For 1990-2009 cars

## Quarter Panel Replacement Coupe

### Removal Procedure

The quarter panel is a service assembly that includes the gutter, lock-striker cagenut and an extension panel for the tail lamp pocket. THE TAIL LAMP POCKETS ARE SERVICED SEPARATELY.

Important: Replacement of the quarter panel requires removal of the back and quarter glass on coupe models. On both the coupe and sedan models, the quarter panel is attached to the roof panel by a silicon-bronze welded joint. To maintain the integrity of this joint, sectioning of the quarter panel at sail panel will be performed 100 mm (4 in) below this joint where the roof overlaps quarter panel.

1. Visually inspect and restore as much of the damage as possible to factory specifications.
2. Remove all related panels and components, including the side and back glass.
3. Remove the following as necessary:

• | Sealers

• | Sound deadeners

• | Anti-corrosion materials

4. Remove the damaged quarter panel.
5. Remove the majority of the baffle material in the sail panel and along the rocker panel.

### Installation Procedure

Important: Care must be taken to ensure that the fuel filler neck is properly sealed when replacing the right side quarter panel. Use SPO Sealing strip P/N 12399117 between the quarter panel and the fuel filler neck. Install according to the provided instruction sheet.

1. Measure and mark a line at the sail panel, 100 mm (4 in) from the step at the top edge of the service part.
2. Measure the distance between the lower 2 trim holes at the B-Pillar location on the outer panel only.
3. Scribe a line at half the distance between the 2 holes. This is the recommended sectioning point.
4. Cut along the line to trim the service part.
5. Create a 100 mm (4 in) backing plate so that it will fit behind the sectioning joint.
6. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original panel.
7. Drill plug weld holes along the sectioning areas of the service apart and original panel. These holes should be located approximately 13 mm (1/2 in) from the edge of the cuts.
8. Prepare the mating surfaces.
9. Position and secure both backing plates with half of the backing plate exposed at each joint.
10. Position the service part to overlap the backing plates and butt up to the original panel.
11. Check for proper fit and alignment.

Important: Leave a gap of one and one half times the thickness of the metal at the sectioning joint.

12. Plug weld accordingly.
13. Stitch weld along the entire sectioning joint.
14. Make 25 mm (1 in) welds along the seam with 25 mm (1 in) gaps between them.
15. Complete the stitch weld.
16. Plug weld all other areas as noted from the original panel.
17. Clean and prepare all welded surfaces.

Important: Prior to refinishing, refer to the publication GM 4901M-2000 "GM Approved Refinish Materials" for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

18. Install all related panels and components.

## Quarter Panel Replacement Sedan

### Removal Procedure

1. Remove all related panels and components, including the back glass.
2. Visually inspect and restore as much of the damage as possible to factory specifications.
3. Remove sealers and anti-corrosion materials as necessary.
4. Note the size of the service part and locate the sectioning joint at the sail panel.
5. Mark a line 100 mm (4 in) below the silicon bronze joint and cut.
6. Locate, mark and drill out all factory welds. Note the number and location of welds for installation of the service assembly.
7. Remove the damaged quarter panel.

### Installation Procedure

1. Prepare the mating surfaces as necessary.
2. Temporarily position the service panel on the vehicle.
3. Trim the original panel to leave a gap of one and one half time the thickness of the metal at the sectioning joint.
4. Cut 100 mm (4 in) piece from the original quarter panel for backing plates.
5. Remove the flange on each side of the backing plate so that they will fit behind the sectioning joints.
6. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original panel.
7. Drill plug weld holes along the sectioned area of the service part. The welds should be located approximately 25 mm (1 in) from the edge of the cuts.
8. Prepare the mating surfaces.
10. Position the service part to overlap the backing plate and butt up to the original panel.

Important: Leave a gap of one and one half times the thickness of the metal at the sectioning joint.

11. Plug weld all other areas as noted from the original panel.
12. Clean and prepare all welded surfaces.

Important: Prior to refinishing, refer to GM 4901M-2000 "GM Approved Refinish Materials" for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

13. Apply an approved anti-corrosion primer.
14. Apply the following as necessary:

• | Sealers

• | Sound deadeners

• | Anti-corrosion materials

15. Refinish as necessary.
16. Install all related panels and components previously removed for access.