Sill reinforcement - 5 door

SILL REINFORCEMENT - 5 DOOR

NOTE: In this procedure, the lower outer body side panel is replaced in conjunction with the sill reinforcement.

Remove

1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL, Repairs.
3. Disconnect all ECUs.
4. Remove road wheel(s).
5. Remove front wing. See BODY, Exterior fittings.
6. Remove front door. See BODY, Doors.
7. Remove rear door. See BODY, Doors.
8. Remove B/C post lower finisher. See BODY, Interior trim components.
9. Remove front seat. See BODY, Seats and seat belts.
10. Remove rear seat. See BODY, Seats and seat belts.
11. Remove treadplate from side door apertures.
12. Remove side door aperture seals.
13. Release carpet from inner sill and position aside.
14. Release vehicle harness from inner sill and position aside.

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. Secure vehicle harness to inner sill.
2. Position carpet to inner sill.
3. Fit side door aperture seals.
4. Fit treadplate to side door apertures.
5. Fit rear seat. See BODY, Seats and seat belts.
6. Fit front seat. See BODY, Seats and seat belts.
7. Fit B/C post lower finisher. See BODY, Interior trim components.
8. Fit rear door. See BODY, Doors.
9. Fit front door. See BODY, Doors.
10. Fit front wing. See BODY, Exterior fittings.
11. Fit road wheel(s) and tighten nuts to correct torque. See INFORMATION, Torque wrench settings.
12. Connect all ECUs.
13. Connect alternator. See ELECTRICAL, Repairs.
14. Connect battery earth lead.