| Removal and Installation Removal | | -
General Notes - Required disassembly operations: Bumper, rear lamp, rubber seal - liftgate, bezel - forced air extraction, tank cap, fuel tank filler neck, side window, trims, inner fender, seat cushion, rear seat, safety belt, rubber seal - door and lock striker.
- Fold back the carpets and move the wiring out of the working area.
| | | -
Quarter panel - Cut locations.
- Separate clinched flange.
| Installation | | -
Quarter panel - Continuous MIG weld seam.
- Spot weld backing strips to the cut edge and weld using MIG continuous seam.
- Apply two-component metal adhesive prior to inserting the quarter panel. Clinch the flange in several stages.
- Puddle welding.
| | | -
Cut around the marked line on the new quarter panel. | | | -
Cut out the wheel arch liner, following the line in the panel. | | | -
Cut out the fuel filler flap housing around the outer lip of the hole. | | | -
Indent the new quarter panel for approximately 175 mm. to accommodate the joining flange inside the overpanel. | | | -
Position the wheel arch inner liner and secure temporarily with four rivets. | | | -
Lay the overpanel onto the vehicle and when positioned correctly, secure temporarily with two rivets. | | | -
Mark the position where the overpanel meets the C-pillar. | | | -
Remove the overpanel and wheel arch liner. | | | -
Drill and countersink ten holes in the wheel arch liner to accommodate the rivets. | | | -
Apply seam sealer to the back of the wheel arch liner. | | | -
Secure the wheel arch liner with ten rivets. | | | -
Prepare surfaces and MIG weld the wheel arch liner to the quarter panel in five places. | | | -
Drill two pilot holes and cut a slot along the mark made in step 8. This is necessary to accommodate the flange on the overpanel. | | | -
Scothbrite and degrease the inside of the overpanel within the bolded area shown. | | | -
Scotchbrite and degrease the existing quarter panel in line with the area on the overpanel in step 15. | | | -
Apply seam sealer around the inside edge of the overpanel where shown. | | | -
NOTE:Do not allow the seam sealer and body adhesive to come in contact with each other, as curing will be impaired. Apply body panel adhesive within the bolded area shown. | | | -
Install the overpanel to the vehicle, starting from the rear and making sure the flange fits into the slot. | | | -
Secure the overpanel using two rivets in the holes made in step 7. | | | -
Secure the overpanel in the liftgate opening with a rivet through the tang. | | | -
Prepare the surfaces and MIG weld the flange joint at the C-pillar. | | | -
Fill the flange joint on the overpanel. | | | -
Fill and smooth joints on the overpanel at C-pillar and rocker panel. | | |
