Quarter Panel Sectioning Sedan

Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

Important: Section in specified areas only. Sectioning outside of these areas may compromise the structural integrity of the vehicle. The quarter panel can be replaced at factory seams, but requires the roof flange spot welds to be removed along the top of the quarter panel. The sectioning procedures have been developed as a more cost-effective alternative to complete replacement.

1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
3. Remove all related panels and components.
4. Remove the rear window. Refer to Rear Window Replacement in Stationary Windows.
5. Remove the quarter window. Refer to Quarter Window Replacement in Stationary Windows.
6. Restore as much of the damage as possible to factory specifications. Refer to Dimensions - Body .
7. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.

Important: Do not damage any inner panels or reinforcements.

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 installations of the service part.
10. Remove the damaged quarter panel.

1. Cut the replacement quarter panel section in corresponding locations to fit the original panel. The sectioning joint should be trimmed to allow 1½ times the metal thickness at the sectioning joint.
2. Create a 50 mm (2 in) backing plate (A) from the unused portion of the service part. Trim the backing plate as necessary to fit behind the sectioning joint where there is no reinforcement.
3. Drill 8 mm (5/16 in) plug weld holes along the sectioning cut on the remaining original part. Locate these holes 13 mm (1/2 in) from the edge and spaced 40 mm (1½ in) apart.

Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart.

Some panels may have structural weld-thru adhesive. It is necessary to replace the weld-thru adhesive with an additional spot weld between each factory spot weld.
4. 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.
5. Prepare all attachment surfaces as necessary.
6. Apply 3m weld-thru coating P/N 05916 or equivalent to all mating surfaces.



7. Fit the backing plate halfway into the sectioning joint, clamp and plug weld to the vehicle.
8. Position the outer quater panel to the vehicle using 3-dimensional measuring equipment. Clamp the outer quater panel into place.
9. Plug weld accordingly.
10. Stitch weld the sectioning joint, make 25 mm (1 in) stitch welds along the seam with 25 mm (1 in) gaps between them.
11. Complete the stitch weld filling in the gaps creating a solid weld with minimum heat distortion.
12. Clean and prepare all welded surfaces.
13. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
14. Paint and repair the area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
15. Install all related panels and components.
16. Install the quarter window. Refer to Quarter Window Replacement in Stationary Windows.
17. Install the rear window. Refer to Rear Window Replacement in Stationary Windows.
18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
19. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.