GM Service Manual Online
For 1990-2009 cars only

Coupe


Object Number: 867212  Size: MF

Number

Location

Clearance Gap

Flushness

1

Front fascia to hood

7.0± 1.0 mm (0.28 ± 0.04 in)

--

2

Front fascia to fender

0.5 + 1.0 or - 0.5 mm

(0.02 + 0.04 or - 0.02 in)

--

3

Front fender to hood

4.0 ± 1.0 mm (0.16 ± 0.04 in)

± 1.0 mm ( ± 0.04 in)

4

Front fender to door

7.0 ± 1.0 mm (0.28 ± 0.04 in)

+ 1.5, - 0.0 mm (+0.06 - 0.0 in)

5

Front door to rocker

7.0 ± 3.0 mm (0.28 ± 0.12 in)

--

6

Top windshield to roof

No gap permissible

--

7

Front door panel to rear quarter panel

7.0 ± 1.0 mm (0.28 - 0.04 in)

+1.5 - 00 mm (0.06 - 0.0 in)

8

Rear fascia to rear quarter panel

0.0 + 1.5 mm (0.0 + 0.06 in)

--

9

Quarter to decklid (top)

4.0 ± 1.00 mm (0.16 - 0.04 in)

± 1.0 mm (±0.04 in)

10

Top backlight to roof

No gap permissible

--

11

Quarter to decklid (rear)

5.0 ± 1.0 mm (0.20 ± 0.04 in)

±1.0 mm(± 0.04 in)

12

Decklid to rear fascia

9.0 ± 1.5 mm (0.36 ± 0.06 in)

--

13

Front door applique to side window

5.0 ± 1.0 mm (0.20 ± 0.04 in)

--

Three Door Coupe (RAD)


Object Number: 867212  Size: MF

Number

Location

Clearance Gap

Flushness

1

Front fascia to hood

7.0± 1.0 mm (0.28 ± 0.04 in)

--

2

Front fascia to fender

0.5 + 1.0 or - 0.5 mm

(0.02 + 0.04 or - 0.02 in)

--

3

Front fender to hood

4.0 ± 1.0 mm (0.16 ± 0.04 in)

± 1.0 mm ( ± 0.04 in)

4

Front fender to door

7.0 ± 1.0 mm (0.28 ± 0.04 in)

+ 1.5, - 0.0 mm (+0.06 - 0.0 in)

5

Front door to rocker

7.0 ± 3.0 mm (0.28 ± 0.12 in)

--

6

Top windshield to roof

No gap permissible

--

7

Front door panel to rear quarter panel

7.0 ± 1.0 mm (0.28 - 0.04 in)

+1.5 - 00 mm (0.06 - 0.0 in)

8

Rear fascia to rear quarter panel

0.0 + 1.5 mm (0.0 + 0.06 in)

--

9

Quarter to decklid (top)

4.0 ± 1.00 mm (0.16 - 0.04 in)

± 1.0 mm (±0.04 in)

10

Top backlight to roof

No gap permissible

--

11

Quarter to decklid (rear)

5.0 ± 1.0 mm (0.20 ± 0.04 in)

±1.0 mm(± 0.04 in)

12

Decklid to rear fascia

9.0 ± 1.5 mm (0.36 ± 0.06 in)

--

13

Front door applique to side window

5.0 ± 1.0 mm (0.20 ± 0.04 in)

--

14

Rear door to rocker

7.0 ± 3.0 mm (0.28 ± 0.12 in)

--

15

Front door applique to side window

7.0 ± 1.0 mm (0.28 ± 0.04 in)

--

Sedan


Object Number: 867264  Size: MF

Number

Location

Clearance Gap

Flushness

1

Front fascia to hood

6.0 ± 1.0 mm (0.24 ± 0.04 in)

--

2

Front fascia to fender

2.0±1.0 mm (0.08 ± 0.04 in)

--

3

Front fender to hood

4.0 ± 1.0 mm (0.16 ± 0.04 in)

--

4

Front fender to door

6.0 ± 1.0 mm (0.24 ± 0.04 in)

+1.5 - 0.0 mm (0.06, - 0.0 in)

5

Front door to rocker

8.0 ± 3.0 mm (0.32 ± 0.12 in)

--

6

Front door panel to rear quarter panel

6.5 ± 1.0 mm (0.26 ± 0.04 in)

+1.5 - 0.0 mm (0.06 - 0.0 in)

7

Top windshield to roof

No gap permissible

--

8

Rear door to rocker

8.0 ± 3.0 mm (0.32 ± 0.12 in)

--

9

Rear door to quarter

6.0 ± 1.0 mm (0.24 ± 0.04 in)

+ 1.5 - 0.0 mm (0.06 - 0.0 in)

10

Quarter to rear fascia

2.0 ± 1.0 mm (0.08 ± 0.04 in)

--

11

Quarter to deck lid

4.0 ± 1.0 mm (0.16 ± 0.04 in)

+ 1.0 mm (+ 0.04 in)

12

Top backlight to roof

No gap permissible

--

13

Decklid to rear fasica

8.0 ± 2.0 mm (0.32 ± 0.08 in)

--

14

15

Front door applique to rear door applique

5.0 + 3.0 -1.0 mm (0.20 + 0.12, -0.04 in)

+ 1.5, -0.0 mm (0.06 - 0.0 in)

16

Roof side applique to roof

3.8 ± 2.0 mm (0.15 ± 0.08 in)

--

Wagon


Object Number: 867267  Size: MF

Number

Location

Clearance Gap

Flushness

1

Roof panel to liftgate

8.0 ± 1.5 mm (0.32 ± 0.06 in)

+ 0.0 to + 2.0 mm ( + 0.0 to + 0.08 in)

2

Liftgate applique to roof side rear center applique

4.5 ±1.0 - 0.0 mm (0.18 + 0.04 - 0.0 in)

+ 1.0 - 0.0 mm (± 0.04 - 0.0 in)

3

Liftgate to quarter panel gap

8.0 ± 2.0 mm (0.32 ± 0.081 in)

-2.00 + 0.0 mm (-0.08 + 0.0 in)

4

Taillamp to liftgate gap

8.0 ± 2.0 mm (0.32 ± 0.08 in)

+ 0.0 to + 2.00 mm (+ 0.0 to +0.08 in)

5

Liftgate to fascia gap

8.5 + 1.5-3.5 mm (0.33+0.06 - 0.14) in

--

6

Centerline liftgate to fascia

7.0 ± 1.5-3.5 mm (0.28+0.06 -0.14 in)

--

7

Taillamp to rear quarter gap

2.5 ± 1.5 mm (0.10 ± 0.06 in)

+ 2.0 to + 4.0 mm (+ 0.08 to + 0.16 in)

8

Roof side center applique to rear quarter

2.0 mm (0.08 in)

--

9

Fuel filler door to quarter panel gap

3.5 ± 0.5 mm (0.14 ± 0.02 in)

+ 1.0 + 0.0 mm - 0.5 (+ 0.04 - 0.0 in)