For 1990-2009 cars

#### Special Tools

• | BO-6396 Bonding Pliers

• | BO-6392 Flanging Tool Kit

For equivalent regional tools, refer to Special Tools.

### Removal Procedure

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

Warning: Refer to Collision Sectioning Warning in the Preface section.

Warning: Refer to Glass and Sheet Metal Handling 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.
4. Visually inspect the damage. Repair as much of the damage as possible.
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
6. Create cut lines on the quarter outer panel.

Note: Do not damage any inner panels or reinforcements.

7. Cut the panel where sectioning is to be performed.
8. Open the wheelhouse flanging.
9. Locate and mark all the necessary factory welds of the quarter outer panel.
10. Drill all factory welds. Note the number and location of welds for installation of the service assembly.
11. Remove the damaged quarter outer panel.

### Installation Procedure

1. Cut the quarter outer panel in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of one-and-one-half-times the metal thickness at the sectioning joint.
2. Create a 50 mm (2 in) backing plate from the unused portion of the service part.
3. Drill 8 mm (5/16 in) along the sectioning cut on the remaining original part. Locate these holes 13 mm (1/2 in) from the edge of part and spaced 40 mm (1 1/2 in) apart.
4. Prepare all mating surfaces as necessary.
5. Fit the backing plates halfway into the sectioning joints, clamp in place and plug weld to the vehicle.
6. Align the quarter outer panel.
7. Drill 8 mm (5/16 in) for plug welding along the edges of the quarter outer panel as noted from the original panel.
8. Clean and prepare the attaching surfaces for welding.
9. Apply one-part windshield urethane adhesive (1) as noted from the original panel.
10. Position the quarter outer panel on the vehicle.
11. Verify the fit of the quarter outer panel.
12. Clamp the quarter outer panel into position.
13. Plug weld accordingly.
14. To create a solid weld with minimum heat distortion, make 25 mm (1 in) stitch welds along the seam with 25 mm (1 in) gaps between them. Then go back and complete the stitch weld.
15. Pre-flanging the flange with BO-6396 pliers and BO-6392 tool kit .
16. Finish closing the wheelhouse flanging.
17. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
18. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
19. Install all related panels and components.
20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
21. Enable the SIR system. Refer to SIR Disabling and Enabling.