GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Malibu 🢒 Body Repair 🢒 Collision Repair 🢒 Body Rear End Panel Replacement

Removal Procedure

    Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

    Important: Before beginning the repair, refer to Metal Panel Bonding for proper adhesive applicator preparations and general information.

  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: 1818907 Size: SH

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

  6. Locate and drill out all the necessary factory welds.

    7. Object Number: 1818911 Size: SH

    Important: The rear end panel comes complete with reinforceents. The panel is shingled on last for easy access.

  7. Remove the rear end panel.

Installation Procedure

    Object Number: 1818915 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. Clean and prepare all mating surfaces as necessary.

    3. Important: Remove excess weld and sealer

  3. Apply GM-approved Weld-Thru coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair .

    4. Object Number: 1818918 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: 1818920 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 .