Page C-6
BODY
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
B
Fender Liner
(Ref. Fig. 2)
(Ref. Fig. 10)
Tool LIst
Qty.
Notched Pry Bar .......................................................... 1
NOTE — The fender liner can be removed without remov-
ing the rear body of the vehicle.
1. Remove four christmas tree rivets (42) that secure the
liner (41) to the frame of the vehicle. Two christmas
tree rivets are located on the lower front edge of the
fender liner, the two remaining are located along the
inside surface above the wheel.
Installation is in the reverse order of removal.
Replace any worn or damaged hardware with new as
required.
Rear Body
(Ref. Fig. 10)
Tool LIst
Qty.
Torx Bit, T-45IP ............................................................ 1
Torx Bit, T-47IP ............................................................ 1
Torx Bit, T-50 ............................................................... 1
Ratchet ........................................................................ 1
Insulated Wrench 9/16" ............................................... 1
Torque Wrench ............................................................ 1
Remove the lower and upper rocker panels and the
sweater basket. Fold the back edge of the floormat
towards the front of the vehicle. If the vehicle is equipped
as a 2 + 2 with a rear facing seat or with a sun top and
windshield, these must also be removed.
1. Raise and remove the seat bottom assembly from the
vehicle. Remove four torx screws (26) securing the
seat back (25) to the seat back supports.
2. Using an insulated wrench, disconnect the battery
cable at the negative (-), BL-, battery terminal.
3. Remove the two Torx head screws that secure the
controller splash shield to the body on the passenger
side of the vehicle.
4. Remove the two strut covers (36) by sliding the covers
up and off of the struts.
5. Disconnect the wires from the charging receptacle to
the battery and unplug the wire to the main wiring har-
ness. If vehicle is equipped with an on board battery
charger skip this step.
6. Remove two torx screws (33) securing each hinge
plate (32) along the front edge of the rear body then
remove both hinge plates.
7. Remove two inner torx screws (34) from the back
edge of seat opening in the rear body.
8. Remove four torx screws (31) from the lower edge of
the rear body, two on the driver side and two on the
passenger side.
9. Remove two torx screws (35) from the bagwell floor.
It is recommended that the removal of the rear body
is done using two people, one on each side of the
vehicle
.
10. Lift the rear body, pivot the seat opening upward and
towards the back of the vehicle to clear the seat back
supports.
Reassemble in reverse order of removal. Replace
any worn or damaged hardware with new as
required. It is recommended that all locking nuts be
replaced after 5 removals
.
Rear Bumper
(Ref. Fig. 10)
Tool LIst
Qty.
Ratchet ........................................................................1
Ratchet Extension, 9" ..................................................1
Universal Joint .............................................................1
Socket, 15mm..............................................................1
Torx Bit, T-47IP ............................................................1
Torque Wrench, ft. lbs. .................................................1
NOTE — The rear
bumper can be removed without
removing the rear body of the vehicle.
1. Remove two torx head screws (item 35) from the bag
well floor. If the rear body has been removed from the
vehicle go to step 2.
2. Remove four hex head bolts (37) securing the bumper
to the vehicle frame.
3. Pull the rear bumper backwards off the frame; lifting
the rear edge of the body may make removal easier.
ITEM
TORQUE SPECIFICATION
26
13 - 16 ft. lbs. (18 - 22 Nm)
ITEM
TORQUE SPECIFICATION
26, 30, 33, 34
13 - 16 ft. lbs. (18 - 22 Nm)
31
26 - 44 in. lbs. (3 - 5 Nm)
35
6 - 9 ft. lbs. (8 - 12 Nm)
37
10 - 13 ft. lbs. (14 - 17 Nm)
