Page 710 of 1007
SEATS
REPAIRS 76-5-15
9.Release squab from arm rest aperture.
10.Release squab from seat belt aperture and rear
of frame.
11.Release squab from sides and bottom of frame.
Release latch escutcheon and remove back
cloth.12.Release and remove 4 head restraint guide
tubes.
13.Release squab lock warning button
escutcheon.
14.Remove squab cover and pad from frame.
Page 711 of 1007

SEATS
76-5-16 REPAIRS
15.Remove and discard 12 hog rings and remove
cover from pad.
Refit
1.Position squab cover to pad and secure hog
rings.
2.Fit squab cover and pad to frame.
3.Fit head restraint guide tubes and seat lock
warning button escutcheon.
4.Fit cover to sides and bottom of frame.
5.Fit cover to rear of frame and seat belt aperture.
6.Position latch escutcheon to back cloth and fit
to frame. Ensure that the latch escutcheon is
secured correctly into latch housing.
7.Fit cover to arm rest aperture.
8.Fit arm rest and tighten screws.
9.Fit arm rest aperture trim.
10.Fit head restraints.
11.Fit cushion to squab and tighten Torx bolts.
12.Fit side covers and tighten screws.
13.Position seat belt reel in seat squab and tighten
nut to 32 Nm (24 lbf.ft).
14.Fit seat belt reel cover and tighten screws.
15.Secure rear seat in locked position.
Cover - squab - rear single seat - 3 door
$% 78.90.85
Remove
1.Remove rear seat assembly.
+ SEATS, REPAIRS, Cushion & squab
- rear seat - bench type - 3 door.
2.Remove 2 screws securing console cover and
remove cover.
3.Remove 4 screws and remove rear seat centre
console.
4.Remove 4 screws securing end covers and
remove covers.
5.Remove 4 Torx bolts and remove squab
assembly from cushion assembly.
Page 712 of 1007
SEATS
REPAIRS 76-5-17
6.Release back board assembly from squab
frame and remove back board.
7.Remove head restraint
8.Release bottom of squab cover from frame.
9.Release sides of squab cover from frame.10.Raise cover and pad to access head restraint
guide tubes.
11.Remove guide tubes.
12.Release cover from top of frame.
13.Remove cover and pad.
Page 713 of 1007
SEATS
76-5-18 REPAIRS
14.Release cover from pad, remove and discard 5
hog rings.
15.Remove cover from pad.Refit
1.Position cushion cover to pad and secure with
hog rings.
2.Fit cover to pad.
3.Secure cover to top of frame.
4.Fit guide tubes.
5.Secure sides and bottom of cover to frame.
6.Fit head restraint.
7.Fit cushion to squab and tighten Torx bolts to
28 Nm (21 lbf.ft).
8.Position back board and secure to frame.
9.Fit end covers and tighten screws.
10.Position rear seat console and secure with
screws.
11.Position console cover and secure with screws.
12.Fit rear seat.
+ SEATS, REPAIRS, Cushion & squab
- rear seat - bench type - 3 door.
Page 795 of 1007

PANEL REPAIRS
77-2-40 REPAIRS
'A' post - 3 door
In this procedure, the front outer body side panel is
replaced in conjunction with the inner 'A' post and the
'A' post reinforcements.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove front wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
6.Remove front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
7.Remove front door.
+ DOORS, REPAIRS, Door assembly
- front - remove for access & refit.
8.Remove front seat.
+ SEATS, REPAIRS, Front seat.
9.Remove fascia.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
10.Remove duct of outboard face level ventilator.
11.Remove headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 3 door.
12.Remove windscreen.
+ SCREENS, REPAIRS, Windscreen.
13.Remove treadplate from front door aperture.
Release front carpet and position aside.
14.Remove front door aperture seal.
15.Remove engine bulkhead insulation.
16. Driver's side: Remove passenger
compartment fuse box.
Repair1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Page 796 of 1007

PANEL REPAIRS
REPAIRS 77-2-41
Refit
1. Driver's side: Fit passenger compartment fuse
box.
2.Fit insulation pads to engine bulkhead.
3.Fit front door aperture seal.
4.Position front carpet and fit treadplate to front
door aperture.
5.Fit windscreen.
+ SCREENS, REPAIRS, Windscreen.
6.Fit headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 3 door.
7.Fit duct of outboard face level ventilator.
8.Fit fascia.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
9.Fit front seat.
+ SEATS, REPAIRS, Front seat.
10.Fit front door.
+ DOORS, REPAIRS, Door assembly
- front - remove for access & refit.
11.Fit front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
12.Fit front wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
13.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
14.Connect all ECUs.
15.Connect alternator.
16.Connect battery earth lead.
'A' post - 5 door
In this procedure, the front outer body side panel is
replaced in conjunction with the inner 'A' post and the
'A' post reinforcements.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove front wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
6.Remove front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
7.Remove front door.
+ DOORS, REPAIRS, Door assembly
- front - remove for access & refit.
8.Remove front seat.
+ SEATS, REPAIRS, Front seat.
9.Remove fascia.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
10.Remove duct of outboard face level ventilator.
11.Remove headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.
12.Remove windscreen.
+ SCREENS, REPAIRS, Windscreen.
13.Remove treadplate from front door aperture.
Release front carpet and position aside.
14.Remove front door aperture seal.
15.Remove engine bulkhead insulation.
16. Driver's side: Remove passenger
compartment fuse box.
Page 797 of 1007

PANEL REPAIRS
77-2-42 REPAIRS
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1. Driver's side: Fit passenger compartment fuse
box.
2.Fit insulation pads to engine bulkhead.
3.Fit front door aperture seal.
4.Position front carpet and fit treadplate to front
door aperture.
5.Fit headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.
6.Fit windscreen.
+ SCREENS, REPAIRS, Windscreen.
7.Fit duct of outboard face level ventilator.
8.Fit fascia.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
9.Fit front seat.
+ SEATS, REPAIRS, Front seat.
10.Fit front door.
+ DOORS, REPAIRS, Door assembly
- front - remove for access & refit.
11.Fit front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
12.Fit front wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
13.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
14.Connect all ECUs.
15.Connect alternator.
16.Connect battery earth lead.
Page 798 of 1007

PANEL REPAIRS
REPAIRS 77-2-43
Sill reinforcement - 3 door
In this procedure, the lower outer body side panel is
replaced in conjunction with the sill reinforcement.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
6.Remove front door.
+ DOORS, REPAIRS, Door assembly
- front - remove for access & refit.
7.Remove front seat.
+ SEATS, REPAIRS, Front seat.
8.Remove rear seat.
+ SEATS, REPAIRS, Rear seat - LH.
+ SEATS, REPAIRS, Rear seat - RH.
9.Remove treadplate from front door aperture.
10.Remove side door aperture seal.
11.Remove rear body side casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - body side - rear - 3
door.
12.Release carpet from inner sill and position
aside.
13.Release vehicle harness from inner sill and
position aside.
Repair1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Secure vehicle harness to inner sill.
2.Position carpet to inner sill.
3.Fit rear body side casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - body side - rear - 3
door.
4.Fit side door aperture seal(s).
5.Fit treadplate to side door aperture(s).
6.Fit rear seat.
+ SEATS, REPAIRS, Rear seat - LH.
+ SEATS, REPAIRS, Rear seat - RH.
7.Fit front seat.
+ SEATS, REPAIRS, Front seat.
8.Fit front door.
+ DOORS, REPAIRS, Door assembly
- front - remove for access & refit.
9.Fit front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
10.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
11.Connect all ECUs.
12.Connect alternator.
13.Connect battery earth lead.