Page 2836 of 3039

(414-01 Battery, Mounting and Cables, General Procedures).
6. Disconnect the generator electrical connectors.
7. Remove the windshield glass.
For additional information, refer to: Windshield Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
8. Remove the rear window glass.
For additional information, refer to: Rear Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
9. Remove the headliner.
For additional information, refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and Installation).
10. Remove the driver and passenger side front scuff plate trim panels.
For additional information, refer to: Front Scuff Plate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
11. Remove the driver and passenger side rear scuff plate trim panels.
For additional information, refer to: Rear Scuff Plate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
12. Remove the driver and passenger side air curtain modules.
For additional information, refer to: Side Air Curtain Module (501-20B Supplemental Restraint System, Removal and Installation).
13. Remove the rear seat backrest.
14. Remove the driver and passenger side rear safety belt retractors.
For additional information, refer to: Rear Safety Belt Retractor (501-20A Safety Belt System, Removal and Installation).
15. Remove the rear center safety belt retractor.
For additional information, refer to: Rear Center Safety Belt Retractor (501-20A Safety Belt System, Removal and Installation).
16. Remove the driver and passenger side RF filters.
17. Remove the diversity antenna module.
18. Remove the antenna.
For additional information, refer to: Navigation System Antenna (419-07 Navigation System, Removal and Installation).
19. Release and position the roof wiring harnesses to one side
20. Remove the driver and passenger side roof mouldings.
21. Drill out the spot welds.
Page 2893 of 3039

Interior Trim and Ornamentation, Removal and Installation).
9. Remove the front safety belt retractor.
For additional information, refer to: Front Safety Belt Retractor (501-20A Safety Belt System, Removal and Installation).
10. Remove the B-pillar side impact sensor.
For additional information, refer to: B-Pillar Side Impact Sensor (501-20B Supplemental Restraint System, Removal and Installation).
11. Remove the C-pillar side impact sensor.
For additional information, refer to: C-Pillar Side Impact Sensor (501-20B Supplemental Restraint System, Removal and Installation).
12. Release and position the floor covering to one side.
13. Release and position the inner rocker panel wiring harness to one side.
14. Remove the rear wheel and tire.
For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
15. Remove the rear fender splash shield.
16.
Remove the rocker panel outer moulding.
17. Remove the underfloor splash shield.
18. If the right-hand rocker panel is to be repaired, release and position the
underfloor wiring harness to one side.
19. Remove the front fender.
For additional information, refer to: Front Fender (501-27 Front End Sheet Metal Repairs, Removal and Installation).
20. Remove the front door.
Page 2903 of 3039

and Installation).
5. Disconnect the generator electrical connectors.
6. Remove the right-hand and left-hand front scuff plate trim panels.
For additional information, refer to: Front Scuff Plate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
7. Remove the front and rear door weatherstrips.
8. Remove the right-hand and left-hand rear scuff plate trim panels.
For additional information, refer to: Rear Scuff Plate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
9. Remove the headliner.
For additional information, refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and Installation).
10. Remove the side air curtain module.
For additional information, refer to: Side Air Curtain Module (501-20B Supplemental Restraint System, Removal and Installation).
11. Remove the rear seat cushion.
For additional information, refer to: Rear Seat Cushion (501-10 Seating, Removal and Installation).
12. Remove the rear seat backrest.
13. Release and position the roof wiring harness to one side.
14. Remove the roof moulding.
15. Remove the cowl side trim panel.
For additional information, refer to: Cowl Side Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
16. Remove the front safety belt retractor.
For additional information, refer to: Front Safety Belt Retractor (501-20A Safety Belt System, Removal and Installation).
17. Remove the B-pillar side impact sensor.
For additional information, refer to: B-Pillar Side Impact Sensor (501-20B Supplemental Restraint System, Removal and Installation).
18. Remove the C-pillar side impact sensor.
For additional information, refer to: C-Pillar Side Impact Sensor (501-20B Supplemental Restraint System, Removal and Installation).
19. Release and position the floor covering to one side.
20. Release and position the inner rocker panel wiring harness to one side.
21. Remove the rear wheel and tire.
For additional information, refer to: Wheel and Tire (204-04 Wheels and
Page 2916 of 3039

Interior Trim and Ornamentation, Removal and Installation).
9. Remove the front safety belt retractor.
For additional information, refer to: Front Safety Belt Retractor (501-20A Safety Belt System, Removal and Installation).
10. Remove the B-pillar side impact sensor.
For additional information, refer to: B-Pillar Side Impact Sensor (501-20B Supplemental Restraint System, Removal and Installation).
11. Remove the C-pillar side impact sensor.
For additional information, refer to: C-Pillar Side Impact Sensor (501-20B Supplemental Restraint System, Removal and Installation).
12. Release and position the floor covering to one side.
13. Release and position the inner rocker panel wiring harness to one side.
14. Remove the rocker panel outer moulding.
15. Remove the underfloor splash shield.
16. If the right-hand rocker panel front section is to be repaired, release and
position the underfloor wiring harness to one side.
17. Remove the front fender.
For additional information, refer to: Front Fender (501-27 Front End Sheet Metal Repairs, Removal and Installation).
18. Remove the front door.
For additional information, refer to: Front Door (501-03 Body Closures, Removal and Installation).
19. Remove the rear door.
For additional information, refer to: Rear Door (501-03 Body Closures, Removal and Installation).
20. Cut the new rocker panel front section from the new rocker panel service
panel.
Page 2925 of 3039
6. NOTES:
A drill bit suitable for drilling DP600 should be used.
There are spot welds located under the adhesive residue left by the
removal of the B-pillar reinforcement.
Drill out the spot welds.
7. Using a belt sander, release the rocker panel inner reinforcement from
the MAG welds at the points indicated.
Page 2932 of 3039

Interior Trim and Ornamentation, Removal and Installation).
9. Remove the front safety belt retractor.
For additional information, refer to: Front Safety Belt Retractor (501-20A Safety Belt System, Removal and Installation).
10. Remove the B-pillar side impact sensor.
For additional information, refer to: B-Pillar Side Impact Sensor (501-20B Supplemental Restraint System, Removal and Installation).
11. Remove the C-pillar side impact sensor.
For additional information, refer to: C-Pillar Side Impact Sensor (501-20B Supplemental Restraint System, Removal and Installation).
12. Release and position the floor covering to one side.
13. Release and position the inner rocker panel wiring harness to one side.
14. Remove the rear wheel and tire.
For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
15. Remove the rear fender splash shield.
16.
Remove the rocker panel outer moulding.
17. Remove the underfloor splash shield.
18. If the right-hand rocker panel rear section is to be repaired, release and
position the underfloor wiring harness to one side.
19. Remove the front door.
For additional information, refer to: Front Door (501-03 Body Closures, Removal and Installation).
20. Remove the rear door.
Page 2951 of 3039
33.
34. NOTE: The upper butt joint must be performed below
the 4 metal thickness parts of the door and rear window
apertures, (to enable spot welding back).
Cut the old panel at the points illustrated, allowing for
overlap, ensuring the final cut is performed below the 4
metal thickness parts of the door and rear window aperture.
NOTE: This procedure assumes that the door striker
reinforcement panel is undamaged. In this case, the
original remains on the vehicle and the new door striker
reinforcement panel is removed from the quarter panel
service panel and discarded.
Drill out the spot weld.
35. NOTE: Use a belt sander where there is no access to drill.
Drill out the spot welds.
Page 2961 of 3039
11. Release and lay aside the back panel and loadspace wiring harness.
12. Remove the rear bumper cover side retainer.
13. Remove the rear wheel and tire.
For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
14.
15. Remove the rear fender splash shield.
NOTE: Where applicable spot welds must be drilled
from the inside, this will enable the new panel to be spot
welded on installation. Use a belt sander where there is no
access to drill.
Drill out the spot welds.