Page 2641 of 3229
15. MIG braze the slots.
16. Dress the tack welds.
17. MIG weld the butt joint.
18. Dress all welded joints.
19. The installation of associated panels and mechanical
components is the reverse of removal.
Page 2642 of 3229

Publ is hed: 11-May-2011
Rear End Sheet Metal Repairs - Rear Side Member Section
Removal and Installation
Removal
• NOTE: The rear side member section is cut from the rear side member service panel. The section is approximately
410mm in length and is serviced with the rear side member lower extension.
• NOTE: It is necessary to remove the spare wheel well to allow access to the rear side member section.
1. The rear side member section is replaced in conjunction with:
Rear bumper cover
Re a r bumpe r a rma t ure
Back panel
Re a r bumpe r mo unt i ng
Inner back panel assembly
Re a r s i de me mbe r cl os i ng pa ne l .
Spare wheel well
Fuel t ank
Rear subframe and suspension assembly
2. Fo r a d d i t i o na l i nf o rma t i o n re l a t i ng t o t hi s re p a i r p ro ce d ure
please see the following:
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
St a nd a rd W o rks ho p P ra ct i ce s
(100-00 Ge ne ra l I nf o rma t i o n,
Description and Operation).
3. Re move t he re a r s i de me mbe r cl os i ng pa ne l .
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Rear Side Member Closing
Panel (501-30 Rear End Sheet Metal Repairs, Removal and
Installation).
4. Remove the rear subframe / suspension as an assembly.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Rear Subframe
(502-00
Uni-Body, Subframe and Mounting System, Removal and
Installation).
5. Remove the fuel tank.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Fuel Tank
(310-01A Fuel
Tank and Lines - I6 3.2L Petrol, Removal and Installation).
6. Mill out the spot welds.
Page 2643 of 3229
7. Saw cut the old panel at the point illustrated.
8. Separate the joints and remove the old panel.
Installation
1. NO TE: Ens ure t he re i s a 50mm mi ni mum s t a gge r be t we e n
the old side member and the new reinforcement section cuts.
Remove a section of reinforcement from the old panel:
1. Saw cut the reinforcement at the point illustrated,
do not cut through the side member.
2. Mil l out 5 s pot welds .
3. Se p a ra t e a nd re mo ve t he re i nf o rce me nt re mna nt .
2. NO TE: Ens ure t he re i s a 50mm mi ni mum s t a gge r be t we e n
the old side member and the new reinforcement section
cut s .
Remove the rear side member section from the service
panel:
1. Sa w cut t he s i de me mbe r a t t he poi nt
illustrated, do not cut through the
re i nf o rce me nt .
2. Mil l out 5 s pot welds .
3. Saw cut the reinforcement at the point
illustrated.
4. Se pa ra t e a nd re move t he s i de me mbe r s e ct i on.
3. Prepare the old and new panel joint surfaces.
Page 2644 of 3229
4. Drill holes in the new panel ready for MIG plug welding.
5. Offer up the new panel and clamp into position. Check
al ignment , i f correct , proceed t o next s t ep, i f not , rect i fy and
recheck before proceeding.
6. With panels clamped into position, tack weld the butt
joints.
7. Dress the tack welds.
Page 2645 of 3229
8. MIG weld the butt joints.
9. MIG pl ug we l d.
10. Dress all welded joints.
11. The installation of associated panels and mechanical
components is the reverse of removal.
Page 2646 of 3229

Publ is hed: 11-May-2011
Rear End Sheet Metal Repairs - Rear Side Member Closing Panel
Removal and Installation
Removal
• NOTE: The rear side member closing panel is serviced as a separate weld-on panel.
• NOTE: The panel is serviced less its weld studs.
• NOTE: It is necessary to remove the spare wheel well to allow access to the rear side member closing panel.
1. The rear side member closing panel is replaced in conjunction
with:
Rear bumper cover
Re a r bumpe r a rma t ure
Back panel
Re a r bumpe r mo unt i ng
Inner back panel assembly
Re a r s i de me mbe r s e ct i o n
Spare wheel well
Fuel t ank
Rear subframe and suspension assembly
2. Fo r a d d i t i o na l i nf o rma t i o n re l a t i ng t o t hi s re p a i r p ro ce d ure
please see the following:
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
St a nd a rd W o rks ho p P ra ct i ce s
(100-00 Ge ne ra l I nf o rma t i o n,
Description and Operation).
3. Re move t he re a r s i de me mbe r s e ct i on.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : R e a r Si d e Me mb e r Se ct i o n
(501-30 Rear End Sheet Metal Repairs, Removal and
Installation).
4. Remove the rear subframe / suspension as an assembly.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Rear Subframe
(502-00
Uni-Body, Subframe and Mounting System, Removal and
Installation).
5. Remove the fuel tank.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Fuel Tank
(310-01A Fuel
Tank and Lines - I6 3.2L Petrol, Removal and Installation).
6. Mill out the spot welds.
7. Separate the joints and remove the old panel.
Installation
1. Prepare the old and new panel joint surfaces.
Page 2647 of 3229
2. Drill hole in the new panel ready for MIG plug welding.
3. Offer up the new panel and clamp into position. Check
al ignment , i f correct , proceed t o next s t ep, i f not , rect i fy and
recheck before proceeding.
4. Remove the new panel.
5. Apply adhesive to the areas illustrated.
6. Offer up the new panel and clamp into position.
7. Sp o t w e l d .
8. MIG pl ug we l d.
Page 2648 of 3229
9. Install weld studs.
10. Dress all welded joints.
11. The installation of associated panels and mechanical
components is the reverse of removal.