SECTION 7D – BODY SIDE – COUPE

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 TAIL LAMP HOUSING, QUARTER PANEL

UPPER EXTENSION & QUARTER PANEL

LOWER EXTENSION – REPLACE

REMOVE

REPLACE

2.3 DOOR OPENING FRAME ASSEMBLY –

REPLACE

REMOVE

REPLACE

2.4 DOOR OPENING FRAME ASSEMBLY –

PARTIAL REPLACE, HINGE PILLAR

REMOVE

REPLACE

2.5 DOOR OPENING FRAME ASSEMBLY –

PARTIAL REPLACE, CENTRE PILLAR

REMOVE

REPLACE

2.6 DOOR OPENING FRAME ASSEMBLY –

PARTIAL REPLACE, ROCKER PANEL

REMOVE

REPLACE

2.7 FENDER LOWER REAR BRACKET –

REPLACE

2.8 HINGE PILLAR INNER PANEL ASSEMBLY –

REPLACE

REMOVE

REPLACE

2.9 QUARTER PANEL INNER ASSEMBLY –

REPLACE

REMOVE

REPLACE

2.10 QUARTER PANEL INNER ASSEMBLY –

PARTIAL REPLACE

REMOVE

REPLACE

1. GENERAL DESCRI PTI O N

This Section des c ribes the r eplacement proc edur es for the body side components of the MY 2003 V2 Series II 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 occupant

protection system to function correctly.

Partial replacement procedures are included for the door opening frame assembly hinge pillar, centre 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.

A partial replacement procedure is also included for the rear section of the quarter panel inner assembly.

NOTE: It is imperative that the correct body adhesives, sealers, deadeners and cavity waxes are used when

repairing the body structure of MY 2003 V2 Series II vehicles. Refer to 5. BODY SEALING, ADHESIVES &

DEADENERS and 6. CAVITY WAX in Section 3D for details of the correct materials and their commercially

available equivalents.

1.1 BODY SIDE COMPONENTS

The shaded components in Figure 7D-1 are the body

side component dealt with in this Section.

The components and assemblies shown in Figure 7D-

2 are the parts serviced for MY 2003 V2 Series II

vehicles which 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 your Authorised Retailer for

spare parts availability configurations.

IMPORTANT: Cavity foam may be used within the

hinge, centre and lock pillar cavities. Car e 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 7D-1

Figure 7D-2

Legend

1. Hinge Pillar Trim Panel Bracket

2. Hinge Pillar Inner Panel Assembly

3. Hinge Pillar Upper Reinforcement

4. Quarter Panel Inner Assembly

5. Body Pillar Inner Panel Reinforcement

6. Door Opening Frame Assembly

7. Fender Lower Rear Bracket

8. Fender Rear Bracket

9. Fender Upper Rear Bracket

10. Front Door Striker Anchor Plate

11. Underbody Jacking Locator

12. Rear Quarter Panel

13. Quarter Panel Lower Extension

14. Tail Lamp Housing

15. Quarter Panel Upper Extension

16. Fuel Filler Pipe Housing

NOTE 1: The door opening frame assembly includes parts 7, 8, 9, 10 and 11.

NOTE 2: The quarter panel inner assembly includes the rear wheelhouse inner panel assembly which is also

available separately, refer Section 10D BODY REAR – COUPE.

2. SERVICE OPERATIONS

2.1 REAR QUARTER P ANEL – REPLACE

NOTE 1: The rear quarter panel is not available as an

assembly with the tail lamp housing, quarter panel

upper extension, quarter panel lower extension or fuel

filler pipe housing (for right-hand side).

This procedure details the removal of the rear quarter

panel as an assembly with the above parts.

Replacement of the smaller panels is described in this

and the subsequent procedure.

NOTE 2: Full replacement of the rear quarter panel

requires removal of the roof panel. An alternative is

also provided in this procedure where the panel is

joined through the lock-pillar, approximately 100 mm

below the top of the rear window.

NOTE 3: Cavity Foam is used within the hinge,

centre and lock pillar cavities. Care is required

when repairing the vehicle in these areas, refer to

Section 2, 10. CAVITY FOAM prior to beginning

work for further information.

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 window and quarter window

assembly, refer to Section 1A6 STATIONARY

WINDOWS in the MY 2003 VY & V2 Series II

Service Information.

3. Remove the rear bumper impact bar, refer to

Section 3, 2. BUMPER IMPACT BAR

ASSEMBLIES.

Figure 7D-3

4. Spot cut the tail lamp housing and quarter panel

lower extension from the rear end lower panel.

NOTE: If the tail lam p hous ing and quarter panel lower

extension are to remain, modify this procedure

accordingly .

5. Spot cut the rear quarter panel from the rear end

lower panel and rear compartment floor panel

outer extension.

6. Spot cut the welds attaching the rear quarter panel

to the quarter panel inner 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

7D-5.

Figure 7D-4

Figure 7D-5

7. Spot cut the welds attaching the rear quarter panel

to the door opening frame assembly and quarter

panel inner assembly.

Figure 7D-6

8. Spot cut the welds attaching the rear quarter panel

to the door opening frame assembly.

Figure 7D-7

9. Spot cut the welds attaching the rear quarter panel

to the door opening frame assembly and quarter

panel inner assembly.

NOTE: If the roof panel has been removed, cut the

welds all the way along the quarter window opening to

the braze joint (1). Remove the three welds attaching

the rear quarter panel to the body pillar inner panel

reinforcement and using an oxy / acetylene torch and

wire brush, carefully remove the brazing from the joint.

If the roof panel has not been removed, only remove

the spot welds as far as point (2). Mark a line and cut

the rear quarter panel at this area, ensuring not to cut

into the quarter panel inner assembly.

10. At the base of the loc k pillar, the rear quar ter panel

is sandwiched between the quarter inner panel

assembly and rear window panel assembly.

Cutting the panel at this point, as desc ribed below,

rather than removing extra panels, will save

considerable tim e and ef fort as s tructural adhesive

(1) is used in this area, refer to Figure 7D-9.

11. Using a saw or other appropriate equipment, cut

through the rear quarter panel as shown (2) at

View A. The cut should pass across the drain

channel, then along the inner face of the rear

quarter panel.

NOTE: It is important to leave enough material (3) to

facilitate a lap joint of the old and new panels. The

drain channel and rear window opening flange will be

butt joined.

12. As required spot cut the welds attaching the rear

quarter panel to the quarter panel inner assembly.

Figure 7D-8

Figure 7D-9

13. Remove the panel from the vehicle and then repair any damage to adjacent parts.

NOTE: For the right-hand side, the fuel filler pipe housing is attached to the quarter inner panel assembly with

acrylic spot weld sealer, which will require separating while the panel is being removed.

14. Check and rectify the alignment of the body as required, refer to 3. BODY DIMENSIONS in Section 3D.

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. On the replacement panel, remove the section (1)

to facilitate the join at the base of the lock pillar.

IMPORTANT: If surrounding panels have been

replaced, this section may be required to remain intact.

2. If the roof panel has not been removed, remove

the upper section of the lock pillar on the new

panel to match the removed panel.

Figure 7D-10

3. From the scrap piece, manufacture a

reinforcement (1) to fit inside the remaining rear

quarter panel on the vehicle as shown.

NOTE: The reinforcement must not extend to the

flanges.

4. Mark the panel with drilling locations in preparation

for plug welding. Drill holes as required.

5. Prepare all mating surfaces and treat with Weld

Through Primer (Item 1) as required, refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3D.

6. Clam p the reinforcem ent in position and plug weld

it to the vehicle.

Figure 7D-11

7. For the right-hand side, if required spot or plug

weld (1) the fuel filler pipe housing to the rear

quarter panel in four places.

Figure 7D-12

8. Open the flange (1) at the base of the lock pillar

outwards slightly to allow the new panel to seat

correctly.

9. As required, mark the new panel with drilling

locations in prepar ation f or plug welding. Drill holes

as required.

10. Prepare all mating surfaces and treat with Weld

Through Primer (Item 1) as required, refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3D.

11. Apply Acrylic Spot Weld Sealer (Item 2), refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3D.

12. Clamp the rear quarter panel in position ensuring it

is seated correctly at the base of the lock pillar (2).

13. Test fit the alignm ent of the rear quarter panel with

the front door and rear compartment lid.

Figure 7D-13

14. Spot or plug weld the rear quarter panel to the

quarter panel inner assembly.

Figure 7D-14

15. Spot or plug weld the rear quarter panel to the

door opening frame assembly and quarter panel

inner assembly.

NOTE: If the roof panel was rem oved, weld all the way

along the quarter window opening to the braze joint (1).

Plug weld the rear quarter panel to the body pillar inner

panel reinforcement and using an oxy / acetylene

torch, carefully braze weld the joint.

If the roof panel was not removed, weld only as far as

point (2). Plug weld the rear quarter panel to the

manufactured reinforcement and using an oxy /

acetylene torch, carefully braze weld the joint.

IMPORTANT: To reduce the risk of panel distortion,

place wet rags adjacent to the braze joints.

Figure 7D-15

16. Spot or plug weld the rear quarter panel to the

door opening frame assembly .

Figure 7D-16

17. Spot or plug weld the rear quarter panel to the

door opening frame assembly and rear quarter

panel inner assembly.

18. Spot or plug weld the r ear quar ter panel to the rear

quarter panel inner assembly and rear

compartment floor panel outer extension. There

are a different number of welds on the left-hand

side to the right-hand side, refer to Figure 7D-18.

Figure 7D-17

Figure 7D-18

19. Spot or plug weld the rear quarter panel to the

flange at the base of the lock pillar and MIG butt

weld across the water channel and rear window

flange.

20. Either:

a. Install the tail lamp housing, quarter panel

lower extension and quarter panel upper

extension, or

b. Weld the rear quarter panel to these panels.

Refer to the following procedure in this Section

21. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

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

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3D.

Figure 7D-19

23. Add an additional bead of Joint Sealer to the lap

joint at the base of the lock pillar.

24. Apply Cavity Wax (Item 8) as r equired to the inside

of any box sections or areas inaccessible to paint,

refer 6. CAVITY WAX in Section 3D.

25. Install rear bum per impact bar, refer to Section 3,

2. BUMPER IMPACT BAR ASSEMBLIES.

26. Insert Cavity Foam into the lock pillar as required,

refer to Section 2, 10. CAVITY FOAM.

27. Install the remaining components as described in

the MY 2003 VY & V2 Series II Service

Information.

Figure 7D-20

2.2 TAIL LAMP HOUSING, QUARTER PANEL UPPER EXTENSION &

QUARTER PANEL LOWER EXTENSION – REPLACE

NOTE: The components described in this procedure

may be replaced as an assembly or individually as

required.

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.

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 7D-21

2. Spot cut the welds attaching the quarter panel

upper extension (1) to the rear quarter panel and

to the tail lamp housing as required.

Figure 7D-22

3. Spot cut the welds attaching the tail lamp housing

(1) to the rear quarter panel, quarter panel lower

extension (2) and rear end lower panel.

4. The quarter panel lower extens ion (2) m ay then be

rem oved fr om the vehicle by s pot cutting the welds

attaching it to the rear quarter panel and rear end

lower panel.

5. Repair any damage to adjacent parts as required.

Figure 7D-23

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 3D.

3. Apply Acrylic Spot Weld Sealer (Item 2), refer to 5. BODY SEALING, ADHESIVES & DEADENERS in

Section 3D.

4. Clamp the removed parts in position and fit the tail lamp to check for correct fit with the surrounding panels.

5. Spot or plug weld the quarter panel lower

extension (2) to the rear quarter panel and rear

end lower panel.

6. Spot or plug weld the tail lamp housing (1) to the

rear quarter panel, rear end lower panel and

quarter panel lower extension (2).

Figure 7D-24

7. Spot or plug weld the quarter panel upper

extension (1) to the rear quarter panel and tail

lamp housing.

8. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

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

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3D.

10. Apply Cavity Wax (Item 8) as r equired to the inside

of any box sections or areas inaccessible to paint,

refer 6. CAVITY WAX in Section 3D.

11. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 7D-25

2.3 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:

2.4 DOOR OPENING FRAME ASSEMBLY –

PARTIAL REPLACE, HINGE PILLAR and

2.5 DOOR OPENING FRAME ASSEMBLY –

PARTIAL REPLACE, CENTRE PILLAR.

NOTE 2: Cavity Foam is used within the hinge, centre

and lock pillar cavities . Care is r equired when repairing

the vehicle in these areas, refer to Section 2, 10.

CAVITY FOAM prior to beginning any 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 and rear

window assemblies, 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. Rem ove the rear quarter panel, refer to 2.1 REAR

QUARTER PANEL.

6. Remove the front wheelhouse panel upper side

rail, refer to Section 4. 2.5 FRONT

WHEELHOUSE PANEL UPPER SIDE RAIL.

Figure 7D-26

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. If required, spot cut the welds attaching the inner

rocker panel (1) and hinge pillar inner panel

assembly (2) to the rock er panel reinforcement (3) .

Refer to Figure 7D-28.

NOTE 1: Not all vehicles have these welds.

NOTE 2: The MIG welds should not have to be

removed.

Figure 7D-27

Figure 7D-28

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 7D-29

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).

NOTE: There are several sub-assembly welds which

do not require removing.

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, refer to Figure 7D-31.

Figure 7D-30

Figure 7D-31

12. Spot cut any remaining welds attaching the door opening frame assembly to the quarter panel inner

assembly around the rear wheel arch.

13. Spot cut along the vertic al f lange below the rock er panel to s eparate the door opening f ram e as sem bly from

the inner rocker panel. Refer to Figure 7D-32.

Figure 7D-32

14. Spot cut from below, up into the rocker panel, the welds attaching the door opening frame assembly to the

quarter panel inner assembly. Refer to Figure 7D-33.

Figure 7D-33

15. Spot cut the welds attaching the door opening frame assembly to the quarter panel inner assembly, refer

Figure 7D-34.

Figure 7D-34

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 7D-35

17. Carefully lifting the roof bow panel out of the way,

spot cut the two welds attaching the centre pillar

upper reinforcement to the quarter panel inner

assem bly. The centre pillar upper reinf orcement is

removed as part of the door opening frame

assembly.

Figure 7D-36

18. Spot cut the welds along the roof flange, attaching

the door opening frame assembly to the quarter

panel inner assembly.

NOTE: Also remove any remaining roof panel welds

as required.

19. Structural adhesive is applied within the join of the

centre pillar upper reinforcement (1) to the lock

pillar reinforcement (2). Cut back the rear section

of the outer panel and cut the centre pillar upper

reinforcement forward of the lock pillar

reinforcement. Remove the remaining section

once the frame assembly has been removed.

20. Remove the complete door opening frame

assembly and repair any damage to adjacent

parts.

21. Check and rectify the alignment of the body as

required, refer to 3. BODY DIMENSIONS in

Section 3D.

Figure 7D-37

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 3D.

3. Apply Acrylic Spot Weld Sealer (Item 2), refer to 5. BODY SEALING, ADHESIVES & DEADENERS in

Section 3D.

4. Apply Structural Adhes ive (Item 6) to the r ear inner

side of the centre pillar upper reinfor cement f lange

(1), also ref er to 5. BODY SEALING, ADHESIVES

& DEADENERS in Section 3D.

Figure 7D-38

5. Securely clamp the door opening frame assembly

in position, ensuring the centre pillar upper

reinforcement (1) to lock pillar reinforcement (2)

join is seated correctly.

6. Spot or plug weld the door opening frame

assembly to the quarter inner panel assembly

along the roof panel flange. Complete this flange

when installing the roof panel.

7. Spot or plug weld the door opening frame

assembly to the quarter inner panel assembly

around the front door opening flange, refer to

Figure 7D-40.

Figure 7D-39

Figure 7D-40

8. Spot or plug weld the door opening fram e assem bly to the quarter inner panel ass embly, refer to Figure 7D-

41.

Figure 7D-41

9. 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 7D-42

10. Spot or plug weld along the windshield flange,

attaching the door opening frame assembly (1) to

the hinge pillar inner panel assembly (2).

Figure 7D-43

11. Spot or plug weld the door opening frame

assembly (1) to the hinge pillar inner panel

assembly (2) at the base of the hinge pillar.

Figure 7D-44

12. Spot or plug weld the door opening frame

assembly to the inner rocker panel and to the

hinge pillar inner panel assembly. If the sheet

metal was modified to allow access to these welds,

it should be repaired to its original configuration.

Figure 7D-45

13. If removed, plug weld the inner rocker panel and

hinge pillar inner panel assembly to the rocker

panel reinforcement.

14. Plug weld up through the rocker panel to attach

the door opening frame assembly to the quarter

panel inner assembly, refer to Figure 7D-47.

Figure 7D-46

Figure 7D-47

15. Spot or plug weld along the vertical flange below the rocker panel attaching the door opening frame

assembly to the inner rocker panel, refer to Figure 7D-48.

Figure 7D-48

16. Spot or plug weld two places, the door opening f rame as sem bly to the quarter panel inner assem bly ar ound

the rear wheel arch.

NOTE: This joint will be completed when the rear quarter panel is installed.

17. Replace front wheelhouse panel upper side rail, refer to Section 4, 2.5 FRONT WHEELHOUSE PANEL

UPPER SIDE RAIL FRONT END – REPLACE.

18. Replace the rear quarter panel, refer to 2.1 REAR QUARTER PANEL – REPLACE.

19. Replace the roof panel, refer to Section 9, ROOF.

NOTE: Refinish and prime any bare metal as required prior to replacing these panels.

20. Install the door hinges, refer to 2.3 DOOR HINGE (BODY SIDE) – REPLA CE in Section 8.

21. Refinish and paint panels and other components as required. Refer to Section 3, 1.3 PAINT REFINISHING.

22. Apply Joint Sealer (Item 3) as required. Refer to 5. BODY SEALING, ADHESIVES & DEADENERS in

Section 3D.

23. Apply Cavity W ax (Item 8) as required to the ins ide of any box s ections or areas inacces sible to paint, refer

6. CAVITY WAX in Section 3D.

24. Apply Spray-on Deadener (Item 7) where applicable, refer to 5. BODY SEALING, ADHESIVES &

DEADENERS in Section 3D.

25. Install the dash panel retaining bolt through the hinge pillar and tighten to the specified torque.

26. Replace the windshield and the quarter and rear window assemblies, refer to Section 1A6, STATIONARY

GLASS in the MY 2003 VY & V2 Series II Service Information.

27. Insert Cavity Foam into the hinge & centre pillars as required, refer to Section 2, 10. CAVITY FOAM.

28. 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

2.4 DOOR OPENING FRAME ASSEMBLY – PARTIAL REPLACE, HINGE PILLAR

NOTE: Cavity Foam is used within the hinge, centre

and lock pillar cavities . Care is r equired 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. 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 7D-49

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. If required, spot cut the welds attaching the inner

rocker panel (1) and hinge pillar inner panel

assembly (2) to the rock er panel reinforcement (3).

Refer to Figure 7D -51.

NOTE 1: Not all vehicles have these welds.

NOTE 2: The MIG welds should not have to be

removed.

Figure 7D-50

Figure 7D-51

8. Spot cut the two welds at the base of the hinge

pillar, attaching the door opening frame assembly

(1) to the hinge pillar inner panel assembly (2).

Figure 7D-52

9. Select a cutting point on the hinge pillar

approximately 100 mm from the top of the

windshield flange.

Figure 7D-53

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 100 mm section of inner panel (3).

Figure 7D-54

12. Spot cut the welds on the windshield side flange,

up to the point of the cut.

Figure 7D-55

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 7D-56

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 3D.

Figure 7D-57

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 7D-58

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 7D-59

3. Either manufacture a new section or cut an

existing length of surplus rocker panel section, to

form a reinforcement (1), approximately 100 mm in

length.

4. Prepare all mating surfaces and treat with Weld

Through Primer (Item 1) as required, refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3D.

5. Clamp this reinforcement firmly behind the cut

section of rocker panel on the vehicle and spot or

plug weld in place. Position welds at a maximum

spacing of 35 mm apart.

Figure 7D-60

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 3D.

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 3D.

11. Apply Cavity Wax (Item 8) as r equired to the inside

of any box sections or areas inaccessible to paint,

refer 6. CAVITY WAX in Section 3D.

Figure 7D-61

12. Clamp the replacem ent panel (1) in position on the

vehicle and check the door opening dimensions.

Refer to 3. BODY DIMENSIONS in Section 3D.

Adjust position as required.

Figure 7D-62

13. Plug weld (1) the top of the pillar to the

manufactured reinforcement, then MIG butt

weld (2) the two sections together.

Figure 7D-63

14. Plug weld (1) the new panel in the rocker panel

region, then MIG butt weld (2) the two sections

together.

Figure 7D-64

15. Gaining access through the removed section of

inner panel, MIG butt weld (1) the reinforcement

panels together.

16. Butt weld the removed access panel (2) in

position. Replace the spot welds with the same

number that was removed.

Figure 7D-65

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 7D-66

19. Spot weld (1) the hinge pillar section along the

windshield opening flange.

Figure 7D-67

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 7D-68

21. If removed, plug weld the inner rocker panel and

hinge pillar inner panel assembly to the rocker

panel reinforcement.

Figure 7D-69

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. Replac e the rem oved section of inner r ock 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 3D.

Figure 7D-70

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

6. CAVITY WAX in Section 3D.

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. Insert Cavity Foam into the hinge pillar as required, refer to Section 2, 10. CAVITY FOAM.

32. 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

2.5 DOOR OPENING FRAME ASSEMBLY – PARTIAL REPLACE, CENTRE PILLAR

NOTE: Cavity Foam is used within the hinge, centre

and lock pillar cavities . Care is r equired 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.

3. Rem ove the rear quarter panel, refer to 2.1 REAR

QUARTER PANEL – REPLACE.

Figure 7D-71

4. Cut the door opening frame assembly (1) and

centre pillar reinforcement (2) at point A as shown.

NOTE: Do not cut through the centre pillar inner

reinforcement (3) or quarter panel inner assembly (4).

5. Make a second cut through the door opening

frame assembly (1) ONLY at point B as shown.

6. Spot cut the welds between the two cuts and

remove the shaded section of the door opening

frame assembly.

Figure 7D-72

7. Cut through the door opening frame assembly (1)

at the join of the rocker panel reinforcement and

centre pillar reinforcement (2).

NOTE: Make the cut carefully as the rocker panel

reinforcement must not be cut. The centre pillar

reinforcement is removed with the centre pillar section.

Figure 7D-73

8. Cut through the door opening frame assembly (1)

rearward of the dimple (2) in the flange.

NOTE: Make the cut carefully as the quarter panel

inner assembly must not be cut.

Figure 7D-74

9. Spot cut the welds attac hing the underbody jac king

locator (1) and remove.

10. Spot cut the welds on the flange attaching the

centre pillar section to the inner rocker panel (6).

Refer to weld group A.

11. Spot cut the welds on the underside of the rocker

panel attaching the centre pillar section to the

quarter panel inner assembly (7). Refer to weld

group B.

Figure 7D-75

12. Spot cut the welds on the door opening frame

flanges both sides of the centre pillar and remove

the centre pillar section from the vehicle.

13. Repair any damage to surrounding area as

required.

Figure 7D-76

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 the rocker

section as shown. Accur ately measure the position

of cuts to match the removed panel section.

Figure 7D-77

2. At point B, cut the replacement panel completely

through.

NOTE: This point matches point B on the remaining

section on the vehicle.

3. At point C, cut along each s ide of the door opening

frame (outer panel) ONLY.

NOTE 1: Do not cut through the front face of the door

opening frame and do not cut the reinforcement.

NOTE 2: T his point is approxim ately 10–15 m m below

point A on the remaining section on the vehicle.

Figure 7D-78

4. On the replacement panel, bend back the outer

skin (1). This will expose the reinforcement which

is to be cut down each corner (2).

5. Remove the front and rear flanges (3) which will

align at point A on the remaining section on the

vehicle.

6. Form a joggle on each of the faces to enable the

replacement reinforcement to fit behind the

remaining section on the vehicle.

Figure 7D-79

7. Cut two sections from surplus rocker panel

pieces, or manufacture new sections (1), each

approximately 100 mm in length.

8. Prepare all mating surfaces and treat with Weld

Through Primer (Item 1) as required, refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3D.

9. 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.

10. Mark the new panel with drilling locations in

preparation for plug welding where required. Drill

holes as marked.

Figure 7D-80

11. Drill three holes (1) on each face of the

reinforcement on the vehicle to facilitate plug

welding.

12. Prepare all mating surfaces and treat with Weld

Through Primer (Item 1) as required, refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3D.

13. Install the replacement panel in position, sliding the

tongue of the centr e pillar reinf or c ement (2) behind

the upper section of the reinforcement (3).

NOTE: Manipulate the rock er panel section in position,

inserting the front first, then the rear.

14. Clamp the assembly in place and plug weld the

centre pillar reinforcement at the upper join.

Figure 7D-81

15. Close over the outer panel flap.

16. Spot weld along the flanges on both sides of the

centre pillar.

17. Plug weld the rocker panel section to the

reinforcement sections.

18. MIG butt weld the rocker panel joins (1).

Figure 7D-82

19. MIG butt weld the centre pillar joins.

Figure 7D-83

20. Plug weld the flange attaching the centre pillar

section (1) to the inner rocker panel (2). Refer weld

group A.

21. Plug weld on the underside of the rock er panel the

centre pillar section to the quarter panel inner

assembly (3). Refer weld group B.

22. Plug weld the underbody jacking locator (4) in

place.

23. Install the door hinge, refer to 2.3 DOOR HINGE

(BODY SIDE) – REPLACE in Section 8.

24. Dress the welds by grinding or sanding, ensuring

sufficient material remains to guarantee the

strength of the weld. Finish the area using an

appropriate technique.

25. Prim e any bare metal areas as required and install

the rear quarter panel, refer to 2.1 REAR

QUARTER PANEL – REPLACE.

26. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

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

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3D.

28. Apply Cavity Wax (Item 8) as r equired to the inside

of any box sections or areas inaccessible to paint,

refer 6. CAVITY WAX in Section 3D.

29. Insert Cavity Foam into the centre pillar as

required, refer to Section 2, 10. CAVITY FOAM.

30. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 7D-84

2.6 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 rock er panel section 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 2.4 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. Rem ove the rear quarter panel, refer to 2.1 REAR

QUARTER PANEL – REPLACE.

3. Secure the vehicle on a suitable fixture. As a

minimum, support the appropriate structural

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 7D-85

4. Cut through the rocker panel section of the door

opening frame assembly. The cut point (1) must

not be further forward than the third rocker panel

moulding attaching hole (2). Cut through both the

outer panel and the reinforcement.

Figure 7D-86

5. Using a suitable cutting tool, cut through the door

opening frame assembly (1), including the centre

pillar reinforcement (2), near the base of the centre

pillar.

Figure 7D-87

6. If required, select a cutting point through the door

opening frame assembly, rearward of point (1). Cut

through the door opening frame assembly (2) only.

NOTE: It may be preferable to remove the complete

rear section.

7. Depending on the cut location, spot cut any

remaining welds attaching the door opening frame

assembly to the quarter panel inner assembly

around the rear wheel arch.

8. Spot cut the welds attaching the rocker panel

section to the quarter panel inner assembly as

required. Refer to Figure 7D-89.

Figure 7D-88

Figure 7D-89

9. Spot cut along the flanges around the door opening frame assembly as required, to separate the rocker

panel section from the inner rocker panel and quarter panel inner assembly, refer to Figure 7D-90.

Figure 7D-90

10. Remove the rocker panel section from the vehicle and then repair any damage to adjacent parts as required.

11. Check and rectify the alignment of the body as required, refer to 3. BODY DIMENSIONS in Section 3D.

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 rocker panel section from a new door opening frame assembly. 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 7D-91

3. Either manufacture a new section or cut an

existing length of surplus rocker panel section, to

form a reinforcement (1), approximately 100 mm in

length.

4. Prepare all mating surfaces and treat with Weld

Through Primer (Item 1) as required, refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3D.

5. Clamp this reinforcement firmly behind the cut

section of rocker panel on the vehicle and spot or

plug weld in place. Position welds at a maximum

spacing of 35 mm apart.

Figure 7D-92

6. Manufacture or cut a reinforcement (1),

approximately 100 mm long, to fit inside of the

existing B-pillar section at the point of the cut.

7. Prepare all mating surfaces and treat with Weld

Through Primer (Item 1) as required, refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3D.

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. 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.

Figure 7D-93

10. Prepare all mating surfaces and treat with Weld

Through Primer (Item 1) as required, refer to

5. BODY SEALING, ADHESIVES & DEAD ENERS

in Section 3D.

11. Install the replacement section onto the vehicle by

sliding the front and centre pillar sections onto the

reinforcements, while lifting the rear into position.

12. Clamp the panel in position.

13. Weld the new rocker panel section in position by

plug welding (1) to the reinforcement.

14. MIG butt weld the reinforcement panel from inside

the centre pillar, thr ough the large hole in the inner

panel immediately behind the weld.

15. Finish the centre pillar attachment by MIG

welding (2) along the join of the outer panel.

Figure 7D-94

16. Plug weld (1) the replacement section at the front

join, then MIG butt weld (2) the two sections

together.

Figure 7D-95

17. 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.

18. Replace the removed section of inner rocker

panel (2) by MIG butt welding it in place and spot

welding it along the door opening flange. Replace

the spot welds with the same number of as were

removed.

19. Spot or plug weld along the flanges of the door

opening frame assembly, refer to Figure 7D-97.

Figure 7D-96

Figure 7D-97

20. Plug weld up through the rocker panel to attach the replacement section to the quarter panel inner assembly.

Refer to Figure 7D-98.

Figure 7D-98

21. Spot or plug weld two places, the door opening f rame as sem bly to the quarter panel inner assem bly ar ound

the rear wheel arch.

NOTE: This joint will be completed when the rear quarter panel is installed.

22. Clean up the welds made where the rear quarter panel is located and prime all bare metal.

23. Replace the rear quarter panel, refer to 2.1 REAR QUARTER PANEL – REPLACE.

24. Refinish and paint panels and other components as required. Refer to Section 3, 1.3 PAINT REFINISHING.

25. Apply Joint Sealer (Item 3) as required. Refer to 5. BODY SEALING, ADHESIVES & DEADENERS in

Section 3D.

26. Apply Cavity W ax (Item 8) as required to the ins ide of any box s ections or areas inacces sible to paint, refer

6. CAVITY WAX in Section 3D.

27. Install the rem aining com ponents as described in the appr opriate Section of the MY 2003 VY & V2 Series II

Service Information.

2.7 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

6. CAVITY WAX in Section 3D.

Figure 7D-99

2.8 HINGE PILLAR INNER PANEL ASSEMBLY – REPLACE

Replacement of the full hinge pillar inner panel

assembly requires removal of the door opening frame

assem bly and the roof panel. Alternatives are pr ovided

which avoid removal of the full door opening frame

assembly and roof panel. It is advisable to read the

options available in this procedure before removing

any panels.

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 or the

hinge pillar section of the door opening frame

assembly as described earlier in this Section.

3. If required, rem ove the dash panel assem bly, ref er

to Section 5 COCKPIT MODULE in this

Supplement.

NOTE: If the das h panel assem bly is not dam aged, an

alternative is provided in this procedure which avoids

having to remove it.

4. Add bracing as required to maintain the alignment

of the vehicle structure.

Figure 7D-100

5. Grind the MIG welds (1) attaching the hinge pillar

inner panel assembly to the inner rocker panel.

Figure 7D-101

6. If full replacem ent is being perfor med, spot cut the

welds attaching the hinge pillar inner panel

assembly to the roof front header assembly and

quarter panel inner assembly.

NOTE 1: Some welds may have been removed with

the door opening frame assembly and roof panel.

NOTE 2: Structural adhesive is applied to join (1). If

the roof panel has not been removed, it will be very

difficult to remove the panel. As an alternative remove

hinge pillar section of the door opening frame

assembly then:

- If only the lower section is damaged, detach the

hinge pillar inner upper panel (1) from the hinge

pillar inner lower panel (2) and replace the lower

panel only, or

- Cut the hinge pillar inner panel assembly (3)

approximately 50 mm from the top of the

windscreen aperture. If a partial replacement of

the door opening frame assembly is being

performed, this point is 50 mm above the cut in

the outer panels (4). Refer to Figure 7D-103.

Figure 7D-102

Figure 7D-103

7. Spot cut the welds attaching the hinge pillar inner

panel assembly (or lower panel) to the front

wheelhouse panel and front floor panel extension,

refer 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 weld group B.

9. If required, remove any remaining spot welds

where the front wheelhouse panel upper side rail

attached the front wheelhouse panel and hinge

pillar inner panel assembly.

10. Cut the adhesive between the dash panel

assembly and hinge pillar inner panel assembly.

11. Remo ve the hinge pillar inner panel as sembly 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 7D-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. If an alternate removal method was used, referring to Figure 7D-103 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 3D.

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 adhes ive to fill the

adhesive channels on the replacement section.

IMPORTANT: Only the correct material described in Section 5 COCKPIT MODULE is to be used.

7. If the f ull hinge pillar inner panel as s 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 assembly, refer to

5. BODY SEALING, ADHESIVES & DEADENERS in Section 3D.

8. Install and clamp the 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 assembly

attaching bolts through the hinge pillar inner panel

assembly and within the plenum chamber.

10. Finish the application of dash panel adhesive, refer

to Section 5 COCKPIT MODULE.

Figure 7D-105

11. If the full hinge pillar inner panel assembly was

removed, spot or plug weld the hinge pillar inner

panel assembly to the roof front header assembly

and quarter panel inner assembly.

NOTE: Ensure the structural adhesive (Item 6) is

applied to join (1), refer to 5. BODY SEALING,

ADHESIVES & DEADENERS in Section 3D.

12. If only the lower section was removed, spot or plug

weld the hinge pillar inner upper panel (1) to the

hinge pillar inner lower panel (2), refer to Figure

7D-107.

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 7D-107.

NOTE: This join forms the top access cut point

for joining of the reinforcement as described in

2.4 DOOR OPENING FRAME ASSEMBLY –

PARTIAL REPLACE, HINGE PILLAR.

Figure 7D-106

Figure 7D-107

14. Spot or plug weld the hinge pillar inner panel

assembly to the front wheelhouse panel and front

floor extension.

Figure 7D-108

15. MIG weld (1) across the inner rocker panel and

hinge pillar inner panel assembly.

16. Replace the door opening f rame assembly, refer to

2.3 DOOR OPENING FRAME ASSEMBLY –

REPLACE or the hinge pillar section of the

door opening frame assembly, refer to

2.4 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 3D.

19. Apply Cavity Wax (Item 8) as r equired to the inside

of any box sections or areas inaccessible to paint,

refer 6. CAVITY WAX in Section 3D.

20. If required replace the dash panel assembly,

refer Section 5 COCKPIT MODULE in this

Supplement.

21. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 7D-109

2.9 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. Rem ove the rear quarter panel, refer to 2.1 REAR

QUARTER PANEL – REPLACE.

4. Remove the roof panel, and partially remove the

roof bow panel and roof rear panel, refer to

Section 9 ROOF.

5. Remove the door opening frame assembly, refer

to 2.3 DOOR OPENING FRAME ASSEMBLY –

REPLACE.

6. Add further bracing tools as required, to maintain

the alignment of the vehicle structure.

Figure 7D-110

7. Grind the MIG welds (1), 11 places, attaching the

quarter panel inner assembly to the inner rocker

panel.

8. Spot cut the welds attaching the rear wheelhouse

inner (1) to the rear floor panel assembly, refer to

Figure 7D-112.

Figure 7D-111

Figure 7D-112

9. Spot cut the welds attaching the rear window panel assembly to the rear seat back extension assembly,

refer to Figure 7D-113.

Figure 7D-113

10. The hinge pillar inner panel assembly is attached

to the quarter panel inner assembly with spot

welds and structural adhesive (1) (Item 6, refer to

5. BODY SEALING, ADHESIVES & DEAD ENERS

in Section 3D). As the adhesive is extremely

strong, cut through the quarter panel inner

assembly just behind the join and remove the

remaining joint piece with a grinder.

11. As required, spot cut the welds attaching the rear

window panel assembly (1 & 4) to the quarter

panel inner (2) and rear seat back extension

assembly (3).

NOTE 1: Structural adhesive (Item 6) is applied in the

areas shown shaded. As this material is extremely

strong, the rear seat back extension assembly may

require removing with a grinder.

NOTE 2: Remove the remaining flange of the rear

quarter panel (5), leaving only the rear window panel

assembly.

Figure 7D-114

Figure 7D-115

12. Remove the quarter panel inner assembly from the vehicle, then repair any damage to adjacent parts as

required.

13. Check and rectify the alignment of the body as required, refer to 3. BODY DIMENSIONS in Section 3D.

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 3D.

3. Apply Structural Adhesive (Item 6, re f er to 5. BO DY SEALING, ADHESIVES & DEADENERS in Sect ion 3D)

to the mating surfaces of the:

- Hinge pillar inner panel assembly, refer to Figure 7D-116, and

- Inner joint ONLY of the rear seatback extension (part of the quarter panel inner assembly), refer to Figure

7D-117.

NOTE: Adhesive will be applied to the outer rear window panel assembly joint when the rear quarter panel is

installed.

4. Clamp the new panel in position on the vehicle.

5. Plug or s pot weld the quarter panel inner as sembly

to the hinge pillar inner assembly join.

Figure 7D-116

6. Spot or plug weld two places, the rear window

panel assembly (1 & 3) to the, rear seat back

extension (2).

NOTE: T his ar ea will be completed as the rear quarter

panel is installed.

7. Spot or plug weld the r ear window panel assem bly

to the rear seat back extension assembly, refer to

Figure 7D-118.

Figure 7D-117

Figure 7D-118

8. Spot or plug weld the rear wheelhouse inner (1) to the rear floor panel assembly, refer to Figure 7D-119.

Figure 7D-119

9. MIG weld 11 places (1), the quarter panel inner

assembly to the inner rocker panel.

10. Clean up welds as required and prime any bare

metal.

11. Install the door opening frame assembly, refer to

2.3 DOOR OPENING FRAME ASSEMBLY –

REPLACE.

12. Replace the roof and roof bow panel and roof rear

panel, refer to Section 9 ROOF.

13. Prepare the rear quarter panel f or installation, ref er

to 2.1 REAR QUARTER PANEL – REPLACE.

IMPORTANT: Do NOT modify the rear quarter panel

flange at the base of the rear window as stated in the

rear quarter panel replacement procedure, as the

flange is required for this procedure.

Figure 7D-120

14. Apply structural adhesive (Item 6, refer to

5. BODY SEALING, ADHESIVES & DEAD ENERS

in Section 3D) to the rear quarter panel flange as

shown.

15. Fit and clamp the rear quarter panel into position,

refer to 2.1 REAR QUARTER PANEL –

REPLACE.

IMPORTANT: Ensure the rear quarter flange (1) is

fitted between the quarter panel inner assembly (2)

and rear window panel assembly (3). If required prise

up the rear window panel assembly to provide

clearance, also refer to Figure 7D-122.

Figure 7D-121

16. Spot or plug weld through the rear window panel

assembly as shown.

17. Complete the rear quarter panel, refer to

2.1 REAR QUARTER PANEL – REPLACE.

18. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

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

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3D.

20. 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 3D.

21. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 7D-122

2.10 QUARTER PANEL INNER ASSEMBLY – PARTIAL 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. Rem ove the rear quarter panel, refer to 2.1 REAR

QUARTER PANEL – REPLACE.

4. Remove the rear section of the door opening

frame assembly, refer to 2.3 DOOR OPENING

FRAME ASSEMBLY – PARTIAL REPLACE,

ROCKER PANEL.

Figure 7D-123

5. Carefully cut through the quarter panel inner

assembly at the rocker panel region.

NOTE: The position of the cut (1) should be a

minimum of 50 mm shorter than that of the door

opening frame (2) to allow sufficient access for

rejoining.

Figure 7D-124

6. Depending on the cut location, grind the MIG

welds (1), attaching the quarter panel inner

assembly to the inner rocker panel.

7. Spot cut the welds attaching the rear wheelhouse

inner (1) to the rear floor panel assembly, refer to

Figure 7D-126.

Figure 7D-125

Figure 7D-126

8. Spot cut the welds attaching the rear window panel assembly to the rear seat back extension assembly,

refer to Figure 7D-127.

Figure 7D-127

9. As required, spot cut the welds attaching the r ear window panel ass embly (1 & 4) to the quarter panel inner

(2) and rear seat back extension assembly (3).

NOTE 1: Str uctur al adhes ive ( Item 6) is applied in the areas s hown shaded. As this material is ex tremely strong,

the rear seat back extension assembly may require removing with a grinder.

NOTE 2: Remove the remaining flange of the rear quarter panel (5), leaving only the rear window panel

assembly.

Figure 7D-128

10. Cut the quarter panel inner assembly through the

lock (1) at a point 50 mm below the end of the door

opening frame.

11. Cut through the quarter panel inner assembly at a

point rearward of the centre pillar (2).

12. Remove the partial quarter panel inner assembly

from the vehicle, then repair any damage to

adjacent parts as required.

13. Check and rectify the alignment of the body as

required, refer to 3. BODY DIMENSIONS in

Section 3D.

Figure 7D-129

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. Accurately cut the replacem ent s ection f rom a new

quarter panel inner assembly. The new section

should be cut 40 mm longer at the mating f aces to

allow for overlap.

NOTE: Cut the quarter panel inner at the upper lock

pillar join correct length to facilitate a butt joint.

2. Rem ove the flanges from the overlapping sections

and form a joggle to facilitate a lap joint. Make the

lock pillar reinforcement joggle inward and the

other joggles outward.

3. Mark the new panel and the existing panels with

drilling locations in preparation for plug welding

where required. Drill holes as marked.

4. Prepare all mating surfaces and treat with Weld

Through Primer (Item 1) as required, refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3D.

Figure 7D-130

5. Apply Structural Adhesive (Item 6, refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3D) to the inner joint ONLY of the rear

seatback extension (par t of the quarter panel inner

assembly).

NOTE: Adhesive will be applied to the outer rear

window panel assembly joint when the rear quarter

panel is installed.

6. Position the new panel on the vehicle and clamp in

place.

7. Spot or plug weld two places, the rear window

panel assembly (1 & 3) to the, rear seat back

extension (2).

NOTE: T his ar ea will be completed as the rear quarter

panel is installed.

Figure 7D-131

8. Plug weld the lap joints.

9. Finish the joints by MIG welding along the join.

10. From inside the vehicle, MIG weld the quarter

panel inner at the upper lock pillar join.

11. Spot or plug weld the rear window panel assembly

to the rear seat back extension assembly, refer to

Figure 7D-133.

Figure 7D-132

Figure 7D-133

12. Spot or plug weld the wheelhouse inner (1) to the rear floor panel assembly, refer to Figure 7D-134.

Figure 7D-134

13. As required, MIG weld (1), the quarter panel inner

assembly to the inner rocker panel.

14. Clean up the welds as required and prime any

bare metal.

15. Install the rear section of the door opening frame

assembly, refer to 2.3 DOOR OPENING FRAME

ASSEMBLY – PARTIAL REPLACE, ROCKER

PANEL.

16. Prepare the rear quarter panel f or installation, ref er

to 2.1 REAR QUARTER PANEL – REPLACE.

IMPORTANT: Do NOT modify the rear quarter panel

flange at the base of the rear window as stated in the

rear quarter panel replacement procedure, as the

flange is required for this procedure.

Figure 7D-135

17. Apply structural adhesive (Item 6, refer to

5. BODY SEALING, ADHESIVES & DEAD ENERS

in Section 3D) to the rear quarter panel flange as

shown.

18. Fit and clamp the rear quarter panel into position,

refer to 2.1 REAR QUARTER PANEL –

REPLACE.

IMPORTANT: Ensure the rear quarter flange (1) is

fitted between the quarter panel inner assembly (2)

and rear window panel assembly (3). If required prise

up the rear window panel assembly to provide

clearance, also refer to Figure 7D-137.

Figure 7D-136

19. Spot or plug weld through the rear window panel

assembly as shown.

20. Complete the rear quarter panel, refer to

2.1 REAR QUARTER PANEL – REPLACE.

21. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

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

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3D.

23. 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 3D.

24. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 7D-137