm (5/16 in) plug weld holes along the sectioning cut on the original reinforcement. Locate these holes 13 mm (1/2 in) from the edge and spaced 40 mm (1 1/2 in) apart.
6. Drill 8 mm (5/16 in) plug weld holes in the service reinforcement as necessary in the locations noted from the original panel.
7. Prepare all mating surfaces as necessary.
8. Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.
9. Align the service part on the vehicle using 3-dimensional measuring equipment.
10. Plug weld accordingly.
11. To create a solid weld with minimum heat distortion, make 25 mm (1 in) stitch welds along the seam with 25 mm (1 in) gaps between them. Go back and complete the stitch weld.
12. Clean and prepare all of the welded surfaces.
13. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
14. Paint the repaired area. Refer to «Basecoat/Clearcoat Paint Systems»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__basecoatclearcoat-paint-systems) in Paint and Coatings.
15. Install all of the related panels and components.
16. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
17. Enable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.

1. Remove all related panels and components.
2. Disable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.
3. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
4. Remove the sealers and anti-corrosion materials from the repair area, as necessary, and note their location. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
5. Remove sound deadeners, as necessary.
6. Repair as much of the damage as possible.
7. At the top of the center pillar, mark a line (a) 130 mm (5 5/32 in) from the edge of the door opening.
8. Create cut lines on the rocker panel within the approved sectioning locations.
9. Cut the panel where sectioning is to be performed.
10. Locate and drill out all factory welds. Note the number and location of welds for installation of the service part.
11. Remove the damaged center pillar.

1. Cut the outer center pillar in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of 11/2 times the metal thickness at the sectioning joint.
2. Create a 100 mm (4 in) backing plate from the unused portion of the service part for the rocker area. Trim the backing plates, as necessary, to fit behind the sectioning joint.
3. In the upper center pillar area, use the existing pillar reinforcement as a backing plate.
4. Drill 8 mm (5/16 in) along the sectioning cut on the remaining original part. Locate these holes 13 mm (1/2 in) from the edge of part and spaced 40 mm (11/2 in) apart.
5. Drill 8 mm (5/16 in) plug weld holes in the service part, as necessary, in the locations noted from the original panel and along the sectioning cut.
6. Prepare all mating surfaces, as necessary.
7. Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.
8. Fit the backing plates halfway into the sectioning joints, clamp in place and plug weld to the vehicle.
9. Align outer center pillar using 3-dimensional measuring equipment.
10. Plug weld accordingly.
11. To create a solid weld with minimum heat distortion, make a 25 mm (1 in) stitch weld along the seam with 25 mm (1 in) gaps between them. Go back and complete the stitch weld.
12. Clean and prepare all of the welded surfaces.
13. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
14. Paint the repaired area. Refer to «Basecoat/Clearcoat Paint Systems»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__basecoatclearcoat-paint-systems) in Paint and Coatings.
15. Install all of the related panels and components.
16. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
17. Enable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
2. Disable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.
3. Remove the door from the vehicle. Refer to «Door, Hinge Replacement - Front Door»(/cadillac/sts/i-2004-2007/remont/door-locks-anti-theft-systems/#door-system-mirror-system-window-system) in Doors.
4. Remove the outer door handle. Refer to «Door Handle Replacement - Front Outside»(/cadillac/sts/i-2004-2007/remont/door-locks-anti-theft-systems/#door-system-mirror-system-window-system) in Doors.
5. Remove the outside rearview mirror. Refer to «Mirror, Mirror Face Replacement - Front Door»(/cadillac/sts/i-2004-2007/remont/door-locks-anti-theft-systems/#door-system-mirror-system-window-system) in Doors.
6. Cut a hole in the outer door panel to access the welds on the belt reinforcement.
7. Drill out the spot welds that attach the outer belt reinforcement to the outer door panel flange.
8. Grind the edges of the door outer panel to separate the outer door panel from the door shell.
9. Remove the outer door panel.
10. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint/Coatings.
11. Straighten the edges of the door shell.

1. Grind the surface of the door shell mating flanges to bare steel.
2. Scuff the opposing mating surfaces of the door outer panel to remove the gloss of the E-Coat.
3. Drill 8 mm (5/16 in) plug weld holes, as necessary, in locations noted from the original panel.
4. Prepare all mating surfaces, as necessary.
5. Apply 3M® Weld-Thru coating P/N 05916, or equivalent, to all mating surfaces.
6. Apply a 3-6 mm (1/8 to 1/4 in) bead of metal panel bonding adhesive GM P/N 12378566/7 (Canadian P/N 88901674/5), or equivalent, to both of the mating surfaces.
7. Using a small acid brush, spread a coat of adhesive to cover all the bare metal surfaces to ensure corrosion protection.
8. Apply a 9-13 mm (3/8 to 1/2 in) bead of metal panel bonding adhesive GM P/N 12378566/7 (Canadian P/N 88901674/5), or equivalent, to the service part mating surfaces.
9. Install the door outer panel to the door shell.
10. Clamp the door outer panel into position, as required.
11. Using a hammer re-hem the hem flanges around the door shell. Continue to hammer in stages along the hem flanges.
12. Using lacquer thinner remove the excess adhesive from the door panel area.
13. Install the door to the vehicle, then check the door outer panel for proper alignment. Adjust the alignment, as required. Refer to «Door, Hinge Replacement - Front Door»(/cadillac/sts/i-2004-2007/remont/door-locks-anti-theft-systems/#door-system-mirror-system-window-system) in Doors.
14. Remove the door from the vehicle to complete the repair.
15. Using metal-inert gas (MIG), weld the door outer panel to the door frame in the locations noted at the upper door frame.
16. Clean and prepare all welded surfaces.
17. Apply Fusor super flexible anti-flutter foam - fast set, Fusor P/N 121/124, or equivalent, in 4-5 evenly spaced locations between the door outer panel and the inner safety beam.
18. Apply sealers and anti-corrosion materials to the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint/Coatings.
19. Paint the repaired area. Refer to «Basecoat/Clearcoat Paint Systems»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__basecoatclearcoat-paint-systems) in Paint/Coatings.
20. Install the door to the vehicle. Inspect the door outer panel for proper alignment and adjust the alignment, as required. Refer to «Door, Hinge Replacement - Front Door»(/cadillac/sts/i-2004-2007/remont/door-locks-anti-theft-systems/#door-system-mirror-system-window-system) in Doors.
21. Install the outer door handle. Refer to «Door Handle Replacement - Front Outside»(/cadillac/sts/i-2004-2007/remont/door-locks-anti-theft-systems/#door-system-mirror-system-window-system) in Doors.
22. Install the outside rearview mirror. Refer to «Mirror, Mirror Face Replacement - Front Door»(/cadillac/sts/i-2004-2007/remont/door-locks-anti-theft-systems/#door-system-mirror-system-window-system) in Doors.
23. Enable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.
24. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.

The roof panel is attached to the steel roof structure with beads of adhesive on the sides and spot-welds on the side rail, windshield and back-glass flanges. Replacement of the roof panel can be performed using conventional procedures, however, the windshield and back glass must be removed. Factory roof panel is attached with spot welds on the side rails, the service part will use adhesive only on both side rails.

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
3. Remove all related panels and components.
4. Visually inspect the damage. Repair as much of the damage as possible.
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
6. Locate and mark all factory welds.
7. Drill all factory welds. Note the number and location of welds for installation of the service assembly.
8. Cut the adhesive with an appropriate tool after removing the panel.
9. Remove the remaining portion of the original panel.

1. Clean and prepare the attaching surfaces for welding.
2. Drill 8 mm (5/16 in) for plug welding along the windshield and back glass edges of the service panel as noted from the original panel. Drill the holes for plug welding along the front and rear flanges every 40 mm (1 1/2 in).
3. Position the service panel.
4. Install the panel using one-part windshield urethane to side flanges.
5. Inspect the fit.
6. Plug weld accordingly.
7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
8. Paint the repaired area. Refer to «Basecoat/Clearcoat Paint Systems»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__basecoatclearcoat-paint-systems) in Paint and Coatings.
9. Install all related panels and components.
10. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
11. Enable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.

Scheme 24

The full body-side outer panel comes as a complete assembly and an be replaced at factory seams after the removal of the fixed glass and roof. Any one of these service procedures can be performed separately or in any combination, dependent upon the extent of damage to the vehicle. Sectioning must take place in specified areas only.

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
3. Remove the rear window. Refer to «Rear Window Replacement»(/cadillac/sts/i-2004-2007/remont/heated-glassdefoggers/#stationary-windows__rear-window-replacement) in Stationary Windows.
4. Remove all related panels and components.
5. Restore as much of the damage as possible.
6. Remove sound deadeners as necessary and note their location.
7. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
8. Create cut lines on the rocker panel within the approved sectioning locations.
9. In the back-glass opening, measure down 150 mm (6 in) from the rear edge of the roof.
10. Mark a cut line to the door opening.
11. Cut the panel where sectioning is to be performed.
12. Locate, mark, and drill out all the necessary factory welds.
13. Remove the damaged quarter panel.

1. Cut the body side assembly in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of one-and-one-half-times the metal thickness at the sectioning joint.
2. Create a 50 mm (2 in) backing plate from the unused portion of the service part for the back glass area. Create a 100 mm (4 in) backing plate from the unused portion of the service part for the rocker area. Trim the backing plates as necessary to fit behind the sectioning joints.
3. Drill 8 mm (5/16 in) along the sectioning cut on the remaining original part. Locate these holes 13 mm (1/2 in) from the edge of part and spaced 40 mm (1 1/2 in) apart. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel and along the sectioning cut.
4. Prepare all mating surfaces as necessary.
5. Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.
6. Fit the backing plates halfway into the sectioning joints, clamp in place and plug weld to the vehicle.
7. Align quarter panel using three-dimensional measuring equipment.
8. Plug weld accordingly.
9. To create a solid weld with minimum heat distortion, make 25 mm (1 in) stitch welds along the seam with 25 mm (1 in) gaps between them. Then go back and complete the stitch weld.
10. On vehicles equipped with 18 inch wheels, locate the wheel opening flange between the 10 o'clock and 2 o'clock positions.
11. On vehicles equipped with 18 inch wheels, hand form the wheel opening flange to 62 degrees from 90 degrees for proper tire clearance. This is a 28 degree change.
12. Clean and prepare all of the welded surfaces.
13. Apply sound deadening materials as necessary.
14. Paint the repaired area. Refer to «Basecoat/Clearcoat Paint Systems»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__basecoatclearcoat-paint-systems) in Paint and Coatings.
15. Install the rear window. Refer to «Rear Window Replacement»(/cadillac/sts/i-2004-2007/remont/heated-glassdefoggers/#stationary-windows__rear-window-replacement) in Stationary Windows.
16. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
17. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
18. Enable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
3. Remove all related panels and components.
4. Remove and note the location of any sound deadening materials.
5. Remove and note the location of the sealers and anti-corrosion materials from the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
6. Repair as much of the damage as possible.
7. Locate, mark, and drill out all factory welds. Note the number and location of welds for installation of the service assembly.
8. Remove the damaged rail section.

1. Drill 8 mm (5/16 in ) plug weld holes in the service part, as necessary, in the locations noted from the original panel.
2. Prepare the mating surfaces, as necessary.
3. Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.
4. Position the rear rail service part. Verify the fit with 3-dimensional measuring equipment.
5. Plug weld accordingly.
6. Clean and prepare all welded surfaces.
7. Apply the sealers, and anti-corrosion materials to the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
8. Paint the repaired area. Refer to «Basecoat/Clearcoat Paint Systems»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__basecoatclearcoat-paint-systems) in Paint and Coatings.
9. Install all related panels and components.
10. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
11. Enable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
3. Remove all related panels and components.
4. Restore as much of the damage as possible.
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
6. Apply a piece of 20 mm (3/4 in) tape (2) along the flat area above the outer wheel housing as shown. This is your sectioning location.
7. In the rocker panel area, mark a vertical line in the flat area rearward of the triangle shaped opening as shown (1). This is your sectioning location.
8. Cut the panel where sectioning is to be performed.
9. Locate, mark, and drill out all the necessary factory welds.
10. Remove the damaged wheelhouse section.

1. Cut the service part in the corresponding locations to the sectioning cuts. Allow for a 25 mm (1 in) overlap to the vehicle.
2. In the door opening location notch as shown.
3. Drill 8 mm (5/16 in) plug weld holes along the sectioning cut on the original reinforcement. Locate these holes 13 mm (1/2 in) from the edge and spaced 40 mm (11/2 in) apart.
4. Drill 8 mm (5/16 in) plug weld holes in the service reinforcement as necessary in the locations noted from the original panel.
5. Prepare all mating surfaces as necessary.
6. Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.
7. Align the service part on the vehicle using 3-dimensional measuring equipment.
8. Plug weld accordingly.
9. To create a solid weld with minimum heat distortion, make 25 mm (1 in) stitch welds along the seam with 25 mm (1 in) gaps between them. Go back and complete the stitch weld.
10. Clean and prepare all of the welded surfaces.
11. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
12. Paint the repaired area. Refer to «Basecoat/Clearcoat Paint Systems»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__basecoatclearcoat-paint-systems) in Paint and Coatings.
13. Install all of the related panels and components.
14. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
15. Enable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
3. Remove all related panels and components.
4. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
5. Repair as much of the damage as possible.
6. Cut the rear compartment panel at the rear edge of the number 5 crossbar.
7. Locate, mark, and drill out all factory welds. Note the number and location of welds for installation of the service assembly.
8. Remove the damaged rear compartment panel from the vehicle.

1. Prepare the mating surfaces as necessary.
2. Drill 8 mm (5/16 in) plug weld holes along the front edge of the service part. Locate these holes 13 mm (1/2 in) from the edge of the service part spaced 40 mm (1 1/2 in) apart.
3. Drill 8 mm (5/16 in ) plug weld holes in the service part as necessary in the locations noted from the original panel. Do not drill holes in the vertical flange along the wheelhouse area. This area will be bonded.
4. Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.
5. Apply bonding material Lord 108 to the vertical flanges in the wheelhouse areas only.
6. Install and align the service part using three dimensional measuring equipment.
7. Plug weld accordingly.
8. To create a solid weld along the front of the service part with a minimum of heat distortion, make a 25 mm (1 in) stitch weld along the seam with 25 mm (1 in) gaps between them.
9. Clean and prepare all welded surfaces.
10. Apply sound deadening materials as necessary.
11. Paint the repaired area. Refer to «Basecoat/Clearcoat Paint Systems»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__basecoatclearcoat-paint-systems) in Paint and Coatings.
12. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
13. Install all related panels and components.
14. Connect the battery ground (negative) cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
15. Enable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
3. Remove all related panels and components.
4. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
5. Repair as much of the damage as possible.
6. Apply a 25 mm (1 in) wide piece of masking tape (1) to the rear compartment panel along the contour of the wheelhouse, from the #5 crossbar to the rear of the compartment panel. Apply the tape on both sides of the rear compartment panel.
7. Cut along the inboard side of the tape to create a weld flange.
8. Cut the rear compartment panel at the rear edge of the #5 crossbar.
9. Locate, mark, and drill out all factory welds. Note the number and location of welds for installation of the service assembly.
10. Remove the damaged rear compartment panel from the vehicle.

1. Prepare the mating surfaces as necessary.
2. Apply a 25 mm (1 in) piece of masking tape along the contour of the wheelhouse from the front edge to the rear edge of the rear compartment floor service part on both sides. Cut along the outside of the tape and remove the up-turned flange.
3. Drill 8 mm (5/16 in) plug weld holes along the front edge of the service part spaced 40 mm (1 1/2 in) apart.
4. Drill 8 mm (5/16 in) plug weld holes in the service part, as necessary, in the locations noted from the original panel.
5. Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.
6. Install and align the service part using 3-dimensional measuring equipment.
7. Plug weld accordingly.
8. To create a solid weld along the front of the service part with a minimum of heat distortion, make a 25 mm (1 in) stitch weld along the seam with 25 mm (1 in) gaps between them.
9. Clean and prepare all welded surfaces.
10. Paint the repaired area. Refer to «Basecoat/Clearcoat Paint Systems»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__basecoatclearcoat-paint-systems) in Paint and Coatings.
11. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
12. Install all related panels and components.
13. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
14. Enable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
3. Remove all related panels and components.
4. Repair as much of the damage as possible.
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
6. Locate, mark, and drill out all the necessary factory welds.
7. Remove the rear end panel.

1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
2. Prepare all mating surfaces as necessary.
3. Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.
4. Position the rear end panel.
5. Plug weld accordingly.
6. Clean and prepare all of the welded surfaces.
7. Install all of the related panels and components.
8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__anti-corrosion-treatment-and-repair) in Paint and Coatings.
9. Paint the repaired area. Refer to «Basecoat/Clearcoat Paint Systems»(/cadillac/sts/i-2004-2007/remont/paintcoatings/#paintcoatings__basecoatclearcoat-paint-systems) in Paint and Coatings.
10. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/cadillac/sts/i-2004-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
11. Enable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/cadillac/sts/i-2004-2007/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) in SIR.

Metal Panel Bonding

This is intended to provide general guidelines for adhesive bonding of exterior panels as an alternative to Metal-Inert Gas (MIG) welding. Panel bonding may be seen as an alternative to MIG welding to provide full panel replacement in regards to collision repair procedures. The benefits of panel bonding is

1. No heat or burn damage when additional welding is not required
2. Corrosion protection
3. Can act as a sealant
4. Improved process for complicated shapes (wheelhouse area)

The General Motors specification for metal bonding adhesives is GM 6449G. The scope of this specification is intended to provide the performance guidelines of structural adhesive systems used to repair (metallic) automotive bodies in the aftermarket. These types of adhesives are intended for use when bonding replacement body panels as an option to welding as the attachment means. GM information outlines the use of room temperature cure acrylic adhesives that contain glass bead technology.

Bonding procedures in general are applicable only to a factory seams type approach.

Sectioning or partial paneling of full panels is not supported by General Motors unless specifically documented in a Service Bulletin or Manual.

Applicable components for this technology are EXTERIOR PANELS ONLY, including door skins, tail panels, roof outer panels and quarter panels.

Adhesives currently meeting the performance requirements include General Motors materials and products manufactured by Lord Adhesives. At this time, ONLY the adhesive products listed below meet this guideline

Metal Panel Bonding

See also:
• Approved Equipment for Collision Repair Caution
• SIR Disabling and Enabling Zones
• Battery Negative Cable Disconnect/Connect Procedure
• Anti-Corrosion Treatment and Repair
• Basecoat/Clearcoat Paint Systems
• Door, Hinge Replacement - Front Door
• Rear Window Replacement
• Wheelhouse Replacement - Front
• Metal Panel Bonding