GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Lumina Ute 🢒 Body Repair 🢒 Collision Repair 🢒 Body Side Outer Panel Extension Replacement

Removal Procedure

    Caution: Refer to Approved Equipment for Collision Repair 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 .

    2. 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 wheelhouse liner. Refer to Front Wheelhouse Liner Replacement .
  5. Remove the cargo liner. Refer to Cargo Box Liner Replacement .
  6. Remove the tail lamp assemblies. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement .

    7. Object Number: 2015526 Size: SH
  7. Locate, mark and drill out the spot welds in the lower extension panel to the body side (1).

Installation procedure

    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 spot weld holes can not be determined, or if structural weld-thru adhesive is present, space the puddle weld holes every 32 mm (1¼ in).

    Important: Secondary sealer must be applied to the perimeter of all flanges. Secondary sealer must be applied to all welds/joints that were originally covered by secondary sealer.


    Object Number: 2017907 Size: SH
  1. Apply the primary sealer along the lower extension panel to the body side (1).
  2. Position the lower extension panel to the vehicle.

    3. Object Number: 2017905 Size: SH
  3. Weld the lower extension panel to the body side (1).
  4. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
  5. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
  6. Install the tail lamp assemblies. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement .
  7. Install the cargo liner. Refer to Cargo Box Liner Replacement .
  8. Install the rear wheelhouse liner. Refer to Front Wheelhouse Liner Replacement .
  9. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
  10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  11. Enable the SIR system. Refer to SIR Disabling and Enabling .