This procedure covers the replacement of the rear outer side body panel complete with the rear sidewall assembly.
Dismantling
1. Disconnect "negative" battery terminal.
2. Disconnect the generator.
3. Disconnect all electronic units.
4. Remove the wheel (wheels).
5. Remove a decorative overlay of a threshold.
EXTERIOR PARTS, REPAIR WORKS, Door sill.
6. Remove the rear bumper.
EXTERIOR PARTS, REPAIRS, Rear bumper assembly - for vehicles up to 2004 model year.
7. Remove the rear wheel arch liner.
8. Remove the door lock bracket from the pillar "B".
9. Remove an overlay of a threshold of an aperture of a forward door.
10. Remove the door seal.
11. Release the floor mat from the inner sill panel and slide it to the side.
12. Remove the canopy/hard top.
13. Remove the luggage compartment door seal.
14. Remove an upholstery of the back panel of a roof.
EXTERIOR PARTS, REPAIR WORKS, 5-door car roof moldings.
15. Remove a back lantern.
LIGHTING, Headlight assembly - pre-2004 models, Rear combination lamp.
16. Remove the bottom panel of a back part of a sidewall of a body.
INTERIOR TRIM PARTS, REPAIRS, 3-door luggage compartment lower decorative panel.
17. Remove the top panel of a back part of a sidewall of a body.
INTERIOR TRIM PARTS, REPAIR WORKS, 3-door upper luggage compartment trim panel.
18. Remove the rear seat side seat belt.
PASSIVE SECURITY SYSTEMS, REPAIR WORK, Left rear seat seat belt.
19. Remove the luggage compartment mat.
INTERIOR TRIM PARTS, REPAIRS, Luggage compartment flooring.
20. Remove the rear seat.
SEATS, REPAIRS, Rear left seat.
SEATS, REPAIR WORKS, Rear right seat.
21. Remove the rear side upholstery panel.
INTERIOR TRIM PARTS, REPAIR WORKS, 3-door rear side decorative panel.
22. Remove an upholstery of a ceiling of salon.
INTERIOR TRIM PARTS, REPAIR WORKS, 3-door headliner.
23. Remove the rear side glass and its seal.
EXTERIOR PARTS, REPAIR WORKS, Rear small glass assembly - 3-door car.
24. Remove the rear shock absorber.
REAR SUSPENSION, REPAIR WORKS, Shock absorber.
25. Release the cable harness from the back of the sidewall and lay it aside.
26. Left side: Remove the tailgate lock bracket from the pillar "E".
27. Right side: Remove the tailgate.
DOORS, Removing the front door assembly to gain access to other components, installing the front door, Removing the tailgate assembly to gain access to other components, installing the tailgate.
28. Right side: Remove the fuel filler neck.
FUEL SUPPLY SYSTEM OF PETROL ENGINE, ADJUSTMENTS, Filler pipe.
29. Right side: Remove the fuel tank from the vehicle.
PETROL ENGINE FUEL SUPPLY, CONTROLS, Fuel Tank: Except North American Market.
Repair work
1. Remove damaged panels, prepare joint edges and install new panels in accordance with the Body Panel Repair Code. Punch or drill holes in the panel to be installed for the cork weld as shown.
2. Arrow A shown means there are also cork welds on the other side of the inner wheel arch panel. They connect the rear side member to the inner wheel arch panel.
Installation
1. Left side: Install the tailgate lock bracket on the pillar "E".
2. Right side: Install the fuel tank on the vehicle.
PETROL ENGINE FUEL SUPPLY, CONTROLS, Fuel Tank: Except North American Market.
3. Right side: Install the fuel filler neck.
FUEL SUPPLY OF PETROL ENGINE, ADJUSTMENTS, Filler pipe.
4. Right side: Install the tailgate.
DOORS, Removing the front door assembly to gain access to other components, installing the front door, Removing the tailgate assembly to gain access to other components, installing the tailgate.
5. Attach the wiring harness to the back of the sidewall.
6. Install the rear shock absorber.
REAR SUSPENSION, REPAIR WORKS, Shock absorber.
7. Install the rear side window seal and the rear side window.
EXTERIOR PARTS, REPAIR WORKS, Rear small glass assembly - 3-door car.
8. Establish an upholstery of a ceiling of salon.
INTERIOR TRIM PARTS, REPAIR WORKS, 3-door headliner.
9. Establish the back side panel of an upholstery of salon.
INTERIOR TRIM PARTS, REPAIR WORKS, 3-door rear side decorative panel.
10. Reinstall the rear seat.
SEATS, REPAIRS, Rear left seat.
SEATS, REPAIR WORKS, Rear right seat.
11. Lay and secure the luggage compartment mat.
INTERIOR TRIM PARTS, REPAIRS, Luggage compartment flooring.
12. Establish a seat belt of a lateral back seat.
PASSIVE SECURITY SYSTEMS, REPAIR WORK, Left rear seat seat belt.
13. Establish the top panel of a back part of a sidewall of a body.
INTERIOR TRIM PARTS, REPAIR WORKS, 3-door upper luggage compartment trim panel.
14. Establish the bottom panel of a back part of a sidewall of a body.
INTERIOR TRIM PARTS, REPAIRS, 3-door luggage compartment lower decorative panel.
15. Install the rear light assembly.
LIGHTING, Headlight assembly - pre-2004 models, Rear combination lamp.
16. Establish an upholstery of the back panel of a roof.
EXTERIOR PARTS, REPAIR WORKS, 5-door car roof moldings.
17. Install the luggage compartment door seal.
18. Install the canopy/hard top.
19. Attach the floor mat to the inside sill panel and back bar.
20. Install the side door seal.
21. Establish overlays of a threshold of a lateral doorway.
22. Install the door lock bracket on the pillar "B".
23. Reinstall the rear wheel arch liner.
24. Reinstall the rear bumper.
EXTERIOR PARTS, REPAIRS, Rear bumper assembly - for vehicles up to 2004 model year.
25. Establish the bottom decorative overlay of a threshold.
EXTERIOR PARTS, REPAIR WORKS, Door sill.
26. Replace the wheel (wheels) and tighten the nuts to a torque of 115 Nm.
27. Attach all electronic units.
28. Attach the generator.
29. Attach "negative" battery terminal.
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