Body Tail Lamp Filler 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 end trim finish panel. Refer to Rear End Trim Finish Panel Replacement.
4. Remove the rear compartment floor panel carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
5. Remove the load floor stationary panel carpet. Refer to Load Floor Stationary Panel Carpet Replacement.
6. Remove the load floor front panel carpet. Refer to Load Floor Front Panel Carpet Replacement.
7. Remove the liftgate weatherstrip. Refer to Liftgate Weatherstrip Replacement.
8. Remove the quarter inner trim finish panel. Refer to Quarter Inner Trim Finish Panel Replacement.
9. Remove the battery. Refer to Battery Replacement.
10. Remove the battery tray. Refer to Battery Tray Replacement.
11. Remove the liftgate. Refer to Liftgate Replacement.
12. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement.
13. Remove the tail lamp. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement.
14. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.




Important: Measure from the centre of the datum hole to create an accurate cut line.

15. Mark a horizontal sectioning line 16 mm above datum point  (1) on the Tail Lamp Filler Panel. Datum point  (1) is a 10 mm dia hole in the Tail Lamp Filler Panel.




Important: Do not damage any inner panels or reinforcements.

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

Important: Only remove welds below the sectioning line.

16. Locate, mark and drill out the spot welds  (1) that attach the body tail lamp filler panel lower section to vehicle body.




Important: Only cut through the Tail Lamp Filler Panel. Do not damage any inner panels or reinforcements.

17. Cut along the cut line (1) on the body side outer panel with a suitable cutting tool.
18. Remove the body tail lamp filler panel lower portion of 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.

1. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted when disassembling.
2. Cut the new Tail Lamp Filler Panel in corresponding locations to fit the remaining original Tail Lamp Filler Panel. The sectioning joint should be trimmed to allow a gap of one-and-one-half-times the metal thickness at the sectioning joint.
3. Clean and prepare the mating surfaces of the body tail lamp filler panel and the body side panel assembly.
4. Align the body Tail Lamp Filler Panel repair section to the vehicle using three dimensional measuring equipment. Refer to Dimensions - Body



5. Weld the body tail lamp filler panel repair section  (1) to the vehicle body.




Important: To create a solid weld with minimum heat distortion, make 25 mm (1 in) stitch welds along the seam with 25 mm (1 in) gaps between them.

6. Stitch weld the Tail Lamp Filler Panel repair section to the vehicle body at the sectioning location.



7. Apply secondary sealer GM9984532 or equivalent to the edge of the body tail lamp filler panel  (1).



8. Apply secondary sealer GM9984532 or equivalent to the edge of the body tail lamp filler panel (1).
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. Install the tail lamp. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement.
12. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement.
13. Install the liftgate. Refer to Liftgate Replacement.
14. Install the battery tray. Refer to Battery Tray Replacement.
15. Install the battery. Refer to Battery Replacement.
16. Install the quarter inner trim finish panel. Refer to Quarter Inner Trim Finish Panel Replacement.
17. Install the liftgate weatherstrip. Refer to Liftgate Weatherstrip Replacement.
18. Install the load floor front panel carpet. Refer to Load Floor Front Panel Carpet Replacement.
19. Install the load floor stationary panel carpet. Refer to Load Floor Stationary Panel Carpet Replacement.
20. Install the rear compartment floor panel carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
21. Install the rear end trim finish panel. Refer to Rear End Trim Finish Panel Replacement.
22. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
23. Enable the SIR system. Refer to SIR Disabling and Enabling.