Quarter Outer Panel Replacement Weld-on

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

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 including the rear compartment lid. Refer to Rear Compartment Lid Replacement and to Endgate Replacement in Body Rear End.
4. Repair as much of the damage as possible to factory specifications. Refer to Rear Compartment in Dimensions - Body .
5. Open the folding top stowage compartment lid. Refer to Folding Top Stowage Compartment Lid Release Mech .

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

6. 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.



7. Locate and drill completely through all layers of metal at the factory welds along the rear compartment end gate opening.




Important: Do NOT damage the inner panels or the reinforcements.

8. Locate and drill out all factory welds along the rear compartment opening. Note the number and location of the welds for installation of the service quarter panel.



9. Locate and drill out all factory welds along the lock pillar. Note the number and location of the welds for installation of the service quarter panel.



10. Verify the existence of structural weld-thru adhesive. Refer to Structure Adhesive Identification . If necessary use a chisel to separate the outer quarter panel from the adjacent panels.



11. Remove the damaged quarter panel.

Important: Do NOT drill plug weld holes along the edge of the service quarter panel by the rear compartment end gate opening.

1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted on the original panel.
2. Replace the structural adhesive with an additional plug weld between the existing plug welds where necessary.
3. Prepare all mating surfaces as necessary.
4. Apply 3M® Weld-Thru coating P/N 05916 or equivalent to all mating surfaces.



5. Position the quarter panel. Refer to Rear Compartment in Dimensions - Body .



6. Plug weld accordingly.
7. Clean and prepare all welded surfaces.
8. Apply the sealers and the anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
9. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
10. Install all related panels, including the rear compartment lid. Refer to Rear Compartment Lid Replacement and to Endgate Replacement in Body Rear End.
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
12. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.

Quarter Outer Panel Replacement Bond-on

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





Important: Before you begin the repair, refer to Metal Panel Bonding for proper adhesive preparations and general information.

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 including the rear compartment lid. Refer to Rear Compartment Lid Replacement and to Endgate Replacement in Body Rear End.
4. Repair as much of the damage as possible to factory specifications. Refer to Rear Compartment in Dimensions - Body .
5. Open the folding top stowage compartment lid. Refer to Folding Top Stowage Compartment Lid Release Mech .

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

6. 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.



7. Locate and drill completely through all layers of metal at the factory welds along the rear compartment end gate opening.




Important: Do NOT damage the inner panels or the reinforcements.

8. Locate and drill out all factory welds along the rear compartment opening



9. Locate and drill out all factory welds along the lock pillar.



10. Verify the existence of structural weld-thru adhesive. Refer to Structure Adhesive Identification . If necessary use a chisel to separate the outer quarter panel from the adjacent panels.



11. Remove the damaged quarter panel.

1. Grind the surface of the body mating flanges to bare steel. Do not damage the corners or thin the metal during the grinding process.



2. Grind the quarter panel mating flanges to remove the E-coating. Take care not to damage the corners or thin the metal during the grinding operation.
3. Clean the mating surfaces.




Important: The adhesive has a 40-50 minute working time. Do not allow the adhesive to cure prior to installing the quarter panel.

4. 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.



5. 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.



6. Apply a 9-13 mm (3/8 to 1/2 in) bead of metal panel bonding adhesive GM P/N 12378567 (Canadian P/N 88901675) or equivalent, to the mating surface of the service quarter panel.




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

7. Position the quarter panel to the body. Refer to Dimensions - Body



8. Clamp the quarter panel into position at the lock pillar area.



9. Clamp the quarter panel into position at the rear compartment opening.
10. Using lacquer thinner remove the excess adhesive from the quarter panel area.
11. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
12. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
13. Install all related panels and components, including the rear compartment lid. Refer to Rear Compartment Lid Replacement and to Endgate Replacement in Body Rear End.
14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
15. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.