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 rear door lock bracket from the pillar "D".
9. Remove overlays of a threshold of an aperture of a back lateral door.
10. Remove the rear door seal.
11. Release the floor mat from the inner sill panel and slide it to the side.
12. Remove the upper overlay of glass of a door of a luggage space.
13. Remove a lateral overlay of glass of a door of a luggage space.
DOORS, Removing the front door assembly to gain access to other components, installing the front door, 5-door rear window side trim.
14. Remove the luggage compartment door seal.
15. Remove an overlay of the back panel of a roof.
EXTERIOR PARTS, REPAIR WORKS, 5-door car roof moldings.
16. Remove a back lantern.
LIGHTING, Headlight assembly - pre-2004 models, Rear combination lamp.
17. Remove the bottom panel of a back part of a sidewall of a body.
INTERIOR TRIM DETAILS, REPAIR WORKS, 5-door luggage compartment lower decorative panel.
18. Remove the top panel of a back part of a sidewall of a body.
INTERIOR TRIM DETAILS, REPAIR WORKS, 5-door upper luggage compartment trim panel.
19. Remove the rear seat side seat belt.
PASSIVE SECURITY SYSTEMS, REPAIR WORK, Left rear seat seat belt.
20. Remove the luggage compartment mat.
INTERIOR TRIM PARTS, REPAIRS, Luggage compartment flooring.
21. Remove the rear seat.
SEATS, REPAIRS, Rear left seat.
SEATS, REPAIR WORKS, Rear right seat.
22. Remove an upholstery of a ceiling of salon.
INTERIOR TRIM PARTS, REPAIR WORKS, 5-door ceiling panel.
23. Remove the side glass of the rear of the cabin.
GLASS, REPAIR WORKS, Rear side glass.
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 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. Establish lateral glass of a back part of salon.
GLASS, REPAIR WORKS, Rear side glass.
8. Establish an upholstery of a ceiling of salon.
INTERIOR TRIM PARTS, REPAIR WORKS, 5-door ceiling panel.
9. Reinstall the rear seat.
SEATS, REPAIRS, Rear left seat.
SEATS, REPAIR WORKS, Rear right seat.
10. Lay and secure the luggage compartment carpet.
INTERIOR TRIM PARTS, REPAIRS, Luggage compartment flooring.
11. Establish a seat belt of a lateral back seat.
PASSIVE SECURITY SYSTEMS, REPAIR WORK, Left rear seat seat belt.
12. Establish the top panel of a back part of a sidewall of a body.
INTERIOR TRIM DETAILS, REPAIR WORKS, 5-door upper luggage compartment trim panel.
13. Establish the bottom panel of a back part of a sidewall of a body.
INTERIOR TRIM DETAILS, REPAIR WORKS, 5-door luggage compartment lower decorative panel.
14. Install the rear light assembly.
LIGHTING, Headlight assembly - pre-2004 models, Rear combination lamp.
15. Establish an overlay of the back panel of a roof.
EXTERIOR PARTS, REPAIR WORKS, 5-door car roof moldings.
16. Install the luggage compartment door seal.
17. Establish a lateral overlay of glass of a door of a luggage compartment.
DOORS, Removing the front door assembly to gain access to other components, installing the front door, 5-door rear window side trim.
18. Establish the top overlay of glass of a door of a luggage compartment.
19. Attach the floor mat to the inside sill panel and back bar.
20. Install the rear door seal.
21. Establish overlays of a threshold of a lateral doorway.
22. Install the rear door lock bracket on the pillar "D".
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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