SECTION 7B – BODY SIDE – WAGON
IMPORTANT
Before performing any Service Operation or other procedure described in this Section, refer to
Section 00 CAUTIONS AND NOTES and Section 2 PRECAUTIONS in this Supplement for correct
workshop practices with regard to safety and/or property damage.
CAUTION
The Structure of the M Y 2003 VY & V2 Series II body shell has been developed using complex design
and development techniques. In addition to meeting all required standards, the v ehicle 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
1.1 BODY SIDE COMPONENTS
2. SERVICE OPERATIONS
2.1 REAR QUARTER PANEL – REPLACE
REMOVE
REPLACE
2.2 QUARTER PANEL EXTENSION –
REPLACE
REMOVE
REPLACE
2.3 QUARTER PANEL INNER LOWER REAR
EXTENSION – REPLACE
REMOVE
REPLACE
2.4 QUARTER OUTER LOWER REAR PANEL –
REPLACE
REMOVE
REPLACE
2.5 DOOR OPENING FRAME ASSEMBLY –
REPLACE
REMOVE
REPLACE
2.6 DOOR OPENING FRAME ASSEMBLY –
PARTIAL REPLACE, HINGE PILLAR
REMOVE
REPLACE
2.7 DOOR OPENING FRAME ASSEMBLY –
PARTIAL REPLACE, CENTRE PILLAR
REMOVE
REPLACE
2.8 DOOR OPENING FRAME ASSEMBLY –
PARTIAL REPLACE, LOCK PILLAR
REMOVE
REPLACE
2.9 DOOR OPENING FRAME ASSEMBLY –
PARTIAL REPLACE, ROCKER PANEL
REMOVE
REPLACE
2.10 FENDER LOWER REAR BRACKET –
REPLACE
2.11 HINGE PILLAR INNER PANEL ASSEMBLY –
REPLACE
REMOVE
REPLACE
2.12 QUARTER PANEL INNER ASSEMBLY –
REPLACE
REMOVE
REPLACE
2.13 QUARTER PANEL INNER ASSEMBLY –
PARTIAL REPLACE
REMOVE
REPLACE
1. GENERAL DESCRI PTI O N
This Section describes the replacement procedures for the body side components of the MY 2003 VY Series
Wagon body structure. Removal of bolt-on panels and mechanical components is not covered.
When repairing the body side of the vehicle, care must be taken to ensure the structure is returned to its original
production configuration. This is especially important to maintain side impact standards and for the vehicle’s
occupant protection system to operate correctly.
This Section includes door opening frame assembly partial replacement procedures for the hinge pillar, centre pillar,
lock pillar and rocker panel. These procedures must be followed carefully, as they regularly involve hidden
reinforcement panels. The cutting locations specified are the only places allowable.
NOTE: It is imperative that the correct body adhesives, sealers, deadeners and cavity waxes are used when
repairing the body structure of MY 2003 VY Wagon vehicles. Refer to 5. BODY SEALING, ADHESIVES &
DEADENERS and 6. CAVITY WAX in Section 3B for details of the correct materials and their commercially
available equivalents.
1.1 BODY SIDE COMPONENTS
The shaded components in Figure 7B-1 are those
dealt with in this Section.
The components and assemblies shown in Figure 7B-
2 are the parts serviced for MY 2003 VY Series Wagon
vehicles which form the basis of the repair procedures
in this Section. For a detailed view of the body
components, refer to Section 3B BODY
CONSTRUCTION – WAGON.
NOTE: Always refer to your Authorised Retailer for
spare parts availability configurations.
IMPORTANT: Cavity foam may be used within
the centre pillar. Care needs to be taken when
repairing the vehicle in these areas, refer to
Section 2, 10. CAVITY FOAM prior to beginning any
work for further information. Figure 7B-1
Figure 7B-2
Legend
1. Hinge Pillar Trim Panel Bracket
2. Hinge Pillar Inner Panel Assembly
3. Hinge Pillar Upper Reinforcement
4. Door Opening Frame Assembly
5. Underbody Jacking Locator
6. Fender Rear Bracket
7. Fender Lower Rear Bracket
8. Fender Upper Rear Bracket
9. Front or Rear Door Striker Anchor Plate
10. Rear Door Check Link Bracket
11. Rear Quarter Panel
12. Quarter Panel Extension
13. Quarter Outer Lower Rear Panel
14. Fuel Filler Pipe Housing, RH
15. Quarter Panel Inner Assembly
16. Quarter Panel Inner Extension
NOTE 1: Door opening frame assembly includes parts 3, 5, 6, 7, 8, 9 and 10.
NOTE 2: Q uarter panel inner as sem bly includes part 16 and the rear wheelhouse inner panel ass em bly which is
also available separately, refer to Section 10B BODY REAR – WAGON.
2. SERVICE OPERATIONS
2.1 REAR QUARTER P ANEL – REPLACE
NOTE: The rear quarter panel service part is not
supplied with the quarter panel extension or for the
right-hand side, the fuel filler pipe housing. This
Procedure details the replacement of the rear quarter
panel and fuel filler pipe housing. If required, the
quarter panel extension can be replaced with the rear
quarter panel by including the procedures from
2.2 QUARTER PANEL EXTENSION – REPLACE.
IMPORTANT: Before performing any operations on
the rear quarter panel, remove the Stuffer Block from
within the rear quarter panel inner cavity. Refer to
5. BODY SEALING, ADHESIVES & DEADENERS in
Section 3B.
NOTE: Full replacement of the rear quarter panel
requires removal of the roof panel. This procedure
includes both full panel replacement and partial
replacement that avoids removal of the roof panel.
REMOVE
Figure 7B-3
CAUTION: To av oid the possibility of fire, take particular care when cutt ing 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 2003 VY & V2 Series II Service Information.
2. Remove the quar ter window assembly, refer to Sectio n 1A6, ST ATIO NARY WINDO WS in the MY 2003 VY
& V2 Series II Service Information.
3. If full panel replacement is to be performed, remove the roof joint moulding, refer to Section 3B, 7. ROOF
JOINT MOULDING, and remove the roof panel, refer to Section 9 ROOF.
4. Partial replacement of the rear quarter panel is
possible by cutting the panel through the lock
pillar, 50 mm above the datum hole (1) and the
back pillar, 100 mm above the quarter panel
extension (2). Ensure that only the outer panel is
cut.
Figure 7B-4
5. Spot c ut the welds attac hing the rear quarter panel
around the r ear door opening and under the r ocker
panel area. If a partial replacement is being
performed, remove the welds only to the cut
point (1).
Figure 7B-5
6. Spot c ut the welds attac hing the rear quarter panel
to the quarter panel inner assembly and quarter
outer lower rear panel and quarter panel
extension. If a partial replacement is being
performed, remove the welds only to the cut
points.
NOTE 1: T he quarter panel extens ion can be removed
with the rear quarter panel if required. Refer to
2.2 QUARTER PANEL EXTENSION – REPLACE.
NOTE 2: = left-hand, = right-hand.
7. Remove the rear quarter panel from the vehicle,
then repair any damage to adjacent parts as
required.
8. Check and rectify the alignment of the body as
required, refer to 3. BODY DIMENSIONS in
Section 3B.
Figure 7B-6
REPLACE
NOTE 1: 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.
NOTE 2: The s ame number and pos ition of spot welds ( or plug welds) s hould be used when replac ing the panel,
as was used during manufacture, in order to maintain the original structural strength of the vehicle.
1. If performing a partial panel replacement, cut the new panel at the lock and back pillars to match the vehicle.
2. For the right-hand side, if required spot or plug
weld (1) the fuel filler pipe housing to the rear
quarter panel in four places.
3. As required, mark the new panel with drilling
locations in prepar ation f or plug welding. Drill holes
as required.
4. Prepare all mating surfaces and treat with Weld
Through Primer (Item 1) as required, refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
5. Apply Acrylic Spot Weld Sealer (Item 2), refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
6. Clamp the new panel in position on the vehicle and
test fit the alignment with the rear door and liftgate.
Figure 7B-7
7. MIG butt weld across the panel joins if a partial
panel replacement was performed.
Figure 7B-8
8. Spot or plug weld the rear quarter panel around
the door opening and rocker panel.
Figure 7B-9
9. Spot or plug weld the rear quarter panel to the
quarter panel inner assembly, quarter outer lower
rear panel and the quarter panel extension if still
installed.
NOTE: = left-hand, = right-hand.
10. If removed, install the quarter panel extension,
refer to 2.2 QUARTER PANEL EXTENSION –
REPLACE.
11. If a partial replacement was performed, grind or
sand the lock and back pillar butt welds to achieve
a sm ooth finish ensuring that too m uch material is
not removed.
12. Refinish and paint panels and other components
as required. Refer to Section 3, 1.3 PAINT
REFINISHING.
13. Apply Joint Sealer (Item 3) as required. Refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
14. Apply Cavity Wax (Item 8) as r equired to the inside
of any box sections or areas inaccessible to paint,
refer to 6. CAVITY WAX in Section 3B.
15. Replace the Stuf f er Bloc k between the side panel -
inner and the rear quarter panel. Refer to
Section 3B, 5. BODY SEALING, ADHESIVES &
DEADENERS.
16. Install the quarter window assembly, refer to
Section 1A6, STATIONARY WINDOWS in the
MY 2003 VY & V2 Series II Service Information
17. Install the remaining components as described in
the MY 2003 VY & V2 Series II Service
Information.
Figure 7B-10
2.2 QUARTER PANEL EXTENSION – REPLACE
REMOVE
CAUTION: 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 2003 VY & V2 Series II Service
Information.
2. Remove the rear bumper impact bar, refer
to Section 3, 2. BUMPER IMPACT BAR
ASSEMBLIES.
Figure 7B-11
3. Spot cut the welds attaching the quarter panel
extension to the rear quarter panel, the quarter
outer lower rear panel and the quarter panel inner
assembly.
4. Remove the panel from the vehicle, then repair
any damage to adjacent parts as required.
5. Check and rectify the alignment of the body as
required, refer to 3. BODY DIMENSIONS in
Section 3B.
Figure 7B-12
REPLACE
NOTE 1: 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.
NOTE 2: The s ame number and pos ition of spot welds ( or plug welds) s hould be used when replac ing 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
5. BODY SEALING, ADHESIVES & DEADENERS in Section 3B.
3. Tack weld the quarter panel extension in position and install the tail lamp to check for correct location and
alignment. Adjust the position of the quarter panel extension as required.
4. Spot or plug weld the quarter panel extension in
place.
5. Refinish and paint panels and other components
as required. Refer to Section 3, 1.3 PAINT
REFINISHING.
6. Apply Joint Sealer (Item 3) as required. Refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
7. Apply Cavity Wax ( Item 8) as requir ed to the inside
of any box sections or areas inaccessible to paint,
refer to 6. CAVITY WAX in Section 3B.
8. Install the rear bumper impact bar, refer to Section
3, 2. BUMPER IMPACT BAR ASSEMBLIES.
9. Install the remaining components as described in
the MY 2003 VY & V2 Series II Service
Information.
Figure 7B-13
2.3 QUARTER PANE L INNE R LOWER REAR EXTENSION – REPLACE
REMOVE
1. Remove the adjacent bolt-on panels and
components as described in the appropriate
Section of the MY 2003 VY & V2 Series II Service
Information.
2. Remove the quar ter panel ex tens ion and any other
adjoining panels as required, refer to the
appropriate procedure in this Section.
Figure 7B-14
3. Spot cut the welds attaching the quarter panel
inner lower rear extension to the quarter panel
inner, rear quarter panel and rear end panel
extension as required.
4. Remove the panel from the vehicle, and then
repair any damage to adjacent parts as required.
Figure 7B-15
REPLACE
NOTE 1: 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.
NOTE 2: The s ame number and pos ition of spot welds ( or plug welds) s hould be used when replac ing 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
5. BODY SEALING, ADHESIVES & DEADENERS in Section 3B.
3. Clamp the quarter panel inner lower rear extens ion
in position on the vehicle and spot or plug weld to
the quarter panel inner as sembly, rear quarter and
rear end panel extension as required.
4. Replace any removed panels as required, refer to
the appropriate procedure in this Section.
5. Refinish and paint panels and other components
as required. Refer to Section 3, 1.3 PAINT
REFINISHING.
6. Apply Joint Sealer (Item 3) as required. Refer to
5. BODY SEALING, ADHESIVES & DEAD ENERS
in Section 3B.
7. Apply Cavity Wax ( Item 8) as requir ed to the inside
of any box sections or areas inaccessible to paint,
refer to 6. CAVITY WAX in Section 3B.
8. Install the remaining components as described in
the MY 2003 VY & V2 Series II Service
Information.
Figure 7B-16
2.4 QUARTER OUTER LOWER REAR PANEL – REPLACE
REMOVE
CAUTION: 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 components and panels as
required to gain the necessary access. Refer to
the appropriate Section.
Figure 7B-17
2. Spot cut the welds attaching the quarter panel
outer lower rear panel to the rear quarter panel
and quarter panel inner assembly as required.
NOTE: = left-hand, = right-hand.
3. Remove the panel from the vehicle, and then
repair any damage to adjacent parts as required.
Figure 7B-18
REPLACE
NOTE 1: 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.
NOTE 2: The s ame number and pos ition of spot welds ( or plug welds) s hould be used when replac ing 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
5. BODY SEALING, ADHESIVES & DEADENERS in Section 3B.
3. Spot or plug weld the quarter panel outer lower
rear panel to the rear quarter panel and quarter
panel inner assembly as required.
NOTE: = left-hand, = right-hand.
4. Replace any removed panels as required, refer to
the appropriate procedure in this Section.
5. Refinish and paint panels and other components
as required. Refer to Section 3, 1.3 PAINT
REFINISHING.
6. Apply Joint Sealer (Item 3) as required. Refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
7. Apply Cavity Wax ( Item 8) as requir ed to the inside
of any box sections or areas inaccessible to paint,
refer to 6. CAVITY WAX in Section 3B.
8. Install the remaining components as described in
the MY 2003 VY & V2 Series II Service
Information.
Figure 7B-19
2.5 DOOR OPENING FRAME ASSEMBLY – REPLACE
NOTE 1: This procedure requires the removal of the
roof panel. As an alternative, the door opening frame
assembly can be cut at the upper pillar sections by
following the procedures in:
2.6 DOOR OPENING FRAME ASSEMBLY –
PARTIAL REPLACE, HINGE PILLAR,
2.7 DOOR OPENING FRAME ASSEMBLY –
PARTIAL REPLACE, CENTRE PILLAR and
2.8 DOOR OPENING FRAME ASSEMBLY –
PARTIAL REPLACE, LOCK PILLAR.
NOTE 2: Cavity Foam is used within centre pillar
cavity. Care is required when repairing the vehicle in
these areas, refer to Section 2, 10. CAVITY FOAM
prior to beginning work for further information.
REMOVE
1. Remove the adjacent bolt-on panels and
components as described in the appropriate
Section of the MY 2003 VY & V2 Series II Service
Information.
2. Remove the windshield and the quarter window
assembly, refer to Section 1A6, STATIONARY
WINDOWS in the MY 2003 VY & V2 Series II
Service Information.
3. Remove the dash panel retaining bolt from the
hinge pillar.
4. Remove the roof panel, refer to Section 9, ROOF.
5. Remove the rear quarter panel, refer to
2.1 REAR QUARTER PANEL – REPLACE.
6. Remove the front wheelhouse panel upper side
rail, refer to Section 4. 2.5 FRONT
WHEELHOUSE PANEL UPPER SIDE RAIL.
Figure 7B-20
7. Spot cut the welds attaching the door opening
frame assembly to the inner rocker panel and to
the hinge pillar inner panel assembly.
NOTE: In order to spot cut the uppermost of these
welds it may be necessary to cut and peel back the
section of hinge reinforcement panel covering the
welds, to gain the required access.
8. Spot cut the welds attac hing the inner r ock er panel
(1) and hinge pillar inner panel as semb ly (2) to the
rocker panel reinforcement (3). Refer to Figure
7B-22.
NOTE: It is not required to cut the MIG welds.
Figure 7B-21
Figure 7B-22
9. Spot cut the two welds at the base of the hinge
pillar, attaching the door opening frame assembly
(1) to the hinge pillar inner panel assembly (2).
Figure 7B-23
10. Spot cut the welds on the windshield side flange,
attaching the door opening frame assembly (1) to
the hinge pillar inner panel assembly (2).
Figure 7B-24
11. Spot cut the welds on the flange surrounding the
front door opening, attaching the door opening
frame assembly to the hinge pillar inner panel
assembly, inner rocker panel and quarter panel
inner assembly.
Figure 7B-25
12. Spot cut the welds around the rear wheel arch,
joining the door opening f ram e assem bly (1) to the
quarter panel inner assembly (2).
NOTE: Many may have been removed with the rear
quarter panel.
13. Spot cut along the vertical flange below the rocker
panel to separate the door opening frame
assem bly from the inner rock er panel and the rear
floor panel outer extension. Refer to Figure 7B-27.
Figure 7B-26
Figure 7B-27
14. Spot cut from below, up into the rocker panel, to separate the welds attaching the door opening frame
assembly to the quarter panel inner assembly. Refer to Figure 7B-28.
Figure 7B-28
15. Spot cut the welds on the rear door opening
flange, attaching the door opening f ram e ass em bly
to the quarter panel inner assembly.
NOTE: Some welds may have been rem oved with the
quarter panel.
Figure 7B-29
16. Spot cut the two welds attaching the roof bow
panel (2) to the centre pillar upper reinforcement,
and the s ingle weld attaching the roof bow panel to
the door opening frame assembly (1).
Figure 7B-30
17. Spot cut the two welds attaching roof bow panel
No. 2 (1) to the door opening frame assembly (2).
Figure 7B-31
18. Spot cut the two welds attaching the roof bow
panel No. 3 to the door opening frame assembly
and the quarter panel inner assembly.
Figure 7B-32
19. Spot cut the welds along the roof attachment
flange.
NOTE: Many may have been removed with the roof
panel.
20. Remove the door opening frame assembly and
repair any damage to adjacent parts as required.
21. Check and rectify the alignment of the body shell
as Check and rectify the alignment of the body as
required, refer to 3. BODY DIMENSIONS in
Section 3B.
Figure 7B-33
REPLACE
NOTE 1: 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.
NOTE 2: The same number and position of s pot welds ( or plug welds) s hould 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
5. BODY SEALING, ADHESIVES & DEADENERS in Section 3B.
3. Apply Acrylic Spot Weld Sealer (Item 2), refer to 5. BODY SEALING, ADHESIVES & DEADENERS in
Section 3B.
4. Securely clamp the door opening frame assembly
in position on the vehicle body.
5. Begin attaching the door opening frame assembly
by spot welding around the front door opening
flange.
Figure 7B-34
6. Spot weld around the flange of the rear door
opening.
Figure 7B-35
7. Spot or plug weld in two places around the rear
wheel arch, attaching the door opening frame
assembly to the quarter panel inner assembly.
NOTE: These welds will be completed when the rear
quarter panel is replaced.
Figure 7B-36
8. Spot or plug weld the door opening frame
assembly to the inner rocker panel and to the
hinge pillar inner panel assembly. If the sheet
metal was modified to allow access to these welds,
it should be repaired to its original configuration.
Figure 7B-37
9. Plug weld the inner rocker panel and hinge pillar
inner panel assembly to the rocker panel
reinforcement.
Figure 7B-38
10. Spot or plug weld the door opening frame
assembly (1) to the hinge pillar inner panel
assembly (2) at the base of the hinge pillar
Figure 7B-39
11. Spot or plug weld along the windshield flange,
attaching the door opening frame assembly (1) to
the hinge pillar inner panel assembly (2).
Figure 7B-40
12. Spot or plug weld the door opening frame
assembly (1) to the quarter inner panel assembly,
then spot or plug weld the roof bow panel (2) to the
door opening frame assembly as shown.
Figure 7B-41
13. Spot or plug weld the door opening frame
assembly to the quarter inner panel assembly
along the roof panel flange. Complete this flange
when installing the roof panel.
14. Spot or plug weld the door opening frame along
the vertical flange below the rocker panel, refer to
Figure 7B-43.
Figure 7B-42
Figure 7B-43
15. Plug weld up through the roc ker panel to attac h the door opening f ram e assembly to the quarter panel inner
assembly. Refer to Figure 7B-44.
NOTE: Leave some welds to until the rear quarter panel is installed.
Figure 7B-44
16. Replace front wheelhouse panel upper side rail, refer to Section 4, 2.5 FRONT WHEELHOUSE PANEL
UPPER SIDE RAIL FRONT END – REPLACE.
17. Replace the rear quarter panel, refer to 2.1 REAR QUARTER PANEL - REPLACE.
18. Replace the roof panel, refer to Section 9, 2.2 ROOF.
NOTE: Refinish and prime any bare metal as required prior to replacing these panels.
19. Install the door hinge flaps, refer to 2.3 DOOR HINGE – (BODY SIDE) – REPLACE in Section 8.
20. Refinish and paint panels and other components as required. Refer to Section 3, 1.3 PAINT REFINISHING.
21. Apply Joint Sealer (Item 3) as required. Refer to 5. BODY SEALING, ADHESIVES & DEADENERS in
Section 3B.
22. Apply Cavity W ax (Item 8) as required to the ins ide of any box s ections or areas inacces sible to paint, refer
to 6. CAVITY WAX in Section 3B.
23. Apply Spray-on Deadener (Item 7) where applicable, refer to 5. BODY SEALING, ADHESIVES &
DEADENERS in Section 3B.
24. Install the dash panel retaining bolt through the hinge pillar and tighten to the specified torque.
25. Replace the windshield and quarter window assembly, refer to Section 1A6, STATIONARY GLASS in the
MY 2003 VY & V2 Series II Service Information.
26. Insert Cavity Foam into the centre pillar as required, refer to Section 2, 10. CAVITY FOAM.
27. Install the rem aining com ponents as described in the appr opriate Section of the MY 2003 VY & V2 Series II
Service Information.
DASH PANEL RETAINING BOLT
TORQUE SPECIFICATION 35.0 – 45.0 Nm
2.6 DOOR OPENING FRAME ASSEMBLY – PARTIAL REPLACE, HINGE PILLAR
REMOVE
1. Remove the adjacent bolt-on panels and
components as described in the appropriate
Section of the MY 2003 VY & V2 Series II Service
Information.
2. Secure an appropriate tool between the front door
opening flanges to maintain correct body
alignment.
3. Remove the windshield, refer to Section 1A6,
STATIONARY WINDOWS in the MY 2003 VY &
V2 Series II Service Information.
4. Remove the dash panel retaining bolt from the
hinge pillar.
5. Remove the front wheelhouse panel upper side
rail, refer to Section 4. 2.5 FRONT
WHEELHOUSE PANEL UPPER SIDE RAIL.
Figure 7B-45
6. Spot cut the welds attaching the door opening
frame assembly to the inner rocker panel and to
the hinge pillar inner panel assembly.
NOTE: In order to spot cut the uppermost of these
welds it may be necessary to cut and peel back the
section of hinge reinforcement panel covering the
welds, to gain the required access.
7. Spot cut the welds attac hing the inner r ock er panel
(1) and hinge pillar inner panel assem bly (2) to the
rocker panel reinforcement (3). Refer to Figure
7B-47.
NOTE: It is not required to cut the MIG welds.
Figure 7B-46
Figure 7B-47
8. Spot cut the two welds at the base of the hinge
pillar, attaching the door opening frame assembly
(1) to the hinge pillar inner panel assembly (2).
Figure 7B-48
9. Select a cutting point on the hinge pillar. This cut
point should be within the region specified.
Figure 7B-49
10. At the selected point (1), cut through the outer and
reinforcement panels, leaving the inner panel
intact.
11. Mark the inner panel at points 50 mm either side of
the cut line on the outer panel and cut the inner
panel at these two points (2). Spot cut the welds
and remove the 100 mm section of inner panel (3).
Figure 7B-50
12. Spot cut the welds on the windshield side flange,
up to the point of the cut.
Figure 7B-51
13. Cut through the rocker panel section of the door
opening frame assembly. The cut point (1) should
be through the third rocker panel moulding
attaching hole (2). Cut through both the outer
panel and the reinforcement.
Figure 7B-52
14. Spot cut the welds on the flange along the front
door opening, from the cut near the top of the
hinge pillar (1) to the cut in the rocker panel (2).
15. Spot cut the welds along the flange (3) below the
rocker panel to the point of the cut.
16. Remove the partial hinge pillar from the vehicle,
then repair any damage to adjacent parts.
17. Check and rectify the alignment of the body as
required, refer to 3. BODY DIMENSIONS in
Section 3B
Figure 7B-53
REPLACE
NOTE 1: 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.
NOTE 2: The same number and position of s pot welds ( or plug welds) s hould be used when replacing the panel,
as was used during manufacture, in order to maintain the original structural strength of the vehicle.
1. Cut a replacement panel section (1), accurately
measuring the position of cuts to match the section
removed.
Figure 7B-54
2. Remove a section of inner rocker panel (1). Cut
50 mm each side of the cut in the rocker panel.
This allows access for welding the rocker panel
reinforcement.
Figure 7B-55
3. Either manufacture a new section or cut an
existing length of surplus rocker panel section, to
form a reinforcement (1), appr oximately 100 mm in
length.
4. Prepare all mating surfaces and treat with Weld
Through Primer (Item 1) as required, refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
5. Clamp this reinforcement firmly behind the cut
section of rocker panel on the vehicle and spot or
plug weld in place. Position welds at a maximum
spacing of 35 mm apart.
Figure 7B-56
6. Using a similar technique, manufacture or cut a
section of reinforcement panel (1) approximately
60 mm long, to fit on the inside the outer panel of
the replacement hinge pillar (2) at the point of the
cut.
NOTE: Remove the flanges from this reinforcement
panel.
7. Prepare all mating surfaces and treat with Weld
Through Primer (Item 1) as required, refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
8. Clamp the reinforcement panel firmly behind the
outer panel of the cut section of the hinge pillar
and spot weld (3) in place.
9. Mark the new hinge pillar with drilling locations in
preparation for plug welding where required. Drill
holes as marked.
10. Prepare all mating surfaces and treat with Weld
Through Primer (Item 1) as required, refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
11. Apply Acrylic Spot Weld Sealer (Item 2), refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
Figure 7B-57
12. Clamp the replacement panel (1) in position on the
vehicle and check the door opening dimensions.
Refer to 3. BODY DIMENSIONS in Section 3B.
Adjust position as required.
Figure 7B-58
13. Plug weld (1) the top of the pillar to the
manufactured reinforcement, then MIG butt
weld (2) the two sections together.
Figure 7B-59
14. Plug weld (1) the new panel in the rocker panel
region, then MIG butt weld (2) the two sections
together.
Figure 7B-60
15. Gaining access through the removed section of
inner panel, MIG butt weld (1) the reinforcement
panel together.
16. Butt weld the removed access panel (2) in
position. Replace the spot welds with the same
number that was removed.
Figure 7B-61
17. Spot weld (1) the hinge pillar section along the
door opening flange.
18. Spot weld (2) the flange beneath the rocker panel,
attaching the new panel to the inner rocker panel.
Figure 7B-62
19. Spot weld (1) the pillar along the windshield
opening flange.
Figure 7B-63
20. Spot or plug weld the door opening frame
assembly to the inner rocker panel and to the
hinge pillar inner panel assembly. If the sheet
metal was modified to allow access to these welds,
it should be repaired to its original configuration.
Figure 7B-64
21. Plug weld the inner rocker panel and hinge pillar
inner panel assembly to the rocker panel
reinforcement.
Figure 7B-65
22. Gaining access through the section of removed
inner rocker panel, MIG butt weld (1) the new
section of rocker panel reinforcement to the
existing section.
23. Replace the rem oved section of inner roc k er panel
(2) by MIG butt welding it in place and spot welding
it along the door opening flange. Replace the spot
welds with the same number of as were cut out.
24. Dress the butt welds by grinding or sanding,
ensuring sufficient material remains to guarantee
the strength of the weld.
25. Install the door hinges, refer to 2.3 DOOR HINGE
(BODY SIDE) – REPLACE in Section 8
26. Refinish and paint panels and other components
as required. Refer to Section 3, 1.3 PAINT
REFINISHING.
27. Apply Joint Sealer (Item 3) as required. Refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
Figure 7B-66
28. Apply Cavity W ax (Item 8) as required to the ins ide of any box s ections or areas inacces sible to paint, refer
to 6. CAVITY WAX in Section 3B.
29. Install the dash panel bolt through the hinge pillar and tighten to the specified torque.
30. Replace the windshield, refer to Section 1A6, STATIONARY GLASS in the MY 2003 VY & V2 Series II
Service Information.
31. Install the rem aining com ponents as described in the appr opriate Section of the MY 2003 VY & V2 Series II
Service Information.
DASH PANEL RETAINING BOLT
TORQUE SPECIFICATION 35.0 – 45.0 Nm
2.7 DOOR OPENING FRAME ASSEMBLY – PARTIAL REPLACE, CENTRE PILLAR
NOTE: Cavity Foam is used within the hinge and
centre pillar cavities. Care is required when repairing
the vehicle in these areas, refer to Section 2, 10.
CAVITY FOAM prior to beginning work for further
information.
REMOVE
1. Remove the adjacent bolt-on panels and
components as described in the appropriate
Section of the MY 2003 VY & V2 Series II Service
Information.
2. Install the vehicle on a suitable fixture. As a
minimum, support the appropriate structural
sections of the vehicle on safety stands. Secure a
suitable tool between the front door opening
flanges to maintain alignment.
Figure 7B-67
3. Cut through the door opening frame assembly (1)
at the join of the rocker panel reinforcement and
centre pillar reinforcement (2).
NOTE: Make the cut carefully as the rocker panel
reinforcement must not be cut. The centre pillar
reinforcement is removed with the centre pillar section.
Figure 7B-68
4. Cut through the door opening frame assembly (1)
rearward of the dimple (2) in the flange.
NOTE: Make the cut carefully as the quarter panel
inner assembly must not be cut.
Figure 7B-69
5. Spot c ut the welds attac hing the underbody jac king
locator (1) and remove.
6. Spot cut the welds on the flange attaching the
centre pillar section to the inner rocker panel (6).
Refer to weld group A.
7. Spot cut the welds on the underside of the rocker
panel attaching the centre pillar section to the
quarter panel inner assembly (7). Refer to weld
group B.
Figure 7B-70
8. Cut the door opening frame assembly (1) and
centre pillar reinforcement (2) at the intersection
point of the centre pillar upper reinforcement (3).
The intersection point can be seen by looking at
the side of the flange.
NOTE: Do not cut through the centre pillar inner
reinforcement assembly (4) or quarter panel inner
assembly (5).
Figure 7B-71
9. Spot c ut the welds on the door opening flanges on
both sides of the centre pillar and remove the
centre pillar section from the vehicle.
Figure 7B-72
10. From the remaining section of centre pillar,
carefully remove enough of the outer skin (1) to
expose the spot welds joining the overlapping
sections of centre pillar upper reinforcement (2)
and centre pillar reinforcement (3).
NOTE: Do not c ut the centre pillar inner reinf orcement
assembly (4) and quarter panel inner assembly (5).
Figure 7B-73
11. Spot cut as shown, to remove the remaining
tongue (1) of the c entre pillar reinforcement. Leave
the holes drilled in reinforcement to facilitate plug
welding the replacement section.
Figure 7B-74
REPLACE
NOTE 1: 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.
NOTE 2: The same number and position of s pot welds ( or plug welds) s hould be used when replacing the panel,
as was used during manufacture, in order to maintain the original structural strength of the vehicle.
1. Cut the replacement panel through rocker section
as s hown. Ac curately m easure the position of c uts
to match the removed panel section.
Figure 7B-75
2. Cut the replacement panel at the top of the centre
pillar (1).
NOTE: Position the cut above the tongue on the c entre
pillar reinforcement, which is visible from the back of
the panel.
3. Adjust the cut on the vehicle side of the outer
panel so that it matches the cut on the
replacement section.
Figure 7B-76
4. On the replacement panel, cut along each side
and bend back the outer panel (3). This will
expose the spot welds attaching the remaining
piece of upper reinforcement (1) to the tongue (2)
of the centre pillar reinforcement.
Figure 7B-77
5. Spot c ut the nine welds and remove the rema ining
section of centre pillar upper reinforcement (1)
from the replacement panel.
Figure 7B-78
6. Cut two sec tions f rom sur plus roc ker panel pieces,
or manufacture new sections (1), each
approximately 100 mm in length.
7. Prepare the mating surfaces and treat with Weld
Through Primer (Item 1) as required, refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
8. Clamp these sections firmly behind both the cut
faces of rocker panel on the vehicle and spot or
plug weld in place. Perform the welds at a
maximum spacing of 35 mm.
9. Mark the new panel with drilling locations in
preparation for plug welding where required. Drill
holes as marked.
10. Prepare all mating surfaces and treat with Weld
Through Primer (Item 1) as required, refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
Figure 7B-79
11. Install the replacement panel in position, sliding the
tongue of the centr e pillar reinf or c ement (1) behind
the centre pillar upper reinforcement (2).
NOTE: Manipulate the rock er panel section in position,
inserting the front first, then the rear.
12. Clamp the assembly in place and plug weld the
centre pillar upper reinforcement to the centre
pillar reinforcement at the upper join.
13. Plug weld the rocker panel section to the
reinforcement sections.
14. Spot weld along the door opening flanges on both
sides of the centre pillar.
Figure 7B-80
15. Fold the outer panel back in position at the top of
the centre pillar. Spot weld along the door flange
section and MIG butt weld the sections together as
shown.
16. MIG butt weld the joins in the rocker panel.
Figure 7B-81
17. Plug weld the flange attaching the centre pillar
section (1) to the inner rocker panel (2). Refer to
weld group A .
18. Plug weld on the underside of the rock er panel the
centre pillar section to the quarter panel inner
assembly (3). Refer to weld group B.
19. Plug weld the underbody jacking locator (4) in
place.
20. Install the door hinges, refer to 2.3 DOOR HINGE
(BODY SIDE) – REPLACE in Section 8.
21. Dress the welds by grinding or sanding, ensuring
sufficient material remains to guarantee the
strength of the weld. Finish the area using an
appropriate technique.
22. Refinish and paint panels and other components
as required. Refer to Section 3, 1.3 PAINT
REFINISHING.
23. Apply Joint Sealer (Item 3) as required. Refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
24. Apply Cavity Wax (Item 8) as r equired to the inside
of any box sections or areas inaccessible to paint,
refer to 6. CAVITY WAX in Section 3B.
25. Insert Cavity Foam into the centre pillar as
required, refer to Section 2, 10. CAVITY FOAM.
26. Install the remaining components as described in
the appropriate Section of the MY 2003 VY & V2
Series II Service Information.
Figure 7B-82
2.8 DOOR OPENING FRAME ASSEMBLY – PARTIAL REPLACE, LOCK PILLAR
REMOVE
1. Remove the adjacent bolt-on panels and
components as described in the appropriate
Section of the MY 2003 VY & V2 Series II Service
Information.
2. Install the vehicle on a suitable fixture. As a
minimum, support the appropriate structural
sections of the vehicle on safety stands.
3. Remove the quarter window assembly, refer to
Section 1A6, STATIONARY WINDOWS in the
MY 2003 VY & V2 Series II Service Information.
4. Remove the rear quarter panel, refer to
2.1 REAR QUARTER PANEL – REPLACE.
Figure 7B-83
5. Select a cut point (1) on the upper region of the
lock pillar within the area specified.
6. Carefully cut through the outer panel, leaving the
quarter panel inner assembly (2) intact.
NOTE: There is no reinforcem ent panel in this area of
the vehicle.
Figure 7B-84
7. Select a cutting position on the rocker panel
section of the door opening frame assembly, rear
of the dimple in the flange (1). If possible, make
the cut in the area that will be covered by the rear
quarter panel. Cut through the outer panel (2),
leaving the quarter panel inner assembly (3) intact.
Figure 7B-85
8. Spot cut the welds on the flange around the rear
door opening attaching the section of the door
opening fram e ass embly to the quarter panel inner
assembly. Begin from the cut through the top of
the pillar (1) and continue to the cut through the
rocker panel section (2) as required.
NOTE: Some of the welds shown may have been
removed with the rear quarter panel.
9. Spot c ut the welds down the flange of the r ear s ide
glass opening (3), beginning at the point of the cut
through the lock pillar.
Figure 7B-86
10. Spot cut the welds on the flange below the rocker
panel as required, attaching the door opening
frame assembly to the inner rocker panel.
NOTE: Spots rear of those shown may have been
rem oved with the rear quar ter panel, if not rem ove any
remaining.
Figure 7B-87
11. Spot cut the welds below the rocker panel as
required, attaching the door opening frame
assembly to the quarter panel inner assembly.
NOTE: Spots rear of those shown may have been
rem oved with the rear quar ter panel, if not rem ove any
remaining.
Figure 7B-88
12. Spot cut any welds remaining around the
wheelhouse as required (most would have been
rem oved with the rear quarter panel) , attaching the
door opening frame assembly (1) to the quarter
panel inner assembly (2).
13. Rem ove the replacem ent section from the vehicle,
then repair any damage to adjacent parts as
required.
14. Check and rectify the alignment of the body as
required, refer to 3. BODY DIMENSIONS in
Section 3B.
Figure 7B-89
REPLACE
NOTE 1: 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.
NOTE 2: The same number and position of s pot welds ( or plug welds) s hould be used when replacing the panel,
as was used during manufacture, in order to maintain the original structural strength of the vehicle.
1. Cut the r eplacement lock pillar section f rom a new door opening f rame ass embly, accurately m easuring the
position of cuts, to match the removed section.
2. Manufacture a reinforcement (1), or cut a piece
from ex ces s pillar s ection, approx im ately 80 mm in
length to matc h the inside face only of the cut lock
pillar section.
3. Prepare the mating surfaces and treat with Weld
Through Primer (Item 1) as required, refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
4. Clam p the reinf orcement f irm ly behind the cut face
of the lock pillar section of the door opening fram e
assembly on the vehicle and spot or plug weld in
place.
Figure 7B-90
5. Using the same technique, manufacture or cut a
section of reinforcement panel (1), approx.
100 m m long, to f it inside the existing rock er panel
at the point of the cut.
6. Prepare the mating surfaces and treat with Weld
Through Primer (Item 1) as required, refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
7. Clamp the manufactured reinforcement panel
inside the rock er panel s ection of the door opening
frame assembly on the vehicle and plug weld in
position. Position welds at a maximum spacing of
35 mm.
8. Mark the replacement section with drilling locations
in preparation for plug welding. Drill holes as
required.
9. Prepare all mating surfaces and treat with Weld
Through Primer (Item 1) as required, refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
Figure 7B-91
10. Clamp the new lock pillar section in place on the
vehicle and check the door opening dimensions,
refer to 3. BODY DIMENSIONS in Section 3B.
11. Plug weld the replacement panel to the
manuf actured reinf orcem ent sections in the rock er
panel area and at the top of the pillar.
12. MIG butt weld the joins in both these areas.
Figure 7B-92
13. Spot weld several places along the flange around
the rear door opening (1) to retain new section in
position.
NOTE: Fully spot weld this flange when the rear
quarter panel is installed, welding through all three
panels, refer to 2.1 REAR QUARTER PANEL –
REPLACE.
14. The flange of the rear side glass opening (2) may
be spot welded in one or two places to hold in
position.
NOTE: Final weld this flange when the rear quarter
panel is installed, refer to 2.1 REAR QUARTER
PANEL – REPLACE.
Figure 7B-93
15. Spot weld the flange below the rocker panel as
required, attaching the replacement section to the
inner rocker panel.
NOTE: Where the rear quarter panel locates, place
two welds to secure the replacement section. Final
weld this flange when the rear quarter panel is
installed, refer to 2.1 REAR QUARTER PANEL –
REPLACE.
Figure 7B-94
16. Plug weld below the rocker panel as required,
attaching the replacement section to the quarter
panel inner assembly.
NOTE: Where the rear quarter panel locates, place
two welds to secure the replacement section. Final
weld this flange when the rear quarter panel is
installed, refer to 2.1 REAR QUARTER PANEL –
REPLACE.
Figure 7B-95
17. Spot weld several places around the wheelhouse
to retain new section in position.
NOTE: Fully spot weld this flange when the rear
quarter panel is installed, refer to 2.1 REAR
QUARTER PANEL – REPLACE.
18. Clean up the welds made where the rear quarter
panel is located and prime all bare metal.
19. Replace rear quarter panel, refer to 2.1 REAR
QUARTER PANEL – REPLACE.
20. Refinish and paint panels and other components
as required. Refer to Section 3, 1.3 PAINT
REFINISHING.
21. Apply Joint Sealer (Item 3) as required. Refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
22. Apply Cavity Wax (Item 8) as r equired to the inside
of any box sections or areas inaccessible to paint,
refer to 6. CAVITY WAX in Section 3B.
23. Install the quarter window assembly, refer to
Section 1A6, STATIONARY WINDOWS in the
MY 2003 VY & V2 Series II Service Information.
24. Install the remaining components as described in
the appropriate Section of the MY 2003 VY & V2
Series II Service Information.
Figure 7B-96
2.9 DOOR OPENING FRAME ASSEMBLY – PARTIAL REPLACE, ROCKER PANEL
IMPORTANT: This procedure details the replacement
of the rocker panel section of the door opening frame
assembly.
As there are several critical reinforcements in the lower
hinge pillar area, the rocker panel must not be cut
forward of the area shown. If the rocker panel is
damaged forward of this ar ea, replac e the rock er panel
and partial hinge pillar as one section. Modify this
procedure accordingly, also referring to 2.6 DOOR
OPENING FRAME ASSEMBLY – PARTIAL
REPLACE, HINGE PILLAR.
REMOVE
1. Remove the adjacent bolt-on panels and
components as described in the appropriate
Section of the MY 2003 VY & V2 Series II Service
Information.
2. Secure the vehicle on a suitable fixture. As a
minimum, support the appropriate structural
sections of the vehicle on safety stands. Install
suitable bracing in the vehicle to ensure that the
correct body alignment is maintained when the
rocker panel section is removed.
Figure 7B-97
3. Cut through the rocker panel section of the door
opening frame assembly. The cut point (1) should
be through the third rocker panel moulding
attaching hole (2). Cut through both the outer
panel and the reinforcement.
Figure 7B-98
4. Using a suitable cutting tool, cut through the
centre pillar at a position 30 mm below the lower
edge of the door hinge. Cut through both the door
opening frame assembly (1) and centre pillar
reinforcement (2).
Figure 7B-99
5. Select a cutting point through the rocker panel,
rearward of the dimple (1) in the flange. Cut
through the door opening frame assembly (2) only.
NOTE: T he cutting point can be anywhere r earward of
point 1, however if it is rear of point 3 the rear quarter
panel will require removal, refer to 2.1 REAR
QUARTER PANEL – REPLACE.
Figure 7B-100
6. Depending on the cut location, spot cut any
welds remaining around the wheelhouse as
required (most would have been removed with the
rear quarter panel), attaching the door opening
frame assembly (1) to the quarter panel inner
assembly (2).
7. Spot cut along the vertical flange below the rock er
panel to separate the door opening frame
assem bly from the inner rocker panel and the rear
floor panel outer extension. Refer to Figure
7B-102.
NOTE: Depending on the cut line position, many of
these welds may have been previously removed if the
rear quarter panel has been removed.
Figure 7B-101
Figure 7B-102
8. Spot c ut the welds attac hing the rock er panel s ection to the quarter panel inner ass em bly as required. Refer
to Figure 7B-103.
NOTE: Depending on the cut line position, m any of these welds may have been previously removed if the rear
quarter panel has been removed.
Figure 7B-103
9. Spot cut the welds along the lower edge of the
front and rear door openings as required, to
complete the detachment of the rocker panel
section.
10. Remove the panel from the vehicle, then repair
any damage to adjacent parts.
11. Check and rectify the alignment of the body as
required, refer to 3. BODY DIMENSIONS in
Section 3B.
Figure 7B-104
REPLACE
NOTE 1: 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.
NOTE 2: The same number and position of s pot welds ( or plug welds) s hould be used when replacing the panel,
as was used during manufacture, in order to maintain the original structural strength of the vehicle.
1. Cut a new replacement rocker panel section. Accurately measure the position of the cuts on the removed
section.
2. Remove a section of inner rocker panel (1), cut
50 mm each side of the cut in the rocker panel.
This allows access for welding the rocker panel
reinforcement.
Figure 7B-105
3. Manufacture or cut a reinforcement (1)
(approxim ately 100 m m long) to f it on the inside of
the existing rocker panel at the point of the cut.
4. Prepare the mating surfaces and treat with Weld
Through Primer (Item 1) as required, refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
5. Clamp the manufactured reinforcement firmly to
the inside of the rocker panel section of the door
opening frame assembly on the vehicle and plug
weld in position. Position welds at a maximum
spacing of 35 mm.
Figure 7B-106
6. Manufacture or cut a reinforcement (1)
(approximately 100 mm long) to fit inside of the
existing centre pillar section at the point of the cut.
7. Prepare the mating surfaces and treat with Weld
Through Primer (Item 1) as required, refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
8. Clamp the manufactured reinforcement panel
firmly to the inside of the outer panel of the door
opening frame assembly on the vehicle and plug
weld in position. Position welds at a maximum
spacing of 35 mm.
9. Repeat steps 6, 7 & 8 and install a reinforcement
at the rear rocker panel / lock pillar lower cut as
required.
10. Mark the replacement rocker panel section with
drilling positions in preparation for plug welding as
required.
NOTE: The outer panel will be plug welded from the
outer side of the vehicle, while the rocker panel and
centre pillar reinforcements will be butt welded from
the inner side of the vehicle.
11. Prepare all mating surfaces and treat with Weld
Through Primer (Item 1) as required, refer to
5. BODY SEALING, ADHESIVES & DEAD ENERS
in Section 3B.
Figure 7B-107
12. Install the replacement section onto the vehicle by
sliding the front and centre pillar sections onto the
reinforcements, while lifting the rear into position.
13. Clamp the panel in position.
14. Weld the new section to the centre pillar by plug
wel ding (1).
15. MIG butt weld the centre pillar reinforcement from
inside the centre pillar, through the large hole in
the inner panel immediately behind the weld.
16. Finish the centre pillar attachment by MIG
welding (2) along the join of the outer panel.
Figure 7B-108
17. Plug weld (1) the replacement section at the front
join, then MIG butt weld (2) the two sections
together.
Figure 7B-109
18. Gaining access through the section of removed
floor side panel, MIG butt weld (1) the new s ection
of rocker panel reinforcement to the existing
section.
19. Replace the removed section of floor side
panel (2) by MIG butt welding it in place and spot
welding it along the door opening flange. Replace
the spot welds with the same number as were
removed.
Figure 7B-110
20. Plug weld the rear join as required.
21. MIG butt weld the joint line between the panels.
Figure 7B-111
22. Spot or plug weld the flanges of the front and rear
door openings as required.
NOTE: Us e the same number and pos ition of welds as
removed during removal.
23. Spot or plug weld the door opening frame along
the flange below the rocker panel as required,
refer to Figure, 7B-113.
NOTE: If the rear quarter panel was removed, place
two welds where the rear quarter panel will overlap the
flange to hold the replac ement sec tion in pos ition. Fully
spot weld this flange when the rear quarter panel is
being attached, welding through all panels, refer to
2.1 REAR QUARTER PANEL – REPLACE.
Figure 7B-112
Figure 7B-113
24. Plug weld up through the rocker panel to attach the replacement section to the quarter panel inner assembly .
Refer to Figure 7B-114.
NOTE: If the rear quarter panel was removed, place two welds where the rear quarter panel will overlap the
panel to hold the replacem ent section in position. Fully spot weld this area when the rear quarter panel is being
attached, welding through all panels. Refer to 2.1 REAR QUARTER PANEL – REPLACE.
Figure 7B-114
25. If required, spot weld the replacement section to
the quarter panel inner assembly around the rear
wheel arch at several places to retain new section
in position.
NOTE: Fully spot weld this flange when the rear
quarter panel is installed, welding through all three
panels. Refer to 2.1 REAR QUARTER PANEL –
REPLACE.
26. Clean up the welds made where the rear quarter
panel is located and prime all bare metal.
27. Install the rear quarter panel, refer to 2.1 REAR
QUARTER PANEL – REPLACE.
28. Refinish and paint panels and other components
as required. Refer to Section 3, 1.3 PAINT
REFINISHING.
29. Apply Joint Sealer (Item 3) as required. Refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
30. Apply Cavity Wax (Item 8) as r equired to the inside
of any box sections or areas inaccessible to paint,
refer to 6. CAVITY WAX in Section 3B.
31. Install the remaining components as described in
the appropriate Section of the MY 2003 VY & V2
Series II Service Information.
Figure 7B-115
2.10 FENDER LOWER REAR BRACKET – REPLACE
The fender lower rear bracket (1) is spot welded at four
places to the door opening frame assembly.
Clamp the f ender lower rear brack et pos ition as shown
prior to plug welding and check the alignment of the
fender to the body and front door.
Refinish and paint panels and other components as
required. Refer to Section 3, 1.3 PAINT
REFINISHING.
Apply Cavity W ax (Item 8) as required to the inside of
any box sections or areas inaccessible to paint, refer to
6. CAVITY WAX in Section 3B.
Figure 7B-116
2.11 HINGE PILLAR INNER PANEL ASSEMBLY – REPLACE
REMOVE
1. Remove the adjacent bolt-on panels and
components as described in the appropriate
Section of the MY 2003 VY & V2 Series II Service
Information.
2. Remove the door opening frame assembly, refer
to 2.5 DOOR OPENING FRAME ASSEMBLY –
REPLACE, or remove the hinge pillar section of
the door opening frame assembly, refer to
2.6 DOOR OPENING FRAME ASSEMBLY –
PARTIAL REPLACE, HINGE PILLAR.
3. If requir ed, remove the das h panel as sembly, refer
to Section 5 COCKPIT MODULE in this
Supplement.
NOTE: If the cockpit module is not damaged an
alternative is provided in this procedure.
4. Add bracing as required to maintain the alignment
of the vehicle structure.
Figure 7B-117
5. Grind the MIG welds (1) attaching the hinge pillar
inner panel assembly to the inner rocker panel.
Figure 7B-118
6. Spot cut the welds attaching the hinge pillar inner
panel assembly to the roof front header and
quarter panel inner extension.
NOTE: Structural adhesive is applied to join (1). If the
roof panel has not been r emoved, it will be very diff ic ult
to remove the panel. As an alternative:
- If only the lower section is dam aged, detach the
hinge pillar inner upper panel (1) from the hinge
pillar inner lower panel (2) and replace the lower
panel, or
- Cut the hinge pillar inner panel assembly (3)
approximately 50 mm from the top of the
windscreen aperture. If a partial replacement of
the door opening frame assembly is being
performed, this point is 50 mm above the cut in
the outer panels (4). Refer to Figure 7B-120.
Figure 7B-119
Figure 7B-120
7. Spot cut the welds attaching the hinge pillar inner
panel assem bly to the f ront wheelhouse panel and
front floor panel extension, refer to weld group A.
8. If the dash panel assem bly was not removed, spot
cut the eight welds attaching the adhesive
channels to the hinge pillar inner panel assembly,
refer to weld group B.
9. If required, remove any remaining spot welds
where the wheelhouse panel upper side rail
attached the front wheelhouse panel and hinge
pillar inner panel assembly.
10. Cut the adhesive between the dash panel
assembly and hinge pillar inner panel assembly.
11. Rem ove the hinge pillar inner panel ass embly from
the vehicle and as required, clean off any
remaining adhesive and ensure the adhesive
channels are removed.
12. Repair any damage to adjacent parts as required. Figure 7B-121
REPLACE
NOTE 1: 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.
NOTE 2: The same number and position of s pot welds ( or plug welds) s hould be used when replacing the panel,
as was used during manufacture, in order to maintain the original structural strength of the vehicle.
1. If an alternate removal method was used, referring to Figure 7B-120 either:
- Cut the replacement section to match the cut at the top of the hinge pillar, or
- Spot cut the welds attaching the hinge pillar inner upper panel to the hinge pillar inner lower panel.
2. Mark the new panel and drill holes in preparation for plug welding where required.
3. Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to
5. BODY SEALING, ADHESIVES & DEADENERS in Section 3B.
4. If the dash panel assembly was removed, it will be installed later, proceed to Step 7.
5. If the dash panel assembly was NOT removed, prepare the adhesive channels on the replacement section
and the dash panel assembly, refer to Section 5 COCKPIT MODULE.
6. Mix the dash panel silicone adhesive refer to Section 5 COCKPIT MODULE. Apply the adhesive to fill the
adhesive channels on the replacement section.
NOTE: Only the correct material described in Section 5 COCKPIT MODULE is to be used.
7. If the f ull hinge pillar inner panel ass embly is being replaced, apply structural adhes ive ( Item 6) to the mating
surfaces of the hinge pillar inner panel assembly and quarter panel inner extension, refer to
5. BODY SEALING, ADHESIVES & DEADENERS in Section 3B.
8. Install and clamp the new panel in position on the
vehicle.
NOTE: If the dash panel assembly was not removed,
place the hinge pillar inner panel assembly (1) slightly
lower and slide it upwards ensuring the dash panel
flange (2) seats into the adhesive channel.
9. Temporarily install the dash panel attaching bolts
through the hinge pillar inner panel assembly and
within the plenum chamber.
10. Finish the application of the dash panel adhesive,
refer to Section 5 COCKPIT MODULE.
Figure 7B-122
11. If the full hinge pillar inner panel assembly was
removed, spot or plug weld the hinge pillar inner
panel assembly to the roof front header and
quarter panel inner extension.
NOTE: Ensure the structural adhesive Item 6, is
applied to the join (1) refer to 5. BODY SEALING,
ADHESIVES & DEADENERS in Section 3B.
12. If only the lower section was rem oved, spot or plug
weld the hinge pillar inner upper panel (1) to the
hinge pillar inner lower panel (2), refer to Figure
7B-124.
13. If the pillar was cut near the top of the windscreen
aperture, either MIG butt weld the join (3) if the full
door opening frame assembly was removed, or
make two tack welds to secure it until the door
opening frame assembly hinge pillar section is
installed, refer to Figure 7B-124.
NOTE: This join forms the top access cut point for
joining of the reinforcement as described in
2.6 DOOR OPENING FRAME ASSEMBLY –
PARTIAL REPLACE, HINGE PILLAR.
Figure 7B-123
Figure 7B-124
14. Spot or plug weld the hinge pillar inner panel
assembly to the front wheelhouse panel and front
floor extension.
Figure 7B-125
15. MIG weld two places (1) across the inner rocker
panel and hinge pillar inner panel assembly.
16. Replace the door opening frame assem bly, refer to
2.5 DOOR OPENING FRAME ASSEMBLY –
REPLACE or the hinge pillar section of the
door opening frame assembly, refer to
2.6 DOOR OPENING FRAME ASSEMBLY –
PARTIAL REPLACE, HINGE PILLAR.
17. Refinish and paint panels and other components
as required. Refer to Section 3, 1.3 PAINT
REFINISHING.
18. Apply Joint Sealer (Item 3) as required. Refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
19. Apply Cavity Wax (Item 8) as r equired to the inside
of any box sections or areas inaccessible to paint,
refer to 6. CAVITY WAX in Section 3B.
20. Install the remaining components as described in
the appropriate Section of the MY 2003 VY & V2
Series II Service Information.
Figure 7B-126
2.12 QUARTER PANEL INNER ASSEMBLY – REPLACE
REMOVE
1. Remove the adjacent bolt-on panels and
components as described in the appropriate
Section of the MY 2003 VY & V2 Series II Service
Information.
2. Mount the vehicle on a suitable jig to maintain
correct body alignment when the quarter panel
inner assembly is removed.
3. Remove the rear quarter panel and quarter panel
extension, ref er to 2.1 REAR QUART ER PANEL –
REPLACE and 2.2 QUARTER PANEL
EXTENSION – REPLACE.
4. Remove the roof panel, and partially remove the
roof bow panel and roof rear panel, refer to
Section 9 ROOF.
5. Remove the door opening frame assembly, refer
to 2.5 DOOR OPENING FRAME ASSEMBLY –
REPLACE.
6. Add further bracing tools as required, to maintain
the alignment of remaining vehicle panels.
Figure 7B-127
7. Cut any remaining spot welds and grind the MIG
welds (1), attaching the quarter panel inner
assembly to the inner rocker panel.
8. Spot cut the welds attaching the rear wheelhouse
inner to the rear floor panel assembly, refer to
Figure 7B-129.
Figure 7B-128
Figure 7B-129
9. Spot cut the welds attaching the quarter panel inner assembly to the rear compartment floor assembly. Refer
to Figure 7B-130.
NOTE: Some of the welds rear of the rear wheelhouse inner, also attach the quarter outer lower rear panel
which will be removed with the quarter panel inner assembly but is replaced separately.
Figure 7B-130
10. The quarter panel inner extension (1) is attached
to the hinge pillar inner panel assembly with spot
welds and structural adhesive (2) (Item 6, refer to
5. BODY SEALING, ADHESIVES & DEAD ENERS
in Section 3B). As the adhesive is extremely
strong, cut through the quarter panel inner
extension just behind the join and remove the
remaining joint piece with a grinder.
NOTE: As an alternative, remove the spot welds from
the join (3), leaving the quarter panel inner extension
intact.
11. Rem ove the quar ter panel inner assembly from the
vehicle, then repair any damage to adjacent parts
as required.
12. Check and rectify the alignment of the body as
required, refer to 3. BODY DIMENSIONS in
Section 3B.
Figure 7B-131
REPLACE
NOTE 1: 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.
NOTE 2: The same number and position of s pot welds ( or plug welds) s hould be used when replacing the panel,
as was used during manufacture, in order to maintain the original structural strength of the vehicle.
1. Mark the new panel and drill holes in preparation for plug welding where required.
2. Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to
5. BODY SEALING, ADHESIVES & DEADENERS in Section 3B.
3. Either, apply structural adhesive (Item 6, refer to
5. BODY SEALING, ADHESIVES & DEAD ENERS
in Section 3B) to the mating surfaces of the quarter
panel inner extension and hinge pillar inner panel
assembly (1), if this joint was cut or, remove the
quarter panel inner extension from the
replacement section.
4. Clamp the new panel in position on the vehicle.
5. Depending on removal method either:
- Spot weld the quarter panel inner extension
and hinge pillar inner panel assembly join (1),
or
- Spot weld the quarter panel inner assembly to
the quarter panel inner extension (2).
6. Spot or plug weld the rear wheelhouse inner to the
rear compartment floor assembly, refer Figure
7B-133.
Figure 7B-132
Figure 7B-133
7. Spot or plug weld the quarter panel inner assem bly to the rear com partment floor assem bly, refer to Figure
7B-134.
NOTE: The welds along the rear compartment floor assembly rear of the wheelhouse also attach the quarter
outer lower rear panel, which can be r eplaced now, also ref er to 2.4 QUARTER OUT ER LOWER REAR PANEL
– REPLACE.
8. Weld the quarter panel inner lower extension to the rear end panel extension.
Figure 7B-134
9. Spot or plug weld the quarter panel inner assembly
to the inner rocker panel.
NOTE: Only make several welds in the door opening
flanges as they will be fully welded when the door
opening frame assembly is installed.
10. Perf orm a series of f our MIG welds (1) at the base
of the centre pillar and the lock pillar.
NOTE: Each MIG weld is to be 25 mm long.
11. Clean up the welds and prime any bare metal.
12. Replace the door opening frame assem bly, refer to
2.5 DOOR OPENING FRAME ASSEMBLY –
REPLACE.
13. Replace the roof panel, and partially remove the
roof bow panel and roof rear panel, refer to
Section 9 ROOF.
Figure 7B-135
14. Replace the rear quarter panel and quarter panel extension, refer to 2.1 REAR QUARTER PANEL –
REPLACE and 2.2 QUARTER PA NEL EXTENSION – REPLACE.
15. Refinish and paint panels and other components as required. Refer to Section 3, 1.3 PAINT REFINISHING.
16. Apply Joint Sealer (Item 3) as required. Refer to 5. BODY SEALING, ADHESIVES & DEADENERS in
Section 3B.
17. Apply Cavity W ax (Item 8) as required to the ins ide of any box s ections or areas inacces sible to paint, refer
to 6. CAVITY WAX in Section 3B.
18. Apply spray-on deadener to the wheel side of the wheelhouse, ref er to 5. BODY SEALING, ADHESIVES &
DEADENERS in Section 3B.
19. Install the rem aining com ponents as described in the appr opriate Section of the MY 2003 VY & V2 Series II
Service Information.
2.13 QUARTER PANEL INNER ASSEMBLY – PARTIAL REPLACE
The following procedure allows partial replacement of
a rear corner of the wagon without the need to replace
the roof panel or door opening frame assembly.
If a larger section of the quarter panel inner
assembly requires replacing, this can be achieved by
firstly removing the partial lock pillar section of
the door opening frame assembly. Refer to
2.8 DOOR OPENING FRAME ASSEMBLY –
PARTIAL REPLACE, LOCK PILLAR.
The required partial quarter panel inner assembly
replacement can then be performed using similar
techniques to those in the following operation.
REMOVE
1. Remove the adjacent bolt-on panels and
components as described in the appropriate
Section of the MY 2003 VY & V2 Series II Service
Information.
Figure 7B-136
2. Mount the vehicle on a suitable fixture. Secure a
suitable tool between the rear door opening
flanges to maintain alignment once the sections
are removed.
3. Remove the rear quarter panel and quarter panel
extension, ref er to 2.1 REAR QUART ER PANEL –
REPLACE and 2.2 QUARTER PANEL
EXTENSION – REPLACE.
4. Cut through the quarter panel inner assembly in
the specified region (1) on the back pillar. It is
prefer able to cut below the guss et plate where only
a single thickness is encountered.
5. Cut through the quarter panel inner assembly
approximately 50 mm behind the door opening
frame (2). This will allow sufficient area for joining
of the new panel section.
Figure 7B-137
6. Spot cut the welds attaching the rear wheelhouse
reinforcement to the quarter panel inner assembly
on the relevant side.
Figure 7B-138
7. Spot cut the welds attaching the quarter panel
inner assembly to the rear wheelhouse inner left-
hand (1) or right-hand (2). The spot cutting is only
required on the section of the quarter panel inner
assembly being removed.
8. Spot cut the welds attaching the rear compar tment
floor assem b ly to the quar ter panel inner as sem bly
on the side being removed. Refer to Figure
7B-140.
9. Spot cut the welds attaching the quarter inner
lower rear extension to the rear end panel
extension.
Figure 7B-139
Figure 7B-140
10. Remove the partial quarter panel inner from the vehicle, then repair any damage to adjacent parts.
11. Check and rectify the alignment of the body as required, refer to 3. BODY DIMENSIONS in Section 3B.
REPLACE
NOTE 1: 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.
NOTE 2: The same number and position of s pot welds ( or plug welds) s hould be used when replacing the panel,
as was used during manufacture, in order to maintain the original structural strength of the vehicle.
1. Joggle the edge of the remaining quarter panel
inner assembly and outer wheelhouse (1) towards
the inside of the vehicle. Size the joggle for an
overlap of approximately 30 mm.
2. Cut a replacement quarter panel inner section
from a new panel assembly. The new panel should
be measured and cut accurately to overlap the
joggled panel in the wheelhouse area and to line
up for a butt weld in the back pillar area.
3. Mark the new panel with drilling locations where
required, in prepar ation f or plug welding. Drill holes
as marked.
4. Prepare all mating surfaces and treat with Weld
Through Primer (Item 1) as required, refer to
5. BODY SEALING, ADHESIVES & DEADENERS
in Section 3B.
Figure 7B-141
5. Spot or plug weld the replacement section along
the join (1). Perform welds at a maximum spacing
of 35 mm along the length of the join.
6. Butt weld the new panel section to the vehicle
across the back pillar join (2).
Figure 7B-142
7. Com plete the joint around the wheelhouse by MIG
welding (1) on the outer side of the panel.
Figure 7B-143
8. Weld the quarter panel inner to the rear
wheelhouse inner, either left-hand (1) or right-
hand (2).
Figure 7B-144
9. Spot or plug weld the rear wheelhouse
reinforcement to quarter panel inner.
10. Spot or plug weld the quarter panel inner to the
rear compartment floor assembly, refer to Figure
7B-146.
NOTE: The welds along the rear compartment floor
assembly rear of the wheelhouse also attach the
quarter outer lower rear panel, which can be replaced
now, also refer to 2.4 QUARTER OUTER LOWER
REAR PANEL – REPLACE.
11. Weld the quarter panel inner lower extension to
the rear end panel extension.
Figure 7B-145
Figure 7B-146
12. Replace the rear quarter panel and quarter panel extension, refer to 2.1 REAR QUARTER PANEL –
REPLACE and 2.2 QUARTER PANEL EXTENSION – REPLACE.
13. Refinish and paint panels and other components as required. Refer to Section 3, 1.3 PAINT REFINISHING.
14. Apply Joint Sealer (Item 3) as required. Refer to 5. BODY SEALING, ADHESIVES & DEADENERS in
Section 3B.
15. Apply Cavity W ax (Item 8) as required to the ins ide of any box s ections or areas inacces sible to paint, refer
to 6. CAVITY WAX in Section 3B.
16. Apply spray-on deadener to the wheel side of the wheelhouse, ref er to 5. BODY SEALING, ADHESIVES &
DEADENERS in Section 3B.
17. Install the rem aining com ponents as described in the appr opriate Section of the MY 2003 VY & V2 Series II
Service Information.