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15. 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 the rear side member closing panel section to
the rear side member as indicated.
16. Dress the spot welds.
17. Make sure any remaining areas of bare metal created during this
procedure are treated with a zinc primer prior to the installation of outer
panels.
18. The installation of associated panels and components is the reversal of
removal procedure.
1. Tighten the rear muffler hanger bracket bolts to 25 Nm. www.JagDocs.com
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Rear End Sheet Metal Repairs - Rear Wheelhouse Outer
Removal and Installation
Removal Published: 11-May-2011
1. NOTES:
The rear wheelhouse outer is manufactured from mild
steel.
The illustration shows the right-hand service panel,
the left-hand is similar but without the fuel filler aperture.
The rear wheelhouse outer is serviced as a separate
weld-on panel.
2. The rear wheelhouse outer is replaced in conjunction with:
Rear bumper cover
Quarter Panel
Rocker panel (rear, dog leg, part as a minimum)
Rocker panel inner reinforcement section
Quarter panel inner reinforcement, (new service panel required to
enable rear wheelhouse outer replacement)
Luggage Compartment Lid
Rear window glass
Headliner
3. For additional information relating to this repair procedure please see
the following:
For additional information, refer to: Health and Safety Precautions (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 quarter panel.
For additional information, refer to: Quarter Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
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Section (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
6. Disconnect the generator electrical connectors.
7. Remove the rear safety belt retractor.
For additional information, refer to: Rear Safety Belt Retractor (501-20A Safety Belt System, Removal and Installation).
8. Disconnect, release the inner quarter panel wiring harness and position
it to one side.
9. If the right-hand rear wheelhouse outer is being repaired, release the
battery positive cable and position it to one side.
10. Release the inner quarter panel insulating material and position it to
one side.
11. Drill out the spot welds from the striker reinforcement
panel.
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12.
13.
14.
15. NOTE: A new striker reinforcement panel is supplied
on the quarter panel service panel.
Separate the joints, the adhesive and the NVH (noise,
vibration and harshness) component and remove the striker
reinforcement panel.
NOTE: Care should be taken when separating and
removing the ECM (engine control module) mounting
bracket if it is to be reused.
If the right-hand rear wheelhouse outer is to be repaired,
drill out the spot welds as indicated and remove the ECM
mounting bracket. Retain for reuse on installation.
NOTE: It is necessary to section the quarter panel
inner reinforcement at the point indicated, to make sure the
integrity of the safety belt anchorage point. The right-hand
panel is illustrated, the left-hand is similar.
Cut the quarter panel inner reinforcement, horizontally,
approximately 90mm from the centre of the safety belt bolt
anchorage point as indicated.
NOTE: The right-hand panel is illustrated, the
left-hand is similar although there are additional spot welds
to drill out.
Drill out the spot welds from the quarter panel inner
reinforcement section at the points indicated.
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16. NOTE: Retain the quarter panel inner reinforcement section as part
of this will be used as a template and to form a backing plate.
Separate the joints and remove the quarter panel inner reinforcement
section.
17.
18.
19. Cut the rocker panel inner reinforcement at the point
indicated.
Drill out the spot welds.
NOTE: Care should be taken, when releasing the MAG
weld, as the rocker panel inner reinforcement section is to
be reused.
Using a belt sander, release the rocker panel inner
reinforcement from the MAG weld at the point indicated.
20. NOTE: Care should be taken when separating and removing the
rocker panel inner reinforcement section as it is to be reused.
Separate the joints and remove the rocker panel inner reinforcement
section. Retain for reuse on installation.
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21. NOTES:
Where it is possible, spot welds should be drilled from
inside to enable them to be replicated on installation.
The quarter panel inner reinforcement section is
removed for this procedure, the illustration shows it in
place and is for reference only.
Drill out the spot welds.
22. Separate the joints and remove the old panel.
Installation
1. Offer up the new panel and clamp into position. Check alignment, if
correct, proceed to next step, if not rectify and recheck before
proceeding.
2. With the new panel in position, mark the position of MAG
plug welds as indicated.
3. Remove the new panel. www.JagDocs.com