REPAIRS (page 32 of 34)

PANEL REPAIRS

77-2-52 REPAIRS

Refit

1. Position and secure wiring.
2. Fit and tighten bolts securing body to chassis to 

45 Nm (33 lbf.ft).

3. Fit tail door aperture seal. 
4. Fit head lining rear trim finisher.
5. Fit loadspace carpet retainer.
6. Fit tail door tread plate.
7. Fit rear door aperture seals.
8. Fit tread plate to rear door apertures.
9. Fit exhaust tail pipe heatshields.

10. Fit mud flap bracklets and mud flaps.
11. Fit rear bumper assembly.

 

 + 

 EXTERIOR FITTINGS, REPAIRS, 

Bumper assembly - rear - up to 03MY. 

12. Fit rear carpet.

 

 + 

 INTERIOR TRIM COMPONENTS, 

REPAIRS, Carpet - rear.

13. Fit rear seats.

 

 + 

 SEATS, REPAIRS, Seat - rear.

14. Fit loadspace carpet.

 

 + 

 INTERIOR TRIM COMPONENTS, 

REPAIRS, Carpet - loadspace.

15. Connect leads/multiplug to alternator. 
16. Connect battery leads, negative lead last.

Rear floor (rear section)

In this procedure, the cross member rear assembly, 
cross member outer rear panel, cross member 
closing rear panel, 'E' post assembly, 'E' post closing 
assembly and the panel body side assembly are 
replaced in conjunction with the rear floor (rear 
section).

Remove

1. Disconnect both battery leads, negative lead 

first.

2. Disconnect leads/multiplug from alternator. 
3. Remove cross member rear assembly.

 

 + 

 PANEL REPAIRS, REPAIRS, Cross 

member rear assembly.

4. Remove mud flap mounting brackets.
5. LH side: Remove exhaust heatshield from rear 

floor.

Repair

1. Remove existing panel(s), prepare panel joint 

faces and install new panel(s) in accordance 
with Panel Replacement Procedure. Punch or 
drill holes in new panel for plug welding as 
shown. Welds for RH side are symmetrically 
opposite to those shown.

Refit

1. LH side: Fit exhaust heatshield to rear floor.
2. Fit mud flap mounting brackets.
3. Fit cross member rear assembly.

 

 + 

 PANEL REPAIRS, REPAIRS, Cross 

member rear assembly.

4. Connect leads/multiplug to alternator. 
5. Connect battery leads, negative lead last.