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 Front Wheelhouse Liner Replacement .
5. Remove the tail lamp assemblies. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement .
6. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
7. Remove the endgate. Refer to Endgate Replacement .
8. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

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

9. Locate, mark and drill out the spot welds in the rear bumper fascia centre support to the rear end panel assembly (1).
10. Note and mark the location of the aligning notch (2).

### 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 spot weld holes cannot be determined, or if structural weld-thru adhesive is present, space the puddle weld holes every 32 mm (1¼ in).

1. Clean and prepare the mating surfaces of both parts of the panel.

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.

2. Align the rear bumper fascia centre support assembly alignment notch (2) and weld to rear end panel assembly (1).
3. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
4. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
5. Install the endgate. Refer to Endgate Replacement .
6. Install the tail lamp assemblies. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement .
7. Install the rear wheelhouse liner. Refer to Front Wheelhouse Liner Replacement .
8. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
9. Install the cargo liner. Refer to Cargo Box Liner Replacement .
10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
11. Enable the SIR system. Refer to SIR Disabling and Enabling .