Body Side Panel and Rear Quarter Panel (5 Door Vehicles)
Body Side Panel and Rear Quarter Panel (5 Door Vehicles)
Remove
NOTE: The procedure for removing right or left hand body side panels is identical except for disconnecting the fuel filler pipe on the right hand panel.
1. Disconnect battery negative lead.
2. Remove the rear bumper assembly.
3. Working inside the vehicle remove the side facing rear seat.
4. Remove the rear side, alpine light and 'D' post trim panels.
5. If renewing the side panel remove the side window and its mounting rubber.
6. Remove the rear lamp assembly and displace the rubber boot from the outer panel.
7. Drill out the two pop-rivets securing the rear speaker mounting bracket to the body side panel.
CAUTION: Prior to disconnecting the fuel filler and breather hoses check the level of fuel in the tank. Drain as necessary to prevent spillage. Observing the safety warnings detailed in Section 1.
8. Working under the vehicle loosen the jubilee clips securing the filler and breather hoses and disconnect the hoses from the tank, RH body side panel only.
9. Disconnect the fuel filler negative lead, RH body side panel only.
10. Working through the three apertures in the 'D' post, remove the nuts and washers and detach the 'D' post capping.
11. Remove the three countersunk self tapping screws securing the side panel to the 'D' post.
12. Remove the six countersunk self tapping screws securing the rear quarter panel to the 'E' post.
13. Remove the two bolts, one inside the wheel arch and one at the bottom of the side panel.
14. From the interior of the vehicle remove the ten bolts securing the side panel.
15. Starting from the 'D' post and working towards the rear of the vehicle, ease the panel away from the body to break the seal. When the seal hold has been completely broken, push the panel towards the rear of the vehicle, to disengage the rear quarter panel from the 'E' post, then lift the side and rear quarter panel assembly clear.
16. If the panel being removed is a right hand panel and is being renewed, remove the fuel filler pipe.
Cleaning/painting
17. Thoroughly clean all traces of existing sealant from the mating faces of the body and panel.
18. Paint the cleaned surfaces with etch primer.
Refit
19. Apply a 6 mm bead of 3M 8645 Auto Joint and Seam Sealer to the areas of the monocoque illustrated.
20. Apply 20 x 20 mm squares of 3M 8572 Bolted Panel Sealer to the inner faces of the six securing screw holes in the rear quarter panel.
21. Locate the panel with the body, ensuring that the sealant is not displaced, and loosely fit the ten bolts securing the panel from inside the body.
22. Loosely fit the countersunk self tapping screws securing the rear quarter panel to the 'E' post and the side panel to the 'D' post.
23. Loosely fit the two bolts, one inside the wheel arch and one at the bottom of the side panel.
24. Starting with the three bolts securing the top of the panel, evenly tighten the bolts to draw the panel upwards to its correct location.
25. Tighten the remaining bolts and the self tapping screws ensuring a satisfactory seal between the mating faces.
26. Clean oft any surplus sealant from exposed surfaces.
27. Thumb 3M 8572 Bolted Panel Sealer into all corners of the window aperture to seal any panel mismatches.
28. Apply a bead of 3M 8651 Flexseal to the joint at the lower portion of the 'D' post, tooling the bead to produce a smooth cosmetically acceptable finish.
29. Paint as necessary, referring to the paint manual.
30. Refit the capping to the 'D' post and secure with the nuts and washers.
31. Reverse the removal operations to refit the fuel filler pipe and breather (where applicable), the window, internal trim and rear lamp etc.
Rear quarter panel replacement
1. Remove the body side panel and rear quarter panel assembly from the vehicle.
2. Using a suitable high-speed saw cut oft the rear quarter panel at approximately 30 mm from the flange joint.
NOTE: The use of an air chisel is not recommended as damage to the body side panel could occur.
3. Remove the flange from the body side panel using a spotweld cutter.
4. On the flange center line, of the replacement rear quarter panel, set out and drill six 6,5 mm holes in the locations illustrated.
5. Align and clamp the rear quarter panel to the body side panel and transfer the hole locations to the flange on the body side panel.
6. Remove the clamps and drill the six 6,5 mm holes in the locations marked on the body side panel flange.
7. Deburr all holes and etch prime all bare metal.
8. Bolt the panels together using M6 X 20 mm plated bolts, plain nuts and spring washers.
9. Refit the panel assembly to the vehicle.
10. Paint as necessary, referring to the paint manual.