10D Body Rear – Coupe Page 10D-1
Page 10D-1
Section 10D
Body Rear – 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 ...............................................................................................................................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................................................................................................................... 9
Remove................................................................................................................................................................... 9
Replace................................................................................................................................................................. 11
2.3 Fuel Tank Support Reinforcement Assembly – Replace.................................................................................. 13
Remove................................................................................................................................................................. 13
Replace................................................................................................................................................................. 14
2.4 Rear Compartment Floor Panel Outer Extension – Replace............................................................................ 15
Remove................................................................................................................................................................. 15
Replace................................................................................................................................................................. 16
2.5 Rear Compartment Floor Panel Assembly – Replace....................................................................................... 17
Remove................................................................................................................................................................. 17
Replace................................................................................................................................................................. 19
2.6 Rear Floor Panel Reinforcement – Replace....................................................................................................... 21
Left-hand Side...................................................................................................................................................... 21
Remove............................................................................................................................................................ 21
Replace............................................................................................................................................................ 21
Right-hand Side ................................................................................................................................................... 22
Remove............................................................................................................................................................ 22
Replace............................................................................................................................................................ 22
2.7 Fuel Tank Retaining Strap Assembly – Replace............................................................................................... 23
Remove................................................................................................................................................................. 23
Replace................................................................................................................................................................. 24
10D Body Rear – Coupe Page 10D-2
Page 10D-2
2.8 Rear Compartment Lid Strut Bracket Assembly – Replace............................................................................. 25
Remove................................................................................................................................................................. 25
Replace................................................................................................................................................................. 25
2.9 Rear Window Panel Assembly – Replace.......................................................................................................... 26
Remove................................................................................................................................................................. 26
Replace................................................................................................................................................................. 28
2.10 Rear Seat Back Panel Extension Assembly or Rear Wheelhouse Inner Panel Assembly – Replace........... 30
Remove................................................................................................................................................................. 30
Replace................................................................................................................................................................. 33
2.11 Rear Bumper Impact Bar Brace Assembly – Replace ...................................................................................... 35
Remove................................................................................................................................................................. 35
Replace................................................................................................................................................................. 36
2.12 Rear Tie Down Assembly – Replace .................................................................................................................. 37
Remove................................................................................................................................................................. 37
Replace................................................................................................................................................................. 38
2.13 Rear Floor Panel Outer Extension – Replace.................................................................................................... 39
Remove................................................................................................................................................................. 39
Replace................................................................................................................................................................. 40
2.14 Rear Underbody Assembly – Replace ............................................................................................................... 41
Remove................................................................................................................................................................. 41
Replace................................................................................................................................................................. 44
10D Body Rear – Coupe Page 10D-3
Page 10D-3
1 General Description
This Section describes replacement procedures for the rear section components of the Coupe body structure. Removal
of bolt-on and mechanical compon ents is not covered. Reference must be made to the appropriate Sections in the
MY2005 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 3D Body Construction – Coupe for details
of the correct materials and their commercially
available equivalents.
1.1 Body Rear Components
The shaded components in Figure 10D – 1 are those dealt
with in this Section.
The components and assemblies shown in
Figure 10D – 2 are the serviceable parts that form the basis
of the repair procedures in this Section.
For a detailed view of the body components, refer to
Section 3D Body Construction – Coupe.
NOTE
Always refer to an Authorised Retailer for spare
parts availability configurations.
Figure 10D – 1
10D Body Rear – Coupe Page 10D-4
Page 10D-4
Figure 10D – 2
Legend
1 Fuel Tank Strap Bracket Assembly
2 Rear Compartment Lid Strut Bracket Assembly
3 Rear Window Panel Assembly
4 Rear Seat Back Panel Extension Assembly
5 Rear Wheelhouse Panel Assembly
6 Rear Underbody Assembly
7 Rear Floor Panel Reinforcement, Right-hand
8 Rear Compartment Floor Panel Outer Extension, Right-hand
9 Rear Compartment Floor Panel Assembly
10 Spare Wheel Anchor Plate Assembly
11 Fuel Tank Support Reinforcement Assembly
12 Rear End Lower panel
13 Rear End Panel Assembly
14 Rear Compartment Floor Panel Outer Extension, Left-hand
15 Rear Floor Panel Reinforcement, Left-hand
16 Rear Bumper Impact Bar Brace Assembly
17 Rear Tie Down Assembly
18 Rear Floor Panel Outer Extension
NOTE
• Rear Wheelhouse Panel Assembly (5)
includes part number 4 which includes part
number 2.
• Rear Underbody Assembly (6) includes parts
1, 7, 8, 9, 10, 11, 13, 14, 15, 16, 17 and 18.
• Rear Compartment Floor Panel Assembly (9)
includes parts 8, 10, 11 and 14.
10D Body Rear – Coupe Page 10D-5
Page 10D-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 the MY2005
VZ Service Information.
2 Remove the rear bumper impact bar assembly,
refer to Section 3D Body Construction – Coupe .
Figure 10D – 3
3 Spot cut the welds attaching the rear end lower panel
to the tail lamp housing.
4 Spot cut the welds attaching the rear end lower panel
to the rear end panel assembly, rear quarter panel and
quarter panel lower extension, refer to Figure 10D – 5.
Figure 10D – 4
10D Body Rear – Coupe Page 10D-6
Page 10D-6
Figure 10D – 5
5 Spot cut the welds attaching rear end lower panel to the rear end panel a ssembly and remove the panel, refer to
Figure 10D – 6.
NOTE
If the rear quarter panel and quarter panel lower
extension have not been removed, carefully bend
the flange of the rear quarter panel and lower
extension to allow removal of the rear end lower
panel.
Figure 10D – 6
6 Repair any damage to adjacent parts and check and rectify the alignment of the body as required,
refer to Section 3D Body Construction – Coupe .
10D Body Rear – Coupe Page 10D-7
Page 10D-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 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 rear end lower panel in position on the vehicle.
NOTE
If the rear quarter panel and quarter panel lower
extension were not removed, ensure the r ear end
lower panel is positioned behind the flange of
these panels.
5 Spot or plug weld the rear end lo wer panel to the rear end panel assembl y, rear quarter panel and quar ter panel
lower extension, refer to Figure 10D – 7.
Figure 10D – 7
10D Body Rear – Coupe Page 10D-8
Page 10D-8
6 Spot or plug weld the rear end lo wer panel to the rear end panel assembly, refer to Figure 10D – 8.
Figure 10D – 8
7 Spot or plug weld the rear end lo wer panel to the 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 3D Body Construction – Coupe.
10 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 .
11 Install the front bumper impact bar assembly,
refer to Section 3 Body Construction.
12 Install the remaining components as described in the
appropriate Service Information. Figure 10D – 9
10D Body Rear – Coupe Page 10D-9
Page 10D-9
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 t he removal of th e 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 the MY2005
VZ Service Information.
2 Remove the rear bumper impact bar assembly,
refer to Section 3 Body Construction.
Figure 10D – 10
3 Spot cut the welds attaching the rear end panel
assembly to the tail lamp housing, rear quarter panel
and quarter panel lower extension.
4 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,
refer to Figure 10D – 12.
Figure 10D – 11
10D Body Rear – Coupe Page 10D-10
Page 10D-10
Figure 10D – 12
5 Spot cut the welds attaching the rear end panel assembly to the rear compartment floor panel assembly,
refer to Figure 10D – 13.
Figure 10D – 13
6 Spot cut the welds attaching the fuel tank support
reinforcement to the rear end panel assembly.
NOTE
As an alternative, remove the fuel tank support
reinforcement from the rear compartment floor
panel assembly, refer to 2.3 Fuel Tank Support
Reinforcement Assembly – Replace..
7 Remove the rear end panel assembl y from the vehicle.
NOTE
If the rear quarter panel and quarter panel lo wer
extension have not been removed, carefully
bend the flange of the rear quarter panel and
lower extension to allo w removal of the rear end
panel assembly.
8 Repair any damage to adjacent parts and check and
rectify the alignment of the body as required,
refer to Section 3D Body Construction – Coupe . Figure 10D – 14
10D Body Rear – Coupe Page 10D-11
Page 10D-11
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 3D Body Construction – Coupe .
3 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3D Body Construction – Coupe.
4 Clamp the rear end panel assembly in position on the vehicle.
NOTE
If the rear quarter panel and quarter panel lower
extension were not removed, ensure the r ear end
lower panel is positioned behind the flange of
these panels.
5 Spot or plug weld the rear end panel ass embly to the rear compartment floor panel assembly.
Figure 10D – 15
10D Body Rear – Coupe Page 10D-12
Page 10D-12
6 Spot or plug weld the rear end panel ass embly to the rear side rail assembly on each side of the vehicle. The left-
hand side is different to the right-han d side, refer to Figure 10D – 16.
Figure 10D – 16
7 If removed, install the fuel tank support reinforcement and weld to the rear compartment floor panel assembly,
refer to 2.3 Fuel Tank Support Reinforcement Assembly – Replace..
8 Spot or plug weld the fuel tank support reinforcement
to the rear end panel assembly.
9 In the areas where the rear end lower pane l will fit,
grind the welds and prime any bare metal.
10 Install the rear end lower panel, refer to
2.1 Rear End Lower Panel – Replace.
11 Refinish and paint panels and other components as
required. Refer to Section 3 Body Construction .
12 Apply Joint Sealer (Item 3) as required.
Refer to Section 3D Body Construction – Coupe.
13 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 .
14 Install the rear bumper impact bar assembly,
refer to Section 3 Body Construction.
15 Install the remaining components as described in the
appropriate Section of the MY2005 VZ Service
Information.
Figure 10D – 17
10D Body Rear – Coupe Page 10D-13
Page 10D-13
2.3 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 the MY2005
VZ Service Information.
2 Remove the deadener panels and joint sealer from
around the fuel tank support reinforc ement assembly
as required.
Figure 10D – 18
3 Spot cut the welds attaching the fuel tank support
reinforcement to the rear end panel assembly and to
the rear compartment floor assembly.
4 Remove the reinforcement and then repair any
damage to adjacent parts as required.
Figure 10D – 19
10D Body Rear – Coupe Page 10D-14
Page 10D-14
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 3D Body Construction – Coupe .
3 Plug weld the fuel tank support reinforceme nt to the
rear compartment floor panel 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 3D Body Construction – Coupe.
6 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 .
7 Install the deadener panels as required,
refer to Section 3D Body Construction – Coupe .
8 Install the remaining components as described in the
appropriate Section of the MY2005 VZ Service
Information
Figure 10D – 20
10D Body Rear – Coupe Page 10D-15
Page 10D-15
2.4 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 the MY2005
VZ Service Information.
2 Remove the joint sealer from around the rear
compartment floor panel outer exte nsion joins as
required.
3 As required, remove the adjacent panels, refer to the
appropriate Section in this Supplement.
4 Spot cut the welds attaching the rear compartment
floor panel outer extension to the rear compartment
floor panel, rear side rail asse mbly, rear quarter panel
and rear wheelhouse panel as required.
Refer to Figure 10D – 22.
NOTE
Also remove several welds from the left-hand
rear floor panel reinforcement.
5 Remove the extension from the vehicle and then
repair any damage to adjacent parts as required.
6 Check and rectify the alignme nt of
the body as required, refer to
Section 3D Body Construction – Coupe.
Figure 10D – 21
Figure 10D – 22
10D Body Rear – Coupe Page 10D-16
Page 10D-16
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 3D Body Construction – Coupe .
3 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3D Body Construction – Coupe.
4 Fit the rear compartment floor panel outer extension in position, ensuring the front edge of the left-hand side is
seated under the rear floor panel reinforcement.
5 Spot or plug weld the extension to the rear compartment floor panel, rear floor panel reinforcement, rear side rail
assembly, rear quarter panel and the rear wheelhouse panel as required, refer to F igure 10D – 23.
Figure 10D – 23
6 Replace any other remov ed panels as described in this Supplem ent.
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 3D Body Construction – Coupe.
9 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 .
10 Apply Spray-on Dea dener (Item 7) where applicab le, refer to Section 3D Body Construc tion – Coupe.
11 Install the remaining components as described in the appr opriate Section of the MY2005 VZ Service Information.
10D Body Rear – Coupe Page 10D-17
Page 10D-17
2.5 Rear Compartment 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 the MY2005
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.
5 As required, spot cut the welds attaching the rear
compartment floor panel assembly to the rear floor
panel assembly and to the rear side rail assemblies,
refer to Figure 10D – 25.
NOTE
Structural adhesive (Item 6) is applied to the
area shown (1) between the rear side rail and
rear compartment floor panel. As this material is
extremely hard, this area may require cutting,
also refer to Section 3 Body Construction.
Figure 10D – 24
10D Body Rear – Coupe Page 10D-18
Page 10D-18
Figure 10D – 25
10D Body Rear – Coupe Page 10D-19
Page 10D-19
6 As required, spot cut each rear compartment floor panel outer extension from the rear wheelhouse panel , rear
quarter panel and rear end panel assembly, refer to Figure 10D – 26.
Figure 10D – 26
7 Remove the rear compartment floor pane l assembly from the vehicle and repair any damage to adjacent parts as
required.
8 Check and rectify the alignme nt of the body 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 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 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3D Body Construction – Coupe.
4 Apply Structural Adhesive (Item 6) to the area sho wn (1) refer to Figure 1 0D – 27, b etween the rear side rail and
rear compartment floor panel, also refer to Section 3 Body Construction.
5 Install rear compartment floor panel assembly ensuring it is seated under the left-hand rear floor panel
reinforcement.
10D Body Rear – Coupe Page 10D-20
Page 10D-20
6 Plug weld along the join of the rear floor pan el assembly and to the rear si de rail assemblies,
refer to Figure 10D – 27.
Figure 10D – 27
7 As required, spot or plug weld each rear compartment floor panel outer extension to the rear wheelhouse panel,
rear quarter panel, rear end panel assembly and for the left-hand side, the rear floor panel reinforcem ent,
refer to Figure 10D – 28.
Figure 10D – 28
8 Install the rear end panel and other panels as required, refer to the relevant procedure in this Supplement.
9 Refinish and paint panels and other components as required. Refer to Section 3 Body Construction.
10 Apply Joint Sealer (Item 3) as required. Refer to Section 3D Body Construction – Coupe.
11 Apply deadener panels to the rear compartment floor panel, refer to Section 3D Body Construction – Cou pe.
12 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 .
13 Apply Spray-on Dea dener (Item 7) where applicab le, refer to Section 3D Body Construc tion – Coupe.
14 Install the remaining components as described in the appr opriate Section of the MY2005 VZ Service Information.
10D Body Rear – Coupe Page 10D-21
Page 10D-21
2.6 Rear Floor Panel Reinforcement –
Replace
Left-hand Side
Remove
The left-hand rear floor panel reinforcement is spot welded
to the rear floor panel assembly, rear wheelhouse panel
assembly, rear compartment floor panel assembly outer
extension and rear side rail assembly.
As required spot cut the welds and remove the
reinforcement.
Replace
NOTE
• Spot welding is the preferred method for
attaching of panels and should be used
whenever possible. Where the spot welding
equipment available to the repairer will not
access the required weld position, a plug
weld should be performed.
• The same number a nd position of spot welds
(or plug welds) should be used when
replacing the panel, as was used during
manufacture, in order to ma intain 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 Spot or plug weld the rear floor panel reinforcement to
the vehicle, ensuring it is correctly located and welded
through the correct panels.
Figure 10D – 29
10D Body Rear – Coupe Page 10D-22
Page 10D-22
Right-hand Side
Remove
The right-hand rear floor panel reinforcement is spot welded
to the rear floor panel assembly, rear wheelhouse panel
assembly and rear side rail assembly.
As required spot cut the welds and remove the
reinforcement.
Replace
NOTE
• Spot welding is the preferred method for
attaching of panels and should be used
whenever possible. Where the spot welding
equipment available to the repairer will not
access the required weld position, a plug
weld should be performed.
• The same number a nd position of spot welds
(or plug welds) should be used when
replacing the panel, as was used during
manufacture, in order to ma intain 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 Spot or plug weld the rear floor panel reinforcement to
the vehicle, ensuring it is correctly located and welded
through the correct panels.
Figure 10D – 30
10D Body Rear – Coupe Page 10D-23
Page 10D-23
2.7 Fuel Tank Retaining Strap Assembly –
Replace
Remove
To avoid the possibility of fire, take particular
care when cutting or welding at the rear of
the vehicle. Remove the fuel tank and plug all
fuel lines.
Figure 10D – 31
1 Spot cut the welds attaching the fuel tank retaining
strap assembly to the vehicle.
2 Remove the strap assembly and repeat for the
opposite side as required.
Figure 10D – 32
10D Body Rear – Coupe Page 10D-24
Page 10D-24
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 3D Body Construction – Coupe .
3 Install the fuel tank retaining strap assembly,
positioning the inner flange in line with the edge of the
rear seat back panel extension (1).
4 Plug weld the strap assembly to the underbod y
assembly
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 3D Body Construction – Coupe .
7 Install the remaining components as described in the
appropriate Section of the MY2005 VZ Service
Information.
Figure 10D – 33
10D Body Rear – Coupe Page 10D-25
Page 10D-25
2.8 Rear Compartment Lid Strut Bracket
Assembly – Replace
Remove
1 Remove the adjacent bolt-on panels and components as described in the appropriate Section of the MY2005 VZ
Service Information.
2 Grind off the MIG weld (1) attaching the rear
compartment lid strut bracket assembly to the rear
seat back panel extension assembly.
3 Spot cut the welds attaching the bracket assembly to
and remove the rear compartment lid strut bracket
assembly from the vehicle.
4 Repair any damage to adjacent parts as required.
Figure 10D – 34
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 3D Body Construction – Coupe .
3 Install the rear compartment lid strut bracket
assembly, positioning it approximatel y 12 mm from the
edge of the rear seat back panel extension assembly.
4 Plug weld the bracket assembly to the rear seat back
panel extension assembly.
5 MIG weld (1) along the top edge of the bracket to the
rear seat back panel extension assembly.
6 Refinish and paint panels and other components 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 3D Body Construction – Coupe .
8 Install the remaining components as described in the
appropriate Section of the MY2005 VZ Service
Information.
Figure 10D – 35
10D Body Rear – Coupe Page 10D-26
Page 10D-26
2.9 Rear Window Panel Assembly – Replace
NOTE
Depending on the area of damage, it may be
advisable to includ e removal of the rear seat back
panel extension assembly or rear wheelhouse
inner panel assembly. Refer to 2.10 Rear Seat
Back Panel Extension Assembly or Rear
Wheelhouse Inner Pan el Asse mbly – 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 the MY2005
VZ Service Information.
2 As required, remove adjoini ng body structure panels,
refer to the appropriate procedure in this Supplement.
3 Spot cut the welds attaching the rear windo w panel
assembly (1) to the rear seat back panel extension
assembly (2) and the rear floor panel assembly (3),
refer to Figure 10D – 37.
Figure 10D – 36
Figure 10D – 37
10D Body Rear – Coupe Page 10D-27
Page 10D-27
The rear window panel assembly (1) is
attached to the rear seat back extension
assembly (2) and rear quarter panel (3) with
spot welding and structural adhesive (shown
shaded). The adhesive bond is not breakable
by any normal means, so s pot cutting is not a
viable method of removal of the panel.
4 Cut the rear window panel assembl y i nboard of the
join to the rear seat back extension assembly with a
grinder or other cutting tool along l ine (4).
5 Remove the rear window panel assembly from the
vehicle.
Figure 10D – 38
6 Using a grinder, remove the remaining portion of the
rear window panel assembly ( 1) and (2) and the layer
of adhesive below it as required.
7 Repair any damage to adjacent parts as required.
8 Check and rectify the alignme nt of
the body as required, refer to
Section 3D Body Construction – Coupe.
Figure 10D – 39
10D Body Rear – Coupe Page 10D-28
Page 10D-28
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 3D Body Construction – Coupe .
3 Apply Structural adhesive (Item 6) to the areas shown,
refer to Section 3D Body Construction – Coupe .
4 Clamp the rear windo w panel assemb ly in position on
the vehicle.
Figure 10D – 40
5 Spot or plug weld the rear windo w panel assembly to
the rear quarter panel and rear seat back extension
assembly.
6 Spot or plug weld the rear windo w panel assembly (1)
to the rear seat back panel extension assembly (2)
and the rear floor panel assembly (3),
refer to Figure 10D – 42.
Figure 10D – 41
10D Body Rear – Coupe Page 10D-29
Page 10D-29
Figure 10D – 42
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 3D Body Construction – Coupe.
9 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 .
10 Install the remaining components as described in the appr opriate Section of the MY2005 VZ Service Information.
10D Body Rear – Coupe Page 10D-30
Page 10D-30
2.10 Rear Seat Back Panel Extension
Assembly or Rear Wheelhouse Inner
Panel Assembly – Replace
Remove
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate Section of the MY2005
VZ Service Information.
2 Either remove, or detach the rear windo w panel
assembly from the rear seat back panel extension
assembly, refer to 2.9 Rear Window Panel Assembly
– Replace.
Figure 10D – 43
3 Spot cut the welds attaching the rear seat back panel
extension asse mbly:
• seven places to the quarter panel inner
assembly,
• 10 places to rear wheelhouse inner panel
assembly, if required,
• five places to the rear floor panel assembly.
4 If the rear window panel assembly has not been
removed, spot cut the welds 19 places, attaching the
rear seat back panel extension assembly to the rear
window panel assembly.
Figure 10D – 44
10D Body Rear – Coupe Page 10D-31
Page 10D-31
5 Spot cut the welds 15 places, attaching the rear seat
back panel extension assembly to the quarter panel
inner assembly.
6 If the rear window panel assembly has not been
removed, spot cut the welds attaching the rear seat
back panel extension assembly:
• one place to the quarter panel inner assembly,
rear quarter panel and rear window panel
assembly,
• five places to the rear window panel assembly,
• one place to the rear windo w panel assembly,
• one place to the rear windo w panel assembly.
Carefully cut the rear seat back pane l extension
assembly around the structural adhesive (1).
NOTE
Once the panel is removed, grind off the
remaining piece and adhesive.
Figure 10D – 45
7 If the rear wheelhouse inner panel assembly is not bein g replaced, remo ve the rear seat back panel extension
assembly.
8 If the rear wheelhouse inner panel assembly is being replaced, spot cut the welds attaching the rear wheelhouse
inner panel assembly to the rear floor pane l assembly and rear compartment floor pane l assembly as required,
refer to Figure 10D – 46.
Figure 10D – 46
10D Body Rear – Coupe Page 10D-32
Page 10D-32
9 Spot cut the welds attaching the rear wheelhouse inn er panel assembly to the quarter panel inner assembly,
refer to Figure 10D – 47.
NOTE
The front three welds may be concealed,
requiring the front of the wheelhouse to be cut to
gain access.
Figure 10D – 47
10 Remove the rear wheelhouse inner panel assembly.
11 Repair any damage to adjacent parts as required.
12 Check and rectify the alignme nt of the body as required, refer to Section 3 D Body Construction – Coupe.
10D Body Rear – Coupe Page 10D-33
Page 10D-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 requir ed,
refer to Section 3D Body Construction – Coupe .
3 If the rear wheelhouse inner panel assembly is being replaced, spot or plug weld around the wheelhouse inner
panel assembly to the quarter pane l inner assembly, refer to Figure 10D – 48.
Figure 10D – 48
10D Body Rear – Coupe Page 10D-34
Page 10D-34
4 Spot or plug weld the rear wheelhouse inner panel assembly to the rear floor panel assembly and rear
compartment floor panel assembly, refer to Figure 10D – 49.
Figure 10D – 49
5 If the rear window panel assembly was not removed,
apply Structural Adhesive (1) (Item 6, refer to
Section 3D Body Construction – Coupe) between the
rear seat back panel extension assembly and rear
window panel assembly.
6 Spot or plug weld the rear seat back panel extension
assembly to the quarter panel inner assembly and rear
window panel assembly as required.
Figure 10D – 50
7 Spot or plug weld the rear seat back panel extension
assembly to the quarter panel inner assembly, rear
floor panel assembly and if re quired, the rear window
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 3D Body Construction – Coupe.
10 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 .
11 Install the remaining components as described in the
appropriate Section of the MY2005 VZ Service
Information.
Figure 10D – 51
10D Body Rear – Coupe Page 10D-35
Page 10D-35
2.11 Rear Bumper Impact Bar Brace
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 the
fuel lines.
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate Section of the MY2005
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 of this Supplement.
4 Spot cut the 14 welds (seven each side) atta ching the
left-hand or right-hand rear bumper impact bar brace
assembly to the rear side rail assembly,
refer to Figure 10D – 53. Figure 10D – 52
Figure 10D – 53
10D Body Rear – Coupe Page 10D-36
Page 10D-36
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 3D Body Construction – Coupe .
3 Clamp and plug weld the rear bumper impact bar brace assembly in position on th e rear side rail assembly
refer to Figure 10D – 54.
Figure 10D – 54
4 Install other panels as require d, refer to the appropriate Section in this Sup plement.
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 3D Body Construction – Coupe.
7 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 .
8 Install the remaining components as described in the appropriate Section of the MY2005 VZ Service Information.
10D Body Rear – Coupe Page 10D-37
Page 10D-37
2.12 Rear Tie Down Assembly – Replace
Remove
1 Remove the adjacent components as described in the
appropriate Section of the MY2005 VZ Service
Information.
Figure 10D – 55
2 Spot cut the welds attaching the tie down hook
assembly to the rear side rail assembly and remove.
Figure 10D – 56
10D Body Rear – Coupe Page 10D-38
Page 10D-38
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 3D Body Construction – Coupe .
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 3D Body Construction – Coupe .
7 Install the remaining components as described in the
appropriate Section of the MY2005 VZ Service
Information. Figure 10D – 57
10D Body Rear – Coupe Page 10D-39
Page 10D-39
2.13 Rear Floor Panel Outer Extension –
Replace
Remove
1 Remove the adjacent components as described in the
appropriate Section of the MY2005 VZ Service
Information.
Figure 10D – 58
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 10D – 59
10D Body Rear – Coupe Page 10D-40
Page 10D-40
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 3D Body Construction – Coupe .
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 3D Body Construction – Coupe.
5 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 .
6 Install the remaining components as described in the
appropriate Section of the MY2005 VZ Service
Information.
Figure 10D – 60
10D Body Rear – Coupe Page 10D-41
Page 10D-41
2.14 Rear Underbody 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 the
fuel lines.
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate Section of the MY2005
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 deadener panels from the
relevant areas using a scraper and heat gun.
4 Remove the adjoining panels as required, refer to the
appropriate Section of this Supplement.
Figure 10D – 61
5 Spot cut the welds attaching the rear end panel
assembly to the tail lamp housing, rear quarter panel
and quarter panel lower extension.
6 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 10 D – 63.
Figure 10D – 62
10D Body Rear – Coupe Page 10D-42
Page 10D-42
Figure 10D – 63
7 Spot cut the welds attaching the rear wheelhouse inn er panel assembly to the rear floor panel assembly and rear
compartment floor panel assembly as required, refer to Figure 10D – 64.
Figure 10D – 64
8 Spot cut the welds attaching the rear floor panel
assembly to the rear window panel assembly and the
rear seat back panel extension assembly.
Figure 10D – 65
10D Body Rear – Coupe Page 10D-43
Page 10D-43
9 Spot cut the welds attaching the rear floor panel outer
extension to the inner rocker panel.
Figure 10D – 66
10 Spot cut the welds attaching the park brake cabl e
bracket to the rear floor panel assembly.
Figure 10D – 67
11 Spot cut the welds joining the front floor panel
assembly (1) and rear floor panel assembly (2).
12 Spot cut the welds attaching the rear floor panel
assembly to the inner rocker panel (3) each side.
13 Remove the rear floor panel assembly from the vehicle
and then repair any damage t o adjacent parts as
required.
14 Check and rectify the alignme nt of the bod y as
required, refer to Section 3 Body Construction.
Figure 10D – 68
10D Body Rear – Coupe Page 10D-44
Page 10D-44
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 3D Body Construction – Coupe .
3 Plug weld the rear floor panel assembly (2) to the front
floor panel assembly (1).
4 Plug weld the rear floor panel assembly to the inner
rocker panel (3) each side.
Figure 10D – 69
5 Plug weld the park brake cable brack et to the rear
floor panel assembly.
Figure 10D – 70
10D Body Rear – Coupe Page 10D-45
Page 10D-45
6 Plug weld the rear floor panel outer extens ion to the
inner rocker panel assembly.
Figure 10D – 71
7 Plug weld the rear floor panel assembly to the rear
window panel assembl y and the rear seat back panel
extension asse mbly.
8 Spot or plug weld rear wheelhouse inner panel
assembly to the rear floor panel assembly and rear
compartment floor panel assembly as required,
refer to Figure 10D – 46.
Figure 10D – 72
Figure 10D – 73
10D Body Rear – Coupe Page 10D-46
Page 10D-46
9 Spot or plug weld the rear quarter panel to the quarter panel in ner assembly and rear compartment floor panel
outer extension. There are a different number of welds on the left-hand panel to the right-hand panel.
Refer to Figure 10D – 74.
Figure 10D – 74
10 Spot or plug weld the rear end panel ass embly to the
tail lamp housing, rear quarter panel and quarter panel
lower extension.
11 Replace any other remov ed panels as described in the
appropriate Section of this Supplement.
12 Refinish and paint panels and other components as
required. Refer to Section 3 Body Construction .
13 Apply Joint Sealer (Item 3) as required.
Refer to Section 3 Body Construction.
14 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.
15 Apply deadener panels to the rear compartment floor
panel, refer to Section 3 Body Construction.
16 Apply Spray-on Dea dener (Item 7) where applicab le,
refer to Section 3 Body Construction.
17 Install the remaining components as described in the
appropriate Section of the MY2005 VZ Service
Information.
Figure 10D – 75