GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Malibu 🢒 Body Repair 🢒 Collision Repair 🢒 Underbody Rear Side Rail 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. Object Number: 1200442 Size: SH
  3. Remove all related panels and components.
  4. Repair as much of the damaged area 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. Remove the inner and outer quarter panel to access the welds from the rail to the inner rocker panel area. Refer to Quarter Outer Panel Sectioning .
  7. Remove the filler rocker reinforcement inner panel.

    8. Object Number: 1333687 Size: SH
  8. Remove the shock reinforcement wheel house extension (1).

    9. Object Number: 1333695 Size: SH
  9. Locate and drill out all the necessary factory welds under the inner rocker reinforcement.

    10. Object Number: 1333700 Size: SH
  10. Locate and drill out all necessary factory welds to remove the five bar (1).

    11. Object Number: 1201069 Size: SH
  11. Remove the rear rail.

Installation Procedure

    Object Number: 1200456 Size: SH

    Important: If the location of the original plug weld holes cannot 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 for welding as necessary.
  3. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair .

    4. Object Number: 1201069 Size: SH

    Important: The service part includes a rear wheelhouse extension.

  4. Position the rear rail to the vehicle using 3-dimensional measuring equipment. Clamp the rail in place.

    5. Object Number: 1200442 Size: SH
  5. Plug weld accordingly.

    6. Object Number: 1333705 Size: SH
  6. Install the five bar (1).

    7. Object Number: 1333711 Size: SH
  7. Install the rear rocker inner panel reinforcement (1).
  8. Install the quarter panel.
  9. Install the inner panel.
  10. Install all of the related panels and components.
  11. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
  12. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
  13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  14. Enable the SIR system. Refer to SIR Disabling and Enabling .