10B Body Rear – Wagon and AWD Wagon Page 10B-1
Page 10B-1
Section 10B
Body Rear – Wagon and AWD Wagon
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 Rear Components........................................................................................................................................ 3
2 Service Operations.................................................................................................................................5
2.1 Rear End Lower Panel – Replace ......................................................................................................................... 5
Remove................................................................................................................................................................... 5
Replace................................................................................................................................................................... 7
2.2 Rear End Panel Assembly – Replace................................................................................................................... 8
Remove................................................................................................................................................................... 8
Replace................................................................................................................................................................. 10
2.3 Rear End Panel Extension – Replace................................................................................................................. 13
Remove................................................................................................................................................................. 13
Replace................................................................................................................................................................. 14
2.4 Fuel Tank Support Reinforcement Assembly – Replace.................................................................................. 16
Remove................................................................................................................................................................. 16
Replace................................................................................................................................................................. 17
2.5 Rear Compartment Floor Panel Outer Extension – Replace............................................................................ 18
Remove................................................................................................................................................................. 18
Replace................................................................................................................................................................. 19
2.6 Rear Compartment Floor Panel Assembly – Replace....................................................................................... 20
Remove................................................................................................................................................................. 20
Replace................................................................................................................................................................. 21
2.7 Rear Wheelhouse Inner Panel Assembly – Replace......................................................................................... 23
Remove................................................................................................................................................................. 23
Replace................................................................................................................................................................. 25
2.8 Rear Floor Panel Assembly – Replace............................................................................................................... 27
Remove................................................................................................................................................................. 27
Replace................................................................................................................................................................. 29
10B Body Rear – Wagon and AWD Wagon Page 10B-2
Page 10B-2
2.9 Crossmember Assembly No. 2 – Replace ......................................................................................................... 32
Remove................................................................................................................................................................. 32
Replace................................................................................................................................................................. 33
2.10 Crossmember Assembly No. 2 – Replace ......................................................................................................... 34
Remove................................................................................................................................................................. 34
Replace................................................................................................................................................................. 35
2.11 Rear Tie Down Assembly – Replace .................................................................................................................. 36
Remove................................................................................................................................................................. 36
Replace................................................................................................................................................................. 37
2.12 Rear Bumper Impact Bar Brace Assembly – Replace ...................................................................................... 38
Remove................................................................................................................................................................. 38
Replace................................................................................................................................................................. 38
2.13 Rear Side Rail Assembly – Replace................................................................................................................... 39
Remove................................................................................................................................................................. 39
Replace................................................................................................................................................................. 41
10B Body Rear – Wagon and AWD Wagon Page 10B-3
Page 10B-3
1 General Description
This Section describes replacement procedures for the rear section components of the Wagon and AWD W agon body
structure. Removal of bolt-on and mechanical components is not covered. Refere nce must be made to the appropri ate
Sections in the MY 2005 VZ Service Information.
When repairing the rear of the vehicle, care must be taken to ensure the structure is returned to its original production
configuration.
NOTE
It is imperative that the correct body adhesives,
sealers, deadeners and cavity waxes are used
when repairing the body structure. Refer to
Section 3 Body Construction for details of the
correct materials and their commercially available
equivalents.
1.1 Body Rear Components
The shaded components in Figure 10B – 1 are those dealt
with in this Section. The components and assemblies
shown in Figure 10B – 2 are the serviceable parts that form
the basis of the repair procedures in this Secti on.
For a detailed view of the body components, refer to
Section 3 Body Construction or
Section 3G Body Construction – AWD Wagon.
NOTE
Always refer to an Authorised Retailer for spare
parts availability configurations.
Figure 10B – 1
10B Body Rear – Wagon and AWD Wagon Page 10B-4
Page 10B-4
Figure 10B – 2
Legend
1 Rear Side Rail Assembly, Left-hand / Right-hand
2 Rear Floor Panel Outer Extension, Left-hand / Right-hand
3 Rear Tie Down Hook Assembly, Left-hand / Right-hand
4 Rear Bumper Impact Bar Brace Assembly, Left-hand / Right-
hand
5 Crossmember Assembly No. 2, Left-hand / Right-hand
6 Rear Wheelhouse Inner Panel Assembly, Left-hand / Right-
hand
7 Rear Floor Panel Assembly
8 Rear Compartment Floor Panel Outer Extension, Left-Hand
9 Rear Compartment Floor Panel Assembly
10 Rear Compartment Floor Panel Outer Extension, Right-
Hand
11 Fuel Tank Support Reinforcement Assembly
12 Spare Wheel Anchor Plate Assembly
13 Rear End Panel Assembly
14 Rear End Panel Extension
15 Rear End Lower Panel
NOTE
• Rear side rail assembl y (1) includes parts No.
2, 3 and 4.
• Rear compartment floor panel assembly (9)
includes parts No. 8, 10, 11 and 12.
• Rear end panel assembly (13) incudes part
No. 14.
10B Body Rear – Wagon and AWD Wagon Page 10B-5
Page 10B-5
2 Service Operations
2.1 Rear End Lower Panel – Replace
Remove
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 all fuel
lines.
NOTE
If the rear end panel assembly (inner) is also to
be replaced, remove the rear end panels as an
assembly. Refer to 2.2 Rear End Panel
Assembly – Replace.
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 bumper impact bar assembly, refer
to Section 7B Body Side – Wagon.
Figure 10B – 3
10B Body Rear – Wagon and AWD Wagon Page 10B-6
Page 10B-6
3 If the quarter panel extensions are not being
removed, spot cut the welds attaching the
rear end lower panel. If they are to be removed,
refer to Section 7B Body Side – Wagon.
NOTE
The rear end lower panel is fitted under each
quarter panel extension.
Figure 10B – 4
4 Spot cut the welds attaching the rear end lower panel
to the rear end panel assembly.
5 Remove the rear end lo wer panel.
Figure 10B – 5
10B Body Rear – Wagon and AWD Wagon Page 10B-7
Page 10B-7
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 3 Body Construction.
3 Clamp the rear end lower panel in position and spot or
plug weld to the rear end panel assembl y.
Figure 10B – 6
4 As required, weld the quarter pan el extension to the
rear end panel assembl y or replace the quarter panel
extension, refer to Section 7B Body Side – Wagon.
5 Refinish and paint panels and other components as
required. Refer to Section 3 Body Construction .
6 Apply Joint Sealer (Item 3) as required.
Refer to Section 3 Body Construction.
7 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.
8 Install the rear bumper impact bar assembly,
refer to Section 3 Body Construction.
9 Install the remaining components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information.
Figure 10B – 7
10B Body Rear – Wagon and AWD Wagon Page 10B-8
Page 10B-8
2.2 Rear End Panel Assembly – Replace
Remove
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 all fuel
lines.
NOTE
This procedure describes the removal of the rear
end lower panel and rear end panel assembly
together. As the panels are supplied individually,
this procedure contains the replacement of the
rear end panel assembly only. Reference should
be then made to 2.1 Rear End Lower Panel –
Replace for the relevant replacement procedures
of the remaining panel.
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 bumper impact bar assembly,
refer to Section 3 Body Construction.
Figure 10B – 8
10B Body Rear – Wagon and AWD Wagon Page 10B-9
Page 10B-9
3 Either:
a Remove the quarter panel extensions, refer to
Section 7B Body Side – Wagon and, spot cut the
welds attaching the rear end panel extensions to
the vehicle, refer to 2.3 Rear End Panel
Extension – Replace..
b To avoid removal of the quarter panel
extensions:
Spot cut the welds attaching the rear end lower
panel to the quarter panel extensi on, refer to
2.1 Rear End Lower Panel – Replace a nd spot
cut the welds attaching the rear end panel to
rear end panel extension each side and leave
the rear end panel extensions in place.
Figure 10B – 9
4 Spot cut the welds attaching the fuel tank support
reinforcement to the rear end panel assembly.
NOTE
As an alternative, the fuel tank support
reinforcement can be removed from the rear
compartment floor panel assembly, refer to
2.4 Fuel Tank Support Reinforcement Asse mbly
– Replace.
5 Spot cut the welds attaching the rear end panel
assembly to the rear compartment floor panel
assembly, refer to Figure 10B – 11.
Figure 10B – 10
10B Body Rear – Wagon and AWD Wagon Page 10B-10
Page 10B-10
Figure 10B – 11
6 Spot cut the welds attaching the rear side rail
assemblies to the rear end panel ass embl y. Note that
the left-hand side is different to the right-hand side.
7 Remove the panel from the vehicle, then repair any
damage to adjacent parts.
8 Check and rectify the alignme nt of the bod y shell.
Refer to Section 3 Body Construction.
Figure 10B – 12
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.
10B Body Rear – Wagon and AWD Wagon Page 10B-11
Page 10B-11
2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required,
refer to Section 3 Body Construction.
3 If the rear end panel extensions were left attached to the vehicle, spot cut the welds attaching the extensions to the
rear end panel on the replac ement section.
4 Install the rear end panel assembly in position and spot or plug weld to the rear compartment floor pa nel assembly,
refer to Figure 10B – 13.
Figure 10B – 13
5 Spot or plug weld the rear side rail assemblies to the
rear end panel assembl y. Note that the left-hand si de
is different to the right-hand side.
Figure 10B – 14
10B Body Rear – Wagon and AWD Wagon Page 10B-12
Page 10B-12
6 Spot or plug weld the fuel tank support reinforcement
to the rear end panel assembly or replac e the fuel tank
support reinforcement, refer to 2.4 Fuel Tank Support
Reinforcement Assembly – Replace.
NOTE
Complete the top row of welds when welding the
rear end lower panel.
7 Depending on removal method either:
a Spot or plug weld the rear end panel extensions
to the vehicle, refer to 2.3 Rear End Panel
Extension – Replace., or
Figure 10B – 15
b If the quarter panel extensions were left attached
to the vehicle, spot or plug weld the rear end
panel to rear end panel extension each side.
8 In the areas where the rear end lower pane l will fit,
grind the welds and prime any bare metal.
9 Install the rear end lower panel,
refer to 2.1 Rear End Lower Panel – Replace.
10 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 to Section 3 Body Construction.
11 Install the rear bumper impact bar assembly, refer to
Section 3 Body Construction.
12 Install the remaining components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information.
Figure 10B – 16
10B Body Rear – Wagon and AWD Wagon Page 10B-13
Page 10B-13
2.3 Rear End Panel Extension – Replace.
Remove
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 all fuel
lines.
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 bumper impact bar assembly,
refer to Section 3 Body Construction.
3 Remove the quarter panel extension,
refer to Section 7B Body Side – Wagon.
Figure 10B – 17
4 From underneath the vehicle, spot cut the welds
attaching the rear end panel extension to the quarter
panel inner assembly and rear end panel assembly.
5 Spot cut the welds attaching the rear end panel
extension to the quarter pan el inner assembly, rear
end panel assembly and rear compartme nt floor pa nel
assembly, refer to Figure 10B – 19.
6 Remove the extension from the vehicle and then
repair any damage to adjacent parts.
Figure 10B – 18
10B Body Rear – Wagon and AWD Wagon Page 10B-14
Page 10B-14
Figure 10B – 19
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 3 Body Construction.
3 Clamp the rear end panel e xtensi on in position on the
vehicle and spot or plug weld to the quarter panel
inner assembly, rear end panel assembly and rear
compartment floor panel assembly.
Figure 10B – 20
10B Body Rear – Wagon and AWD Wagon Page 10B-15
Page 10B-15
4 From underneath the vehicle, plug or spot weld the
rear end panel extension to the quarter panel inner
assembly and rear end panel assembly.
5 Replace the quarter panel extension,
refer to Section 7B Body Side – Wagon
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 3 Body Construction.
8 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.
9 Install the rear bumper impact bar assembly,
refer to Section 3 Body Construction.
10 Install the remaining components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information.
Figure 10B – 21
10B Body Rear – Wagon and AWD Wagon Page 10B-16
Page 10B-16
2.4 Fuel Tank Support Reinforcement
Assembly – Replace
Remove
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 all fuel
lines.
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 floor deadener panels and joint sealer
from around the fuel tank support reinforcement
assembly as required.
Figure 10B – 22
3 Spot cut the 14 welds attaching the reinforcement to
the rear end panel assembly.
4 Spot cut the 14 welds attaching the reinforcement to
the rear compartment floor panel assembly.
5 Remove the fuel tank support reinforcem ent assembly
and then repair any damage t o adjacent parts as
required.
Figure 10B – 23
10B Body Rear – Wagon and AWD Wagon Page 10B-17
Page 10B-17
Replace
NOTE
• Spot welding is the preferred method for
attaching of panels and should be used
whenever possible. Where the spot welding
equipment 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 3 Body Construction.
3 Plug weld the fuel tank support reinforceme nt
assembly to the rear compartment floor panel
assembly and rear end panel assembly.
4 Refinish and paint panels and other components as
required. Refer to Section 3 Body Construction .
5 Apply Joint Sealer (Item 3) as required.
Refer to Section 3 Body Construction.
6 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.
7 Install the deadener panels as required,
refer to Section 3 Body Construction.
8 Install the remaining components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information.
Figure 10B – 24
10B Body Rear – Wagon and AWD Wagon Page 10B-18
Page 10B-18
2.5 Rear Compartment Floor Panel Outer
Extension – Replace
Remove
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 all fuel
lines.
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 joint sealer from around the rear
compartment floor panel outer exte nsion joins as
required.
3 Spot cut the welds attaching the rear compartment
floor panel outer extension to the rear compartment
floor panel, rear side rail asse mbly, quarter panel inner
assembly and rear wheelhouse inner panel as
required, refer to Figure 10B – 26.
Figure 10B – 25
Figure 10B – 26
4 Remove the extension from the vehicle and then repair any damage to adjacent parts as requ ired.
5 Check and rectify the alignme nt of the body as required, ref er to Section 3 Body Construction.
10B Body Rear – Wagon and AWD Wagon Page 10B-19
Page 10B-19
Replace
NOTE
• Spot welding is the preferred method for
attaching of panels and should be used
whenever possible. Where the spot welding
equipment 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 3 Body Construction.
3 Spot or plug weld the left-hand web plate in position as
shown.
Figure 10B – 27
4 Spot weld the right-hand web plate in position as
shown.
5 Refinish and paint panels and other components as
required. Refer to Section 3 Body Construction .
6 Apply Joint Sealer (Item 3) as required.
Refer to Section 3 Body Construction.
7 Apply Cavity Wax (Item 8) as required to the inside of
any box sections or areas inaccessible to paint,
refer toSection 3 Body Construction.
8 Apply Spray-on Dea dener (Item 7) where applicab le,
refer to Section 3 Body Construction.
9 Install the remaining components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information.
Figure 10B – 28
10B Body Rear – Wagon and AWD Wagon Page 10B-20
Page 10B-20
2.6 Rear Compartment Floor Panel
Assembly – Replace
NOTE
Depending on the area of damage, it may be
advisable to include removal of the rear seat
back panel extension assembly or rear
wheelhouse inner panel assembly. Refer to
2.7 Rear Wheelhouse Inner Panel Assembly –
Replace.
Remove
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 all fuel
lines.
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 the vehicle on a suitable fixture and us e a
suitable brace to maintain the alignment of the rear
side rail assemblies prior to removal of the re ar end
panel assembly.
3 Remove the rear end panel assembly, refer to
2.2 Rear End Panel Assembly – Replace.
4 Remove the joint sealer from the surrounding area
using a scraper and heat gun.
Figure 10B – 29
5 Spot cut the welds attaching the rear compartment floor panel assembly to the rear floor panel assembly,
refer to Figure 10B – 30.
6 Spot cut the welds attaching the rear compartment floor panel assem bl y to the rear side ra il assemblies.
Figure 10B – 30
10B Body Rear – Wagon and AWD Wagon Page 10B-21
Page 10B-21
7 Spot cut the welds attaching the rear compartment floor panel assembly to the quarter panel inner assembly and
rear wheelhouse inner pa nel assembly, refer to Figure 10B – 31.
Figure 10B – 31
8 Remove the floor panel assembly from the vehicle, then repair any damage to adjacent parts as required.
9 Check and rectify the alignme nt of the body as required, ref er to Section 3 Body Construction.
Replace
NOTE
• Spot welding is the preferred method for
attaching of panels and should be used
whenever possible. Where the spot welding
equipment 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 3 Body Construction.
3 Clamp the new rear compartment floor panel assembly in position and plug weld along the join to the rear floor
assembly, refer to Figure 10B – 32.
4 Plug weld the rear compartment floor panel assembly to the rear side rail assemblies.
10B Body Rear – Wagon and AWD Wagon Page 10B-22
Page 10B-22
Figure 10B – 32
5 Spot or plug the rear compartment floor panel assembly to the quarter panel inner assembly and rear wheelhouse
inner panel assembly, refer to Figure 10B – 33.
Figure 10B – 33
6 Replace the rear end panel assembly, refer to 2.2 Rear End Panel Assembly – 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 3 Body Construction.
9 Apply deadener panels to the rear compartment floor panel, refer to Section 3 Body Construction.
10 Apply Cavity Wax (Item 8) as required to the inside of any box secti ons or areas inaccessible to paint,
refer to Section 3 Body Construction.
11 Install the remaining components as described in the appropriate Section of the MY 2005 VZ Service Informatio n.
10B Body Rear – Wagon and AWD Wagon Page 10B-23
Page 10B-23
2.7 Rear Wheelhouse Inner Panel 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 Secure the vehicle on a suitable fixture. As a
minimum, support the appropriate structural s ections
of the vehicle on safety stands. Ensure that the stands
are clear of the sections being removed.
3 Remove the adjoining panels as required, refer to the
appropriate Section in this Supplement.
Figure 10B – 34
4 Spot cut the welds attaching the rear wheelhouse
bracket to the quarter panel inner assembly on the
relevant side of the vehicle.
5 Spot cut the welds attaching the rear wheelhouse
inner panel assembly to the rear floor pane l assembly
and rear compartment floor panel assembly on the
relevant side of the vehicle, refer to Figure 10 B – 36.
Figure 10B – 35
10B Body Rear – Wagon and AWD Wagon Page 10B-24
Page 10B-24
Figure 10B – 36
6 Spot cut the welds attaching the left-hand (1) or right-
hand (2) rear wheelhouse inner panel assembly to the
quarter panel inner assembly.
7 Remove the panel from the vehicle and th en repair
any damage to adjacent parts as required.
Figure 10B – 37
10B Body Rear – Wagon and AWD Wagon Page 10B-25
Page 10B-25
Replace
NOTE
• Spot welding is the preferred method for
attaching of panels and should be used
whenever possible. Where the spot welding
equipment 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 3 Body Construction.
3 Clamp the new rear wheelhouse inner pa nel assembly in position and spot or plug weld to the rear floor panel
assembly and rear compartment floor panel assembly, refer to Figure 10B – 38.
Figure 10B – 38
10B Body Rear – Wagon and AWD Wagon Page 10B-26
Page 10B-26
4 Plug weld the left-hand (1) or right-hand (2) rear
wheelhouse inner panel assembly to the quarter panel
inner assembly.
Figure 10B – 39
5 Spot or plug weld the rear wheelhous e bracket to the
quarter panel inner assembly on the relevant side of
the vehicle.
6 Replace the adjoining panels as required, refer to the
appropriate Section in this Supplement.
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 3 Body Construction
9 Apply Spray-on Dea dener (Item 7) where applicab le,
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 to Section 3 Body Construction.
11 Install the remaining components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information.
Figure 10B – 40
10B Body Rear – Wagon and AWD Wagon Page 10B-27
Page 10B-27
2.8 Rear Floor Panel Assembly – Replace
Remove
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 all fuel
lines.
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 the vehicle on a suitable fixture. As a
minimum, support the appropriate structural s ections
of the vehicle on safety stands. Ensure that the stands
are clear of the sections being removed.
3 Remove the sealer and floor dead ener panels from the
relevant areas using a scraper and heat gun.
4 Remove the adjoining panels as required, refer to the
appropriate Section in this Supplement.
Figure 10B – 41
5 Spot cut the welds attaching the park brake cabl e
bracket to the rear floor panel assembly.
Figure 10B – 42
10B Body Rear – Wagon and AWD Wagon Page 10B-28
Page 10B-28
6 Spot cut the welds joining the front floor panel
assembly (1) and rear floor panel assembly (2).
7 Spot cut the welds attaching the rear floor panel
assembly to the inner rocker panel (3) each side.
Figure 10B – 43
8 Spot cut the welds attaching the rear floor panel
assembly to the rear wheelhouse inner p anel
assembly on both sides of the vehicle.
9 Spot cut the welds attaching the rear floor panel
assembly to the rear compartment floor panel
assembly and crossmember assembly No. 2,
refer to Figure 10B – 45.
10 Spot cut the welds attaching the rear floor panel
assembly to the rear side rail assemblies, refer to
2.13 Rear Side Rail Assembly – Repl ace.
11 Remove the rear floor panel assembly from the vehicle
and then repair any damage t o adjacent parts.
12 Check and rectify the alignme nt of the bod y as
required, refer to Section 3 Body Construction.
Figure 10B – 44
10B Body Rear – Wagon and AWD Wagon Page 10B-29
Page 10B-29
Figure 10B – 45
Replace
NOTE
• Spot welding is the preferred method for
attaching of panels and should be used
whenever possible. Where the spot welding
equipment 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 3 Body Construction.
3 Clamp the new rear floor panel assembly in position and plug weld to the rear compartment floor assembly and
crossmember assembly No 2, refer to Figure 10B – 46.
Figure 10B – 46
10B Body Rear – Wagon and AWD Wagon Page 10B-30
Page 10B-30
4 Spot weld the rear floor assembly to the rear
wheelhouse inner panel assembly on both sides of the
vehicle.
5 Plug weld the rear floor panel assembly
to the rear side rail assemblies, refer to
2.13 Rear Side Rail Assembly – Repl ace.
Figure 10B – 47
6 Plug weld the rear floor panel assembly (2) to the front
floor panel assembly (1).
7 Plug weld the rear floor panel assembly to the inner
rocker panel (3) each side.
Figure 10B – 48
10B Body Rear – Wagon and AWD Wagon Page 10B-31
Page 10B-31
8 Plug weld the park brake cable brack et to the rear
floor panel assembly.
9 Replace any other remov ed panels as described in the
appropriate Section in this Supplement.
10 Refinish and paint panels and other components as
required. Refer to Section 3 Body Construction .
11 Apply Joint Sealer (Item 3) as required.
Refer to Section 3 Body Construction
12 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.
13 Apply Spray-on Dea dener (Item 7) where applicab le,
refer to Section 3 Body Construction.
14 Apply deadener panels to the rear compartment floor
panel, refer to Section 3 Body Construction.
15 Install the remaining components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information.
Figure 10B – 49
10B Body Rear – Wagon and AWD Wagon Page 10B-32
Page 10B-32
2.9 Crossmember Assembly No. 2 – Replace
Remove
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 all fuel
lines.
1 Remove the adjacent components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information.
2 Secure the vehicle on a suitable fixture. As a
minimum, support the appropriate structural s ections
of the vehicle on safety stands. Ensure that the stands
are clear of the sections being removed.
3 Remove the adjoining panels as required, refer to the
appropriate Section of this Supplement.
4 Spot cut the welds attaching the left-hand (1) or
right-hand (2) rear bumper im pact bar brace assembly
to the rear side rail assembly (3),
refer to Figure 10B – 51.
5 If required, for the right-hand rear bumper impact bar
brace assembly, remove the closing plate (4).
Figure 10B – 50
Figure 10B – 51
10B Body Rear – Wagon and AWD Wagon Page 10B-33
Page 10B-33
Replace
NOTE
• Spot welding is the preferred method for
attaching of panels and should be used
whenever possible. Where the spot welding
equipment 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 3 Body Construction.
3 Clamp and plug weld the rear bumper impact bar brace assembly (1)or (2) in position on the rear si de rail assembly
(3).
4 If required, for the right-hand side clamp and plug weld the closing plate (4) in position, refer to Figure 10B – 52.
Figure 10B – 52
5 Install other panels as require d, refer to the appropriate Section in this Sup plement.
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 3 Body Construction.
8 Apply Cavity Wax (Item 8) as required to the inside of any box secti ons or areas inaccessible to paint,
refer to Section 3 Body Construction.
9 Install the remaining components as described in the appropriate Section of the MY 2005 VZ Service Informatio n.
10B Body Rear – Wagon and AWD Wagon Page 10B-34
Page 10B-34
2.10 Crossmember Assembly No. 2 – Replace
Remove
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 all fuel
lines.
1 Remove the adjacent components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information.
2 Secure the vehicle on a suitable fixture. As a
minimum, support the appropriate structural s ections
of the vehicle on safety stands.
Figure 10B – 53
3 Spot cut the welds attaching the crossmember No.2 to
the crossmember bracket and to the rear side rai l, on
each side of the vehicle.
NOTE
Take care not to damage the crossmember
brackets when removing the crossmember, as
these parts are only serviced as part of the rear
side rail assemblies.
Figure 10B – 54
4 Spot cut the welds attaching the crossmember to the
rear compartment floor panel assembly.
5 Remove the crossmember from the vehicle, and then
repair any damage to adjacent parts as required.
6 Check and rectify the alignme nt of the bod y as
required, refer to Section 3 Body Construction.
Figure 10B – 55
10B Body Rear – Wagon and AWD Wagon Page 10B-35
Page 10B-35
Replace
NOTE
• Spot welding is the preferred method for
attaching of panels and should be used
whenever possible. Where the spot welding
equipment 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 3 Body Construction.
3 Plug weld the crossmember to the crossmember
bracket and rear side rail, on each si de of the vehicle.
Figure 10B – 56
4 Plug weld the crossmember to the rear compartment
floor panel assembly.
5 Refinish and paint panels and other components as
required. Refer to Section 3 Body Construction .
6 Apply Joint Sealer (Item 3) as required.
Refer to Section 3 Body Construction.
7 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.
8 Apply Spray-on Dea dener (Item 7) where applicab le,
refer to Section 3 Body Construction.
9 Install the remaining components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information.
Figure 10B – 57
10B Body Rear – Wagon and AWD Wagon Page 10B-36
Page 10B-36
2.11 Rear Tie Down Assembly – Replace
Remove
1 Remove the adjacent components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information.
Figure 10B – 58
2 Spot cut the welds attaching the tie down hook
assembly to the rear side rail assembly and remove.
Figure 10B – 59
10B Body Rear – Wagon and AWD Wagon Page 10B-37
Page 10B-37
Replace
NOTE
• Spot welding is the preferred method for
attaching of panels and should be used
whenever possible. Where the spot welding
equipment 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 3 Body Construction.
3 Install the tie down hook assembly onto the r ear side
rail assembly, approximately 9 mm rearward of the
join.
4 Plug weld the tie down hook assembl y to the rear side
rail assembly, eight places.
5 Refinish and paint panels and other components as
required. Refer to Section 3 Body Construction .
6 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.
7 Install the remaining components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information. Figure 10B – 60
10B Body Rear – Wagon and AWD Wagon Page 10B-38
Page 10B-38
2.12 Rear Bumper Impact Bar Brace
Assembly – Replace
Remove
1 Remove the adjacent components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information..
Figure 10B – 61
2 Spot cut the welds attaching the rear floor panel outer
extension to the inner rocker panel and rear side rail
assembly and remove.
Figure 10B – 62
Replace NOTE
• Spot welding is the preferred method for
attaching of panels and should be used
whenever possible. Where the spot welding
equipment 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 3 Body Construction.
3 Install and plug weld the rear floor pane l outer
extension to the inner rocker panel and rear side rail
assembly.
4 Refinish and paint panels and other components as
required. Refer to Section 3 Body Construction .
5 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.
6 Install the remaining components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information.
Figure 10B – 63
10B Body Rear – Wagon and AWD Wagon Page 10B-39
Page 10B-39
2.13 Rear Side Rail Assembly – Replace
Remove
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 all fuel
lines.
1 Remove the adjacent components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information.
2 Secure the vehicle on a suitable fixture. As a
minimum, support the appropriate structural s ections
of the vehicle on safety stands. Ensure that the stands
are clear of the rear side rail assembly(s) being
removed.
Figure 10B – 64
3 Spot cut the welds attaching the crossmember No.2 to
the crossmember bracket and to the rear side rai l, on
each side of the vehicle.
Figure 10B – 65
4 Spot cut the welds attaching the rear side rail
assembly to the rear floor panel assembly.
Figure 10B – 66
10B Body Rear – Wagon and AWD Wagon Page 10B-40
Page 10B-40
5 Spot cut the welds attaching the rear side rail
assembly to the rear floor panel assembly.
Figure 10B – 67
6 Spot cut the welds attaching the rear floor panel outer
extension to the inner rocker panel assembly.
7 Spot cut the rear side rail assembly from the rear floor
panel assembly, rear compart ment floor panel
assembly and the rear end panel,
refer to Figure 10B – 69.
NOTE
There are a different number of welds between
the left-hand and right-hand sides.
8 Remove the rear side rail assembly from the vehicle.
Figure 10B – 68
Figure 10B – 69
9 Repair any damage to adjacent parts as required.
10 Check and rectify the alignme nt of the body as required, refer to Section 3 Body Construction.
10B Body Rear – Wagon and AWD Wagon Page 10B-41
Page 10B-41
Replace
NOTE
• Spot welding is the preferred method for
attaching of panels and should be used
whenever possible. Where the spot welding
equipment 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 3 Body Construction.
Prior to plug welding in this region, remove
the deadener from the inside floor to remove
the risk of fire.
3 Locate and clamp the new rear side rail assembly in position and check and adjust its alignment,
refer to Section 3 Body Construction.
4 Plug weld the rear side rail assembly to the rear floor panel assembly, rear compartment floor panel assembl y and
the rear end panel, refer to Figure 10B – 70.
Figure 10B – 70
10B Body Rear – Wagon and AWD Wagon Page 10B-42
Page 10B-42
5 Plug weld the rear side rail assembly to the r ear floor
panel assembly.
Figure 10B – 71
6 Plug weld the crossmember assembly No. 2 to the
crossmember bracket and rear side rail.
Figure 10B – 72
7 Plug weld the rear side rail assembly to the r ear floor
panel assembly and the rear floor panel outer
extension to the inner rocker panel assembly.
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 to Section 3 Body Construction.
11 Install the remaining components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information. Figure 10B – 73