GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2007 🢒 ION 🢒 Body Repair 🢒 Bolted Exterior Body Panels and Closures 🢒 Quarter Panel Replacement

Removal Procedure
  1. Remove the rear fascia. Refer to Rear Bumper Fascia Replacement .
  2. Remove the rear wheelhouse liner. Refer to Rear Wheelhouse Panel Liner Replacement .
  3. Remove the front and rear roof moldings. Refer to Roof Weld Joint Reveal Molding Replacement - Front or to Roof Weld Joint Reveal Molding Replacement - Rear .
  4. Remove the tail lamp. Refer to Tail Lamp Replacement .
  5. Remove the rocker panel moldings. Refer to Rocker Panel Molding Replacement .

    6. Object Number: 900017 Size: SH
  6. Remove the attaching bolts above and below the tail lamp.
  7. Remove the remaining attaching bolts/nuts/screws from the quarter panel. Pull the rear bottom of the quarter panel outward. Remove the quarter panel.

Installation Procedure
  1. If you are replacing the quarter panel with a new one, transfer the fascia mounting brackets and the fuel door to the new quarter panel.

    2. Object Number: 857957 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Secure the fuel door with bolts.

    3. Tighten
    Tighten the bolts to 2.8 N·m (25 lb in).


    Object Number: 859315 Size: SH
  3. Position the quarter panel to the body of the vehicle. Loosely install the bolts.
  4. Align the quarter panel with the rear door and compartment lid as necessary.
  5. Install the bolts to the quarter panel in the following order:
    6. 5.1. Install the bolt at the top of the quarter panel (1).

    Tighten
    Tighten the bolt to 10 N·m (89 lb in).

    5.2. Install the bolt at the bottom front of the quarter panel (2).

    Tighten
    Tighten the bolt to 10 N·m (89 lb in).

    5.3. Install the remaining bolts/nuts to the quarter panel.

    Tighten
    Tighten the bolts/nuts to 10 N·m (89 lb in).

    5.4. Install the screw at the top of the quarter panel.

    Tighten
    Tighten the screw to 10 N·m (89 lb in).

  6. Install the rocker panel moldings. Refer to Rocker Panel Molding Replacement .
  7. Install the tail lamp. Refer to Tail Lamp Replacement .
  8. Remove the front and rear roof moldings. Refer to Roof Weld Joint Reveal Molding Replacement - Front or to Roof Weld Joint Reveal Molding Replacement - Rear .
  9. Install the rear wheelhouse liner. Refer to Rear Wheelhouse Panel Liner Replacement .
  10. Install the rear fascia. Refer to Rear Bumper Fascia Replacement .