Installation Procedure

Cut the replacement quarter outer panel section in corresponding locations to fit the original panel. The sectioning joint should be trimmed to allow min. 1 times the metal thickness at the sectioning joint.
NOTE: Pre-spot operation: The number of spots is specified in the documentation from the welding equipment manufacturer.

Prepare inner rocker panel (1) with reinforcement (PSO).

Fig 1: Identifying Inner Rocker Panel With Reinforcement (PSO)
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Prepare new quarter outer panel in the area (1).
7 slots (5x18 mm/0.2x0.7 in)

Fig 2: Identifying Quarter Outer Panel Area
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Prepare new quarter outer panel in the area (2).
6 slots (5x18 mm/0.2x0.7 in)
Position the new body side outer panel on the vehicle.

Fig 3: Identifying Quarter Outer Panel Area
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Verify the fit of the new body side outer panel.
Clamp the new body side outer panel into position.
Drill fastening holes (1) for waterproof rivets.
4 holes (4 mm/0.16 in)

Fig 4: Positioning Body Side Outer Panel On Vehicle
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Remove new quarter outer panel.
Apply bodywork repair through structural adhesive to body. Refer to STRUCTURAL ADHESIVE BODY REPAIRS .
Adhesive on Sound Deadener (1)

Fig 5: Identifying Fastening Holes And Waterproof Rivets
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Position the quarter outer panel on the vehicle.

Fig 6: Identifying Adhesive Applying Area On Sound Deadener
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Verify the fit of the roof outer panel.
Clamp the quarter outer panel into position.
NOTE: Refer to WELDED, BRAZED, AND RIVETED JOINT SPECIFICATIONS .

Spot weld (1) the quarter outer panel accordingly.

Fig 7: Positioning Body Side Outer Panel On Vehicle
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NOTE: Refer to WELDED, BRAZED, AND RIVETED JOINT SPECIFICATIONS .

Spot weld (SPP) the quarter outer panel (2) accordingly.

Fig 8: Identifying Spot Weld On Quarter Outer Panel
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MIG-braze (1) the quarter outer panel.
Rivet (3) on the quarter outer panel.
MIG-braze (1) the quarter outer panel.

Fig 9: Identifying Spot Weld (SPP) On Quarter Outer Panel
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MIG-braze (1) the quarter outer panel.

Fig 10: Identifying MIG-Braze On Quarter Outer Panel
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Grind MIG brazed seams.
Pre-flange wheel housing.
Using a suitable hammer, bend over the flanged edge 45° (1), at the same time holding a small mallet or block against it. Use structural adhesive in the area (2).

Fig 11: Bending Flanged Edge Using Tool
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Bend the wheel arch.

Fig 12: Bending Wheel Arch
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1. 22.1. Apply excess adhesive as a seam seal and corrosion protection using a spatula or flat paintbrush. Use structural adhesive in area (1).
2. 22.2. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to ANTI-CORROSION TREATMENT AND REPAIR (BASE) or ANTI-CORROSION TREATMENT AND REPAIR (CORROSION PROTECTION) .
Install all related panels and components.
1. 23.1. Install the rear side door. Refer to REAR SIDE DOOR REPLACEMENT .
2. 23.2. Install the rear side door weatherstrip - body side. Refer to REAR SIDE DOOR WEATHERSTRIP REPLACEMENT .
3. 23.3. Install the rear compartment floor panel carpet. Refer to REAR COMPARTMENT FLOOR PANEL CARPET REPLACEMENT .
4. 23.4. Install the rear bumper fascia. Refer to REAR BUMPER FASCIA REPLACEMENT .
Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION .
Enable the SIR system. Refer to SIR DISABLING AND ENABLING .