Page 2649 of 3229

Publ is hed: 11-May-2011
Rear End Sheet Metal Repairs - Spare Wheel Well
Removal and Installation
Removal
• NOTE: The spare wheel well is serviced as a separate weld on panel, it includes the spare wheel retaining bracket but
not the crossmember.
• NOTE: The panel is serviced less its weld studs
1. The spare wheel well is replaced in conjunction with:
Rear bumper cover
Rear bumper
Back panel
Back panel assembly
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. Remove the back panel 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 : Back Panel
(501-30 Rear
End Sheet Metal Repairs, Removal and Installation).
4. Remove the rear subframe and suspension as an assembly.
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) /
Fuel Tank
(310-01B Fuel Tank and Li nes - TD4 2.2L Di es el,
Removal and Installation).
6. Remove the rear seat.
7. Remove the RH and LH rocker panel inner trims.
8. Remove the RH and LH rear quarter panel mouldings.
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 Quarter Panel
Moulding (501-08 Ext eri or Trim and Ornament at i on, Removal
and Installation).
9. Release and lay aside the carpet.
10. Remove the RH and LH brake pipes.
11. Release and lay aside the wiring harnesses at the floor panel
and inner quarter panels.
12. Mill out the spot welds.
Page 2650 of 3229
13. Separate the joints and remove the old panel.
Installation
1. Prepare the old and new panel joint surfaces.
2. Drill holes 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. MIG pl ug we l d.
5. Install weld studs.
6. Dress all welded joints.
Page 2651 of 3229
7. The installation of associated panels and mechanical
components is the reverse of removal.
Page 2652 of 3229

Publ is hed: 11-May-2011
Rear End Sheet Metal Repairs - Rear Wheelhouse Outer
Removal and Installation
Removal
• NOTE: The rear wheelhouse outer is serviced as a separate weld-on panel.
1. The rear wheelhouse outer is replaced in conjunction with:
Rear bumper cover
Quarter panel
Rear door
Quarter glass
I nne r q ua rt e r p a ne l
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 mo ve t he i nne r q ua rt e r p a 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 : Inner Quart er Panel
(501-30 Rear End Sheet Metal Repairs, Removal and
Installation).
4. Mill out the spot welds.
5. Separate the joints and remove the old panel.
Installation
1. Prepare the old and new panel joint surfaces.
Page 2653 of 3229
2. Drill holes in the new panel ready for MIG plug welding.
3. Offer up the new panel and clamp into position. Check
alignment, if correct, proceed to next step. If not, rectify 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. Tack weld the butt joints.
Page 2654 of 3229
8. Sp o t w e l d .
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 2655 of 3229

Publ is hed: 11-May-2011
Rear End Sheet Metal Repairs - Rear Bumper Mounting
Removal and Installation
Removal
• NOTE: The rear bumper mount ing i s s ervi ced as a s eparat e wel d-on panel.
1. The rear bumper mounting is replaced in conjunction with:
Rear bumper cover
Re a r bumpe r a rma t ure
Back panel
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. Remove the back panel.
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 : Back Panel
(501-30 Rear
End Sheet Metal Repairs, Removal and Installation).
4. Mill out the spot welds.
5. Separate the joints and remove the old panel.
Installation
1. Prepare the old and new panel joint surfaces.
Page 2656 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. Sp o t w e l d .
5. MIG pl ug we l d.
6. Dress all welded joints.
7. The installation of associated panels and mechanical
components is the reverse of removal.