7C Body Side – Utility Page 7C-1

Page 7C-1

Section 7C

Body Side – Utility

ATTENTION

Before performing any service operation or other procedure described in this Section, refer to Section 2

Precautions in this Supplement and Section 00 Warnings, Cautions and Notes in the MY2005 VZ Service

Information for correct workshop practices with regard to safety and/or property damage.

The structure of the body shell has been

developed using complex design and

development techniques. In addition to

meeting all required standards, the vehicle

body is also a critical part of the overall safety

systems. It is therefore imperative the repair

procedures described here are adhered to

during all vehicle body repairs.

1 General Description ...............................................................................................................................3

1.1 Body Side Components ........................................................................................................................................ 3

2 Service Operations.................................................................................................................................5

2.1 Rear Quarter Panel – Replace............................................................................................................................... 5

Remove................................................................................................................................................................... 5

Replace................................................................................................................................................................... 8

2.2 Quarter Panel Extension – Replace.................................................................................................................... 11

Remove................................................................................................................................................................. 11

Replace................................................................................................................................................................. 13

2.3 Quarter Panel Inner Lower Rear Extension – Replace ..................................................................................... 15

Remove................................................................................................................................................................. 15

Replace................................................................................................................................................................. 16

2.4 Quarter Outer Lower Rear Panel – Replace....................................................................................................... 17

Remove................................................................................................................................................................. 17

Replace................................................................................................................................................................. 18

2.5 Quarter Lower Rear Panel – Replace ................................................................................................................. 20

Replace................................................................................................................................................................. 21

2.6 Door Opening Frame Assembly – Replace........................................................................................................ 22

Remove................................................................................................................................................................. 22

Replace................................................................................................................................................................. 26

2.7 Door Opening Frame Assembly – Partial Replace, Hinge Pillar...................................................................... 32

Remove................................................................................................................................................................. 32

Replace................................................................................................................................................................. 35

2.8 Door Opening Frame Assembly – Partial Replace, Centre Pillar..................................................................... 40

Remove................................................................................................................................................................. 40

Replace................................................................................................................................................................. 42

2.9 Door Opening Frame Assembly – Partial Replace, Rocker Panel................................................................... 46

Remove................................................................................................................................................................. 46

Replace................................................................................................................................................................. 49

7C Body Side – Utility Page 7C-2

Page 7C-2

2.10 Fender Lower Rear Bracket – Replace............................................................................................................... 53

2.11 Hinge Pillar Inner Panel Assembly – Replace ................................................................................................... 54

Remove................................................................................................................................................................. 54

Replace................................................................................................................................................................. 56

2.12 Quarter Inner and Rear Wheelhouse Brace – Replace ..................................................................................... 59

Replace................................................................................................................................................................. 59

2.13 Quarter Panel Inner Assembly – Replace.......................................................................................................... 61

Remove................................................................................................................................................................. 61

Replace................................................................................................................................................................. 64

2.14 Side Inner Upper Panel – Replace...................................................................................................................... 67

Remove................................................................................................................................................................. 67

Replace................................................................................................................................................................. 70

2.15 Side Inner Upper Panel – Partial Replace.......................................................................................................... 73

Remove................................................................................................................................................................. 73

Replace................................................................................................................................................................. 74

2.16 Side Inner Upper Front Panel – Replace............................................................................................................ 76

Remove................................................................................................................................................................. 76

Replace................................................................................................................................................................. 77

2.17 Load Floor Panel Outer Extension and Load Floor Panel Outer Reinforcement – Replace.......................... 79

Replace................................................................................................................................................................. 80

2.18 Rear Wheelhouse Inner Panel – Replace........................................................................................................... 82

Remove................................................................................................................................................................. 82

Replace................................................................................................................................................................. 84

3 Torque Wrench Specifications............................................................................................................87

7C Body Side – Utility Page 7C-3

Page 7C-3

1 General Description

This Section describes the replacement procedures for the body side components of the Utility body structure. Removal

of bolt-on panels and mechanic al components is not covered.

When repairing the body side of the vehicle, care must be taken to ensure the structure is returned to its original

production configuration. This is especially important to maintain side impact standards and for the veh icle’s occupant

protection system to operate correctly.

This Section includes door opening frame assembly partial r eplacement procedures for the hinge pillar, centre pillar, and

rocker panel. These procedures must be followed carefully, as they regula rly involve hidden reinforcement pane ls. The

cutting locations specified are the only places allowable.

NOTE

• It is imperative the correct body adhesives,

sealers, deadeners and cavity waxes are

used when repairing th e body structure. Refer

to Section 3C Body Construction – Util ity.

1.1 Body Side Components

The shaded components in Figure 7C – 1 are those dealt

with in this Section.

The components and assemblies shown in Figure 7C – 2

are the serviceable parts that form the basis of the repair

procedures in this Section. For a detailed view of the body

components, refer to Section 3C Body Construction – Utility.

NOTE

Always refer to an Authorised Retailer for spare

parts availability configurations.

Cavity foam may be used within the hinge

and centre. Care needs to be taken when

repairing the vehicle in these areas, refer to

Section 2 Precautions prior to beginning any

work for further information regarding the

use of cavity foam.

Figure 7C – 1

7C Body Side – Utility Page 7C-4

Page 7C-4

Figure 7C – 2

Legend

1 Hinge Pillar Trim Panel Bracket, Left-hand / Right-hand

2 Hinge Pillar Inner Panel Assembly, Left-hand / Right-hand

3 Fender Upper Rear Bracket, Left-hand / Right-hand

4 Fender Lower Rear Bracket, Left-hand / Right-hand

5 Fender Rear Bracket, Left-hand / Right-hand

6 Underbody Jacking Locator, Left-hand / Right-hand

7 Front Door Striker Anchor Plate, Left-hand / Right-hand

8 Door Opening Frame Assembly, Left-hand / Right-hand

9 Quarter Panel Inner Extension, Left-hand / Right-hand

10 Side Inner Upper Front Panel, Left-hand / Right-hand

11 Seatbelt Guide Anchor Plate Assembly, Left-hand / Right-

hand

12 Fuel Filler Pipe Housing, Right-hand

13 Rear Wheelhouse Outer Extension, Right-hand

14 Front Inner Side Panel Cover, Left-hand / Right-hand

15 Load Floor Panel Outer Extension, Left-hand / Right-hand

16 Rear Wheelhouse Inner Panel, Left-hand / Right-hand

17 Cargo Tie-down Bracket, (three places), Left-hand / Right-

hand

18 Rear Inner Side Panel Cover, Left-hand / Right-hand

19 Side Inner Upper Panel, Left-hand / Right-hand

20 Endgate Striker Anchor Plate Retainer, Left-hand / Right-

hand

21 Quarter Lower Rear Panel, Left-hand / Right-hand

22 Quarter Inner Lower Rear Extension, Left-hand / Right-hand

23 Cargo Tie-down Bracket Anchor Plate Assembly, (three

places), Left-hand / Right-hand

24 Rear Wheelhouse Bracket, Left-hand / Right-hand

25 Load Floor Panel Outer Reinforcement, Left-hand / Right-

hand

26 Quarter Inner and Rear Wheelhouse Brace, Left-hand /

Right-hand

27 Quarter Panel Inner Assembly, Left-hand / Right-hand

28 Quarter Panel Upper Extension, Left-hand / Right-hand

29 Quarter Panel Extension, Left-hand / Right-hand

30 Rear Quarter Panel, Left-hand / Right-hand

31 Quarter Outer Lower Rear Panel, Left-hand / Right-hand

NOTE

• The door opening frame assembly (8)

includes parts 3, 4, 5, 6 and 7.

7C Body Side – Utility Page 7C-5

Page 7C-5

2 Service Operations

2.1 Rear Quarter Panel – Replace

The fuel tank is located under the load floor

front panel. To avoid the possibility of fire,

remove the fuel tank and plug all lines when

grinding, cutting or welding.

NOTE

The rear body wirin g harness is routed behind the

right-hand quarter pa nel; take care not to damage

or burn the harness.

Remove

1 Remove the adjacent bolt-on panels a nd components

as described in the appropriate Section of the MY2005

VZ Service Information.

2 Remove the rear and quarter window, refer to

Section 1A6 Stationary Windows in the MY2005 VZ

Service Information.

Figure 7C – 3

3 To access the spot welds underneath, the quarter

panel upper extension will require removal. Spot cut:

• two welds attaching it to the quarter panel

extension,

• two welds attaching it to the quarter panel

extension and side inner upper panel,

• one weld attaching it and the rear qu arter panel

to the quarter panel extension.

4 Spot cut the six welds attaching the rear quarter pane l

to the quarter outer lower rear panel.

5 Spot cut the weld attaching the rear quarter panel and

quarter panel extension to the quarter outer lower rear

panel.

6 Spot cut the welds attaching the rear quarter panel as

shown in Figure 7C – 5. Note differences between left-

hand and right-hand sides. Figure 7C – 4

7C Body Side – Utility Page 7C-6

Page 7C-6

Figure 7C – 5

7 Spot cut the welds around the wheel arch opening

attaching the rear quarter panel to the d oor opening

frame assembly and quarter panel inn er asse mbly.

Figure 7C – 6

8 Spot cut the welds attaching the rear quarter panel to

the door opening frame assembly.

Figure 7C – 7

7C Body Side – Utility Page 7C-7

Page 7C-7

9 Spot cut the welds attaching the rear quarter panel to

the door opening frame assembly.

10 Spot cut the welds attaching the rear quarter panel to

the side inner upper panel assembly and lock pillar

outer panel brace, refer to Figure 7C – 9.

11 Remove the rear quarter panel and repair any damage

to adjacent parts as required.

NOTE

Acrylic spot weld sealer is used in many of the

joints which may require prisi ng apart.

12 Check and rectify the alignme nt of

the body as requir ed,

refer to Section 3C Body Construction – Utility.

Figure 7C – 8

Figure 7C – 9

7C Body Side – Utility Page 7C-8

Page 7C-8

Replace

NOTE

• Spot welding is the preferred method for

attaching of panels and should be used

whenever possible. Where the spot welding

equipment available will not access the

required weld position, a plug weld should be

performed.

• The same number and position of spot welds

(or plug welds) should be used when

replacing the panel, as was used during

manufacture, in order to maintain the original

structural strength of the vehicle.

1 As required, mark the new panel with drilling locations in preparation for plug welding. Drill holes as required.

2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as requir ed,

refer to Section 3C Body Construction – Utility

3 For the right-hand side, if required spot or plug weld

the fuel filler pipe housing to the rear q uarter panel in

four places.

4 Apply Acrylic Spot Weld Sealer (Item 2),

refer to Section 3C Body Construction – Utility.

5 Clamp the panel into position ensuring correct

alignment with the door and the body structure.

6 Spot or plug weld the rear quarter panel to the side

inner upper panel and lock pil lar outer p anel brace,

refer to Figure 7C – 11.

Figure 7C – 10

Figure 7C – 11

7C Body Side – Utility Page 7C-9

Page 7C-9

7 Spot or plug weld the rear quarter panel to the door

opening frame assembly.

Figure 7C – 12

8 Spot or plug weld the rear quarter panel to the door

opening frame assembly.

Figure 7C – 13

9 Spot or plug weld the rear quarter panel to the door

opening frame assembly and quarter panel inner

assembly around the wheel arch opening.

10 Spot or plug weld the rear quarter panel as shown in

Figure 7C – 15. Note differences between the left-

hand and right-hand sides.

Figure 7C – 14

7C Body Side – Utility Page 7C-10

Page 7C-10

Figure 7C – 15

11 Spot or plug weld the rear quarter panel to the quarter

outer lower rear panel, seven plac es.

12 Install and spot or plug weld the quarter panel upper

extension:

• to the quarter panel extension, two places,

• to the quarter panel extension and side inner

upper panel, two places,

• to the rear quarter panel and quarter panel

extension, one place.

13 Refinish and paint panels and other components as

required. Refer to Section 3 Body Construction .

14 Apply Joint Sealer (Item 3) as required.

Refer to Section 3C Body Construction – Utility.

15 Apply Cavity Wax (Item 8) as required to the inside of

any box sections or areas inaccessible to paint,

refer to Section 3C Body Construction – Utility.

16 Apply Spray-on Dea dener (Item 7) where applicab le,

refer to Section 3C Body Construction – Utility.

17 Replace the rear and quarter wind ows, refer to

Section 1A6 Stationary Windows in the MY2005 VZ

Service Information.

18 Install the remaining components as described in the

appropriate Section of the MY2005 VZ Service

Information.

Figure 7C – 16

7C Body Side – Utility Page 7C-11

Page 7C-11

2.2 Quarter Panel Extension – Replace

Remove

1 Remove the adjacent bolt-on panels a nd components

as described in the appropriate Section of the MY2005

VZ Service Information.

Figure 7C – 17

2 To access the spot welds underneath, the quarter

panel upper extension piece will require removal. Spot

cut:

• two welds attaching it and the quarter panel

extension to the side inner upper panel,

• one weld attaching it and the rear qu arter panel

to the quarter panel extension,

• two welds attaching it to the quarter panel

extension.

3 Spot cut the three welds attaching the quarter panel

extension to the quarter outer lower rear panel.

4 Spot cut the weld attaching the rear quarter panel and

quarter panel extension to the quarter outer lower rear

panel.

Figure 7C – 18

7C Body Side – Utility Page 7C-12

Page 7C-12

5 Spot cut the 8 welds attaching the quarter panel

extension (1) between the rear quarter panel (2) and

quarter inner lower rear extension (3),

refer to Section A-A.

6 Spot cut the 10 welds attaching the quarter pane l

extension to the rear quarter panel.

7 Spot cut the weld attaching the rear quarter panel and

quarter panel extension to the side inner upp er pan el.

8 Spot cut the 15 welds attaching the quarter pane l

extension to the side inner upper panel.

Figure 7C – 19

9 Spot cut the 3 welds attaching the quarter panel

extension to the side inner upper panel.

10 Spot cut the 3 welds attaching the quarter panel

extension to the rear end lower panel.

11 Grind off the MIG weld (1) and two MIG welds (2)

attaching the quarter panel extension to the rear end

lower panel.

12 Remove the quarter panel extension and repair an y

damage to adjacent parts as required.

NOTE

Acrylic spot weld sealer is used between the rear

quarter panel and quarter panel extension which

may require prising apart.

13 Check and rectify the alignme nt of

the body as requir ed,

refer to Section 3C Body Construction – Utility

Figure 7C – 20

7C Body Side – Utility Page 7C-13

Page 7C-13

Replace

NOTE

• Spot welding is the preferred method for

attaching of panels and should be used

whenever possible. Where the spot welding

equipment available will not access the

required weld position, a plug weld should be

performed.

• The same number and position of spot welds

(or plug welds) should be used when

replacing the panel, as was used during

manufacture, in order to maintain the original

structural strength of the vehicle.

1 As required, mark the new panel with drilling locations in preparation for plug welding. Drill holes as required.

2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as requir ed,

refer to Section 3C Body Construction – Utility.

3 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3C Body Construction – Utility.

4 Clamp the panel into position, fitting the quarter panel

extension flange (1) between the rear quarter panel (2)

and quarter inner lower rear extension (3), refer to

Section A-A.

5 Test fit the tail lamp and check for correct alignment

with the endgate and the body structure.

6 Spot or plug weld eight places, the quarter panel

extension (1), rear quarter panel (2) and quarter inner

lower rear extension (3), refer to Section A-A.

NOTE

Take care when welding the rear quarter panel

to avoid heat distortion.

7 Spot or plug weld 10 places, the rear quarter panel to

the quarter panel extension.

8 Spot or plug weld one place, the rear quarter panel

and quarter panel extension to the side inner upper

panel.

9 Spot or plug weld the quarter panel e xtensio n to the

side inner upper panel, 15 pl aces.

Figure 7C – 21

7C Body Side – Utility Page 7C-14

Page 7C-14

10 Spot or plug weld three places, the quarter p anel

extension to the side inner upper panel.

11 Spot or plug weld three places, the quarter p anel

extension to the rear end lower panel.

12 MIG weld one place 55 mm (1) and two places 30 mm

(2), the quarter panel extension to the rear end lower

panel.

Figure 7C – 22

13 Spot or plug weld three places, the quarter p anel

extension to the quarter outer lower rear panel.

14 Spot or plug weld one place, the rear quarter panel

and quarter panel extension to the qu arter outer lower

rear panel.

15 Install and spot or plug weld the quarter panel upper

extension:

• and the quarter panel e xtens ion to the side inner

upper panel two plac es,

• and the rear quarter panel to the quarter panel

extension one place,

• to the quarter panel extension two places.

16 Refinish and paint panels and other components as

required. Refer to Section 3 Body Construction .

17 Apply Joint Sealer (Item 3) as required.

Refer to Section 3C Body Construction – Utility.

18 Apply Cavity Wax (Item 8) as required to the inside of

any box sections or areas inaccessible to paint,

refer to Section 3C Body Construction – Utility.

19 Install the remaining components as described in the

appropriate Section of the MY2005 VZ Service

Information.

Figure 7C – 23

7C Body Side – Utility Page 7C-15

Page 7C-15

2.3 Quarter Panel Inner Lower Rear

Extension – Replace

Remove

1 Remove the adjacent bolt-on panels a nd components

as described in the appropriate Section of the MY2005

VZ Service Information.

2 Remove the quarter panel extension as previously

described.

Figure 7C – 24

3 Spot cut the welds attaching the quarter inner lower

rear extension to the side inner upper panel.

4 Remove the quarter inner lo wer rear extension and

repair any damage to adjacent parts as required.

Figure 7C – 25

7C Body Side – Utility Page 7C-16

Page 7C-16

Replace

NOTE

• Spot welding is the preferred method for

attaching of panels and should be used

whenever possible. Where the spot welding

equipment available will not access the

required weld position, a plug weld should be

performed.

• The same number and position of spot welds

(or plug welds) should be used when

replacing the panel, as was used during

manufacture, in order to maintain the original

structural strength of the vehicle.

1 As required, mark the new panel with drilling locations in preparation for plug welding. Drill holes as required.

2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as requir ed,

refer to Section 3C Body Construction – Utility.

3 Clamp in position and spot or plug weld the quarter

inner lower rear extension to the side inner upper

panel.

4 Replace the quarter panel extension as previously

described.

5 Replace any other remov ed panels as required.

6 Refinish and paint panels and other components as

required. Refer to Section 3 Body Construction .

7 Apply Joint Sealer (Item 3) as required.

Refer to Section 3C Body Construction – Utility.

8 Apply Cavity Wax (Item 8) as required to the inside of

any box sections or areas inaccessible to paint,

refer to Section 3C Body Construction – Utility.

9 Install the remaining components as described in the

MY2005 VZ Service Information.

Figure 7C – 26

7C Body Side – Utility Page 7C-17

Page 7C-17

2.4 Quarter Outer Lower Rear Panel –

Replace

Remove

1 Remove the adjacent bolt-on panels a nd components

as described in the appropriate Section of the MY2005

VZ Service Information.

2 Remove the adjacent panels as required, refer to the

appropriate procedure in this Section.

Figure 7C – 27

3 Spot cut the welds attaching the rear quarter panel

and quarter panel extension to the qu arter outer lower

rear panel.

Figure 7C – 28

7C Body Side – Utility Page 7C-18

Page 7C-18

4 Spot cut the welds attaching the quarter outer lo wer

rear panel (1) to the side inner upper panel (2) and

load floor panel (3), refer to View A-A.

NOTE

If the rear quarter panel was removed, cut these

welds from the outer side.

5 Spot cut the two welds attaching the quarter outer

lower rear panel (1) to the side inner upper pane l (2),

refer to View B-B.

NOTE

These two welds are hidden behind the load

floor flange. If the rear quarter panel has been

removed cut them from the outer side. If it wasn’t

removed, locate the spots through the inner

panel opening and drill through the flange and

side inner upper panel.

6 Remove the quarter outer lower rear pa nel from the

vehicle, then repair any damage to adjacent parts as

required.

Figure 7C – 29

Replace

NOTE

• Spot welding is the preferred method for

attaching of panels and should be used

whenever possible. Where the spot welding

equipment available will not access the

required weld position, a plug weld should be

performed.

• The same number and position of spot welds

(or plug welds) should be used when

replacing the panel, as was used during

manufacture, in order to maintain the original

structural strength of the vehicle.

1 As required, mark the new panel with drilling locations in preparation for plug welding. Drill holes as required.

2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as requir ed,

refer to Section 3C Body Construction – Utility.

3 Spot or plug weld the quarter outer lower rear panel to

the side inner upper panel and load floor flange.

Figure 7C – 30

7C Body Side – Utility Page 7C-19

Page 7C-19

4 Spot or plug weld the quarter outer lower rear panel to

the rear quarter panel and quarter panel extension.

5 Replace any removed panels as required, refer to the

appropriate procedure in this Section.

6 Refinish and paint panels and other components as

required. Refer to Section 3 Body Construction .

7 Apply Joint Sealer (Item 3) as required.

Refer to Section 3C Body Construction – Utility.

8 Apply Cavity Wax (Item 8) as required to the inside of

any box sections or areas inaccessible to paint,

refer to Section 3C Body Construction – Utility.

9 Install the remaining components as described in the

MY2005 VZ Service Information. Figure 7C – 31

7C Body Side – Utility Page 7C-20

Page 7C-20

2.5 Quarter Lower Rear Panel – Replace

1 Remove the adjacent bolt-on panels a nd components

as described in the appropriate Section of the MY2005

VZ Service Information.

2 Remove the adjacent panels as required, refer to the

appropriate procedure in this Section.

Figure 7C – 32

3 Spot cut the welds attaching the quarter lower rear

panel to the:

• side inner upper panel, three places,

• quarter panel extension, three places,

• rear end lower panel, one place,

• rear end panel, three plac es.

4 Carefully grind the MIG weld along the quarter lower

rear panel and rear end lower panel join.

Figure 7C – 33

5 If the quarter panel extension (1) was removed, spot

cut the four welds attaching the quarter lower rear

panel to the side inner upper panel (A).

NOTE

If the quarter panel extension was not removed,

spot cut through the side inner upper panel and

load floor panel, the four welds attaching the

quarter lower rear panel to the side inner upper

panel (B).

6 Carefully grind the MIG weld (2) along the quarter

lower rear panel and side inner upp er panel join.

7 Remove the panel from the vehicle, then repair any

damage to adjacent parts as required.

Figure 7C – 34

7C Body Side – Utility Page 7C-21

Page 7C-21

Replace

NOTE

• Spot welding is the preferred method for

attaching of panels and should be used

whenever possible. Where the spot welding

equipment available will not access the

required weld position, a plug weld should be

performed.

• The same number and position of spot welds

(or plug welds) should be used when

replacing the panel, as was used during

manufacture, in order to maintain the original

structural strength of the vehicle.

1 As required, mark the new panel with drilling locations in preparation for plug welding. Drill holes as required.

2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as requir ed,

refer to Section 3C Body Construction – Utility.

3 If the quarter panel extension (1) was removed, spot

or plug weld four places, the quarter lower rear panel

to the side inner upper panel (A).

NOTE

If the quarter panel extension was not removed,

spot or plug weld the quarter lower rear panel

through the side inner upper p anel and load floo r

panel, four places (B).

Figure 7C – 35

4 Spot or plug weld the quarter lo wer rear panel to the:

• side inner upper panel, three places,

• quarter panel extension, three places,

• rear end lower panel, one place,

• rear end panel, three plac es.

5 MIG weld along the quarter lower rear panel, side

inner upper panel and rear en d panel join.

6 Replace any other remov ed panels as required.

7 Refinish and paint panels and other components as

required. Refer to Section 3 Body Construction .

8 Apply Joint Sealer (Item 3) as required.

Refer to Section 3C Body Construction – Utility.

9 Apply Cavity Wax (Item 8) as required to the inside of

any box sections or areas inaccessible to paint,

refer to Section 3C Body Construction – Utility.

10 Install the remaining components as described in the

appropriate Section of the MY2005 VZ Service

Information.

Figure 7C – 36

7C Body Side – Utility Page 7C-22

Page 7C-22

2.6 Door Opening Frame Assembly –

Replace

Remove

NOTE

• This procedure requires the removal of the

roof panel. As an alternative, the door

opening frame assembly can be cut at the

upper pillar sections by following the

procedures in 2.7 Door Opening Frame

Assembly – Partial Replace, Hinge Pillar and

2.8 Door Opening Frame Assembly – Partial

Replace, Centre Pillar.

• Cavity Foam is used within the hinge and

centre pillar cavities. Care is required when

repairing the vehicle in these areas, refer to

Section 2 Precautions prior to beginning any

work for further information.

1 Remove the adjacent bolt-on panels a nd components

as described in the appropriate Service Information.

2 Remove the windshield and the rear window

assemblies, refer to Section 1A6 Stationary Windows

in the MY2005 VZ Service Information.

3 Remove the dash panel retaining bolt from the hinge

pillar.

4 Remove the roof panel, refer to Section 9C Roof.

5 Remove the rear quarter panel,

refer to 2.1 Rear Quarter Panel – Replace.

6 Remove the front wheelhouse pan el upper side rail,

refer to Section 4 Front End. Figure 7C – 37

7 Spot cut the welds attaching the door openin g frame

assembly to the inner rocker panel and to the hin ge

pillar inner panel assembly.

NOTE

In order to spot cut the uppermost of these welds

it may be necessary to cut and peel back the

section of hinge reinforcement panel covering

the welds, to gain the required access.

Figure 7C – 38

7C Body Side – Utility Page 7C-23

Page 7C-23

8 Spot cut the two welds at the base of the hinge pillar,

attaching the door opening frame assembly (1) to the

hinge pillar inner panel assembly (2).

Figure 7C – 39

9 Spot cut the welds on the windshield side flange,

attaching the door opening frame assembly (1) to the

hinge pillar inner panel assembly (2).

10 Spot cut along the vertical flange below the rocker

panel to separate the door opening frame assembly

from the inner rocker panel, refer to Figure 7C – 41.

Figure 7C – 40

Figure 7C – 41

11 Spot cut from below, up into the rocker panel, the welds attaching the door opening frame assembly to the quarter

panel inner assembly, refer to Figure 7C – 42.

7C Body Side – Utility Page 7C-24

Page 7C-24

Figure 7C – 42

12 Spot cut the welds around the rear wheel arch, joining

the door opening frame assembly (1) to the quarter

panel inner assembly (2).

NOTE

Some welds may have been removed with the

quarter panel.

Figure 7C – 43

13 Spot cut the welds along the roof flange.

NOTE

Many of these welds may have been removed

with the roof panel.

Figure 7C – 44

7C Body Side – Utility Page 7C-25

Page 7C-25

14 Spot cut the welds attaching the door openin g frame

assembly to the side inner upper front panel.

15 Grind off the MIG weld (1) attaching the door opening

frame assembly to the front seatback panel.

16 Grind off the MIG weld (2) attaching the door opening

frame assembly to the side inner upper front panel.

Figure 7C – 45

17 Spot cut the welds attaching the door openin g frame

assembly to the roof rear panel.

Figure 7C – 46

18 Spot cut the welds on the flange surrounding the front

door opening, attaching the door op ening frame

assembly to the hinge pillar inner assembly, inner

rocker panel and quarter panel in ner assembly.

19 Spot cut the welds attaching the door openin g frame

assembly to the side inner upper front panel, side

inner upper panel and quarter panel inner assembl y,

refer to Figure 7C – 48.

NOTE

Welds marked # may have been removed with

the rear quarter panel.

20 Remove the complete door opening frame assembly

and repair any dama ge to adjacent parts.

21 Check and rectify the alignme nt of

the body shell as required,

refer to Section 3C Body Construction – Utility. Figure 7C – 47

7C Body Side – Utility Page 7C-26

Page 7C-26

Figure 7C – 48

Replace

NOTE

• Spot welding is the preferred method for

attaching of panels and should be used

whenever possible. Where the spot welding

equipment available will not access the

required weld position, a plug weld should be

performed.

• The same number and position of spot welds

(or plug welds) should be used when

replacing the panel, as was used during

manufacture, in order to maintain the original

structural strength of the vehicle.

1 As required, mark the new panel with drilling locations in preparation for plug welding. Drill holes as required.

2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required,

refer to Section 3C Body Construction – Utility.

3 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3C Body Construction – Utility.

7C Body Side – Utility Page 7C-27

Page 7C-27

4 Securely clamp the door openin g frame assembly in

position on the vehicle body.

5 Begin attaching the door opening frame assembly by

spot welding around the front door opening flange.

Figure 7C – 49

6 Spot weld the door opening frame assembly to the

roof rear panel.

7 Spot or plug weld the door opening frame assembly to

the side inner upper front panel, side inner u pper

panel and quarter pane l inner assembly,

refer to Figure 7C – 51.

Figure 7C – 50

7C Body Side – Utility Page 7C-28

Page 7C-28

Figure 7C – 51

8 Spot or plug weld the door opening frame assembly

along the roof flange.

NOTE

The remaining welds are made when the roof

panel is installed.

Figure 7C – 52

7C Body Side – Utility Page 7C-29

Page 7C-29

9 Spot or plug weld the door opening frame assembly to

the side inner upper front panel.

10 MIG weld 50 mm (1) the door opening frame assembly

to the front seatback panel.

11 MIG weld 20 mm (2) the side inner upper front panel

to the door opening frame assembly.

Figure 7C – 53

12 Spot weld along the windshield flange, attaching the

door opening frame assembly to the hinge pillar inner

panel assembly.

Figure 7C – 54

13 Spot weld in two places at the base of the hinge pillar,

attaching the door opening frame assembly (1) to the

hinge pillar inner panel assembly (2).

Figure 7C – 55

7C Body Side – Utility Page 7C-30

Page 7C-30

14 Spot or plug weld the door opening frame assembly to

the inner rocker panel and to the hinge pillar inner

panel assembly.

NOTE

If the sheet metal was modified to allow access

to these welds, it should be repaired to its

original configuration.

15 Spot weld the door opening frame assembly along the

vertical flange below the rocker panel,

refer to Figure 7C – 57.

Figure 7C – 56

Figure 7C – 57

16 Plug weld up through the rocker panel to attach the door opening frame assembly to the quarter p anel inner

assembly, refer to Figure 7C – 58.

Figure 7C – 58

7C Body Side – Utility Page 7C-31

Page 7C-31

17 Spot or plug weld in two places arou nd the rear wheel

arch, attaching the door opening frame assembly to

the quarter panel inner assembl y.

NOTE

These welds will be completed when the rear

quarter panel is replaced.

Figure 7C – 59

18 Replace front wheelhous e panel upper side rail, refer to Section 4 Front End.

19 Replace the roof panel, refer to Section 9 Roof.

20 Replace the rear quarter panel, refer to 2.1 Rear Quarter Pane l – Replace.

21 Install the door hinges, refer to Section 8 Do ors, Liftgate and Endgate.

22 Refinish and paint panels and other components as required. Refer to Section 3 Body Construction.

23 Apply Joint Sealer (Item 3) as required. Refer to Section 3C Body Construction – Utility.

24 Apply Cavity Wax (Item 8) as required to the inside of any box secti ons or areas inaccessible to paint,

refer to Section 3C Body Construction – Utility.

25 Apply Spray-on Dea dener (Item 7) where applicab le, refer to Section 3C Body Construc tion – Utility.

26 Install the dash panel retaining bolt throu gh the hinge pil lar and tighten to the specified torque.

Dash panel retaining b olt

torque specification.................................35.0 – 45.0 Nm

27 Replace the windshield and the rear window assembly, refer to Section 1A 6 Stationary Windows in the MY2005 VZ

Service Information.

28 Insert Cavity Foam into the hinge and centre pillars as required, refer to Section 2 Precautions.

29 Install the remaining components as described in the appr opriate Section of the MY2005 VZ Service Information.

7C Body Side – Utility Page 7C-32

Page 7C-32

2.7 Door Opening Frame Assembly – Partial

Replace, Hinge Pillar

Remove

NOTE

Cavity Foam is used within the hinge and

centre pillar cavities. Care is required when

repairing the vehicle in these areas, refer to

Section 2 Precautions prior to beginning work for

further information.

1 Remove the adjacent bolt-on panels a nd components

as described in the appropriate Section of the MY2005

VZ Service Information.

2 Secure an appropriate tool between the front door

opening flanges to maintain correct bod y alignment.

3 Remove the windshield, refer to

Section 1A6 Stationary Windows in the MY2005 VZ

Service Information.

4 Remove the dash panel retaining bolt from the hinge

pillar.

5 Remove the front wheelhouse pan el upper side rail,

refer to Section 4 Front End. Figure 7C – 60

6 Spot cut the welds attaching the door openin g frame

assembly to the inner rocker panel and to the hin ge

pillar inner panel assembly.

NOTE

In order to spot cut the uppermost of these welds

it may be necessary to cut and peel back the

section of hinge reinforcement panel covering

the welds, to gain the required access.

Figure 7C – 61

7C Body Side – Utility Page 7C-33

Page 7C-33

7 Spot cut the two welds at the base of the hinge pillar,

attaching the door opening frame assembly (1) to the

hinge pillar inner panel assembly (2).

Figure 7C – 62

8 Select a cutting point on the hinge pillar. This cut point

should be within the region specified.

Figure 7C – 63

9 At the selected point (1), cut through the outer and

reinforcement panels, leaving the inner panel intact.

10 Mark the inner panel at points 50 mm either side of the

cut line on the outer panel and cut the inner panel at

these two points (2). Spot cut the welds and remove

the 100 mm section of inner panel (3).

Figure 7C – 64

7C Body Side – Utility Page 7C-34

Page 7C-34

11 Spot cut the welds on the windshield side flange, up to

the point of the cut.

Figure 7C – 65

12 Cut through the rocker panel section of the frame door

opening assembly. The cut point (1) should be

approximately 100 mm from the dimple (2) on the

flange. Cut through both the outer pane l and the

reinforcement panel.

Figure 7C – 66

13 Spot cut the welds on the flange along the front door

opening, from the cut near the top of the hinge pill ar

(1) to the cut in the rocker panel (2).

14 Spot cut the welds along the flange (3) below the

rocker panel (to the point of the cut), separ ating the

door opening frame assembly from the inner rocker

panel.

15 Remove the partial hinge p illar from the vehicle, then

repair any damage to adjacent parts.

16 Check and rectify the alignme nt of

the body as requir ed,

refer to Section 3C Body Construction – Utility.

Figure 7C – 67

7C Body Side – Utility Page 7C-35

Page 7C-35

Replace

NOTE

• Spot welding is the preferred method for

attaching of panels and should be used

whenever possible. Where the spot welding

equipment available will not access the

required weld position, a plug weld should be

performed.

• The same number and position of spot welds

(or plug welds) should be used when

replacing the panel, as was used during

manufacture, in order to maintain the original

structural strength of the vehicle.

1 Cut a replacement panel section (1), accurately

measuring the position of cuts to match the section

removed.

Figure 7C – 68

2 Remove a section of inner rocker panel (1), cut 50 mm

each side of the cut in the rocker panel (2). This all ows

access for welding the rocker panel reinf orcement.

Figure 7C – 69

7C Body Side – Utility Page 7C-36

Page 7C-36

3 Either manufacture a new section or cut an existing

length of surplus rocker panel section, to form a

reinforcement (1), approximately 100 mm in length.

4 Prepare all mating surfaces and treat with Weld

Through Primer (Item 1) as required,

refer to Section 3C Body Construction – Utility.

5 Clamp this reinforcement firmly behind the cut section

of rocker panel on the vehicle and spot or plug weld in

place. Position welds at a maximum spacing of 35 mm

apart.

Figure 7C – 70

6 Using a similar technique, ma nufacture or cut a

section of reinforcement panel (1) appro ximat ely

60 mm long, to fit on the inside the outer panel of the

replacement hinge pillar (2) at the point of th e cut.

NOTE

Remove the flanges from this reinforcement

panel.

7 Prepare all mating surfaces and treat with Weld

Through Primer (Item 1) as required,

refer to Section 3C Body Construction – Utility.

8 Clamp the reinforcement panel firmly behind the outer

panel of the cut section of the hinge pillar and spot

weld (3) in place.

9 Mark the new hinge pillar with drilling locations in

preparation for plug welding where required. Drill holes

as marked.

10 Prepare all mating surfaces and treat with Weld

Through Primer (Item 1) as required,

refer to Section 3C Body Construction – Utility.

11 Apply Acrylic Spot Weld Sealer (Item 2),

refer to Section 3C Body Construction – Utility.

Figure 7C – 71

12 Clamp the replacement panel in position on the

vehicle and check the door opening dimensions.

Refer to Section 3C Body Construction – Utility. Adjust

position as required.

Figure 7C – 72

7C Body Side – Utility Page 7C-37

Page 7C-37

13 Plug weld (1) the top of the pillar to the manufactured

reinforcement, then MIG butt weld (2) the two sections

together.

Figure 7C – 73

14 Plug weld (1) the new panel in the rocker panel region,

then MIG butt weld (2) the two sections together.

Figure 7C – 74

15 Gaining access through the removed sectio n of inner

panel, MIG butt weld (1) the reinforcement panel

together.

16 Butt weld the removed access panel (2) in position.

Replace the spot welds with the same number that

was removed.

Figure 7C – 75

7C Body Side – Utility Page 7C-38

Page 7C-38

17 Spot weld (1) the hinge pillar section along the door

opening flange.

18 Spot weld (2) the flange beneath the rocker pan el,

attaching the new panel to the inner rocker panel.

Figure 7C – 76

19 Spot weld (1) the pillar along the windshield opening

flange.

Figure 7C – 77

20 Spot weld in two places at the base of the hinge pillar,

attaching the door opening frame assembly (1) to the

hinge pillar inner panel assembly (2).

Figure 7C – 78

7C Body Side – Utility Page 7C-39

Page 7C-39

21 Spot or plug weld the door opening frame assembly to

the inner rocker panel and to the hinge pillar inner

panel assembly. If the sheetmetal was modified to

allow access to these welds, it should be repaired to

its original configuration.

Figure 7C – 79

22 Gaining access through the section of removed in ner

rocker panel, MIG butt weld (1) the new section of

rocker panel reinforcement to the existing section.

23 Replace the removed section of inner rocker panel (2)

by MIG butt welding it in place and spot welding it

along the door opening flange. Replace the spot welds

with the same number of as were cut out.

24 Install the door hinges,

refer to Section 8 Doors, Liftgate and Endgat e.

25 Refinish and paint panels and other components as

required. Refer to Section 3 Body Construction .

26 Apply Joint Sealer (Item 3) as required.

Refer to Section 3C Body Construction – Utility. Figure 7C – 80

27 Apply Cavity Wax (Item 8) as required to the inside of any box secti ons or areas inaccessible to paint,

refer to Section 3C Body Construction – Utility.

28 Install the dash panel bolt through the hinge pillar and tighten to the specified torque.

Dash Panel Retaining Bolt

Torque Specification ...............................35.0 – 45.0 Nm

29 Replace the windshield, refer to Section 1A6 Stationary Windows in the MY2005 VZ Service Information.

30 Insert Cavity Foam into the hinge pillar as required, refer to Section 2 Precautions.

31 Install the remaining components as described in the appr opriate Section of the MY2005 VZ Service Information.

7C Body Side – Utility Page 7C-40

Page 7C-40

2.8 Door Opening Frame Assembly – Partial

Replace, Centre Pillar

NOTE

Cavity Foam is used within the hinge, centre and

lock pillar cavities. Care is required when

repairing the vehicle in these areas, refer to

Section 2 Precautions prior to beginning any work

for further information.

Remove

1 Remove the adjacent bolt-on panels a nd components

as described in the appropriate Section of the MY2005

VZ Service Information.

2 Install the vehicle on a suitab le fixture. As a minimum,

support the appropriate structural sections of the

vehicle on safety stands. Secure a suitable tool

between the front door openi ng flanges to maintain

alignment.

3 Remove the rear quarter panel,

refer to 2.1 Rear Quarter Panel – Replace.

Figure 7C – 81

4 Cut the door opening frame a ssembly (1) as shown.

NOTE

The upper cut is just below the recess and the

lower cut is approximately level with the centre

pillar upper reinforcement.

5 Spot cut the two welds attaching door opening frame

assembly to the centre pillar reinforcement.

6 Spot cut the welds attaching the door openin g frame

assembly to the quarter panel inner assembly.

7 Referring to Figure 7C – 83, spot cut the welds

attaching the underbody jacking locator (1) and

remove.

8 Referring to Figure 7C – 83, cut through the door

opening frame assembly (2) in two places shown (3):

• At the join of the rocker panel reinforcement (4)

and centre pillar lower reinforcement (5) for the

front cut, and

• At the dimple in the flange for the rear cut.

Figure 7C – 82

NOTE

Make the front cut carefully as the rocker panel

reinforcement (4) must not be cut. The centre

pillar lower reinforcement (5) is removed with the

centre pillar section.

9 Spot cut the welds on the flange attaching the centre pillar section to the inner rocker panel (6).

Refer to weld group A.

10 Spot cut the welds on the underside of the rocker panel attachi ng the centre pillar section to the quarter panel inner

assembly (7). Refer to weld group B.

7C Body Side – Utility Page 7C-41

Page 7C-41

Figure 7C – 83

11 Spot cut the welds attaching the front and rear sides of

the door opening frame assembly to the quarter panel

inner assembly.

NOTE

The number of welds will vary depending on the

cut locations.

12 Spot cut the four welds attaching the centre pillar

upper reinforcement to the centre pillar reinforcement.

13 Remove the centre pillar section from the vehicle.

14 Repair any damage to adjacent parts as required.

Figure 7C – 84

7C Body Side – Utility Page 7C-42

Page 7C-42

Replace

NOTE

• Spot welding is the preferred method for

attaching of panels and should be used

whenever possible. Where the spot welding

equipment available will not access the

required weld position, a plug weld should be

performed.

• The same number and position of spot welds

(or plug welds) should be used when

replacing the panel, as was used during

manufacture, in order to maintain the original

structural strength of the vehicle.

1 Cut the replacement door opening frame assembly

through rocker section as shown. Accurately measure

the position of cuts to match the removed panel

section.

Figure 7C – 85

2 Cut the replacement door opening frame assembly

below the recess to match the removed section from

the vehicle (1).

NOTE

Cut through the outer panel onl y.

3 Make a second cut approximately level with the centre

pillar upper reinforcement (2).

NOTE

Cut through the flange and front side onl y.

4 Cut the required spot welds and carefull y bend the

outer panel down to expose the spot welds attaching

the centre pillar upper reinforc ement to the centre

pillar reinforcement.

Figure 7C – 86

7C Body Side – Utility Page 7C-43

Page 7C-43

5 On the replacement panel, spot cut the five welds

attaching the centre pillar lower section to the centre

pillar upper reinforcement and remove the s ection.

Figure 7C – 87

6 Cut two sections from surplus rocker panel pieces, or

manufacture new sections (1), each ap proximately

100 mm in length.

7 Prepare the mating surfaces and treat with Weld

Through Primer (Item 1) as required,

refer to Section 3C Body Construction – Utility.

8 Clamp these sections firmly behi nd both the cut faces

of rocker panel on the vehicle and spot or plug weld in

place. Perform the welds at a maximum spacing of

35 mm.

9 Mark the new panel with drilling locations in

preparation for plug welding where required. Drill holes

as marked.

10 Prepare the mating surfaces and treat with Weld

Through Primer (Item 1) as required,

refer to Section 3C Body Construction – Utility.

Figure 7C – 88

7C Body Side – Utility Page 7C-44

Page 7C-44

11 Install the replacement panel i n position, sliding the

centre pillar reinforcement (1) and the centre pillar

lower reinforcement (2) behind the centre pillar upper

reinforcement (3), until the front edge of the lo wer

reinforcement butts against the front edge of the upper

reinforcement.

12 Manipulate the rocker panel section in position,

inserting the front first, then the rear and clamp the

assembly in place.

Figure 7C – 89

13 Plug weld the centre pillar upper reinforcement to the

centre pillar lower reinforcement, two places and the

centre pillar reinforcement two places.

Figure 7C – 90

14 Bend the outer panel back in position and MIG butt

weld the sections together as shown (1) and (2).

15 Plug weld the outer panel, centre pillar up per

reinforcement and centre pillar reinforcement two

places.

Figure 7C – 91

7C Body Side – Utility Page 7C-45

Page 7C-45

16 Plug weld (1) the front and rear sides of the door

opening frame assembly to the quarter panel inner

assembly.

NOTE

The number of welds will vary depending on the

cut locations.

17 Plug weld (2) the front and rear sides of the door

opening frame assembly to the rocker panel

reinforcements.

18 MIG butt weld (3) each join across the rocker panel.

Figure 7C – 92

19 Plug weld the flange attaching the centre pil lar section

(1) to the inner rocker panel (2).

Refer to weld group A.

20 Plug weld on the underside of the rocker panel the

centre pillar section to the quarter panel inner

assembly (3). Refer to weld group B.

21 Install the door hinges,

refer to Section 8 Doors, Liftgate and Endgat e.

22 Dress the welds by grinding or sanding, ensuring

sufficient material remains to guarantee the strength of

the weld. Finish the area using an appropriate

technique.

23 Refinish and paint panels and other components as

required. Refer to Section 3 Body Construction .

24 Apply Joint Sealer (Item 3) as required.

Refer to Section 3C Body Construction – Utility.

25 Apply Cavity Wax (Item 8) as required to the inside of

any box sections or areas inaccessible to paint,

refer to Section 3C Body Construction – Utility.

26 Insert Cavity Foam into the centre pillar as r equired,

refer to Section 2 Precautions.

27 Install the remaining components as described in the

appropriate Section of the MY2005 VZ Service

Information.

Figure 7C – 93

7C Body Side – Utility Page 7C-46

Page 7C-46

2.9 Door Opening Frame Assembly – Partial

Replace, Rocker Panel

As there are several critical reinforcements in

the lower hinge pillar area, the rocker panel

section must not be cut forward of the area

shown. If the rocker panel is damaged

forward of this area, replace the rocker panel

and partial hinge pillar as one section. Modify

this procedure accordingly, also referring to

2.7 Door Opening Frame Assembly – Partial

Replace, Hinge Pillar.

Remove

1 Remove the adjacent bolt-on panels a nd components

as described in the appropriate Section of the MY2005

VZ Service Information.

2 Remove the rear quarter panel,

refer to 2.1 Rear Quarter Panel – Replace.

3 Secure the vehicle on a suitable fixture. As a

minimum, support the appropriate structural s ections

of the vehicle on safety stands. Install suitable bracing

in the vehicle to ensure the correct body alignment is

maintained when the rocker pane l section is removed.

4 Remove the rear quarter panel,

refer to 2.1 Rear Quarter Panel – Replace.

Figure 7C – 94

5 Cut through the door opening frame assembly (1) and

the rocker panel reinforcement, no further forward than

the dimple in the flange (2).

Figure 7C – 95

7C Body Side – Utility Page 7C-47

Page 7C-47

6 Using a suitable cutting tool, cut through the centre

pillar. Cut through both the door opening frame (1) and

centre pillar lower reinforcement (2).

Figure 7C – 96

7 If required, select a cutting point through the rocker

panel, anywhere rearward of the dimple (1) i n the

flange. Cut through the door opening frame assembly

(2) only.

NOTE

If required, it may be preferable to remove the

complete rear section.

Figure 7C – 97

8 Depending on the cut location, spot cut any welds

remaining around the wheelhouse as required (most

would have been removed with the rear quarter

panel), attaching the door opening frame assembly (1)

to the quarter panel inner assembly (2).

9 Spot cut along the flange below the rocker panel as

required, to separate the rocker pan el section

(including the underbody jacking locator) from the

inner rocker panel and quarter panel inner assembly.

Refer to Figure 7C – 99.

NOTE

Some of these welds may have been previously

removed with the rear quarter panel.

Figure 7C – 98

7C Body Side – Utility Page 7C-48

Page 7C-48

Figure 7C – 99

10 Spot cut the welds attaching the rocker panel section to the quarter p an el inner assembly as required.

Refer to Figure 7C – 100.

NOTE

Depending on t he cut line position, ma ny of these

welds may have been previously removed if the

rear quarter panel has been remove d.

Figure 7C – 100

11 As required, spot cut the welds along the edge of the door ope ning frame assembly, refer to Figure 7C – 101.

12 Remove the panel from the vehicle, then repair any damage to adjac ent parts.

13 Check and rectify the alignme nt of the body as required, refer to Section 3 C Body Construction – Utility.

Figure 7C – 101

7C Body Side – Utility Page 7C-49

Page 7C-49

Replace

NOTE

• Spot welding is the preferred method for

attaching of panels and should be used

whenever possible. Where the spot welding

equipment available will not access the

required weld position, a plug weld should be

performed.

• The same number and position of spot welds

(or plug welds) should be used when

replacing the panel, as was used during

manufacture, in order to maintain the original

structural strength of the vehicle.

1 Cut a new replacement rocker panel section. Accuratel y measure the p ositi on of the cuts on the removed section.

2 Remove a section of inner rocker panel (1), cut 50 mm

each side of the cut in the rocker panel. This allows

access for welding the rocker panel reinf orcement.

Figure 7C – 102

3 Manufacture or cut a reinforcement (1) (appr oximately

100 mm long) to fit on the inside of the existing rocker

panel at the point of the cut.

4 Prepare the mating surfaces and treat with Weld

Through Primer (Item 1) as required,

refer to Section 3C Body Construction – Utility.

5 Clamp the manufactured reinforcement firmly to the

inside of the rocker panel section of the d oor opening

frame assembly on the vehicle and plug weld in

position. Position welds at a maximum sp acing of

35 mm.

6 If the rear section has been cut, repeat the above

steps for the rear join. Figure 7C – 103

7 Manufacture or cut a reinforcement (1) (appr oximately

100 mm long) to fit inside of the existing centre pillar

section at the point of the cut.

8 Prepare the mating surfaces and treat with Weld

Through Primer (Item 1) as required,

refer to Section 3C Body Construction – Utility.

9 Clamp the manufactured reinforcement panel firmly to

the inside of the outer panel of the door opening frame

assembly on the vehicle and p lug weld in position.

Position welds at a maximum spacing of 35 mm.

10 Mark the replacement rocker panel section with drilling

positions in preparation for plug welding as required.

Figure 7C – 104

7C Body Side – Utility Page 7C-50

Page 7C-50

NOTE

The outer panel will be plug welded from the

outer side of the vehicle, while the rocker panel

and centre pillar reinforcements will be butt

welded from the inner side of the vehicle.

11 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required,

refer to Section 3C Body Construction – Utility.

12 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3C Body Construction – Utility.

13 Install the replacement section onto the vehicle by sliding the front and centre pillar sections onto the

reinforcements, while lifting the rear into posi tion.

14 Clamp the panel in position.

15 Weld the new section to the centre pillar by plug

welding (1).

16 MIG butt weld the centre pillar reinforcement from

inside the centre pillar, through the large ho le in the

inner panel immediately behind the weld.

17 Finish the centre pillar attachment by MIG welding (2)

along the join of the outer panel.

Figure 7C – 105

18 Plug weld (1) the replacement section at the front join,

then MIG butt weld (2) the two sections together.

19 Repeat for the rear join if required.

Figure 7C – 106

7C Body Side – Utility Page 7C-51

Page 7C-51

20 Gaining access through the section of removed floor

side panel, MIG butt weld (1) the new section of rocker

panel reinforcement to the existing section.

21 Replace the removed section of floor side panel (2) by

MIG butt welding it in place and spot welding it along

the door opening flange. Repl ace the spot welds with

the same number as were removed.

22 Spot or plug weld the flanges of the door opening

frame assembly as required, refer to Figure 7C – 108.

NOTE

Use the same number and position of welds as

removed during removal. Figure 7C – 107

Figure 7C – 108

23 Spot or plug weld the door opening frame along the flange below the rocker panel as required,

refer to Figure 7C – 109.

NOTE

Place several welds only where the rear quarter

panel will overlap the flange to hold the

replacement section in position. Fully spot weld

this flange when the rear quarter panel is being

attached, welding through all panels.

Figure 7C – 109

7C Body Side – Utility Page 7C-52

Page 7C-52

24 Plug weld up through the rocker panel to attach the replacement section to the quarter panel inner assembly.

Refer to Figure 7C – 110.

NOTE

Place several welds only where the rear quarter

panel will overlap the flange to hold the

replacement section in position. Fully spot weld

this flange when the rear quarter panel is being

attached, welding through all panels.

Figure 7C – 110

25 If required, spot weld the replacement section to the

quarter panel inner assembly around the rear wheel

arch at several places to retain new section in position

NOTE

Fully spot weld this flan ge when the r ear quarter

panel is installed, welding through all three

panels.

26 Clean up the welds made where the rear quarter panel

is located and prime all bare metal.

27 Install the rear quarter panel,

refer to 2.1 Rear Quarter Panel – Replace.

28 Refinish and paint panels and other components as

required. Refer to Section 3 Body Construction .

29 Apply Joint Sealer (Item 3) as required.

Refer to Section 3C Body Construction – Utility.

30 Apply Cavity Wax (Item 8) as required to the inside of

any box sections or areas inaccessible to paint,

refer to Section 3C Body Construction – Utility.

31 Install the remaining components as described in the

appropriate Section of the MY2005 VZ Service

Information.

Figure 7C – 111

7C Body Side – Utility Page 7C-53

Page 7C-53

2.10 Fender Lower Rear Bracket – Replace

The fender lower rear bracket (1) is spot welded at four

places to the door opening fra m e assembly.

Clamp the fender lower rear bracket positi on as shown prior

to plug welding and check the alig nment of the fender to the

body and front door.

Refinish and paint panels and other components as

required. Refer to Section 3 Body Construction .

Apply Cavity Wax (Item 8) as r equired to the inside of any

box sections or areas inaccessible to paint,

refer to Section 3C Body Construction – Utility.

Figure 7C – 112

7C Body Side – Utility Page 7C-54

Page 7C-54

2.11 Hinge Pillar Inner Panel Assembly –

Replace

Remove

1 Remove the adjacent bolt-on panels a nd components

as described in the appropriate Section of the MY2005

VZ Service Information.

2 Remove the door opening frame assembly, refer to

2.6 Door Opening Frame Assembly – Repl ace, or

remove the hinge pillar section of the door opening

frame assembly, refer to 2.7 Door Opening Frame

Assembly – Partial Replace, Hinge Pil lar .

3 If required, remove the dash panel assembl y, refer to

Section 5 Cockpit Module in this Supplement.

NOTE

If the cockpit module is not damaged an

alternative is provided in this p rocedure.

4 Add bracing as requir ed to maintain the alignment of

the vehicle structure.

Figure 7C – 113

5 Grind the MIG welds (1) attaching the hinge pill ar inner

panel assembly to the inner rocker panel.

Figure 7C – 114

6 Spot cut the welds attaching the hinge pillar i nner

panel assembly to the roof front header and quarter

panel inner extension.

NOTE

Structural adhesive is applied to join (1). If the

roof panel has not been removed, it will be very

difficult to remove the panel. As an alternative:

• If only the lower section is damaged, detach

the hinge pillar inner upper panel (1) from the

hinge pillar inner lo wer panel (2) and replac e

the lower panel, or

• Cut the hinge pillar inner panel assembly (3)

approximately 50 mm from the top

of the windscreen aperture. If a partial

replacement of the door opening frame

assembly is being performed, this point is

50 mm above the cut in the outer panels (4).

Refer to Figure 7C – 116.

Figure 7C – 115

7C Body Side – Utility Page 7C-55

Page 7C-55

Figure 7C – 116

7 Spot cut the welds attaching the hinge pillar i nner

panel assembly to the front wheelhouse panel and

front floor panel extension, refer to weld group A.

8 If the dash panel assembly was not removed, spot cut

the eight welds attaching the adhesive channels to the

hinge pillar inner panel assembly,

refer to weld group B.

9 If required, remove any remainin g spot welds where

the wheelhouse panel upper side rail attached the

front wheelhouse panel a nd hinge pillar inner panel

assembly.

10 Cut the adhesive between the dash panel assembl y

and hinge pillar inner panel assembly.

11 Remove the hinge pillar in ner panel assembly from the

vehicle and as required, cle an off any remaining

adhesive and ensure the adhesive channels are

removed.

12 Repair any damage to adjacent parts as required. Figure 7C – 117

7C Body Side – Utility Page 7C-56

Page 7C-56

Replace

NOTE

• Spot welding is the preferred method for

attaching of panels and should be used

whenever possible. Where the spot welding

equipment available will not access the

required weld position, a plug weld should be

performed.

• The same number and position of spot welds

(or plug welds) should be used when

replacing the panel, as was used during

manufacture, in order to maintain the original

structural strength of the vehicle.

1 If an alternate removal method was used, referring to Figure 7C – 116, either:

• Cut the replacement section to match the cut at the top of the hinge pill ar, or

• Spot cut the welds attaching the hinge pillar i nner upper panel to the hinge pillar inner lower panel.

2 Mark the new panel and drill holes in preparation for plug welding where required.

3 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required,

refer to Section 3C Body Construction – Utility.

4 If the dash panel assembly was removed, it will be installed later, proceed to Step 7.

5 If the dash panel assembly was not removed, prepare the adh esive channels on the replacement section and the

dash panel assembly, refer to Section 5 Cockpit Modu le .

6 Mix the dash panel silic one adhesive refer to Section 5 Cockpit Module . Apply the a dh esive to fill the adhesive

channels on the replaceme nt section.

NOTE

Only the correct material described in

Section 5 Cockpit Module is to be used.

7 If the full hinge pillar inner panel assembly is being replaced, apply structural adhesive (Item 6) to the mating

surfaces of the hinge pillar inner panel as sembly and quarter panel inner extension,

refer to Section 3C Body Construction – Utility.

7C Body Side – Utility Page 7C-57

Page 7C-57

8 Install and clamp the new panel in position on the

vehicle.

NOTE

If the dash panel assembly was not removed,

place the hinge pillar inner panel assembly (1)

slightly lower and slide it upwards ensuring the

dash panel flange (2) seats into the adhesive

channel.

9 Temporarily install the dash p anel attaching bolts

through the hinge pillar i nn er panel assembly and

within the plenum chamber.

10 Finish the application of the dash panel adhesive,

refer to Section 5 Cockpit Module .

Figure 7C – 118

11 If the full hinge pillar inner panel assembly was

removed, spot or plug weld the hinge pillar inner panel

assembly to the roof front header and quarter pane l

inner extension.

NOTE

Ensure the structural adhesive Item 6,

is applied to the join (1)

refer to Section 3C Body Construction – Utility

12 If only the lower section was removed, spot or plug

weld the hinge pillar inner upper panel (1) to the hinge

pillar inner lower panel (2), refer to Figure 7C – 120.

13 If the pillar was cut near the top of the windscreen

aperture, either MIG butt weld the join (3) if the full

door opening frame assembly was remov ed, or make

two tack welds to secure it until the door opening

frame assembly hinge pillar s ection is installed, also

refer to Figure 7C – 120.

Figure 7C – 119

NOTE

This join forms the top access cut point for

joining of the reinforcement as described in

2.7 Door Opening Frame Assembly – Partial

Replace, Hinge Pillar .

7C Body Side – Utility Page 7C-58

Page 7C-58

Figure 7C – 120

14 Spot or plug weld the hinge pillar in ner panel assembly

to the front wheelhouse panel and front floor

extension.

Figure 7C – 121

15 MIG weld two places (1) across the inner rocker panel

and hinge pillar inner panel assembly.

16 Replace the door opening fra me assembly, refer to

2.6 Door Opening Frame Assembly – Repl ace or the

hinge pillar section of the door opening frame

assembly, refer to 2.7 Door Opening Frame Assembly

– Partial Replace, Hinge Pill ar.

17 Refinish and paint panels and other components as

required. Refer to Section 3 Body Construction .

18 Apply Joint Sealer (Item 3) as required.

Refer to Section 3C Body Construction – Utility.

19 Apply Cavity Wax (Item 8) as required to the inside of

any box sections or areas inaccessible to paint,

refer to Section 3C Body Construction – Utility.

20 Install the remaining components as described in the

appropriate Section of the MY2005 VZ Service

Information.

Figure 7C – 122

7C Body Side – Utility Page 7C-59

Page 7C-59

2.12 Quarter Inner and Rear Wheelhouse

Brace – Replace

1 Remove the adjacent bolt-on panels a nd components

as described in the appropriate Section of the MY2005

VZ Service Information.

2 Remove the rear quarter panel,

refer to 2.1 Rear Quarter Panel – Replace.

Figure 7C – 123

3 Spot cut the welds attaching the quarter inner and rear

wheelhouse brace to the qu arter panel inner assemb ly

and side inner upper pa nel, 18 places.

4 If not previously done, spot cut the welds attaching the

quarter inner and rear wheelhouse brace to the side

inner upper panel, two places.

5 Remove the brace and rep air any adjacent damage as

required.

Figure 7C – 124

Replace

NOTE

• Spot welding is the preferred method for

attaching of panels and should be used

whenever possible. Where the spot welding

equipment available will not access the

required weld position, a plug weld should be

performed.

• The same number and position of spot welds

(or plug welds) should be used when

replacing the panel, as was used during

manufacture, in order to maintain the original

structural strength of the vehicle.

1 Mark the new panel with drilling locations in prep aration for plug welding. Drill holes as required.

2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required,

refer to Section 3C Body Construction – Utility.

7C Body Side – Utility Page 7C-60

Page 7C-60

3 Install and clamp the brace in position ensuring it is

located forward of the side inner upper panel hole (1).

4 Spot or plug weld the brace to the side inner upper

panel and quarter, 18 places.

5 Clean up the welds and apply a coat of primer.

6 Install the rear quarter panel,

refer to 2.1 Rear Quarter Panel – Replace.

7 Refinish and paint panels and other components as

required. Refer to Section 3 Body Construction .

8 Apply Joint Sealer (Item 3) as required.

Refer to Section 3C Body Construction – Utility.

9 Apply Cavity Wax (Item 8) as required to the inside of

any box sections or areas inaccessible to paint,

refer to Section 3C Body Construction – Utility.

10 Apply Spray-on Dea dener (Item 7) where applicab le,

refer to Section 3C Body Construction – Utility.

11 Install the remaining components as described in the

appropriate Section of the MY2005 VZ Service

Information.

Figure 7C – 125

7C Body Side – Utility Page 7C-61

Page 7C-61

2.13 Quarter Panel Inner Assembly – Replace

NOTE

This procedure also includes the rear

wheelhouse bracket and rear wheelhouse outer

extension (righ t-hand side only).

Remove

1 Remove the adjacent bolt-on panels a nd components

as described in the appropriate Section of the MY2005

VZ Service Information.

2 Remove rear quarter panel,

refer to 2.1 Rear Quarter Panel – Replace.

3 Remove the door opening frame assembly, refer to

2.6 Door Opening Frame Assembly – Repl ace.

Figure 7C – 126

NOTE

If the damage is to the lower portion of the body,

the partial door opening frame assembly, hinge

pillar and rocker panel sections can be removed.

4 Remove the welds attaching the quarter inner and rear wheelhouse brace to the quarter panel inner asse mbly,

refer to 2.12 Quarter Inner and Rear Wheelhouse Brace – Replace.

5 Spot cut the welds attaching the rear wheelhouse bracket to the quarter panel inner assembly as required,

refer to Figure 7C – 127.

Figure 7C – 127

7C Body Side – Utility Page 7C-62

Page 7C-62

6 Grind the four MIG welds (1) from the inside of the

quarter panel inner assembly, joining the inner rocker

panel.

7 Structural adhesive (2) is applied along the flange

between the quarter panel in ner assembly and inner

rocker panel. Either cut the flange or cut arou nd the

adhesive and grind off the flange once the panel is

removed.

8 Spot cut the welds attaching the quarter panel inner

assembly to the side inner upper panel and side inner

upper front panel, refer to Figure 7C – 129.

NOTE

• If the partial door opening frame assembly

hinge pillar sect ion was removed, remov e the

welds attaching the hinge pillar upper

reinforcement to the quarter panel inner

assembly. Refer to 2.6 Door Opening Frame

Assembly – Replace and cut the welds

attaching the quarter panel inner assemb ly to

the side inner upper front panel from inside

the vehicle.

• For the right-hand side, either remove the

rear wheelhouse outer extension or spot cut

the 10 welds attaching it to the quarter panel

inner assembly.

Figure 7C – 128

7C Body Side – Utility Page 7C-63

Page 7C-63

Figure 7C – 129

9 As required, spot cut any remaining welds from where the door opening frame assembly and re ar quarter panel

attached.

10 Remove the quarter panel inner assembly from the vehicle and repair any damage to adjacent parts as required.

7C Body Side – Utility Page 7C-64

Page 7C-64

Replace

NOTE

• Spot welding is the preferred method for

attaching of panels and should be used

whenever possible. Where the spot welding

equipment available will not access the

required weld position, a plug weld should be

performed.

• The same number and position of spot welds

(or plug welds) should be used when

replacing the panel, as was used during

manufacture, in order to maintain the original

structural strength of the vehicle.

1 Mark the new panel and drill holes in preparation for plug welding where required.

2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required,

refer to Section 3C Body Construction – Utility.

3 Apply structural adhesive (Item 6) to the mating surfac es of the quarter panel inner assembl y and inner rocker

panel, refer to Section 3C Body Construction – Utility.

4 Clamp the new panel in position on the vehicle.

5 Spot or plug weld the quarter panel in ner assembly, to the side inner upper panel and sid e inn er upper front panel,

refer to Figure 7C – 130.

NOTE

For the right-hand side, install the wheelhouse

outer extension (1) if removed, and weld to the

side inner upper panel.

7C Body Side – Utility Page 7C-65

Page 7C-65

Figure 7C – 130

6 Spot or plug weld the rear wheelhous e bracket to quarter panel inner asse mbly, refer to Figure 7C – 131.

Figure 7C – 131

7C Body Side – Utility Page 7C-66

Page 7C-66

7 MIG weld four places 25 – 50 mm each, the quarter

panel inner assembly to the inner rocker pan el (1).

8 Spot or plug the quarter inner and rear wheelhouse

brace to the quarter panel inner assembly, refer to

2.12 Quarter Inner and Rear Wheel house Brace –

Replace.

9 If the centre pillar upper reinforcement was not

removed, spot or plug weld it to the quarter panel inner

assembly, refer to 2.6 Door Opening Frame Assembly

– Replace.

10 Clean up welds and prime any bare metal.

11 Replace the door opening fra me assembly, refer to

2.6 Door Opening Frame Assembly – Repl ace.

12 Replace rear quarter panel,

refer to 2.1 Rear Quarter Panel – Replace.

Figure 7C – 132

13 Refinish and paint panels and other components as required. Refer to Section 3 Body Construction.

14 Apply Joint Sealer (Item 3) as required. Refer to Section 3C Body Construction – Utility.

15 Apply Cavity Wax (Item 8) as required to the inside of any box secti ons or areas inaccessible to paint,

refer to Section 3C Body Construction – Utility.

16 Apply Spray-on Deadener (Item 7) to the wheel side of the rear wheelhouse,

refer to Section 3C Body Construction – Utility.

17 Install the remaining components as described in the appr opriate Section of the MY2005 VZ Service Information.

7C Body Side – Utility Page 7C-67

Page 7C-67

2.14 Side Inner Upper Panel – Replace

NOTE

This procedure also includes the cargo tie-down

brackets.

Remove

1 Remove the adjacent bolt-on panels a nd components

as described in the appropriate Section of the MY2005

VZ Service Information.

2 Mount the vehicle on a suitable jig to mai ntai n correct

body alignment when the side inner upper panel is

removed.

3 Remove the rear quarter panel,

refer to 2.1 Rear Quarter Panel – Replace.

4 Remove the quarter outer lower rear panel, refer to

2.4 Quarter Outer Lower Rear Panel – Replace.

Figure 7C – 133

5 Remove the quarter inner lower rear extension, refer to 2.3 Quarter Panel Inner Lower Rear Extension – Replace.

6 Remove the door opening frame assembly, refer to 2.6 Door Opening Frame Assembly – Rep lace.

NOTE

If required, the partial door opening frame

assembly centre pillar and rocker panel

sections can be removed. Spot cut the welds

attaching the remaining door opening frame

assembly to the side inner upper panel, refer to

2.6 Door Opening Frame Assembly – Repl ace.

7 Remove the quarter inner and rear wheelhouse brace,

refer to 2.12 Quarter Inner and Rear Wheelhouse Brace – Replace.

8 Remove the welds attaching the side inner upper panel to the quarter lower rear panel,

refer to 2.5 Quarter Lower Rear Panel – Replace.

9 Remove the welds attaching the side inner upper panel to the rear end panel,

refer to Section 10C Body Rear – Utility.

10 Spot cut the welds and grind off the MIG welds attaching the side inner upper panel to the load floor panel,

refer to Figure 7C – 134.

7C Body Side – Utility Page 7C-68

Page 7C-68

Figure 7C – 134

11 Spot cut the welds (if not already removed) and grind

off the MIG welds (1) attaching the inner upper side

panel to the load compartment extensio n panel.

12 Spot cut the welds attaching the side inner upper

panel to the quarter panel inner assembly, side inner

upper front panel, rear wheelhouse inner panel, load

floor panel outer extension and front seatback panel

outer, refer to Figure 7C – 136.

13 Remove the side inner upper panel from the vehicle

and repair any dama ge to adjacent parts as required.

Figure 7C – 135

7C Body Side – Utility Page 7C-69

Page 7C-69

Figure 7C – 136

7C Body Side – Utility Page 7C-70

Page 7C-70

Replace

NOTE

• Spot welding is the preferred method for

attaching of panels and should be used

whenever possible. Where the spot welding

equipment available will not access the

required weld position, a plug weld should be

performed.

• The same number and position of spot welds

(or plug welds) should be used when

replacing the panel, as was used during

manufacture, in order to maintain the original

structural strength of the vehicle.

1 Mark the new panel with drilling locations in prep aration for plug welding. Drill holes as required.

2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required,

refer to Section 3C Body Construction – Utility.

3 Clamp the new panel in position on the vehicle.

4 Spot or plug weld the side inner upp er panel to the quarter panel inner assembly, side inne r upper front panel, rear

wheelhouse inner panel, load floor panel outer extension and front seatback panel outer, refer to F igure 7C – 137.

Figure 7C – 137

7C Body Side – Utility Page 7C-71

Page 7C-71

5 MIG weld (1) two places 15 – 20 mm each, the side

inner upper panel to the load compartment extension

panel.

NOTE

Make the two spot welds (2) once the door

opening frame assembly and rear quarter panel

have been installed.

6 MIG weld the right-hand side inner upper panel (1)

four places 25 – 50 mm each, or the left-hand side

inner upper panel (2) two places 25 – 50 mm each, to

the load floor panel, refer to Figure 7C – 139.

7 Install the quarter outer lower rear panel and spot or

plug to the side inner upper panel and l oad floor panel,

refer to Figure 7C – 139.

Figure 7C – 138

NOTE

Also refer to 2.4 Quarter Outer Lower Rear

Panel – Replace.

8 Spot or plug weld the side inner upper panel to the quarter lower rear panel,

refer to 2.5 Quarter Lower Rear Panel – Replace.

Figure 7C – 139

9 Spot or plug weld the side inner upper pa nel to the rear end panel, refer to Section 10C Body Rear – Util ity.

10 Install the quarter inner lower rear extension, refer to 2.3 Quarter Panel Inner Lower Rea r Extension – Replace.

7C Body Side – Utility Page 7C-72

Page 7C-72

11 Clamp the cargo tie-down bracket (1) and the cargo

tie-down bracket anchor plate (2) to the side inner

upper panel (3).

12 Spot or plug the three parts, two places.

13 Repeat for each of the two other brackets.

14 Clean up and prime the areas that will be covered by

the quarter inner and rear wheelhouse brace.

15 Install the quarter inner and rear wheelhouse brace,

refer to 2.12 Quarter Inner and Rear Wheelhouse

Brace – Replace.

16 Clean up and prime areas that will be covered by the

following panels.

17 Install the door opening frame assembly, refer to

2.6 Door Opening Frame Assembly – Repl ace, or the

centre pillar and rocker sections.

18 Install the rear quarter panel,

refer to 2.1 Rear Quarter Panel – Replace.

19 Refinish and paint panels and other components as

required. Refer to Section 3 Body Construction .

Figure 7C – 140

20 Apply Joint Sealer (Item 3) as required. Refer to Section 3C Body Construction – Utility.

21 Apply Cavity Wax (Item 8) as required to the inside of any box secti ons or areas inaccessible to paint,

refer to Section 3C Body Construction – Utility.

22 Apply Spray-on Deadener (Item 7) to the wheel side of the rear wheelhouse as required,

refer to Section 3C Body Construction – Utility.

23 Install the remaining components as described in the appr opriate Section of the MY2005 VZ Service Information.

7C Body Side – Utility Page 7C-73

Page 7C-73

2.15 Side Inner Upper Panel – Partial Replace

The following procedure al lows partial replacement of a rear section of the side inner upper panel without the need to

replace the door opening fram e assembly.

Remove

1 Remove the adjacent bolt-on panels a nd components

as described in the appropriate Section of the MY2005

VZ Service Information.

2 Remove the rear quarter panel,

refer to 2.1 Rear Quarter Panel – Replace.

3 Remove the quarter outer lower rear panel, refer to

2.4 Quarter Outer Lower Rear Panel – Replace.

4 Remove the quarter inner lower rear extensi on,

refer to 2.3 Quarter Panel Inner Lower Rear

Extension – Replace.

5 Remove the quarter inner and rear wheelhouse brace,

refer to 2.12 Quarter Inner and Rear Wheelhouse

Brace – Replace. Figure 7C – 141

6 Cut through the side inner upper panel (1)

approximately central within the joggle (2) for the

quarter inner and rear wheelhouse brace.

7 Remove the welds attaching the rear section of the

side inner upper panel by referring to

2.14 Side Inner Upper Panel – Replace.

8 Remove the partial panel and repair any damage to

the surrounding area as required.

Figure 7C – 142

7C Body Side – Utility Page 7C-74

Page 7C-74

Replace

NOTE

• Spot welding is the preferred method for

attaching of panels and should be used

whenever possible. Where the spot welding

equipment available will not access the

required weld position, a plug weld should be

performed.

• The same number and position of spot welds

(or plug welds) should be used when

replacing the panel, as was used during

manufacture, in order to maintain the original

structural strength of the vehicle.

1 Accurately measure and cut the replacement side

inner upper panel section from a new panel. Allow a

further 25mm for a joggle.

2 Remove the areas (1) and joggle the remaining area

towards the outer side of the vehicle.

3 Mark the new panel and the jogg le with drilling

locations in preparation for plug welding as required.

Mark the holes at a maximum spacing of 35 mm. Drill

holes as marked.

4 Prepare all mating surfaces and treat with Weld

Through Primer (Item 1) as required,

refer to Section 3C Body Construction – Utility.

Figure 7C – 143

5 Fit and clamp the replacement section in position on

the vehicle ensuring the jo ggle is located on the outer

side of the side inner upper panel and the notched out

areas butt to the original section.

6 Spot or plug weld the replacement section al ong the

joggle.

7 Weld the replacement section to the vehicle using the

appropriate procedur es in 2.13 Quarter Panel Inner

Assembly – Replace.

Figure 7C – 144

7C Body Side – Utility Page 7C-75

Page 7C-75

8 Complete the joint by MIG welding (1) on the inner

side of the side inner upper panel.

9 Grind the weld to achieve a sm ooth finish. Do not

remove the surrounding metal. F inish as req uired.

10 Clean up and prime areas that will be covered by the

quarter inner and rear wheelhouse brace.

11 Install the quarter inner and rear wheelhouse brace,

refer to 2.12 Quarter Inner and Rear Wheelhouse

Brace – Replace

12 Install the quarter inner lower rear extension, refer to

2.3 Quarter Panel Inner Lower Rear Extension –

Replace.

13 Install the cargo tie-down bracket (1) and cargo tie-

down bracket anchor plate as required, refer to

2.14 Side Inner Upper Panel – Replace.

Figure 7C – 145

14 Clean up and prime areas that will be covered by the rear quarter panel.

15 Install the rear quarter panel, refer to 2.1 Rear Quarter Panel – Replac e.

16 Refinish and paint panels and other components as required. Refer to Section 3 Body Construction.

17 Apply Joint Sealer (Item 3) as required. Refer to Section 3C Body Construction – Utility.

18 Apply Cavity Wax (Item 8) as required to the inside of any box secti ons or areas inaccessible to paint,

refer to Section 3C Body Construction – Utility.

19 Apply Spray-on Deadener (Item 7) to the wheel side of the rear wheelhouse as required,

refer to Section 3C Body Construction – Utility.

20 Install the remaining compon ents, refer to the appropriate Section of the MY2005 VZ Service Information.

7C Body Side – Utility Page 7C-76

Page 7C-76

2.16 Side Inner Upper Front Panel – Replace

NOTE

This procedure includes the seatbelt guide

anchor plate assembly.

Remove

1 Remove the adjacent bolt-on panels a nd components

as described in the appropriate Section of the MY2005

VZ Service Information.

2 Mount the vehicle on a suitable jig to mai ntai n correct

body alignment when the panels are removed.

3 Remove the roof panel, refer to Section 9C Roof.

4 Remove the rear quarter panel,

refer to 2.1 Rear Quarter Panel – Replace.

5 Remove the door opening frame assembly, refer to

2.6 Door Opening Frame Assembly – Repl ace.

Figure 7C – 146

6 Spot cut the welds and grind off the MIG weld (1)

attaching the side inner upper front panel to the front

seatback panel outer.

Figure 7C – 147

7 Spot cut the welds attaching the side inner upper front

panel to the:

• Quarter panel inner extension roof three places,

• Quarter panel inner assembly and side inner

upper panel 17 places,

• Front seatback panel outer an d side inner upper

panel one plac e.

8 As required, remove any rem aining welds attaching

the side inner upper front panel that may not have

been completely cut through during removal of

adjacent panels.

9 Remove the side inner upper front panel and repair

any damage to the surroundi ng areas as required.

Figure 7C – 148

7C Body Side – Utility Page 7C-77

Page 7C-77

Replace

NOTE

• Spot welding is the preferred method for

attaching of panels and should be used

whenever possible. Where the spot welding

equipment available will not access the

required weld position, a plug weld should be

performed.

• The same number and position of spot welds

(or plug welds) should be used when

replacing the panel, as was used during

manufacture, in order to maintain the original

structural strength of the vehicle.

1 Mark the new panel and drill holes in preparation for plug welding where required.

2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required,

refer to Section 3C Body Construction – Utility.

3 Spot or plug weld the side inner upper front pan el to

the:

• Quarter panel inner extension three places,

• Quarter panel inner assembly and side inner

upper panel 17 places,

• Front seatback panel outer an d side inner upper

panel one plac e.

Figure 7C – 149

4 Spot or plug weld the front seatback panel outer to the

side inner upper front panel.

5 MIG weld (1) 25 mm the front seatback panel outer to

the side inner upper front panel.

Figure 7C – 150

7C Body Side – Utility Page 7C-78

Page 7C-78

6 Locate the seatbelt guide anchor plate assembly (1)

over the seatbelt mounting bolt holes (2) as shown.

7 Spot or plug weld the seatbelt guide anchor plate

assembly to the side inner upper front panel, two

places (3).

8 Clean up and prime areas that will be covered by the

following panels.

9 Install the door opening frame assembly refer to

2.6 Door Opening Frame Assembly – Repl ace.

10 Install the roof panel, refer to Section 9 Roof

11 Install the rear quarter panel,

refer to 2.1 Rear Quarter Panel – Replace.

12 Refinish and paint panels and other components as

required. Refer to Section 3 Body Construction .

13 Apply Joint Sealer (Item 3) as required.

Refer to Section 3C Body Construction – Utility.

14 Apply Cavity Wax (Item 8) as required to the inside of

any box sections or areas inaccessible to paint,

refer to Section 3C Body Construction – Utility.

Figure 7C – 151

15 Install the remaining components as described in the appr opriate Section of the MY2005 VZ Service Information.

7C Body Side – Utility Page 7C-79

Page 7C-79

2.17 Load Floor Panel Outer Extension and

Load Floor Panel Outer Reinforcement –

Replace

1 Remove the adjacent bolt-on panels a nd components

as described in the appropriate Section of the MY2005

VZ Service Information.

2 Remove the adjacent panels as required, refer to the

relevant Section in this Supplement.

Figure 7C – 152

3 Spot cut the welds attaching the load floor panel outer

extension to the side inner upper panel three places,

the front seatback panel outer three places and the

front seatback panel three places.

4 Grind off the MIG weld (1) attaching the load floor

panel outer extension to the front seatback panel.

Figure 7C – 153

7C Body Side – Utility Page 7C-80

Page 7C-80

5 Spot cut the welds attaching the load floor panel outer

extension to the load floor p anel outer reinforcement

two places.

6 Spot cut the welds attaching the load floor panel outer

extension to the side inner upper panel t welve places,

the rear wheelhouse inner panel and side inner up per

panel one place, the rear wheelhouse inner panel six

places and the load floor panel three places.

7 Remove the load floor panel outer extension from the

vehicle.

8 If required, spot cut the welds attaching the load floor

panel outer reinforcement to the door opening frame

assembly two places and remove the rei nforceme nt.

NOTE

The spot welds are not visible from the inside of

the vehicle. If the rear quarter panel is not

removed cut the welds with a saw or chisel.

Figure 7C – 154

Replace

NOTE

• Spot welding is the preferred method for

attaching of panels and should be used

whenever possible. Where the spot welding

equipment available will not access the

required weld position, a plug weld should be

performed.

• The same number and position of spot welds

(or plug welds) should be used when

replacing the panel, as was used during

manufacture, in order to maintain the original

structural strength of the vehicle.

1 Mark the new panel and drill holes in preparation for plug welding where required.

2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required,

refer to Section 3C Body Construction – Utility.

3 Apply Structural Adhesive (Item 6) to the load floor p an el mating surface (1, refer to Figure 7C – 156),

refer to Section 3C Body Construction – Utility.

4 Clamp the load floor panel outer extension in position

and spot or plug weld to the front seatback panel outer

three places and the front seatback panel three

places.

5 MIG weld (1) 25 mm the to the front seatback panel.

6 Spot or plug weld side the load floor pane l outer

extension to the side inner upper panel three places.

Figure 7C – 155

7C Body Side – Utility Page 7C-81

Page 7C-81

7 Spot or plug weld the load floor panel outer extension

to the side inner upper panel twelve plac es.

8 Spot or plug weld the extension to the rear

wheelhouse inner panel and side inner u pper panel

one place.

9 Spot or plug weld the extension to the rear

wheelhouse inner panel six places an d the load floor

panel three places.

10 If removed, spot or plug weld the load floor panel outer

reinforcement to the lower flange two places.

NOTE

If the rear quarter panel was not removed, drill

through the flange from the inside and plug weld

through the flange.

11 Spot or plug weld the reinforcement to the extensio n

two places.

12 Install any other removed pan els as req uire d, refer to

the appropriate Section of this Supplement.

13 Refinish and paint panels and other components as

required. Refer to Section 3 Body Construction .

14 Apply Joint Sealer (Item 3) as required.

Refer to Section 3C Body Construction – Utility.

15 Apply Cavity Wax (Item 8) as required to the inside of

any box sections or areas inaccessible to paint,

refer to Section 3C Body Construction – Utility.

16 Install the remaining components as described in the

appropriate Section of the MY2005 VZ Service

Information.

Figure 7C – 156

7C Body Side – Utility Page 7C-82

Page 7C-82

2.18 Rear Wheelhouse Inner Panel – Replace

Remove

1 Remove the adjacent bolt-on panels a nd components

as described in the appropriate Section of the MY2005

VZ Service Information.

2 Remove the adjacent panels as required, refer to the

relevant Section in this Supplement.

Figure 7C – 157

3 Grind off the MIG welds (1) attaching the rear floor

panel assembly to the rear wheelhouse inner panel.

4 Spot cut the welds attaching the rear wheelhouse

inner panel to the quarter panel in ner assembly and

side inner upper panel six places.

5 Spot cut the weld attaching the load floor outer

extension to the rear wheelhouse inner panel and side

inner upper panel one place.

6 Spot cut the welds attaching the load floor outer

extension to the rear wheelhouse inner panel six

places.

7 Spot cut the welds attaching the load floor panel to the

rear wheelhouse inner panel five places.

8 Grind off the MIG weld (1) attaching the load floor

panel to the rear wheelhouse inner panel and side

inner upper panel, refer to Figure 7C – 159.

9 For the left-hand side, spot cut the welds attaching

rear wheelhouse inner panel to the side inner upper

panel and quarter pane l inner assembly, 18 places,

refer to Figure 7C – 159.

10 For the right-hand side, spot cut the welds attaching

rear wheelhouse inner panel to the side inner upper

panel and quarter pane l inner assembly, 12 places

and the side inner upper panel and rear wheelhouse

outer extension 12 places, refer to Figure 7C – 159.

Figure 7C – 158

7C Body Side – Utility Page 7C-83

Page 7C-83

Figure 7C – 159

11 Spot cut the welds attaching the rear wheelhouse

inner panel to the load floor panel, five places on the

left-hand side or 10 places on the right-hand side.

12 As required, spot cut the welds attaching the rear

wheelhouse bracket to the rear wheelhouse inner

panel and quarter pane l inner assembly.

13 If the rear quarter panel and door op ening frame

assembly have been removed, spot cut the three

welds (1) attaching the quarter panel inn er a ssembly

to the wheelhouse inner, refer to Figure 7C – 161.

NOTE

If the panels have not been removed, cut along

the line (2) and across th e flan ge on the i nsid e of

the vehicle to detach this piece.

14 Spot cut the welds attaching the quarter panel inner

assembly and door opening frame assembly to the

rear wheelhouse inner panel, two places,

refer to Figure 7C – 161.

15 Spot cut the welds attaching the rear wheelhouse

inner panel to the inner rocker panel, three places,

refer to Figure 7C – 161.

Figure 7C – 160

16 Spot cut the welds attaching the rear wheelhouse inn er panel to the load floor panel and rear floor panel assembl y,

23 places, refer to Figure 7C – 161.

17 Remove the rear wheelhouse inner panel and repair any damage to the surrounding are as as required.

7C Body Side – Utility Page 7C-84

Page 7C-84

Figure 7C – 161

Replace

NOTE

• Spot welding is the preferred method for

attaching of panels and should be used

whenever possible. Where the spot welding

equipment available will not access the

required weld position, a plug weld should be

performed.

• The same number and position of spot welds

(or plug welds) should be used when

replacing the panel, as was used during

manufacture, in order to maintain the original

structural strength of the vehicle.

1 Mark the new panel and drill holes in preparation for plug welding where required.

2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required,

refer to Section 3C Body Construction – Utility.

3 If the front piece of the rear wheelhouse was cut off, remove a corresponding piece from the replacement panel.

4 Apply Structural Adhesive (Item 6) to the rear wheelhouse inner panel (3, refer to Figure 7C – 16 4),

refer to Section 3C Body Construction – Utility.

5 Clamp the rear wheelhouse inner panel in position on the vehicle.

6 For the left-hand side, spot or plug weld the rear wheelhouse inner panel to the quarter panel inner assembly and

side inner upper panel, 18 pl aces, refer to F igure 7C – 162.

7 For the right-hand side, spot or plug weld the rear wheelhouse inner panel to the quarter panel inner assembly and

side inner upper panel, 12 pl aces and the side inner upper panel and rear wheelhouse outer extension 12 places,

refer to Figure 7C – 162.

8 MIG weld 25 - 50 mm (1) the load floor panel to the rear wheelhouse inner pane l and side inner upper panel,

refer to Figure 7C – 162.

7C Body Side – Utility Page 7C-85

Page 7C-85

Figure 7C – 162

9 Spot or plug weld the load floor panel to the rear

wheelhouse inner panel five places.

10 Spot or plug weld the load floor outer extension to the

rear wheelhouse inner panel six places.

11 Spot or plug weld the load floor outer extension to the

rear wheelhouse inner panel and side inner upper

panel one plac e.

12 Spot or plug weld the rear wheelhouse inner panel to

the side inner upper panel an d quarter panel inner

assembly six places.

13 MIG weld 25 mm (1) two places, the rear floor panel

assembly to the rear wheelhouse inner p anel.

Figure 7C – 163

14 If the rear quarter panel and door op ening frame assembly were removed, spot or plug weld (1) three places the

quarter panel inner assembly to the rear wheelhouse inner panel, refer to Figure 7 C – 164.

NOTE

If the panels were not removed, MIG weld along

the cut (2) and across the flange on the inside of

the vehicle.

15 Spot or plug weld the rear quarter panel and door open ing frame assembly to the rear wheelhouse inner panel, two

places, refer to Figure 7C – 164.

16 Spot or plug weld the rear wheelhouse inner panel to the inner rocker panel, three places, refer to Figure 7C – 164.

17 Spot or plug weld the rear wheelhouse inner panel to the load floor p an el and rear floor panel assembly, 23 places,

refer to Figure 7C – 164.

7C Body Side – Utility Page 7C-86

Page 7C-86

Figure 7C – 164

18 Spot or plug weld the rear wheelhouse inner panel to

the load floor panel, five places on the left-hand side

or 10 places on the right-hand side.

19 As required, spot or plug weld the rear wheelhouse

bracket to the rear wheelhouse inn er pa nel and

quarter panel inner assembly.

20 Install any other removed pan els as req uire d, refer to

the appropriate Section of this Supplement.

21 Refinish and paint panels and other components as

required. Refer to Section 3 Body Construction .

22 Apply Joint Sealer (Item 3) as required.

Refer to Section 3C Body Construction – Utility.

Figure 7C – 165

23 Apply Cavity Wax (Item 8) as required to the inside of any box secti ons or areas inaccessible to paint,

refer to Section 3C Body Construction – Utility.

24 Apply Spray-o n deadener to the wheel side of the rear wheelhouse panel,

refer to Section 3C Body Construction – Utility.

25 Install the remaining components as described in the appr opriate Section of the MY2005 VZ Service Information.

7C Body Side – Utility Page 7C-87

Page 7C-87

3 Torque Wrench Specifications

Dash Panel Retaining Bolt.........................................................35.0 – 45.0 Nm