Body Rear Page 10–1

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Section 10

Body Rear

ATTENTION

Before performing any service operation or other procedure described in this Section, refer to Section 00

Warnings, Cautions and Notes in the MY 2004 VY and V2 Series Service Information and Section 2

Precautions in the MY 2003 VY and V2 Series Service Information Supplement, Body Structure Repair, for

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

The Structure of the MY 2004 VY and V2

Series 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 Information............................................................................................................................... 2

2 Service Operations................................................................................................................................3

2.1 Rear End Lower Panel – Replace..........................................................................................................................3

Remove ...................................................................................................................................................................3

Replace ...................................................................................................................................................................5

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1 General Information

With the following exceptions, MY 2004 VY and V2 Series Body Rear information carries over from MY 2003 VY and V2

Series vehicles.

• Rear end lower panel - Coupe.

For information not contained within this Section, refer to Section 10 Body Rear in the MY 2003 VY and V2 Series

Service Information Supplement, Body Structure Repair.

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 are used

when repairing the body structure of MY 2004

V2 vehicles. Refer to Section 3, 3 Body

Sealing, Adhesives and Deadeners.

• Cavity waxes are used when repairing the

body structure of MY 2004 V2 vehicles. Refer

to Section 3D, 6 Cavity Wax in the MY 2003

VY and V2 Series Service Information

Supplement, Body Structure Repair.

Body Rear Page 10–3

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2 Service Operations

2.1 Rear End Lower Panel – Replace

NOTE

If the rear end panel assembly (inner) is also to

be replaced, remove the rear end panels as an

assembly. Refer to Section 10, 2.2 Rear End

Panel Assembly – Replace in the MY 2003 VY

and V2 Series Service Information Supplement,

Body Structure Repair.

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.

1 Remove the adjacent bolt-on panels and components

as described in the appropriate Section of the

MY 2004 VY and V2 Series Service Information.

Figure 10 – 1

2 Spot cut the welds attaching the rear end lower panel

to the tail lamp housing.

3 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 10 – 3.

Figure 10 – 2

Body Rear Page 10–4

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Figure 10 – 3

4 Spot cut the welds attaching rear end lower panel to the rear end panel assembly and remove the panel, refer to

Figure 10 – 4.

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 10 – 4

5 Repair any damage to adjacent parts and check and rectify the alignment of the body as required, refer to

Section 3D, 3 Body Dimensions in the MY 2003 VY and V2 Series Service Information Supplement, Body

Structure Repair.

Body Rear Page 10–5

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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 Se ction 3, 3 Body

Sealing, Adhesives and Deadeners.

3 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3, 3 Body Sealing, Adhesiv es and D eaden ers.

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 rear end

lower panel is positioned behind the flange of

these panels.

5 Spot or plug weld the rear end lower panel to the rear end panel assembly, rear quarter panel and quarter panel

lower extension, refer to Figure 10 – 5.

Figure 10 – 5

6 Spot or plug weld the rear end lower panel to the rear end panel assembly, refer to Figure 10 – 6.

Body Rear Page 10–6

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Figure 10 – 6

7 Spot or plug weld the rear end lower panel to the tail

lamp housing.

8 Refinish and paint panels and other components as

required. Refer to Section 3, 1.3 Paint Refinishing in

the MY 2003 VY and V2 Series Service Information

Supplement, Body Structure Repair.

9 Apply Joint Sealer (Item 3) as required. Refer to

Section 3, 3 Body Sealing, Adhesives and Deadeners.

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

any box sections or areas inaccessible to paint, refer

to Sect ion 3, 6 Cavit y Wax in the MY 2003 VY and V2

Series Service Information Supplement, Body

Structure Repair.

11 Install the remaining components as described in the

appropriate Section of the MY 2004 VY and V2 Series

Service Information.

Figure 10 – 7