GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2007 🢒 HHR 🢒 Body Repair 🢒 Collision Repair 🢒 Body Rear End Panel Replacement

Removal Procedure

    Caution: Refer to Approved Equipment for Collision Repair Caution 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. Repair as much of the damage as possible. Refer to Dimensions - Body .
  5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

    6. Object Number: 1591810 Size: SH

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

  6. Use a 10 mm to 12 mm spot weld remover when drilling out welds to the outer side areas of the rear end panel.

    7. Object Number: 1591814 Size: SH
  7. Drill out spot welds in lower end of the gutter.

    8. Object Number: 1591819 Size: SH
  8. Pry the lower edge to expose hidden welds under the gutter.
  9. Drill out hidden spot welds under the gutter.
  10. Locate and drill out all remaining factory welds using an 8 mm (5/16 in) spot weld cutter.

    11. Object Number: 1591823 Size: SH
  11. Remove the rear end panel.

Installation Procedure

    Object Number: 1591825 Size: SH

    Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1½ in) apart.

  1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
  2. Prepare all mating surfaces as necessary.
  3. Apply 3M® Weld-Thru coating P/N 05916 or equivalent to all mating surfaces.

    4. Object Number: 1591823 Size: SH
  4. Position the rear end panel on the vehicle. Use 3-dimensional measuring equipment to inspect the panel.
  5. Clamp the panel in place.

    6. Object Number: 1591810 Size: SH
  6. Plug weld accordingly.
  7. Clean and prepare all of the welded surfaces.
  8. Install all of the related panels and components.
  9. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
  10. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
  11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  12. Enable the SIR system. Refer to SIR Disabling and Enabling .