GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

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

  1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

  3. Object Number: 1686638  Size: SH
  4. Remove all related panels and components.
  5. Restore as much of the damage as possible to factory specifications. Refer to Dimensions - Body .
  6. Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

  7. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
  8. Perform the necessary procedures to gain access to repair. Refer to Quarter Panel Replacement .
  9. Important: Do not damage any inner panels or reinforcements.

  10. Trim off the damaged rear wheelhouse to gain access to the weld flange.
  11. Locate and drill out all factory welds. Note the number and location of welds for installation of the rear outer wheelhouse.
  12. Remove the damaged rear outer wheelhouse.

Installation Procedure


    Object Number: 680983  Size: SH

    Important: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 40 mm (1 ½ in) apart.

  1. Drill 8 mm (5/16 in) plug weld holes as necessary in locations noted from the original rear outer wheelhouse.
  2. Prepare all mating surfaces as necessary.
  3. Apply 3M® Weld-Thru coating P/N 05916 or equivalent to all mating surfaces

  4. Object Number: 1686638  Size: SH
  5. Position the rear outer wheelhouse.
  6. Plug weld accordingly.
  7. Complete the necessary procedures. Refer to Quarter Panel Replacement .
  8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
  9. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
  10. Install all related panels and components.
  11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  12. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.