Rear End Panel Replacement. Chevrolet PJJ 2000

For 1990-2009 cars

The rear end panel is supplied as a complete assembly consisting of the following panels:

• | For Sunfire coupe only, 3 inner reinforcements and the rear end panel has a single reinforcement.

• | For Cavalier and Sunfire sedan only, 1 outer panel.

The taillight mounting panels attached to the outside corners of the rear end panel assembly are available separately.

Service for all these is performed at the factory seams.

### Removal Procedure

1. Remove all the related panels and components.
2. Visually inspect the panel for damage.

Restore as much of the damage as possible to the factory specifications.

3. Remove the following adhesives and components as needed:

• | The sealers

• | The sound deadeners

• | The corrosion materials

4. Perform the following actions on the factory welds:

4.1. | Locate

4.2. | Mark

Drill out

4.3. | Note the number of welds for installation of the service assembly.

5. Remove the damaged assembly.

### Installation Procedure

1. Prepare the mating surfaces.
2. Inspect the proper fit of the service assembly.
3. On the service assembly, drill plug weld holes 8 mm (5/16 in) as needed in the locations noted from the original assembly.
4. Position the service assembly in order to inspect the fit using body dimensions.

Plug weld accordingly with frequent measurements in order to ensure the proper fit.

5. Clean and prepare the welded surfaces.
6. Prime with two-part catalyzed primer.

Important: Prior to refinishing, refer to GM P/N 4901MD-99 Refinish Manual for recommended products.

7. Reinstall all the related panels and components.