Page 807 of 1007
PANEL REPAIRS
77-2-52 REPAIRS
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.
2.Arrow A is shown to highlight the fact that there
are plug welds on the other side of the inner
wheel arch as well. These are to weld the rear
longitudinal to the inner wheel arch.
Refit
1. LH side: Fit tail door striker to 'E' post.
2. RH side: Fit fuel tank.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.
3. RH side: Fit fuel filler neck.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Filler neck.
4. RH side: Fit tail door.
+ DOORS, REPAIRS, Door - tail
assembly - remove for access & refit.
5.Secure vehicle harness to rear quarter.
6.Fit rear damper.
+ REAR SUSPENSION, REPAIRS,
Damper.
7.Fit rear body side glass.
+ SCREENS, REPAIRS, Glass - body
side - rear.
8.Fit headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.9.Fit rear seat.
+ SEATS, REPAIRS, Rear seat - LH.
+ SEATS, REPAIRS, Rear seat - RH.
10.Fit loadspace carpet.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
11.Fit rear side seat belt.
+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - rear - LH.
12.Fit rear quarter upper casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - upper
- 5 door.
13.Fit rear quarter lower casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
14.Fit tail lamp.
+ LIGHTING, REPAIRS, Lamp
assembly - tail.
15.Fit roof panel finisher.
+ EXTERIOR FITTINGS, REPAIRS,
Moulding - roof - 5 door.
16.Fit tail door aperture seal.
17.Fit tail door glass side finisher.
+ DOORS, REPAIRS, Finisher - rear
screen - side - 5 door.
18.Fit tail door glass upper finisher.
19.Secure carpet to inner sill and rear heelboard.
20.Fit rear door aperture seal.
21.Fit treadplate to rear door aperture.
22.Fit rear door striker to 'D' post.
23.Fit rear wheel arch liner.
24.Fit rear bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper valance - rear - up to 04MY.
25.Fit sill lower finisher.
+ EXTERIOR FITTINGS, REPAIRS,
Finisher - sill - lower.
26.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
27.Connect all ECUs.
28.Connect alternator.
29.Connect battery earth lead.
Page 808 of 1007
PANEL REPAIRS
REPAIRS 77-2-53
Outer rear wheel arch - 3 door
In this procedure, the squab side reinforcement is
replaced in conjunction with the outer rear wheel
arch.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove rear bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper valance - rear - up to 04MY.
6.Remove rear wheel arch liner.
7.Remove rear quarter lower casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 3 door.
8.Remove rear seat.
+ SEATS, REPAIRS, Rear seat - LH.
+ SEATS, REPAIRS, Rear seat - RH.
9.Remove rear body side casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - body side - rear - 3
door.
10.Remove rear damper.
+ REAR SUSPENSION, REPAIRS,
Damper.
11. RH side: Remove fuel filler neck.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Filler neck.
12. RH side: Remove fuel tank.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.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. RH side: Fit fuel tank.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.
2. RH side: Fit fuel filler neck.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Filler neck.
3.Fit rear damper.
+ REAR SUSPENSION, REPAIRS,
Damper.
4.Fit rear body side casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - body side - rear - 3
door.
5.Fit rear seat.
+ SEATS, REPAIRS, Rear seat - LH.
+ SEATS, REPAIRS, Rear seat - RH.
6.Fit rear quarter lower casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 3 door.
7.Fit rear wheel arch liner.
8.Fit rear bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper valance - rear - up to 04MY.
9.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
10.Connect all ECUs.
11.Connect alternator.
12.Connect battery earth lead.
Page 809 of 1007
PANEL REPAIRS
77-2-54 REPAIRS
Outer rear wheel arch - 5 door
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove rear bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper valance - rear - up to 04MY.
6.Remove rear wheel arch liner.
7.Remove rear quarter lower casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
8.Remove rear seat.
+ SEATS, REPAIRS, Rear seat - LH.
+ SEATS, REPAIRS, Rear seat - RH.
9.Remove rear damper.
+ REAR SUSPENSION, REPAIRS,
Damper.
10. RH side: Remove fuel filler neck.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Filler neck.
11. RH side: Remove fuel tank.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.
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. RH side: Fit fuel tank.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.
2. RH side: Fit fuel filler neck.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Filler neck.
3.Fit rear damper.
+ REAR SUSPENSION, REPAIRS,
Damper.
4.Fit rear seat.
+ SEATS, REPAIRS, Rear seat - LH.
+ SEATS, REPAIRS, Rear seat - RH.
5.Fit rear quarter lower casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
6.Fit rear wheel arch liner.
7.Fit rear bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper valance - rear - up to 04MY.
8.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
9.Connect all ECUs.
10.Connect alternator.
11.Connect battery earth lead.