Spark

Rear End Panel Replacement

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

Warning: Refer to Glass and Sheet Metal Handling Warning in the Preface section.

1. Disable the SIR system. Refer to SIR Disabling and Enabling .
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Remove all related panels and components.
4. Visually inspect the damage. Repair as much of the damage as possible.
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .




Note: Note the number and location of welds for installation of the service assembly.

6. Locate and mark all the necessary factory welds of the body rear end panel.
7. Drill all factory welds.



8. Remove the body rear end panel.

Note: If the location of the original plug weld holes cannot be determined, space the plug weld holes every 40 mm (1 1/2 in).

1. Drill 8 mm (5/16 in) for plug welding along the edges of the body rear end panel as noted from the original panel.
2. Clean and prepare the attaching surfaces for welding.



3. Position the body rear end panel on the vehicle.
4. Verify the fit of the body rear end panel.
5. Clamp the body rear end panel into position.



6. Plug the weld accordingly.
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 all related panels and components.
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 .