For 1990-2009 cars

### Removal Procedure

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 cargo liner. Refer to Cargo Box Liner Replacement .
4. Remove the rear wheelhouse liner. Refer to Rear Wheelhouse Panel Liner Replacement .
5. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
6. Remove the fuel tank. Refer to Fuel Tank Replacement .
7. Remove the body lock pillar trim. Refer to Body Lock Pillar Applique Replacement .
8. Remove the body side roof drip moulding. Refer to Body Side Roof Drip Molding Replacement .
9. Remove the endgate. Refer to Endgate Replacement .
10. Remove the tail lamps assemblies. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement .
11. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
12. Locate, mark and drill out the factory welds attaching the rear floor panel to the vehicle (1).

### Installation Procedure

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: 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. Weld the rear floor assembly to the vehicle (1).
4. Install the fuel tank. Refer to Fuel Tank Replacement .
5. Install the body side roof drip moulding. Refer to Body Side Roof Drip Molding Replacement .
6. Install the body lock pillar trim. Refer to Body Lock Pillar Applique Replacement .
7. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
8. Install the endgate. Refer to Endgate Replacement .
9. Install the tail lamps assemblies. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement .
10. Install the cargo liner. Refer to Cargo Box Liner Replacement .
11. Install the rear wheelhouse liner. Refer to Rear Wheelhouse Panel Liner Replacement .
12. Connect the negative battery cable to the vehicle. Refer to Battery Negative Cable Disconnection and Connection .
13. Enable the SIR system. Refer to SIR Disabling and Enabling .
14. If re-programming is required. Refer to Control Module References .