Workshop Manuals Factory service & repair Rover
Rover 200 Body Repair Manual (1995-1999)06 · Panel repairs
06 · General

Body side assembly - 5-door

Make
Rover
Model
200 Body Repair Manual
Year
1995–1999
Section
Repairs › Body side assembly - 5-door
Panel repairsBody side assembly - 5-door · page 1 of 2

BODY SIDE ASSEMBLY - 5-DOOR

Remove

  1. Disconnect battery earth lead.
  2. Raise side of vehicle.

WARNING: Place on safety stands.

  1. Disconnect all ECUs.
  2. Disconnect airbags and sensor system.

WARNING: See RESTRAINT SYSTEMS, Precautions.

  1. Disconnect alternator.
  2. Remove rear quarter trim casing. See BODY, Interior trim components.
  3. Remove rear quarter lower trim casing. See BODY, Interior trim components.
  4. Remove front treadplate. See BODY, Exterior fittings.
  5. Remove rear treadplate. See BODY, Exterior fittings.
  6. Remove rear bumper. See BODY, Exterior fittings.
  7. Remove front seat. See BODY, Seats and seat belts.
  8. Remove front seat belt and pre-tensioner. See RESTRAINT SYSTEMS, Repairs.
  9. Remove rear seat belt. See BODY, Seats and seat belts.
  10. Remove headlining. See BODY, Interior trim components.
  11. Remove rear seat cushion. See BODY, Interior trim components.
  12. Remove rear seat squab. See BODY, Interior trim components.
  13. Remove luggage compartment side carpet. See BODY, Interior trim components.
  14. Remove luggage compartment trim casing. See BODY, Interior trim components.
  15. Remove parcel tray support panel. See BODY, Interior trim components.
  16. Remove parcel tray. See BODY, Interior trim components.
  17. Remove tail lamp. See Workshop Manual, Electrical, Repairs.
  18. Remove luggage compartment lamp. See Workshop Manual, Electrical, Repairs.
  19. Remove fuel tank. See Workshop Manual, Fuel delivery systems, Repairs.
  20. Remove rear door.

Refit

Body side assembly - 5-door – Remove rear door.
  1. Prepare and clean panel joint faces. Punch or drill holes in new panel for plug welding, and cut panel to form seam welded butt joints as shown.

WARNING: Remove ALL traces of adhesive from inner sill lower edge before plug welding.

  1. Refit rear door.
  2. Refit fuel tank. See Workshop Manual, Fuel delivery system, Repairs.
  3. Refit luggage compartment lamp. See Workshop Manual, Electrical, Repairs.
  4. Refit tail lamp. See Workshop Manual, Electrical, Repairs.
  5. Refit parcel tray. See BODY, Interior trim components.
  6. Refit parcel tray support panel. See BODY, Interior trim components.
  7. Refit luggage compartment trim casing. See BODY, Interior trim components.
  8. Refit luggage compartment side carpet. See BODY, Interior trim components.
  9. Refit rear seat squab. See BODY, Interior trim components.
  10. Refit rear seat cushion. See BODY, Interior trim components.
  11. Refit headlining. See BODY, Interior trim components.
  12. Refit rear seat belt. See BODY, Seats and seat belts.
  13. Refit front seat belt and pre-tensioner. See RESTRAINT SYSTEMS, Repairs.

Parts & tools for this job For 1995 Rover 200

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