For 1990-2009 cars

### Removal Procedure

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.

### Installation Procedure

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 .