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Installation
1. 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.
Remove the door striker reinforcement panel from the
quarter panel service panel.
2. Trim the excess from the upper part of the service panel.
3. Prepare the old and new panel joint surfaces, including the NVH
components.
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8. If necessary, renew the NVH components.
9. Apply sealer adhesive to the NVH components.
10.
NOTE: Temporarily install the luggage compartment lid and hinge
to aid alignment.
Offer up the new panel, align and clamp into position.
11. Tack weld the butt joints.
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12. NOTE: Spot welds must be installed 5mm away from the originals
and in the same quantities, whenever this is possible. Where this is not
possible, spot welds should be installed adjacent to the original. Where
there is adhesive in the original joint, spot welds should be installed
through the original.
Spot weld.
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13.
14. MAG plug weld.
MAG plug weld the new panel to the door striker
reinforcement panel.
15. Dress the tack welds.
16. MAG weld the butt joints.
17.
NOTE: Stud dimensions: 6mm x 1.0mm thread, 20mm length.
Prepare the new panel and install the weld studs as indicated.
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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 battery.
For additional information, refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
5. Disconnect the generator electrical connectors.
6. Remove any electrical components in the local area of repair to prevent
damage.
7. Remove the Rear Bumper.
For additional information, refer to: Rear Bumper (501-19 Bumpers, Removal and Installation).
8. 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).
9. Remove the exhaust muffler and tailpipe heatshield.
10. Remove the forced air extraction grille.