Quarter Outer Panel Replacement Welding

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

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

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
3. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body .
4. Remove all related panels and components.

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

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 in Paint and Coatings.



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



7. Remove the quarter panel.

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

Important: If the location of the original plug weld holes cannot be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 40 mm (1½ in) apart.

2. Prepare all mating surfaces, as necessary.
3. Apply 3M® Weld-Thru coating P/N 05916 or equivalent to all mating surfaces.



4. Position the quarter panel to the body.



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