Sill outer assembly

Sill outer assembly

Remove

1. Disconnect both battery leads, negative lead first.
2. Disconnect leads/multiplug from alternator.
3. Remove RH or LH front wing. EXTERIOR FITTINGS, REPAIRS, Wing - front - up to 03MY.
4. Remove RH or LH front door. DOORS, REPAIRS, Door - front.
5. Remove RH or LH rear door. DOORS, REPAIRS, Door - rear.
6. Remove RH or LH sill finisher.
7. Remove RH or LH 'A' post inner lower finishers.
8. Remove RH or LH front seat. SEATS, REPAIRS, Seat - front.
9. LH side: Remove power amplifier and EAT ECU. IN CAR ENTERTAINMENT, REPAIRS, Amplifier - power.
10. RH side: Remove CD autochanger. IN CAR ENTERTAINMENT, REPAIRS, CD autochanger.
11. Remove rear seats. SEATS, REPAIRS, Seat - rear.
12. Remove RH or LH front seat belt. RESTRAINT SYSTEMS, REPAIRS, Seat belt - front.
13. Remove tread plates from front and rear door apertures.
14. Release carpet and position aside.
15. Remove front and rear door aperture seals.
16. Release relevant wiring from 'A' post, 'B/C' post and sill areas, and position aside.
17. Remove loadspace lower trim casing. INTERIOR TRIM COMPONENTS, REPAIRS, Trim casing - side - loadspace.
18. RH side: Remove lower ACE accelerometer. FRONT SUSPENSION, REPAIRS, Accelerometer - ACE - lower.
19. LH side: Remove SLS air compressor unit. REAR SUSPENSION, REPAIRS, Compressor unit - air - SLS.
20. Models with rear A/C: Recover refrigerant from A/C system and remove A/C pipes from LH sill. AIR CONDITIONING, REFRIGERANT RECOVERY, RECYCLING AND RECHARGING, Refrigerant recovery, recycling and recharging.
21. Remove 2 bolts securing body to chassis.

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.

Refit

1. Fit 2 bolts securing body to chassis and tighten to 45 Nm (33 lbf.ft).

2. Models with rear A/C: Fit A/C pipes to sill and recharge A/C system. AIR CONDITIONING, REFRIGERANT RECOVERY, RECYCLING AND RECHARGING, Refrigerant recovery, recycling and recharging.

3. LH side: Fit SLS air compressor unit. REAR SUSPENSION, REPAIRS, Compressor unit - air - SLS.

4. RH side: Fit lower ACE accelerometer. FRONT SUSPENSION, REPAIRS, Accelerometer - ACE - lower.
5. Fit loadspace lower trim casing. INTERIOR TRIM COMPONENTS, REPAIRS, Trim casing - side - loadspace.

6. Fit relevant wiring to 'A' post, 'B/C' post and sill areas.

7. Fit front and rear door door aperture seals.

8. Fit carpet and secure into position.

9. Fit tread plates to front and rear door apertures.
10. Fit front seat belt. RESTRAINT SYSTEMS, REPAIRS, Seat belt - front.
11. Fit rear seats. SEATS, REPAIRS, Seat - rear.
12. LH side: Fit CD autochanger. IN CAR ENTERTAINMENT, REPAIRS, CD autochanger.
13. RH side: Fit power amplifier and EAT ECU. IN CAR ENTERTAINMENT, REPAIRS, Amplifier - power.
14. Fit front seat. SEATS, REPAIRS, Seat - front.
15. Fit 'A' post inner lower finishers.