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21. NOTE: Where applicable spot welds must be drilled from the
inside, this will enable the new panel to be spot welded on installation.
The lowest spot weld to the quarter panel lower extension has to be
drilled from outside and MAG plug welded on installation.
Drill out the spot welds.
22. Separate the joints and remove the old panel.
Installation
1. Prepare the old and new panel joint surfaces.
2. Offer up the new panel and clamp into position. Check alignment, if
correct, proceed to next step, if not rectify and recheck before
proceeding.
3. Remove the new panel.
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(100-00 General Information, Description and Operation) /
Body Repairs (501-25A Body Repairs - General Information, Description and Operation) /
Corrosion Protection (501-25B Body Repairs - Corrosion Protection, Description and Operation) /
Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
4. Remove the rear wheel and tire.
For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
5. Remove the rear fender splash shield.
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Removal and Installation).
7. Remove the battery.
For additional information, refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
8. Disconnect the generator electrical connectors.
9. If the left-hand rear quarter panel is to be repaired, remove the
loadspace left-hand trim panel.
For additional information, refer to: Loadspace Trim Panel LH (501-05 Interior Trim and Ornamentation, Removal and Installation).
10. If the right-hand rear quarter panel is to be repaired, remove the
auxiliary junction box (AJB).
For additional information, refer to: Auxiliary Junction Box (AJB) (418-00 Module Communications Network, Removal and Installation).
11. Remove any electrical components in the local area of repair to prevent
damage.
12. Remove the rear muffler.
For additional information, refer to: Rear Muffler (309-00C Exhaust System - V8 5.0L Petrol/V8 S/C 5.0L Petrol, Removal and Installation) /
Rear Muffler (309-00C Exhaust System - V8 5.0L Petrol/V8 S/C 5.0L Petrol, Removal and Installation) /
Rear Muffler (309-00C Exhaust System - V8 5.0L Petrol/V8 S/C 5.0L Petrol, Removal and Installation).
13. Remove the exhaust muffler and tailpipe heatshield.
14. Remove the rear scuff plate trim panel.
For additional information, refer to: Rear Scuff Plate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
15. Remove the loadspace trim panel.
For additional information, refer to: Loadspace Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
16. Remove the forced air extraction grille.
17. Release and lay aside the back panel and loadspace wiring harness.
18. Remove the luggage compartment lid weatherstrip.
19. Remove the rear bumper cover side retainer.
20. Remove the roof moulding.
21. Remove the headliner.
For additional information, refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and Installation).
22. Remove the side air curtain module.
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Supplemental Restraint System, Removal and Installation).
23. Remove the rear window glass.
24. Remove the audio unit antenna amplifier.
For additional information, refer to: Audio Unit Antenna Amplifier (415-01A Information and Entertainment System, Removal and
Installation).
25. If the left-hand rear quarter panel is to be repaired, remove the diversity
antenna module.
26. 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).
27. Remove the rear door striker.
28. Remove the luggage compartment lid.
29. If the right-hand rear quarter panel is to be repaired, drain the fuel tank.
For additional information, refer to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).
30. If the right-hand rear quarter panel is to be repaired, remove the fuel
filler door.
31. If the right-hand rear quarter panel is to be repaired, remove the fuel
tank filler pipe.
For additional information, refer to: Fuel Tank Filler Pipe (310-01 Fuel
Tank and Lines - 3.0L, Removal and Installation) /
Fuel Tank Filler Pipe (310-01 Fuel Tank and Lines - 4.2L, Removal and
Installation).
32. Remove the luggage compartment lid hinge.
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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.
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