Body Side Inner Panel Extension Replacement Sedan

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 .

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 tail lights. Refer to Parking and Turn Signal Lamp Replacement .
6. Remove the spare wheel and emergency kit from the rear compartment.
7. Remove the spare wheel and tyre carrier. Refer to Spare Wheel Carrier Replacement .



8. Locate, mark and drill out the spot welds (1)in the side extension panel to the rear chassis rail.



9. Locate, mark and drill out the spot welds (1) in the side extension panel to the rear extension panel.



10. Locate, mark and drill out the spot welds (1) in the side extension panel to the rear extension panel.

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: Spot welding is the preferred method for attaching panels and should be used wherever possible. A puddle weld should be performed where your spot welder is unable to reach.




1. Apply the primary sealer (1) GM6449G or equivalent along the tail lamp filler panel and rear extension panel to the rear quarter panel.



2. Apply the primary sealer (1) GM6449G or equivalent along the inner side extension panel.



3. Apply the primary sealer (1) GM6449G or equivalent along the outer side extension panel.



4. Weld (1) the rear extension panel to the side extension panel.



5. Weld (1) the rear extension panel to the side extension panel.



6. Weld (1) the side extension panel to the rear chassis rail.
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 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 .
16. If re-programming is required. Refer to Control Module References .

Body Side Inner Panel Extension 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 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 rear bumper bracket. Refer to Rear Bumper Bracket Replacement.
10. Remove the liftgate weatherstrip. Refer to Liftgate Weatherstrip Replacement.
11. Remove the quarter inner trim finish panel. Refer to Quarter Inner Trim Finish Panel Replacement.
12. Remove the battery. Refer to Battery Replacement.
13. Remove the battery tray. Refer to Battery Tray Replacement.
14. Remove the pressure relief valve. Refer to Pressure Relief Valve Replacement.
15. Remove the tail lights. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement.
16. Remove the liftgate. Refer to Liftgate Replacement.
17. Remove the spare wheel and emergency kit from the rear compartment.
18. Remove the spare wheel carrier. Refer to Spare Wheel Carrier Replacement.
19. Remove the rear end filler panel. Refer to Rear End Panel Filler Replacement
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 welds for installation on the new body side inner panel extension.

21. Locate, mark and drill out the spot welds (1) in the body side inner panel extension to the rear chassis rail.




Important: Note the number and location of welds for installation on the new body side inner panel extension.

22. Locate, mark and drill out the spot welds (1) in the body side inner panel extension to the body side panel assembly.




Important: Note the number and location of welds for installation on the new body side inner panel extension.

23. Locate, mark and drill out the spot welds (1) in the body side inner panel extension to the body side panel assembly.




Important: Note the number and location of welds for installation on the new body side inner panel extension.

24. Locate, mark and drill out the spot welds (1) in the body side inner panel extension to the rear end panel assembly.
25. Remove the body side inner panel extension 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: Ensure that all factory welds are replaced in their original locations.

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

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: 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. Clean and prepare the mating surfaces of both parts of the body side panel assembly.

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.




3. Apply structural adhesive  (1) GM6449G or equivalent to the mating surfaces of the body side inner panel extension and rear end panel assembly.

Important: As the new body side inner panel extension is installed to the vehicle, structural adhesive should be visible on the outside edges of both surfaces (squeezed out when pushed together).

4. Position the new body side inner panel extension to the vehicle.



5. Weld (1) the body side inner panel extension to the rear end panel assembly.



6. Weld (1) the body side inner panel extension to the body side panel assembly.



7. Weld (1) the body side inner panel extension to the body side panel assembly.



8. Weld (1) the body side inner panel extension to the rear chassis rail.



9. Apply secondary sealer (1) GM9984532 or equivalent along the rear edge of the body side inner panel extension.



10. Apply secondary sealer  (1) GM9984532 or equivalent along the edge of the body side inner panel extension.



11. Apply secondary sealer (1) GM9984532 or equivalent to the rear compartment floor panel rail.



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