For 1990-2009 cars

#### Special Tools

J 42058 Frame Adapter Clamp

### Removal Procedure

The body-side outer quarter panel comes as a complete assembly made of stamped sheet metal, and is intended to be replaced at the factory seams. The quarter panel assembly is bonded with urethane adhesive, and is welded to the side structure.

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

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.

Warning: Refer to Actions to Take When Working with Fuel Warning in the Preface section.

4. Make sure the fuel inlet is sealed before proceeding with the repair procedure.

Note: Note the location of the original welds.

Note: Do not damage any inner panels or reinforcements.

5. Drill out all of the welds that attach the quarter outer panel to the trunk gutter.
6. Using a panel cutter and attaching blade, trim the quarter panel as necessary to expose the bonding surface.
7. Remove the trimmed quarter panel from the vehicle.

Note: The temperature must reach 300 to 500 degrees for the quarter panel to release from the adhesive.

8. Apply heat and pry to detach the remaining quarter panel from the adhesive along the bonding surface.

Note: Note the location of the urethane adhesive.

9. Use a pneumatic knife or equivalent to remove all of the urethane adhesive.
10. Inspect the side structure and frame rails for damage.
11. Restore as much of the damage as possible to the factory specifications.
12. Use J 42058 to secure the vehicle if pulling and straightening is required.

### Installation Procedure

Note: Shims may be necessary to achieve proper panel alignment.

1. Before applying adhesives, dry fit the quarter panel for proper fit and alignment.
2. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted on the original panel.
3. Prepare all mating surfaces as necessary for welding.
4. Apply GM-approved weld-thru coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair.
5. Clean and prepare all bonding mating surfaces according to the adhesive manufacturer's recommendations.

Note: Do NOT top coat any bonding surface. Use urethane primer only on bonding surfaces. Refer to the adhesive manufacturer's recommendations.

6. Use a urethane adhesive kit or equivalent to apply a consistent bead of urethane adhesive 20 mm (3/4 in) in diameter to the mating surfaces of the quarter panel, the side structure, and the frame rail, and to all areas that were originally bonded. Refer to Urethane Adhesive Panel Bonding.
7. Position the quarter panel to the vehicle.
8. Apply pressure to the quarter panel to set the adhesive.
9. Remove any excess adhesive.
10. Clamp or mechanically fasten the quarter panel in place, as necessary.
11. Using a MIG welder, weld the quarter panel to the trunk gutter in the same location as the original welds.
12. Apply sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
13. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems.
14. Install all related panels and components.
15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
16. Enable the SIR system. Refer to SIR Disabling and Enabling.