Rear End Panel Replacement LWB

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

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

Important: This panel is replaced at factory seams.

Caution: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle and cause personal injury if the vehicle is in a collision.

1. Disable the SIR system. Refer to SIR Disabling and Enabling .

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
4. Remove the rear impact bar. Refer to Rear Bumper Impact Bar Replacement .
5. Remove the rear impact bar bracket. Refer to Rear Bumper Bracket Replacement .
6. Remove the tail lights. Refer to Parking and Turn Signal Lamp Replacement .
7. Remove the spare wheel and emergency kit from the rear compartment.
8. Remove the rear lock striker. Refer to Rear Compartment Lid Latch Striker Replacement .
9. Remove the spare wheel and tyre carrier. Refer to Spare Wheel Carrier Replacement .
10. Repair as much of the damage as possible.
11. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

Important: Note the number and location of the factory welds for installation of the rear end panel.




12. Locate, mark and drill out the spot welds in the rear end panel assembly to the tail lamp filler panel. Repeat for opposite side.
13. Locate, mark and drill out the spot welds in the rear end panel assembly to the rear chassis rail. Repeat for opposite side.



14. Locate, mark and drill out the spot welds (1) of the rear end panel assembly to the side extension. Repeat for opposite side.
15. Remove the rear end panel.

1. Prepare all mating surfaces as necessary.



2. Weld (1) the rear end panel assembly to the side extension. Repeat for opposite side.



3. Weld (2) the rear end panel assembly to the rear chassis rail. Repeat for opposite side.
4. Weld (1) the rear end panel assembly to the tail lamp filler panel. Repeat for opposite side.
5. Clean all of the welded surfaces.
6. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
7. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
8. Install the spare wheel and tyre carrier. Refer to Spare Wheel Carrier Replacement .
9. Install the rear lock striker. Refer to Rear Compartment Lid Latch Striker Replacement .
10. Install the tail lights. Refer to Parking and Turn Signal Lamp Replacement .
11. Install the rear impact bar. Refer to Rear Bumper Fascia Insert Replacement .
12. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
13. Install the spare wheel and emergency kit from the rear compartment.

Caution: Refer to Battery Disconnect Caution in the Preface section.

14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
15. Enable the SIR system. Refer to SIR Disabling and Enabling .

Rear End Panel Replacement SWB

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

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

Important: This panel is replaced at factory seams.

Caution: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle and cause personal injury if the vehicle is in a collision.

1. Disable the SIR system. Refer to SIR Disabling and Enabling .

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
4. Remove the rear impact bar. Refer to Rear Bumper Impact Bar Replacement .
5. Remove the rear impact bar bracket. Refer to Rear Bumper Bracket Replacement .
6. Remove the tail lights. Refer to Parking and Turn Signal Lamp Replacement .
7. Remove the spare wheel and emergency kit from the rear compartment.
8. Remove the rear lock striker. Refer to Rear Compartment Lid Latch Striker Replacement in Body Rear End.
9. Remove the spare wheel and tyre carrier. Refer to Spare Wheel Carrier Replacement .
10. Repair as much of the damage as possible.
11. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

Important: Note the number and location of the factory welds for installation of the rear end panel.




12. Locate, mark and drill out the spot welds in the rear end panel assembly to the tail lamp filler panel. Repeat for opposite side.
13. Locate, mark and drill out the spot welds in the rear end panel assembly to the rear chassis rail. Repeat for opposite side.



14. Locate, mark and drill out the spot welds (1) of the rear end panel assembly to the side extension. Repeat for opposite side.
15. Remove the rear end panel.

1. Prepare all mating surfaces as necessary.



2. Align the rear end panel assembly using the datum points (1) and (2) to the vehicle.



3. Weld (1) the rear end panel assembly to the side extension. Repeat for opposite side.



4. Weld (1) the rear end panel assembly to the rear chassis rail. Repeat for opposite side.
5. Weld the rear end panel assembly to the tail lamp filler panel. Repeat for opposite side.
6. Clean and prepare all of the welded surfaces.
7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
8. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
9. Install the spare wheel and tyre carrier. Refer to Spare Wheel Carrier Replacement .
10. Install the rear lock striker. Refer to Rear Compartment Lid Latch Striker Replacement in Body Rear End.
11. Install the tail lights. Refer to Parking and Turn Signal Lamp Replacement .
12. Install the rear impact bar. Refer to Rear Bumper Fascia Insert Replacement .
13. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
14. Install the spare wheel and emergency kit from the rear compartment.

Caution: Refer to Battery Disconnect Caution in the Preface section.

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 in SIR.
17. If re-programming is required. Refer to Control Module References .

Rear End Panel Replacement Sportwagon

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

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

1. Disable the SIR system. Refer to SIR Disabling and Enabling.

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement.
4. Remove the rear bumper impact bar. Refer to Rear Bumper Impact Bar Replacement.
5. Remove the rear end trim finish panel. Refer to Rear End Trim Finish Panel Replacement.
6. Remove the rear compartment floor panel carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
7. Remove the load floor stationary panel carpet. Refer to Load Floor Stationary Panel Carpet Replacement.
8. Remove the load floor front panel carpet. Refer to Load Floor Front Panel Carpet Replacement.
9. Remove the liftgate latch striker. Refer to Liftgate Latch Striker Replacement.
10. Remove the rear bumper impact bar bracket. Refer to Rear Bumper Bracket Replacement.
11. Remove the liftgate weatherstrip. Refer to Liftgate Weatherstrip Replacement.
12. Remove the quarter inner trim finish panel. Refer to Quarter Inner Trim Finish Panel Replacement.
13. Remove the battery. Refer to Battery Replacement.
14. Remove the battery tray. Refer to Battery Tray Replacement.
15. Remove the pressure relief valve. Refer to Pressure Relief Valve Replacement.
16. Remove the tail lights. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement.
17. Remove the liftgate. Refer to Liftgate Replacement.
18. Remove the spare wheel and emergency kit from the rear compartment.
19. Remove the spare wheel carrier. Refer to Spare Wheel Carrier Replacement.

Important: Note the location of sealers and anti-corrosion materials for installation of the service assembly.

20. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.




Important: Note the number and location of the factory welds for installation of the service assembly.

21. Locate, mark and drill out the factory welds attaching the rear end panel assembly to the back body pillar inner lower panel and rear compartment floor panel extension (1).
22. Repeat for the opposite side.



23. Locate, mark and drill out the factory welds attaching the rear end panel assembly to the body tail-lamp filler panel and rear compartment floor panel rail (1).
24. Repeat for the opposite side.



25. Locate, mark and drill out the factory welds attaching the rear end panel assembly to the rear compartment floor panel outer extension (1).
26. Repeat for the opposite side.
27. Remove the rear end panel assembly from the vehicle.

Important: Spot welding is the preferred method for attaching panels and should be used whenever possible. A plug weld should only be performed where spot welding is not possible.

Important: If the location of the original plug weld holes cannot be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 32 mm (1¼ in).

Important: Ensure that all factory welds are replaced in their original locations.

Important: Ensure that all structural adhesives and sealers are replaced in their original locations.

Important: Follow the adhesive manufacturer's instructions during the assembly process. Heat must be applied as per the manufacturer's specifications to cure the adhesives and to expand the sealing baffles.

Important: Secondary sealer must be applied to the perimeter of all flanges and over all joints.

1. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted when dissembling.

Important: Clean all adhesive mating surfaces in accordance with the adhesive manufacturer's specifications.

2. Clean and prepare the mating surfaces of the rear end panel assembly.
3. Repeat for the opposite side.



4. Apply the approved structural adhesive (1) GM6449G or equivalent along the outer edge of the rear compartment floor panel outer extension.

Important: As the rear end panel assembly is installed to the vehicle, structural adhesive should be visible on the outside edges of both surfaces (squeezed out when pushed together).

5. Install the rear end panel assembly to the vehicle.



6. Weld the rear end panel assembly to the rear compartment floor panel outer extension (1).
7. Repeat for the opposite side.



8. Weld the rear end panel assembly to the body tail-lamp filler panel and the rear compartment floor panel rail (1).
9. Repeat for the opposite side.



10. Weld the rear end panel assembly to the back body pillar inner lower panel and the rear compartment floor panel extension (1).
11. Repeat for the opposite side.



12. Apply secondary sealer (1) GM9984532 or equivalent along the rear edge of the rear compartment floor panel outer extension.
13. Repeat for the opposite side.



14. Apply secondary sealer (1) GM9984532 or equivalent to the rear compartment floor panel rail.
15. Repeat for the opposite side.



16. Apply secondary sealer (1) GM9984532 or equivalent to the body tail-lamp filler panel.
17. Repeat for the opposite side.



18. Apply secondary sealer (1) GM9984532 or equivalent to the body tail-lamp filler panel.
19. Repeat for the opposite side.
20. Apply anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
21. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
22. Install the spare wheel carrier. Refer to Spare Wheel Carrier Replacement.
23. Install the spare wheel and emergency kit to the rear compartment.
24. Install the liftgate. Refer to Liftgate Replacement.
25. Install the tail lights. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement.
26. Install the pressure relief valve. Refer to Pressure Relief Valve Replacement.
27. Install the battery tray. Refer to Battery Tray Replacement.
28. Install the battery. Refer to Battery Replacement.
29. Install the quarter inner trim finish panel. Refer to Quarter Inner Trim Finish Panel Replacement.
30. Install the liftgate weatherstrip. Refer to Liftgate Weatherstrip Replacement.
31. Install the rear bumper impact bar bracket. Refer to Rear Bumper Bracket Replacement.
32. Install the liftgate latch striker. Refer to Liftgate Latch Striker Replacement.
33. Install the load floor front panel carpet. Refer to Load Floor Front Panel Carpet Replacement.
34. Install the load floor stationary panel carpet. Refer to Load Floor Stationary Panel Carpet Replacement.
35. Install the rear compartment floor panel carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
36. Install the rear end trim finish panel. Refer to Rear End Trim Finish Panel Replacement.
37. Install the rear bumper impact bar. Refer to Rear Bumper Impact Bar Replacement.
38. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement.
39. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
40. Enable the SIR system. Refer to SIR Disabling and Enabling.