Quarter Outer Panel Sectioning Quarter Window

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

Caution: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle and cause personal injury if the vehicle is in a collision.

The body side outer panel is available in one piece. You can perform any one of these replacement procedures separately or in any combination, depending upon the extent of damage to the vehicle. Sectioning must take place in specified areas only. Stay away from the door and window opening radius areas. Section only in straight areas of the openings.

1. Disable the SIR system. Refer to SIR Disabling and Enabling.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove all related panels and components.
4. Repair as much of the damaged area as possible. Refer to Dimensions - Body.
5. Remove the sound deadeners as necessary. Note their location.
6. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.




Important: 

•	Perform sectioning only in the recommended areas of the rocker panel and pillars.

•	Avoid areas in the radius corners for the rear header attachment locations.

•	Avoid areas in the radius corners, at the bottom of the quarter window and at the bottom of the dogleg in the door opening.

7. Sectioning can be performed at any of the following locations:

•	Any straight area along the bottom of the rear door opening forward of the rear corner radius and rearward of the center pillar radius. Use a 100 mm (4 in) welding backer.

•	Any straight area along the front quarter window opening. Use a 50 mm (2 in) weld backer.

•	Any straight area along the rear quarter window opening. Use a 50 mm (2 in) weld backer.

8. Within the recommended sectioning areas, mark the location of the sectioning cut lines on the vehicle.

Important: Note the number and location of the factory welds for installation of the quarter panel.

9. Locate and drill out all factory welds.




Important: Do NOT damage any other panels or reinforcements when cutting at the marked locations.

10. Cut the panel at the locations laid out in the previous steps.



11. Remove the damaged quarter panel.

Important: To allow proper layout and cutting of the service port, review the appropriate sectioning area information in the removal procedure.

1. Locate the area on the service panel where you will perform sectioning.
2. Measure and mark the cut line location on the service part.



3. Cut the service panel in corresponding locations to fit the remaining original panel. Trim the sectioning butt joint to allow a gap of 1½ times the metal thickness at the sectioning joint.
4. Create backing plates of the specified length from the unused portion of the service part.
5. Trim the backing plates as necessary to fit behind the panel at the sectioning joints.

Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1½ in) apart.

6. Drill 8 mm (5/16 in) plug weld holes along the sectioning areas in the service part. Drill the plug weld holes 15 mm (5/8 in) from the edges.
7. Drill 8 mm (5/16 in) plug weld holes at the locations noted from the original panel.
8. Prepare all mating surfaces as necessary.
9. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
10. Fit the backing plates halfway into the sectioning joints on the vehicle. Clamp the plates in place, and plug weld to the section joint
11. Weld the plug weld holes on the vehicle half of the backing plates.
12. Position the quarter panel service part to the vehicle using 3-dimensional measuring equipment. Clamp the quarter panel in place.



13. Plug weld accordingly.
14. To create a solid weld with minimum heat distortion, make a 25 mm (1 in) stitch weld along the seam with gaps of 25 mm (1 in). Go back and complete the stitch weld.
15. Clean and prepare all of the welded surfaces.
16. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
17. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
18. Install all of the related panels and components.
19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
20. Enable the SIR system. Refer to SIR Disabling and Enabling.

Quarter Outer Panel Sectioning Panel Van

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

Caution: Refer to Glass and Sheet Metal Handling Caution in the Preface section.

Caution: Refer to Collision Sectioning Caution in the Preface section.

Important: The quarter panel can be serviced as a complete panel or sectioned. When the complete panel replacement is performed, the roof panel must be removed.

1. Disable the SIR system. Refer to SIR Disabling and Enabling.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove all related panels and components.
4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body.
5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.



6. Apply 25 mm (1 in) wide tape (1) along the upper edge of the quarter panel at the roof line.




Important: Do not damage any inner panels or reinforcements.

7. Cut along the upper edge of the quarter panel (1) at the roof line.



8. Trim as necessary leaving a 25 mm (1 in) vertical flange (1) to be used as a bonding surface for installation of the new quarter panel.



9. Locate and drill out all factory welds. Note the number and location of welds for installation of the new quarter panel.



10. Remove the damaged quarter panel.

1. Trim the shaded area (1) from the new quarter panel as necessary to mate with the 25 mm (1 in) vertical flange left from the original panel.




Important: In any area damaged beyond recognition, space plug weld holes every 40 mm (1 1/2 in) apart.

2. Drill 8 mm (5/16 in) plug weld holes in the new quarter panel as necessary in the locations noted from the original panel.



3. Using a 50-grit grinding disk to grind to bare steel the 25 mm (1 in) flange (1) left from the original panel to be used as a bonding surface with the new quarter panel.
4. Scuff the bonding surface of the new quarter panel and remove the gloss of the E-Coat.
5. Prepare all attachment surfaces as necessary for welding and bonding.
6. Before applying adhesive dry fit the quarter panel for proper fit and alignment.
7. Apply GM-approved Weld-Thru Coating or equivalent to all welding mating surfaces. Refer to Anti-Corrosion Treatment and Repair.
8. Apply internal sealers in the locations noted from the removal procedure.



9. Apply a 3-6 mm (1/8-1/4 in) bead of metal panel bonding adhesive to the 25 mm (1 in) flange left from the original panel. Refer to Metal Panel Bonding.
10. Apply a 3-6 mm (1/8-1/4 in) bead of metal panel bonding adhesive (1) to the mating surface of the new quarter panel. Refer to Metal Panel Bonding.
11. Using a small acid brush spread the adhesive to cover all bonding surfaces and bare metal surfaces to ensure corrosion protection.
12. Apply a 9-13 mm (3/8-1/2 in) bead of metal bonding adhesive to the mating surfaces of the new quarter panel. Refer to Metal Panel Bonding.




Important: Do NOT pull the panels apart after being joined together. Slide the panels against each other to realign the panels.

13. Position the quarter panel to the vehicle.
14. Clamp or mechanically fasten the quarter panel into place as necessary.
15. Remove any excess adhesive.



16. Using a Mig welder, plug weld accordingly.
17. Clean and prepare all welded surfaces.
18. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
19. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems.
20. Install all related panels and components.
21. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
22. Enable the SIR system. Refer to SIR Disabling and Enabling.