GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Opel 🢒 2009 🢒 Insignia NB (Global Epsilon) 🢒 Body Repair 🢒 Collision Repair 🢒 Quarter Outer Panel Replacement

Removal Procedure

    Note: Section in specified areas only. Sectioning outside of these areas may compromise the structural integrity of the vehicle. 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.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  3. Remove all related panels and components.
    4. • Remove the rear side door. Refer to Rear Side Door Replacement.
    • Remove the rear side door weatherstrip - body side. Refer to Rear Side Door Weatherstrip Replacement.
    • Remove the rear compartment floor panel carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
    • Remove the liftgate window. Refer to Liftgate Window Replacement.
    • Remove the liftgate. Refer to Liftgate Replacement.
    • Remove the liftgate weatherstrip. Refer to LINK.
    • Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement.
  4. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.

    5. Object Number: 2020360 Size: SH

    Note: Do not damage any inner panels or reinforcements.

  5. Cut out the quarter outer panel.

    6. Note: Note the number and location of the welds for installations of the service part.

  6. Locate and drill out all of the necessary factory welds.

    7. Object Number: 2020361 Size: SH

    Note: Do not damage any inner panels or reinforcements

  7. Cut out the quarter outer panel.

    8. Note: Note the number and location of the welds for installations of the service part.

  8. Locate and drill out all of the necessary factory welds.

    9. Object Number: 2020362 Size: SH

    Note: Note the number and location of the welds for installations of the service part.

  9. Locate and drill out all of the necessary factory welds.
  10. Remove the damaged quarter outer panel.

Installation Procedure
  1. Cut the replacement quarter outer panel section in corresponding locations to fit the original panel. The sectioning joint should be trimmed to allow min. 1 times the metal thickness at the sectioning joint.

    2. Note: Refer SPP, PSO welding parameters for resistance spot welding! See TIS Newsletter for equipment recommendations.


    Object Number: 2020363 Size: SH

    Note: Pre-spot operation: The number of spots is specified in the documentation from the welding equipment manufacturer.

  2. Prepare inner rocker panel with reinforcement.

    3. Object Number: 2156505 Size: SH
  3. Prepare new quarter outer panel in the area (1).

    4. 7 slots (5x18 mm / 0.2x0.7 in)

  4. Prepare new quarter outer panel in the area (2).

    5. 6 slots (5x18 mm / 0.2x0.7 in)


    Object Number: 2156506 Size: SH
  5. Apply bodywork repair through structural adhesive to body. Refer to XXXXX.

    6. Adhesive on Sound Deadener (1)


    Object Number: 2156507 Size: SH
  6. Position the quarter outer panel.

    7. Object Number: 2020367 Size: SH

    Note: Refer to XXXXX.

  7. Spot weld the quarter outer panel accordingly.

    8. Object Number: 2156508 Size: SH

    Note: Refer to XXXXXX.

  8. Spot weld the quarter outer panel accordingly.

    9. Object Number: 2020369 Size: SH
  9. MIG-braze the quarter outer panel.

    10. Object Number: 2020370 Size: SH
  10. MIG-braze the quarter outer panel.
  11. Grind MIG brazed seams.

    12. Object Number: 2020371 Size: SH
  12. Pre-flange wheel housing.

    13. Using a suitable hammer, bend over the flanged edge 45° (1), at the same time holding a small mallet or block against it. Use structural adhesive in the area (2).


    Object Number: 2020372 Size: SH
  13. Bend the wheel arch.
    14. • Apply excess adhesive as a seam seal and corrosion protection using a spatula or flat paintbrush. Use structural adhesive in area (1).
    • Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to XXXXX.
  14. Install all related panels and components.
    15. • Install the rear side door. Refer to Rear Side Door Replacement.
    • Install the rear side door weatherstrip - body side. Refer to Rear Side Door Weatherstrip Replacement.
    • Install the rear compartment floor panel carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
    • Install the liftgate window. Refer to Liftgate Window Replacement.
    • Install the liftgate. Refer to Liftgate Replacement.
    • Install the liftgate weatherstrip. Refer to Liftgate Weatherstrip Replacement.
    • Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement.
  15. Connect the negative battery cable. Refer to XXXXX.
  16. Enable the SIR system. Refer to XXXXX.