7D Body Side – Coupe Page 7D-1
Page 7D-1
Section 7D
Body Side – Coupe
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 ...............................................................................................................................2
1.1 Body Side Components ........................................................................................................................................ 2
2 Service Operations.................................................................................................................................4
2.1 Rear Quarter Panel – Replace............................................................................................................................... 4
Remove................................................................................................................................................................... 4
Replace................................................................................................................................................................... 8
2.2 Tail Lamp Housing, Quarter Panel Upper Extension and Quarter Panel Lower Extension – Replace......... 12
Remove................................................................................................................................................................. 12
Replace................................................................................................................................................................. 13
2.3 Door Opening Frame Assembly – Replace........................................................................................................ 15
Remove................................................................................................................................................................. 15
Replace................................................................................................................................................................. 20
2.4 Door Opening Frame Assembly – Partial Replace, Hinge Pillar...................................................................... 25
Remove................................................................................................................................................................. 25
Replace................................................................................................................................................................. 28
2.5 Door Opening Frame Assembly – Partial Replace. Centre Pillar..................................................................... 33
Remove................................................................................................................................................................. 33
Replace................................................................................................................................................................. 35
2.6 Door Opening Frame Assembly – Partial Replace, Rocker Panel................................................................... 39
Remove................................................................................................................................................................. 39
Replace................................................................................................................................................................. 41
2.7 Fender Lower Rear Bracket – Replace............................................................................................................... 45
2.8 Hinge Pillar Inner Panel Assembly – Replace ................................................................................................... 46
Remove................................................................................................................................................................. 46
Replace................................................................................................................................................................. 48
2.9 Quarter Panel Inner Assembly – Replace.......................................................................................................... 51
Remove................................................................................................................................................................. 51
Replace................................................................................................................................................................. 53
2.10 Quarter Panel Inner Assembly – Partial Replace.............................................................................................. 57
Remove................................................................................................................................................................. 57
Replace................................................................................................................................................................. 60
3 Torque Wrench Specifications............................................................................................................64
7D Body Side – Coupe Page 7D-2
Page 7D-2
1 General Description
This Section describes the replacement procedures for the body side components of the Coupe 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, lock
pillar and rocker panel. These procedures must be followed carefull y, as they regularl y involve hidden reinforceme nt
panels. The cutting locations specified are the only plac es allowable.
NOTE
It is imperative the correct body adhesives,
sealers, deadeners and cavity waxes are
used when repairing the body structure.
Refer to Section 3D Body Construction – Coupe.
1.1 Body Side Components
The shaded components in Figure 7D – 1 are those dealt
with in this Section.
The components and assemblies shown in Figure 7D – 2
are the serviceable parts that form the basis of the r
epair procedures in this Section. F or a detai led
view of the body components, refer to
Section 3D Body Construction – Coupe.
NOTE
Always refer to an Authorised Retailer for spare
parts availability configurations.
Cavity foam may be used within the hinge,
centre and lock pillars. 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 7D – 1
7D Body Side – Coupe Page 7D-3
Page 7D-3
Figure 7D – 2
Legend
1 Hinge Pillar Trim Panel Bracket, Left-hand / Right-hand
2 Hinge Pillar Inner Panel Assembly, Left-hand / Right-hand
3 Quarter Panel Inner Assembly , Left-hand / Right-hand
4 Body Pillar Inner Panel Reinforcement , Left-hand / Right-
hand
5 Door Opening Frame Assembly , Left-hand / Right-hand
6 Fender Lower Rear Bracket , Left-hand / Right-hand
7 Fender Rear Bracket , Left-hand / Right-hand
8 Fender Upper Rear Bracket , Left-hand / Right-hand
9 Front Door Striker Anchor Plate , Left-hand / Right-hand
10 Underbody Jacking Locator , Left-hand / Right-hand
11 Rear Quarter Panel , Left-hand / Right-hand
12 Quarter Panel Lower Extension , Left-hand / Right-hand
13 Tail Lamp Housing , Left-hand / Right-hand
14 Quarter Panel Upper Extension , Left-hand / Right-hand
15 Fuel Filler Pipe Housing
NOTE
• The door opening frame assembly (5)
includes parts 6, 7, 8, 9 and 10.
• The quarter panel inner assembly includes
the rear wheelhouse inner panel assembly
which is also available separately, refer to
Section 10D Body Rear – Coupe.
7D Body Side – Coupe Page 7D-4
Page 7D-4
2 Service Operations
2.1 Rear Quarter Panel – Replace
To avoid the possibility of fire, take particular
care when cuttin g or w elding at the r ear of th e
vehicle. Remove the fuel tank and plug the
fuel lines.
NOTE
• This procedure detai ls the removal of the rear
quarter panel as an assembly with the tail
lamp housing, quarter panel upper extension,
quarter panel lower extension and fuel filler
pipe housing (for right-hand side). However
these parts are not available as an assembly
and must be ordered separately.
• Full replacement of the rear quarter panel
requires removal of the roof panel. An
alternative is also provided in this procedure
where the panel is joined through the lock-
pillar, approxi mately 100 mm belo w t he top of
the rear window.
• 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 Precaution prior to beginning work
for further information.
Remove
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate Section of th e MY
2005 VZ Service Information.
2 Remove the rear window, refer to Section 1A6
Stationary Windows in the MY 2005 VZ Service
Information.
3 Remove the rear bumper impact bar,
refer to Section 3 Body Construction.
Figure 7D – 3
7D Body Side – Coupe Page 7D-5
Page 7D-5
4 For the right-hand side, from within the rear
compartment, disconnect the fuel pipe filler housing
drain tube connector (1).
Figure 7D – 4
5 Spot cut the welds attaching the rear quarter panel to
the door opening frame assembly.
NOTE
If the tail lamp housing, quarter panel lower
extension and quarter pa nel upper extension are
to remain, modify this procedure accordingly.
Refer to 2.2 Tail Lamp Housing, Quarter Panel
Upper Extension and Quarter Panel Lower
Extension – Replace.
6 Spot cut the rear quarter panel from the rear end lower
panel and rear compartment floor panel outer
extension.
7 Spot cut the welds attaching the rear quarter panel to
the quarter panel inner assembly and rear
compartment floor panel outer exte nsion. There are a
different number of welds on the left-hand panel to the
right-hand panel. Refer to Figure 7D – 6. Figure 7D – 5
Figure 7D – 6
7D Body Side – Coupe Page 7D-6
Page 7D-6
8 Spot cut the welds attaching the rear quarter panel to
the door opening frame assembly and quarter panel
inner assembly.
NOTE
Structural adhesive is applied in the area shown
(1). Removal of the panel may be made easier
by cutting the quarter panel around this are a and
then grinding the flange off once the panel is
removed.
Figure 7D – 7
9 Spot cut the welds attaching the rear quarter panel to
the door opening frame assembly.
Figure 7D – 8
10 Spot cut the welds attaching the rear quarter panel to
the door opening frame assembly and quarter panel
inner assembly.
NOTE
If the roof panel has been removed, cut the
welds all the way along the quarter window
opening to the braze joint (1). Remove the three
welds attaching the rear quarter panel to the
body pillar inner panel reinforcement and using
an oxy / acetylene torch and wire br ush, car efully
remove the brazing from the joint.
If the roof panel has not been removed, only
remove the spot welds as far as point (2). Mark a
line and cut the rear quarter panel at this area,
ensuring not to cut into the quarter panel inner
assembly.
11 At the base of the lock pillar, the rear quarter pane l is
sandwiched bet ween the quarter inner panel assembly
and rear window panel assembly. Cutting the pane l at
this point, as described below, rather than removing
extra panels, will save considerable time and effort as
structural adhesive (1) is used in this area,
refer to Figure 7D – 10.
Figure 7D – 9
7D Body Side – Coupe Page 7D-7
Page 7D-7
12 Using a saw or other appropr iate equipment, cut through the rear quarter panel as shown (2) at View A. The cut
should pass across the drain channel, then along the inner face of the rear quarter panel.
NOTE
It is important to leave enough material (3) to
facilitate a lap joint of the old and new panels.
The drain channel and rear window opening
flange will be butt joined.
13 As required spot cut the welds attaching the rear quarter panel to the quarter panel inner assembly.
Figure 7D – 10
14 Remove the panel from the vehicle and th en repair any damage to adjacent parts.
NOTE
For the right-hand side, the fuel filler p ipe h ousin g
is attached to the quarter inner panel assembly
with acrylic spot weld sealer, which will require
separating while the pa nel is being removed.
15 Check and rectify the alignme nt of the body as required, refer to Section 3D Body Construction – Coupe.
7D Body Side – Coupe Page 7D-8
Page 7D-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 On the replacement panel, remove the section (1) to
facilitate the join at the base of the lock pillar.
NOTE
If surrounding panels have been replaced, this
section may be required to re main intact.
2 If the roof panel has not been removed, remove the
upper section of the lock pillar on the new panel to
match the removed panel.
Figure 7D – 11
3 From the scrap piece, manufacture a reinforcement (1)
to fit inside the remaining rear quarter p an el on the
vehicle as shown.
NOTE
The reinforcement must not extend to the
flanges.
4 Mark the panel with drilling loc ations in preparation for
plug welding. Drill holes as required.
5 Prepare all mating surfaces and treat with Weld
Through Primer (Item 1) as required,
refer to Section 3D Body Construction – Coupe .
6 Clamp the reinforcement in position and plug weld it to
the vehicle. Figure 7D – 12
7D Body Side – Coupe Page 7D-9
Page 7D-9
7 For the right-hand side, if required spot or plug weld
(1) the fuel filler pipe housing to the rear quarter panel
in four places.
Figure 7D – 13
8 Open the flange (1) at the base of the lock pillar
outwards slightly to allow the new panel to seat
correctly.
9 As required, mark the new panel with drilling locations
in preparation for plug welding. Drill holes as required.
10 Prepare all mating surfaces and treat with Weld
Through Primer (Item 1) as required,
refer to Section 3D Body Construction – Coupe .
11 Apply Acrylic Spot Weld Sealer (Item 2),
refer to Section 3D Body Construction – Coupe .
12 Apply Structural Adhesive (Item 6), to the area sho wn
(1), refer to Figure 7D – 18.
Also refer to Section 3 Body Construction.
13 Clamp the rear quarter panel i n position ensuring it is
seated correctly at the base o f the lock pillar (2).
14 Test fit the alignment of the rear quarter panel with the
front door and rear compartment lid. Figure 7D – 14
15 Spot or plug weld the rear quarter panel to the quarter
panel inner assembly.
Figure 7D – 15
7D Body Side – Coupe Page 7D-10
Page 7D-10
16 Spot or plug weld the rear quarter panel to the door
opening frame assembly and quarter panel inner
assembly.
NOTE
If the roof panel was removed, weld all the way
along the quarter window opening to the braze
joint (1). Plug weld the rear quarter panel to the
body pillar inner panel reinforcement and using
an oxy / acetylene torch, car efull y braze weld the
joint.
If the roof panel was not removed, weld only as
far as point (2). Plug we ld the rear quarter panel
to the manufactured reinforcement and using an
oxy / acetylene torch, carefully braze weld the
joint.
• To reduce the risk of panel distortion, place
wet rags adjacent to the braze joints.
Figure 7D – 16
17 Spot or plug weld the rear quarter panel to the door
opening frame assembly.
Figure 7D – 17
18 Spot or plug weld the rear quarter panel to the door
opening frame assembly and rear quarter panel inner
assembly.
19 Spot or plug weld the rear quarter panel to the rear
quarter panel inner assembly and re ar compartment
floor panel outer extension. There are a different
number of welds on the left-hand side to the right-hand
side, refer to Figure 7D – 19.
Figure 7D – 18
7D Body Side – Coupe Page 7D-11
Page 7D-11
Figure 7D – 19
20 Spot or plug weld the rear quarter panel to the flange
at the base of the lock pillar and MIG butt weld across
the water channel and rear window flange.
21 Either:
a Install the tail lamp housing, quarter panel lower
extension and quarter panel upper extension, or
b Weld the rear quarter panel to these panels.
Refer to the following procedur e in this Section
22 Refinish and paint panels and other components as
required. Refer to Section 3 Body Construction .
Figure 7D – 20
23 Add an additional bead of Joint Sealer to the lap joint
at the base of the lock pillar.
24 Apply Joint Sealer (Item 3) as required.
Refer to Section 3D Body Construction – Coupe.
25 Apply Cavity Wax (Item 8) as required to the inside of
any box sections or areas inaccessible to paint,
refer to Section 3 Body Construction.
26 Install rear bumper impact bar,
refer to Section 3 Body Construction.
27 Insert Cavity Foam into the lock pillar as required,
refer to Section 2 Precautions.
28 Install the remaining components as described in the
MY 2005 VZ Service Information.
Figure 7D – 21
7D Body Side – Coupe Page 7D-12
Page 7D-12
2.2 Tail Lamp Housing, Quarter Panel Upper
Extension and Quarter Panel Lower
Extension – Replace
To avoid the possibility of fire, take particular
care when cuttin g or w elding at the r ear of th e
vehicle. Remove the fuel tank and plug the
fuel lines.
Remove
NOTE
The components descri bed in this pr ocedure may
be replaced as an assembly or individually as
required.
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate Section of th e MY
2005 VZ Service Information.
Figure 7D – 22
2 Spot cut the welds attaching the quarter panel upper
extension (1) to the rear quar ter panel and to the tail
lamp housing as required.
Figure 7D – 23
7D Body Side – Coupe Page 7D-13
Page 7D-13
3 Spot cut the welds attaching the tail lamp housing (1)
to the rear quarter panel, quarter panel lower
extension (2) and rear end lower panel.
4 The quarter panel lower extension (2) may then be
removed from the vehicle by spot cutting the welds
attaching it to the rear quarter panel an d rear end
lower panel.
5 Repair any damage to adjacent parts as required.
Figure 7D – 24
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 3D Body Construction – Coupe .
3 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3D Body Construction – Coupe.
4 Clamp the removed parts in position and if required, temporarily install the tail lamp to check for correct fit with the
surrounding panels.
7D Body Side – Coupe Page 7D-14
Page 7D-14
5 Spot or plug weld the quarter panel lower extension
(2) to the rear quarter panel and rear end lower pa nel.
6 Spot or plug weld the tail lamp housing (1) to the rear
quarter panel, rear end lower panel and quarter panel
lower extension (2).
Figure 7D – 25
7 Spot or plug weld the quarter panel u pper extension
(1) to the rear quarter panel and tail lamp housing.
8 Refinish and paint panels and other components as
required. Refer to Section 3 Body Construction .
9 Apply Joint Sealer (Item 3) as required.
Refer to Section 3 Body Construction.
10 Apply Cavity Wax (Item 8) as required to the inside of
any box sections or areas inaccessible to paint,
refer Section 3 Body Construction.
11 Install the remaining components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information.
Figure 7D – 26
7D Body Side – Coupe Page 7D-15
Page 7D-15
2.3 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 2.4 Door Opening Frame
Assembly – Partial Replace, Hinge Pillar and
2.5 Door Opening Frame Assembly – Partial
Replace. Centre Pillar.
• 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.
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate Service Information.
2 Remove the windshield, quarter and rear window
assemblies, refer to Section 1A6 Stationary Windows
in the MY 2005 VZ Service Information.
3 Remove the dash panel retaining bolt from the hinge
pillar.
4 Remove the roof panel, refer to Section 9D 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 7D – 27
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 7D – 28
7D Body Side – Coupe Page 7D-16
Page 7D-16
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 7D – 29
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).
NOTE
There are several sub-assembly welds which do
not require removing.
10 Spot cut the welds on the flange surrounding the front
door opening, attaching the door op ening frame
assembly to the hinge pillar inner pa nel assembly,
inner rocker panel and quarter panel inner assembly,
refer to Figure 7D – 31.
Figure 7D – 30
7D Body Side – Coupe Page 7D-17
Page 7D-17
Figure 7D – 31
11 Spot cut any remaining welds attachin g the door opening frame assembly to the quarter panel inner assembly
around the rear wheel arch.
12 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 7D – 32.
Figure 7D – 32
13 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 7D – 33.
7D Body Side – Coupe Page 7D-18
Page 7D-18
Figure 7D – 33
14 Spot cut the welds attaching the door opening frame assem bly to the quarter panel inner assembly,
refer Figure 7D – 34.
Figure 7D – 34
15 Spot cut the two welds attaching the roof bow panel
(2) to the centre pillar upper reinforcement, and the
single weld attaching the roof bow panel to the door
opening frame assembly (1).
Figure 7D – 35
7D Body Side – Coupe Page 7D-19
Page 7D-19
16 Carefully lifting the roof bow panel out of the way, spot
cut the two welds attaching the centre pillar upper
reinforcement to the quarter panel inn er asse mbly.
The centre pillar upper reinforcement is removed as
part of the door opening frame assembl y.
Figure 7D – 36
17 Spot cut the welds along the roof flange, attaching the
door opening frame assembly to the quarter p anel
inner assembly.
NOTE
Also remove any remaining roof panel welds as
required.
18 Structural adhesive is applied within th e join of the
centre pillar upper reinforcement (1) to the lock pillar
reinforcement (2). Cut back the rear section of the
outer panel and cut the centre pillar upper
reinforcement forward of the lock pillar reinforcement.
Remove the remaining sectio n once the frame
assembly has been removed.
19 Remove the complete door opening frame assembly
and repair any dama ge to adjacent parts.
20 Check and rectify the alignme nt of the bod y as
required, refer to Section 3 Body Construction.
Figure 7D – 37
7D Body Side – Coupe Page 7D-20
Page 7D-20
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.
• When welding a relatively flat panel such as
the roof panel, due care must be taken to
minimise the heat absorbed by the panel
which could lead to panel distortion.
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 3D Body Construction – Coupe .
3 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3D Body Construction – Coupe.
4 Apply Structural Adhesive (Item 6) to the rear inner
side of the centre pillar upper reinforc ement flange (1),
also refer to Section 3 Body Construction.
Figure 7D – 38
5 Securely clamp the door openin g frame assembly in
position, ensuring the centre p illar upper reinforcement
(1) to lock pillar reinforcement (2) join is seated
correctly.
6 Spot or plug weld the door opening frame assembly to
the quarter inner panel assembly along the roof panel
flange. Complete this flange when installing the roof
panel.
7 Spot or plug weld the door opening frame assembly to
the quarter inner panel assembly around the front door
opening flange, refer to Figure 7D – 40.
Figure 7D – 39
7D Body Side – Coupe Page 7D-21
Page 7D-21
Figure 7D – 40
8 Spot or plug weld the door opening frame assembly to the quarter inner panel assembly, refer to Figure 7D – 41.
Figure 7D – 41
7D Body Side – Coupe Page 7D-22
Page 7D-22
9 Spot or plug weld the door opening frame assembly
(1) to the quarter inner panel assemb ly, then spot or
plug weld the roof bow panel (2) to the door opening
frame assembly as shown.
Figure 7D – 42
10 Spot or plug weld along the windshield flange,
attaching the door opening frame assembly (1) to the
hinge pillar inner panel assembly (2).
Figure 7D – 43
11 Spot or plug weld the door opening frame assembly
(1) to the hinge pillar inner panel assembly (2) at the
base of the hinge pillar.
Figure 7D – 44
7D Body Side – Coupe Page 7D-23
Page 7D-23
12 Spot or plug weld the door opening frame assembly to
the inner rocker panel and to the hinge pillar inner
panel assembly. If the sheet metal was modified to
allow access to these welds, it should be repaired to
its original configuration.
13 Plug weld up through the rocker panel to attach the
door opening frame assembly to the quarter p anel
inner assembly, refer to Figure 7D – 46.
Figure 7D – 45
Figure 7D – 46
14 Spot or plug weld along the vertical flange below the rocker panel attachi ng the door opening frame assembl y to
the inner rocker panel, refer to Figure 7D – 47.
Figure 7D – 47
7D Body Side – Coupe Page 7D-24
Page 7D-24
15 Spot or plug weld two places, the door opening frame assembly to the quarter panel i nn er assembly around the
rear wheel arch.
NOTE
This joint will be completed when the rear q uarter
panel is installed.
16 Replace front wheelhous e panel upper side rail, refer to Section 4 Front End.
17 Replace the rear quarter panel, refer to 2.1 Rear Quarter Pane l – Replace.
18 Replace the roof panel, refer to Section 9D R oof.
NOTE
Refinish and prime any bare metal as required
prior to replacing these panel s.
19 Install the door hinges, refer to Section 8 Do ors, Liftgate and Endgate.
20 Refinish and paint panels and other components as required. Refer to Section 3 Body Construction.
21 Apply Joint Sealer (Item 3) as required. Refer to Section 3D Body Construction – Coupe.
22 Apply Cavity Wax (Item 8) as required to the inside of any box secti ons or areas inaccessible to paint,
refer to Section 3D Body Construction – Coupe .
23 Apply Spray-on Dea dener (Item 7) where applicab le, refer to Section 3D Body Construc tion – Coupe.
24 Install the dash panel retaining bolt throu gh the hinge pil lar and tighten to the specified torque.
Dash Panel Retaining Bolt
Torque Specification ...............................35.0 – 45.0 Nm
25 Replace the windshield and the rear window assembly, refer to Section 1A 6 Stationary Windows in the MY 2005
VZ Service Information.
26 Insert Cavity Foam into the hinge and centre pillars as required, refer to Section 2 Precautions.
27 Install the remaining components as described in the appropriate Section of the MY 2005 VZ Service Informatio n.
7D Body Side – Coupe Page 7D-25
Page 7D-25
2.4 Door Opening Frame Assembly – Partial
Replace, Hinge Pillar
A sunroof option is available that is fitted on
the production line. To cater for this option, a
stainless steel front drain tube is also fitted
within the hinge pillar cavity, therefore the
partial replacement procedure for the hinge
pillar must not be performed on these
vehicles.
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 th e MY
2005 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 MY 2005 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 7D – 48
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 7D – 49
7D Body Side – Coupe Page 7D-26
Page 7D-26
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 7D – 50
8 Select a cutting point on the hinge pi llar approximately
100 mm from the top of the windshield flange.
Figure 7D – 51
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 7D – 52
7D Body Side – Coupe Page 7D-27
Page 7D-27
11 Spot cut the welds on the windshield side flange, up to
the point of the cut.
Figure 7D – 53
12 Cut through the rocker panel section of the door
opening frame assembly. The cut point (1) sh ould be
through the third rocker panel moulding attaching hole
(2). Cut through both the outer panel and the
reinforcement.
Figure 7D – 54
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.
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 3D Body Construction – Coupe .
Figure 7D – 55
7D Body Side – Coupe Page 7D-28
Page 7D-28
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 7D – 56
2 Remove a section of inner rocker panel (1). Cut
50 mm each side of the cut in the rocker panel. T his
allows access for welding the rocker panel
reinforcement.
Figure 7D – 57
7D Body Side – Coupe Page 7D-29
Page 7D-29
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 3D Body Construction – Coupe .
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 7D – 58
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 3D Body Construction – Coupe .
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 3D Body Construction – Coupe .
11 Apply Acrylic Spot Weld Sealer (Item 2),
refer to Section 3D Body Construction – Coupe .
Figure 7D – 59
12 Clamp the replacement panel (1) in position on the
vehicle and check the door opening dimensions.
Refer to Section 3D Body Construction – Coupe.
Adjust position as required.
Figure 7D – 60
7D Body Side – Coupe Page 7D-30
Page 7D-30
13 Plug weld (1) the top of the pillar to the manufactured
reinforcement, then MIG butt weld (2) the two sections
together.
Figure 7D – 61
14 Plug weld (1) the new panel in the rocker panel region,
then MIG butt weld (2) the two sections together.
Figure 7D – 62
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 7D – 63
7D Body Side – Coupe Page 7D-31
Page 7D-31
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 7D – 64
19 Spot weld (1) the pillar along the windshield opening
flange.
Figure 7D – 65
20 Spot or plug weld the door opening frame assembly
(1) to the hinge pillar inner panel assembly (2) at the
base of the hinge pillar.
Figure 7D – 66
7D Body Side – Coupe Page 7D-32
Page 7D-32
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 7D – 67
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 Dress the butt welds by grinding or sanding, ensuring
sufficient material remains to guarantee the strength of
the weld.
25 Install the door hinges,
refer to Section 8 Doors, Liftgate and Endgat e.
26 Refinish and paint panels and other components as
required. Refer to Section 3 Body Construction .
27 Apply Joint Sealer (Item 3) as required.
Refer to Section 3D Body Construction – Coupe.
Figure 7D – 68
28 Apply Cavity Wax (Item 8) as required to the inside of any box secti ons or areas inaccessible to paint,
refer to Section 3D Body Construction – Coupe .
29 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
30 Replace the windshield, refer to Section 1A6 Stationary Windows in the MY 2005 VZ Service Information.
31 Insert Cavity Foam into the hinge pillar as required, refer to Section 2 Precautions.
32 Install the remaining components as described in the appropriate Section of the MY 2005 VZ Service Informatio n.
7D Body Side – Coupe Page 7D-33
Page 7D-33
2.5 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 th e MY
2005 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 7D – 69
4 Cut the door opening frame a ssembly (1) and centre
pillar reinforcement (2) at point A as shown.
NOTE
Do not cut through the centre pillar inner
reinforcement (3) or quarter panel inner
assembly (4).
5 Make a second cut through the door opening frame
assembly (1) only at point B as shown.
6 Spot cut the welds between the two cuts and remove
the shaded section of the door opening frame
assembly.
Figure 7D – 70
7D Body Side – Coupe Page 7D-34
Page 7D-34
7 Cut through the door opening frame assembly (1) at
the join of the rocker panel reinforcement and centre
pillar reinforcement (2).
NOTE
Make the cut carefully as the rocker panel
reinforcement must not be cut. The centre pillar
reinforcement is removed with the centre pillar
section.
Figure 7D – 71
8 Cut through the door opening frame assembly (1)
rearward of the dimple (2) in the flange.
NOTE
Make the cut carefully as the quarter panel inner
assembly must not be cut.
Figure 7D – 72
9 Spot cut the welds attaching the underbod y jacking
locator (1) and remove.
10 Spot cut the welds on the flange attaching the centre
pillar section to the inner rocker panel (6).
Refer to weld group A.
11 Spot cut the welds on the underside of the rocker
panel attaching the centre pillar section to the quarter
panel inner assembly (7). Refer to weld group B.
Figure 7D – 73
7D Body Side – Coupe Page 7D-35
Page 7D-35
12 Spot cut the welds on the door opening frame flanges
both sides of the centre pillar and remove the centre
pillar section from the vehicle.
13 Repair any damage to surrounding area as required.
Figure 7D – 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 Cut the replacement panel through rocker section as
shown. Accurately measure the positio n of cuts to
match the removed panel section.
Figure 7D – 75
7D Body Side – Coupe Page 7D-36
Page 7D-36
2 At point B, cut the replacement panel compl etel y
through.
NOTE
This point matches point B on the remaining
section on the vehicle.
3 Adjust the cut on the vehicle side of the outer panel so
that it matches the cut on the replacement section.
NOTE
• Do not cut through the front face of the door
opening frame and do not cut the
reinforcement.
• This point is approximately 10 – 15 mm
below point A on the remaining section on
the vehicle.
Figure 7D – 76
4 On the replacement panel, bend back the outer skin
(1). This will expose the reinforcement which is to be
cut down each corner (2).
5 Remove the front and rear flanges (3) which will a lign
at point A on the remaining section on the ve hicle.
6 Form a joggle on each of the faces to ena ble the
replacement reinforcement to fit behind the remaining
section on the vehicle.
Figure 7D – 77
7 Cut two sections from surplus rocker panel pieces, or
manufacture new sections (1), each ap proximately
100 mm in length.
8 Prepare all mating surfaces and treat with Weld
Through Primer (Item 1) as required,
refer to Section 3D Body Construction – Coupe .
9 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.
10 Mark the new panel with drilling locations in
preparation for plug welding where required. Drill holes
as marked. Figure 7D – 78
7D Body Side – Coupe Page 7D-37
Page 7D-37
11 Drill three holes (1) on each face of the rei nforceme nt
on the vehicle to facilitate plug welding.
12 Prepare all mating surfaces and treat with Weld
Through Primer (Item 1) as required,
refer to Section 3D Body Construction – Coupe .
13 Install the replacement panel i n position, sliding the
tongue of the centre pillar reinforcement (2) behind the
upper section of the reinforcement (3).
NOTE
Manipulate the rocker panel section in position,
inserting the front first, then the rear.
14 Clamp the assembly in place and p lug weld the centre
pillar reinforcement at the upper join.
Figure 7D – 79
15 Close over the outer panel fla p.
16 Spot weld along the flanges on both sides of the
centre pillar.
17 Plug weld the rocker panel section to the
reinforcement sections.
18 MIG butt weld the rocker panel joins (1).
Figure 7D – 80
7D Body Side – Coupe Page 7D-38
Page 7D-38
19 MIG butt weld the centre pillar joins.
Figure 7D – 81
20 Plug weld the flange attaching the centre pil lar section
(1) to the inner rocker panel (2). Refer weld group A.
21 Plug weld on the underside of the rocker panel the
centre pillar section to the quarter panel inner
assembly (3). Refer weld group B.
22 Plug weld the underbody jacking locator (4) in place.
23 Install the door hinge,
refer to Section 8 Doors, Liftgate and Endgat e.
24 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.
25 Prime any bare metal areas as requir ed and install the
rear quarter panel,
refer to 2.1 Rear Quarter Panel – Replace.
26 Refinish and paint panels and other components as
required. Refer to Section 3 Body Construction .
27 Apply Joint Sealer (Item 3) as required.
Refer to Section 3D Body Construction – Coupe.
28 Apply Cavity Wax (Item 8) as required to the inside of
any box sections or areas inaccessible to paint,
refer Section 3D Body Construction – Coupe.
29 Insert Cavity Foam into the centre pillar as r equired,
refer to Section 2 Precautions.
30 Install the remaining components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information.
Figure 7D – 82
7D Body Side – Coupe Page 7D-39
Page 7D-39
2.6 Door Opening Frame Assembly – Partial
Replace, Rocker Panel
This procedure details the replacement of the
rocker panel section of the door opening
frame assembly.
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
2.4 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 th e MY
2005 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.
Figure 7D – 83
4 Cut through the rocker panel section of the door
opening frame assembly. The cut point (1) must not be
further forward than the third rocker panel m oulding
attaching hole (2). Cut through both the outer panel
and the reinforcement.
Figure 7D – 84
7D Body Side – Coupe Page 7D-40
Page 7D-40
5 Using a suitable cutting tool, cut through the door
opening frame assembly (1), including the centre pillar
reinforcement (2), near the base of the centre pillar.
Figure 7D – 85
6 If required, select a cutting point through the door
opening frame assembly, rearward of point (1). Cut
through the door opening frame assembly (2) only.
NOTE
It may be preferable to remove the complete rear
section.
7 Depending on the cut location, spot cut any remaining
welds attaching the door opening frame assembly to
the quarter panel inner assembly around the rear
wheel arch.
8 Spot cut the welds attaching the rocker panel section
to the quarter panel inner assembly as requir ed.
Refer to Figure 7D – 87.
Figure 7D – 86
Figure 7D – 87
9 Spot cut along the flanges around the door opening frame assembly as required, to separate the rocker panel
section from the inner rocker panel and quarter panel inner assembly. Refer to Figure 7D – 88.
7D Body Side – Coupe Page 7D-41
Page 7D-41
Figure 7D – 88
10 Remove the rocker panel section from the vehicle and then repair any damage to adjacent parts as required.
11 Check and rectify the alignme nt of the bod y as required, refer to Section 3D Body Construction – Coupe.
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 rocker panel sectio n from a new door opening frame as sembly. Accurately measure the positi 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 7D – 89
7D Body Side – Coupe Page 7D-42
Page 7D-42
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 the mating surfaces and treat with Weld
Through Primer (Item 1) as required,
refer to Section 3D Body Construction – Coupe .
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 7D – 90
6 Manufacture or cut a reinforcement (1), appr oximately
100 mm long, to fit inside of the existing B-pillar
section at the point of the cut.
7 Prepare all mating surfaces and treat with Weld
Through Primer (Item 1) as required,
refer to Section 3D Body Construction – Coupe .
8 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.
9 Mark the replacement rocker panel section with drilling
positions in preparation for plug welding as required.
Figure 7D – 91
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.
10 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required,
refer to Section 3D Body Construction – Coupe .
11 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.
12 Clamp the panel in position.
13 Weld the new rocker panel section in p ositio n by plug
welding (1) to the reinforcement.
14 MIG butt weld the reinforcement panel from inside the
centre pillar, through the large hole in the inner panel
immediately behin d the weld.
15 Finish the centre pillar attachment by MIG welding (2)
along the join of the outer panel.
Figure 7D – 92
7D Body Side – Coupe Page 7D-43
Page 7D-43
16 Plug weld (1) the replacement section at the front join,
then MIG butt weld (2) the two sections together.
Figure 7D – 93
17 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.
18 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 removed.
19 Spot or plug weld along the flanges of the door
opening frame assembly, refer to Figure 7D – 95.
Figure 7D – 94
Figure 7D – 95
20 Plug weld up through the rocker panel to attach the replacement section to the quarter panel inner assembly.
Refer to Figure 7D – 96.
7D Body Side – Coupe Page 7D-44
Page 7D-44
Figure 7D – 96
21 Spot or plug weld two places, the door opening frame assembly to the quarter panel i nn er assembly around the
rear wheel arch.
NOTE
This joint will be completed when the rear q uarter
panel is installed.
22 Clean up the welds made where the rear quarter panel is located and prime all bare metal.
23 Replace the rear quarter panel, refer to 2.1 Rear Quarter Pane l – Replace.
24 Refinish and paint panels and other components as required, refer to Section 3 Body Construction.
25 Apply Joint Sealer (Item 3) as required. Refer to Section 3D Body Construction – Coupe.
26 Apply Cavity Wax (Item 8) as required to the inside of any box secti ons or areas inaccessible to paint,
refer Section 3D Body Construction – Coupe.
27 Install the remaining components as described in the appropriate Section of the MY 2005 VZ Service Informatio n.
7D Body Side – Coupe Page 7D-45
Page 7D-45
2.7 Fender Lower Rear Bracket – Replace
1 The fender lower rear bracket (1) is spot welded at
four places to the door openin g frame assembly.
2 Clamp the fender lower rear bracket positi on as shown
prior to plug welding and che ck the alignment of the
fender to the body and front door.
3 Refinish and paint panels and other components as
required. Refer to Section 3 Body Construction .
4 Apply Cavity Wax (Item 8) as required to the inside of
any box sections or areas inaccessible to paint,
refer to Section 3D Body Construction – Coupe .
Figure 7D – 97
7D Body Side – Coupe Page 7D-46
Page 7D-46
2.8 Hinge Pillar Inner Panel Assembly –
Replace
Remove
NOTE
Replacement of the full hinge pillar inner panel
assembly requires removal of the door opening
frame assembly and the roof panel. Alternatives
are provided which avoid removal of the full door
opening frame assembly and roof panel. It is
advisable to read the options available in this
procedure before removing any panels.
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate Section of th e MY
2005 VZ Service Information.
2 Remove the door opening frame assembly, refer to
2.3 Door Opening Frame Assembly – Repl ace, or
remove the hinge pillar section of the door opening
frame assembly, refer to 2.4 Door Opening Frame
Assembly – Partial Replace, Hinge Pil lar .
3 If required, remove the dash panel assembl y,
refer to Section 5 Cockpit Module.
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 7D – 98
5 Grind the MIG welds (1) attaching the hinge pill ar inner
panel assembly to the inner rocker panel.
Figure 7D – 99
7D Body Side – Coupe Page 7D-47
Page 7D-47
6 If full replacement is being performed, spot cut the
welds attaching the hinge pillar inner panel assembly
to the roof front header assembly and quarter panel
inner assembly.
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 7D – 101. Figure 7D – 100
Figure 7D – 101
7 Spot cut the welds attaching the hinge pillar i nner
panel assembly (or lower panel) to the front
wheelhouse panel and front fl oor panel extension,
refer 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 weld group B.
9 If required, remove any remainin g spot welds where
the front wheelhouse panel upper side rail attached
the front wheelhouse panel and 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 7D – 102
7D Body Side – Coupe Page 7D-48
Page 7D-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 If an alternate removal method was used, referring to Figure 7D – 101, 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 3D Body Construction – Coupe .
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 replac ed, apply structural adhesive (Item 6) to
the mating surfaces of the hinge pillar inner panel assembly and quarter panel inner extension,
refer to Section 3D Body Construction – Coupe .
7D Body Side – Coupe Page 7D-49
Page 7D-49
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 7D – 103
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 assembly and
quarter panel inner assembly.
NOTE
Ensure the structural adhesive Item 6, is applie d
to the join (1) refer to Section 3D Body
Construction – Coupe
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 7D – 105.
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 7D – 105.
Figure 7D – 104
NOTE
This join forms the top access cut point for joining
of the reinforcement as described in
2.4 Door Opening Frame Assembly – Partial
Replace, Hinge Pillar .
7D Body Side – Coupe Page 7D-50
Page 7D-50
Figure 7D – 105
14 Spot or plug weld the hinge pillar in ner panel assembly
to the front wheelhouse panel and front floor
extension.
Figure 7D – 106
15 MIG weld (1) across the inner rocker panel and hinge
pillar inner panel assembly.
16 Replace the door opening fra m e assembly,
refer to 2.3 Door Opening Frame Assembly – Replace
or the hinge pillar section of the door ope nin g frame
assembly, refer to 2.4 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 3D Body Construction – Coupe.
19 Apply Cavity Wax (Item 8) as required to the inside of
any box sections or areas inaccessible to paint,
refer to Section 3D Body Construction – Coupe .
20 Install the remaining components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information.
Figure 7D – 107
7D Body Side – Coupe Page 7D-51
Page 7D-51
2.9 Quarter Panel Inner Assembly – Replace
Remove
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate Section of th e MY
2005 VZ Service Information.
2 Mount the vehicle on a suitable jig to mai ntai n correct
body alignment when the quarter panel inner
assembly is removed.
3 Remove rear quarter panel,
refer to 2.1 Rear Quarter Panel – Replace.
4 Remove the roof panel, and partially remove
the roof bow panel and roof rear panel, refer to
Section 9D Roof.
5 Remove the door opening frame assembly, refer to
2.3 Door Opening Frame Assembly – Repl ace.
6 Add further bracing tools as required, to maintain the
alignment of the vehicle structure.
Figure 7D – 108
7 Grind the MIG welds (1), 11 places, attaching the
quarter panel inner assembly to the inner rocker panel.
8 Spot cut the welds attaching the rear wheelhouse
inner (1) to the rear floor panel assembly,
refer to Figure 7D – 110.
Figure 7D – 109
Figure 7D – 110
9 Spot cut the welds attaching the rear windo w panel assembly to the rear seat back extension assembly,
refer to Figure 7D – 111.
7D Body Side – Coupe Page 7D-52
Page 7D-52
Figure 7D – 111
10 The hinge pillar inner panel assembly is attached to
the quarter panel inner assembl y with spot welds and
structural adhesive (1) (Item 6,
refer to Section 3D Body Construction – Coupe ). As
the adhesive is extremely strong, cut through the
quarter panel inner assembly just behind the join and
remove the remaining joint piece with a grinder.
11 As required, spot cut the welds attaching the rear
window panel assembly (1) and (4) to the quarter
panel inner (2) and rear seat back extension assembly
(3). Refer to Figure 7D – 113.
NOTE
• Structural adhesive (Item 6) is applied in the
areas shown shaded. As this material is
extremely strong, the rear seat back
extension assembly may require removing
with a grinder.
• Remove the remaining flange of the rear
quarter panel (5), leaving only the rear
window panel assembly. Figure 7D – 112
Figure 7D – 113
12 Remove the quarter panel inner assembly from the vehicle, then repair any damage to a djacent parts as required.
13 Check and rectify the alignme nt of the body as required, refer to Section 3 D Body Construction – Coupe.
7D Body Side – Coupe Page 7D-53
Page 7D-53
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 3D Body Construction – Coupe .
3 Apply Structural Adhesive (Item 6, refer to Section 3D Body Construction – Coupe) to the mating surfaces of the:
• Hinge pillar inner panel ass embly, refer to Figure 7D – 114, and
• Inner joint only of the rear seatback extens ion (part of the quarter panel inner assembly),
refer to Figure 7D – 115.
NOTE
Adhesive will be applie d to the outer rear window
panel assembly joint when the rear quarter panel
is installed.
4 Clamp the new panel in position on the vehicle.
5 Plug or spot weld the quarter panel inner assembly to
the hinge pillar inner assembly join.
Figure 7D – 114
7D Body Side – Coupe Page 7D-54
Page 7D-54
6 Spot or plug weld two places, the rear window panel
assembly (1) and (3) to the, rear seat back extension
(2).
NOTE
This area will be completed as the rear quarter
panel is installed.
7 Spot or plug weld the rear windo w panel assembly to
the rear seat back extension assembly,
refer to Figure 7D – 116.
Figure 7D – 115
Figure 7D – 116
8 Spot or plug weld the rear wheelhous e inner (1) to the rear floor panel assembly, refer to Figure 7 D – 117.
7D Body Side – Coupe Page 7D-55
Page 7D-55
Figure 7D – 117
9 MIG weld 11 places (1), the quarter panel inner
assembly to the inner rocker panel.
10 Clean up welds as required and prime any bare metal.
11 Install the door opening frame assembly, refer to
2.3 Door Opening Frame Assembly – Repl ace.
12 Replace the roof and roof support panels, as
described in Section 9D Roof.
13 Prepare the rear quarter panel for installation,
refer to 2.1 Rear Quarter Panel – Replace.
Figure 7D – 118
Do not modify the rear quarter panel flange at
the base of the lock pillar as stated in the rear
quarter panel replacement procedure, as the
flange is required for this procedure.
7D Body Side – Coupe Page 7D-56
Page 7D-56
14 Apply structural adhesive (Item 6, refer to
Section 3D Body Construction – Coupe) to the rear
quarter panel flange as sho wn.
15 Fit and clamp the rear quarter panel into position,
refer to 2.1 Rear Quarter Panel – Replace.
Ensure the rear quarter flange (1) is fitted
between the qu arter panel inner assembly (2)
and rear window panel assembly (3). If
required prise up the rear window panel
assembly to provide clearance, also refer to
Figure 7D – 120. Figure 7D – 119
16 Spot or plug weld through the rear window panel
assembly as shown.
17 Complete the rear quarter panel,
refer to 2.1 Rear Quarter Panel – Replace.
18 Refinish and paint panels and other components as
required. Refer to Section 3 Body Construction .
19 Apply Joint Sealer (Item 3) as required.
Refer to Section 3D Body Construction – Coupe.
20 Apply Cavity Wax (Item 8) as required to the inside of
any box sections or areas inaccessible to paint,
refer to Section 3D Body Construction – Coupe .
21 Install the remaining components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information.
Figure 7D – 120
7D Body Side – Coupe Page 7D-57
Page 7D-57
2.10 Quarter Panel Inner Assembly – Partial
Replace
Remove
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate Section of th e MY
2005 VZ Service Information.
2 If required, mount the vehicle on a suitable fixture.
Secure a suitable tool bet ween the rear door opening
flanges to maintain alignment once the sections are
removed.
3 Remove rear quarter panel,
refer to 2.1 Rear Quarter Panel – Replace.
4 Remove lock pillar section of the door opening frame
assembly, refer to 2.6 Door Opening Frame Assembly
– Partial Replace, Rocker Panel.
Figure 7D – 121
5 Carefully cut through the quarter panel inner assembly
at the rocker panel region.
NOTE
The position of the cut (1) should be a minimum
of 50 mm short er than that of the outer panel (2)
to allow sufficient access for rejoining.
Figure 7D – 122
6 Depending on the cut location, grind the MIG welds
(1), attaching the quarter panel in ner assembly to the
inner rocker panel.
7 Spot cut the welds attaching the rear wheelhouse
inner (1) to the rear floor panel assembly,
refer to Figure 7D – 124.
Figure 7D – 123
7D Body Side – Coupe Page 7D-58
Page 7D-58
Figure 7D – 124
8 Spot cut the welds attaching the rear windo w panel assembly to the rear seat back extension assembly,
refer to Figure 7D – 125.
Figure 7D – 125
9 As required, spot cut the welds attaching the rear window panel assembly (1) and (4) to the quarter panel inner (2)
and rear seat back extension assembl y (3). Refer to Figure 7D – 126.
NOTE
• Structural adhesive (Item 6) is applied in the
areas shown shaded. As this material is
extremely strong, the rear seat back
extension assembly may require removing
with a grinder.
• Remove the remaining flange of the rear
quarter panel, leaving only the rear window
panel assembly.
7D Body Side – Coupe Page 7D-59
Page 7D-59
Figure 7D – 126
10 Cut the quarter panel inner assembly through the lock
(1) at a point 50 mm below the end of the door
opening frame.
11 Cut through the quarter panel inner assembly at a
point rearward of the centre pillar (2).
12 Remove the partial quarter panel inner assembly from
the vehicle, then repair any damage to adjacent parts
as required.
13 Check and rectify the alignme nt of
the body as requir ed,
refer to Section 3D Body Construction – Coupe .
Figure 7D – 127
7D Body Side – Coupe Page 7D-60
Page 7D-60
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 cut a replacement inner lock pillar section from a new quarter panel inner assembly. The new panel
should be cut 40 mm longer at the mating faces to allow for overlap.
NOTE
Cut the quarter panel in ner at the u pper lock pillar
join correct length to facilitate a butt joint.
2 Remove the flanges from the overlapp ing sections and
form a joggle to facilitate a lap joint. Make the lock
pillar reinforcement joggle inward and the other
joggles outward.
3 Mark the new panel and the existing panels with
drilling locations in preparation for plug welding where
required. Drill holes as marked.
4 Prepare all mating surfaces and treat with Weld
Through Primer (Item 1) as required,
refer to Section 3D Body Construction – Coupe .
Figure 7D – 128
7D Body Side – Coupe Page 7D-61
Page 7D-61
5 Apply Structural Adhesive (Item 6,
refer to Section 3D Body Construction – Coupe ) to the
inner joint only of the rear seat back extension (part of
the quarter panel inner assembl y).
NOTE
Adhesive will be applie d to the outer rear window
panel assembly joint when the rear quarter pan el
is installed.
6 Position the new panel on the vehicle and clamp in
place.
7 Spot or plug weld two places, the rear window panel
assembly (1) and (3) to the, rear seat back extension
(2).
NOTE
This area will be completed as the rear quarter
panel is installed.
Figure 7D – 129
8 Plug weld the lap joints.
9 Finish the joints by MIG welding along the join.
10 From inside the vehicle, MIG weld the quarter panel
inner at the upper lock pillar join.
11 Spot or plug weld the rear windo w panel assembly to
the rear seat back extension assembly,
refer to Figure 7D – 131.
Figure 7D – 130
7D Body Side – Coupe Page 7D-62
Page 7D-62
Figure 7D – 131
12 Spot or plug weld the wheelhouse inner (1) to the rear flo or pan el assembly, refer to Figure 7D – 132.
Figure 7D – 132
13 As required, MIG weld (1), the quarter panel inner
assembly to the inner rocker panel.
14 Clean up the welds as requir ed and prime any bare
metal.
15 Install the rear section of the door opening frame
assembly, refer to 2.6 Door Opening Frame Assembly
– Partial Replace, Rocker Panel.
16 Prepare the rear quarter panel for installation,
refer to 2.1 Rear Quarter Panel – Replace.
Do not modify the rear quarter panel flange at
the base of the lock pillar as stated in the rear
quarter panel replacement procedure, as the
flange is required for this procedure.
Figure 7D – 133
7D Body Side – Coupe Page 7D-63
Page 7D-63
17 Apply structural adhesive (Item 6,
refer to Section 3D Body Construction – Coupe ) to the
rear quarter panel flange as shown.
18 Fit and clamp the rear quarter panel into position, refer
to 2.1 Rear Quarter Panel – Replace.
NOTE
Ensure the rear quarter flange (1) is fitted
between the quarter panel inner assembly (2)
and rear window panel assembly (3). If required
prise up the rear window panel assembly to
provide clearance, also refer to Figure 7D – 135.
Figure 7D – 134
19 Spot or plug weld through the rear window panel
assembly as shown.
20 Complete the rear quarter panel,
refer to 2.1 Rear Quarter Panel – Replace.
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 3D Body Construction – Coupe.
23 Apply Cavity Wax (Item 8) as required to the inside of
any box sections or areas inaccessible to paint,
refer to Section 3D Body Construction – Coupe .
24 Install the remaining components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information.
Figure 7D – 135
7D Body Side – Coupe Page 7D-64
Page 7D-64
3 Torque Wrench Specifications
Dash Panel Retaining Bolt Torque Specification.......................35.0 – 45.0 Nm