SECTION 10B – BODY REAR – WAGON

IMPORTANT

Before perfo rming any Service O perat ion or o th er pro cedu re describ ed in th is 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 REAR COMPONENTS

2. SERVICE OPERATIONS

2.1 REAR END LOWER PANEL – REPLACE

REMOVE

REPLACE

2.2 REAR END PANEL ASSEMBLY –

REPLACE

REMOVE

REPLACE

2.3 REAR END PANEL EXTENSION –

REPLACE

REMOVE

REPLACE

2.4 FUEL TANK SUPPORT

REINFORCEMENT – REPLACE

REMOVE

REPLACE

2.5 REAR COMPARTMENT FLOOR PANEL

OUTER EXTENSION – REPLACE

REMOVE

REPLACE

2.6 REAR COMPARTMENT FLOOR PANEL

ASSEMBLY – REPLACE

REMOVE

REPLACE

2.7 REAR WHEELHOUSE INNER PANEL

ASSEMBLY – REPLACE

REMOVE

REPLACE

2.8 REAR FLOOR PANEL ASSEMBLY –

REPLACE

REMOVE

REPLACE

2.9 REAR BUMPER IMPACT BAR BRACE

ASSEMBLY – REPLACE

REMOVE

REPLACE

2.10 CROSSMEMBER ASSEMBLY NO. 2 –

REPLACE

REMOVE

REPLACE

2.11 REAR TIE DOWN ASSEMBLY – REPLACE

REMOVE

REPLACE

2.12 REAR FLOOR PANEL OUTER EXTENSION –

REPLACE

REMOVE

REPLACE

2.13 REAR SIDE RAIL ASSEMBLY – REPLACE

REMOVE

REPLACE

1. GENERAL DESCRI PTI O N

This Section describes replacem ent procedures for the rear section com ponents of the MY 2003 VY Series Wagon

body structure. Removal of bolt-on and mechanical components is not covered. Reference must be made to the

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

When repairing the rear of the vehicle, care must be taken to ensure the structure is returned to its original

production configuration.

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

repairing the body structure of MY 2003 VY Series W agon 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 REAR COMPONENTS

The shaded components in Figure 10B-1 are those

dealt with in this Section.

The components and assemblies shown in Figure

10B-2 are the 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.

Figure 10B-1

Figure 10B-2

Legend (Figure 10B-2)

1. Rear Side Rail Assembly

2. Rear Floor Panel Outer Extension

3. Rear Tie Down Hook Assembly

4. Rear Bumper Impact Bar Brace Assembly

5. Crossmember Assembly No. 2

6. Rear Wheelhouse Inner Panel Assembly

7. Rear Floor Panel Assembly

8. Rear Compartment Floor Panel Outer Extension, Left-

Hand

9. Rear Compartment Floor Panel Assembly

10. Rear Compartment Floor Panel Outer Extension, Right-

Hand

11. Fuel Tank Support Reinforcement Assembly

12. Spare Wheel Anchor Plate Assembly

13. Rear End Panel Assembly

14. Rear End Panel Extension

15. Rear End Lower Panel

NOTE 1: Rear side rail assembly includes parts No. 2, 3 & 4.

NOTE 2: Rear compartment floor panel assembly includes parts No. 8, 10, 11 & 12.

NOTE 3: Rear end panel assembly incudes part No. 14.

2. SERVICE OPERATIONS

2.1 REAR END LOWER PANEL – REPLACE

NOTE: If the rear end panel (inner) is also to be

replaced, rem ove the rear end panels as an assembly.

Refer to 2.2 REAR END 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 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 assembly,

refer to 2. BUMPER IM PACT BAR ASSEMBLIES

in Section 3.

Figure 10B-3

3. If the quarter panel extensions are not being

rem oved, spot cut the welds attaching the rear end

lower panel. If they are to be removed, refer to

2.2 QUARTER PANEL EXTENSION – REPLACE

in Section 7B.

NOTE: The rear end lower panel is fitted under each

quarter panel extension.

Figure 10B-4

4. Spot cut the welds attaching the rear end lower

panel to the rear end panel assembly.

5. Remove the rear end lower panel.

Figure 10B-5

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 s pot 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 rear end lower panel in position and

spot or plug weld to the rear end panel assembly.

Figure 10B-6

4. As required, weld the quarter panel extension to

the rear end panel ass em bly or replace the quarter

panel extension, refer to 2.2 QUARTER PANEL

EXTENSION – REPLA CE in Section 7B.

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 r equired to the inside

of any box sections or areas inaccessible to paint,

refer to 6. CAVITY WAX in Section 3B.

8. Install the rear bum per impact bar assembly, refer

to 2. BUMPER IMPACT BAR ASSEMBLIES in

Section 3.

9. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 10B-7

2.2 REAR END PANEL ASSEMBLY – REPLACE

NOTE: This procedure describes the removal of the

rear end lower panel and rear end panel as an

assembly. As the panels are supplied individually, this

procedure contains the replacement of the rear end

panel only. Reference should be then made to

2.1 REAR END LOWER PANEL – REPLACE for the

relevant replacement procedures of the remaining

panel.

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 assembly,

refer to 2. BUMPER IM PACT BAR ASSEMBLIES

in Section 3.

Figure 10B-8

3. Either:

A. Remove the quarter panel extensions, refer to 2.2 QUARTER PANEL EXTENSION – REPLACE in

Section 7B and, spot cut the welds attaching the rear end panel extensions to the vehicle, refer to

2.3 REAR END PANEL EXTENSION – REPLACE.

B. To avoid removal of the quarter panel extensions:

Spot cut the welds attaching the rear end lower panel to the quarter panel extension, refer to

2.1 REAR END LOWER PANEL – REPLACE and, spot cut the welds attaching the rear end panel to

rear end panel extension each side and leave the rear end panel extensions in place.

Figure 10B-9

4. Spot cut the welds attaching the fuel tank support

reinforcement to the rear end panel assembly.

NOTE: As an alternative, the fuel tank support

reinforcement can be removed from the

rear compartment floor panel assembly, refer to

2.4 FUEL TANK SUPPORT REINFORCEMENT –

REPLACE.

5. Spot cut the welds attaching the rear end panel

assembly to the rear compartment floor panel

assembly, refer to Figure 10B-11.

Figure 10B-10

Figure 10B-11

6. Spot cut the welds attaching the rear side rail

assemblies to the rear end panel assembly. Note

that the left-hand side is different to the right-hand

side.

7. Remove the panel from the vehicle, then repair

any damage to adjacent parts.

8. Check and rectify the alignment of the body

shell. Refer to 3 BODY DIMENSIONS in this

Supplement.

Figure 10B-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 s pot 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 the rear end panel was removed from the rear end panel extensions, spot cut the welds and rem ove the

extensions on the new panel.

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. If the rear end panel extens ions were left attached to the vehicle, spot cut the welds attaching the extensions

to the rear end panel on the replacement section.

4. Install the rear end panel assembly in position and spot or plug weld to the rear compartment floor panel

assembly, refer to Figure 10B-13.

Figure 10B-13

5. Spot or plug weld the rear side rail assemblies to

the rear end panel assembly. Note that the left-

hand side is different to the right-hand side.

Figure 10B-14

6. Spot or plug weld the fuel tank support

reinforcement to the rear end panel assembly or

replace the fuel tank support reinforcement, refer

to 2.4 FUEL TANK SUPPORT REINFORCEMENT

– REPLACE.

NOTE: Complete the top row of welds when welding

the rear end lower panel.

7. Depending on removal method either:

A. Spot or plug weld the rear end panel

extensions to the vehicle, refer to

2.3 REAR END PANEL EXTENSION –

REPLACE, or

Figure 10B-15

B. If the quarter panel extensions were left

attached to the vehicle, spot or plug weld the

rear end panel to rear end panel extension

each side.

8. In the areas where the rear end lower panel will fit,

grind the welds and prime any bare metal.

9. Ins tall the rear end lower panel, refer to 2.1 REAR

END LOWER PANEL – REPLACE.

10. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

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

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3B.

12. 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.

13. Install the rear bum per impact bar assembly, refer

to 2. BUMPER IMPACT BAR ASSEMBLIES in

Section 3.

14. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 10B-16

2.3 REAR END 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 assembly,

refer to 2. BUMPER IM PACT BAR ASSEMBLIES

in Section 3.

3. Remove the quarter panel extension, refer to

2.2 QUARTER PANEL EXTENSION – REPLACE

in Section 7B.

Figure 10B-17

4. From underneath the vehicle, spot cut the welds

attaching the rear end panel extension to the

quarter panel inner assembly and rear end panel

assembly.

5. Spot cut the welds attaching the rear end panel

extension to the quarter panel inner assembly, r ear

end panel assembly and rear compartment floor

panel assembly, refer to Figure 10B-19.

6. Remove the extension from the vehicle and then

repair any damage to adjacent parts.

Figure 10B-18

Figure 10B-19

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 s pot 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 rear end panel extension in position on

the vehicle and spot or plug weld to the quarter

panel inner assembly, rear end panel assembly

and rear compartment floor panel assembly.

Figure 10B-20

4. F rom under neath the vehicle, plug or spot weld the

rear end panel extens ion to the quarter panel inner

assembly and rear end panel assembly.

5. Replace the quarter panel extension, refer to

2.2 QUARTER PANEL EXTENSION – REPLACE

in Section 7B.

6. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

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

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3B.

8. 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.

9. Install the rear bum per impact bar assembly, refer

to 2. BUMPER IMPACT BAR ASSEMBLIES in

Section 3.

10. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 10B-21

2.4 FUEL TANK SUPPORT REINFORCEMENT ASSEMBLY – 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. Rem ove the floor deadener panels and joint s ealer

from around the fuel tank support reinforcement

assembly as required.

Figure 10B-22

3. Spot cut the 14 welds attaching the reinforcement

to the rear end panel assembly.

4. Spot cut the 14 welds attaching the reinforcement

to the rear compartment floor panel assembly.

5. Remove the fuel tank support reinforcement

assem bly and then repair any damage to adjacent

parts as required.

Figure 10B-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 available will not access the required weld position, a plug weld should be

performed.

NOTE 2: The s ame number and pos ition of s pot 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. Plug weld the fuel tank support reinforcement

assembly to the rear compartment floor panel

assembly and rear end panel assembly.

4. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

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

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3B.

6. 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.

7. Install the deadener panels as required, refer to

5.6 DEADENER PANELS & INSULATORS in

Section 3B.

8. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 10B-24

2.5 REAR COMPERTMENT FLOOR PANEL OUTER 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 joint sealer from around the rear

compartment floor panel outer extension joins as

required.

3. Spot cut the welds attaching the rear compar tment

floor panel outer extension to the rear

compartment floor panel, rear side rail assembly,

quarter panel inner as sem bly and rear wheelhouse

inner panel as required, refer to Figure 10B-26.

Figure 10B-25

Figure 10B-26

4. Remove the extension from the vehicle and then repair any damage to adjacent parts as required.

5. 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 s ame number and pos ition of s pot 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 left-hand web plate in

position as shown.

Figure 10B-27

4. Spot weld the right-hand web plate in position as

shown.

5. Refinish and paint panels and other components

as required. Refer to Section 3, 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. Apply Spray-on Deadener (Item 7) where

applicable, refer to 5. BODY SEALING,

ADHESIVES & DEADENERS in Section 3B.

9. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 10B-28

2.6 REAR COMPARTMENT FLOOR PANEL ASSEMBLY – 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. Secure the vehicle on a suitable fixture and use a

suitable brace to maintain the alignment of the rear

side rail assemblies prior to removal of the rear

end panel assembly.

3. Remove the rear end panel assembly, refer to

2.2 REAR END PANEL ASSEMBLY – REPLACE.

4. Remove the j oint sealer f rom the s urrounding area

using a scraper and heat gun.

5. Spot cut the welds attaching the rear compar tment

floor panel assembly (1) to the rear floor panel

assembly (2), refer to Figure 10B-30.

6. Spot cut the welds attaching the rear compar tment

floor panel assembly to the rear side rail

assemblies.

Figure 10B-29

Figure 10B-30

7. Spot cut the welds attac hing the rear c om partm ent floor panel assem bly to the quarter panel inner assem bly

and rear wheelhouse inner panel assembly, refer to Figure 10B-31.

Figure 10B-31

8. Remove the floor panel assembly from the vehicle, then repair any damage to adjacent parts as required.

9. Check and rectify the 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 s ame number and pos ition of s pot 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 new rear compartment floor panel assembly in position and plug weld along the join to the rear

floor assembly, refer to Figure 10B-32.

4. Plug weld the rear compartment floor panel assembly to the rear side rail assemblies.

Figure 10B-32

5. Spot or plug the rear compartment floor panel assembly to the quarter panel inner assembly and rear

wheelhouse inner panel assembly, refer to Figure 10B-33.

Figure 10B-33

6. Replace the rear end panel assembly, refer to 2.2 REAR END PANEL ASSEMBLY – REPLACE.

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

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

Section 3B.

9. Apply deadener panels to the rear compartment floor panel, refer to 5.6 DEADENER PANELS &

INSULATORS in Section 3B.

10. 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.

11. 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 REAR WHEELHOUSE INNER PANEL ASSEMBLY – 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. Secure the vehicle on a suitable fixture. As a

minimum, support the appropriate structural

sections of the vehicle on safety stands. Ensure

that the stands are clear of the sections being

removed.

3. Remove the adjoining panels as required, refer to

the appropriate Section in this Supplement.

Figure 10B-34

4. Spot cut the welds attaching the rear wheelhouse

brack et to the quar ter panel inner assem bly on the

relevant side of the vehicle.

5. Spot cut the welds attaching the rear wheelhouse

inner panel assembly to the rear floor panel

assembly and rear compartment floor panel

assembly on the relevant side of the vehicle, refer

to Figure 10B-36.

Figure 10B-35

Figure 10B-36

6. Spot cut the welds attaching the left-hand (1) or

right-hand (2) rear wheelhouse inner panel

assembly to the quarter panel inner assembly.

7. Remove the panel f r om the vehicle and then r epair

any damage to adjacent parts as required.

Figure 10B-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 s ame number and pos ition of s pot 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 new rear wheelhouse inner panel assembly in position and spot or plug weld to the rear floor

panel assembly and rear compartment floor panel assembly, refer to Figure 10B-38.

Figure 10B-38

4. Plug weld the left-hand (1) or right-hand (2) rear

wheelhouse inner panel assembly to the quarter

panel inner assembly.

Figure 10B-39

5. Spot or plug weld the rear wheelhouse bracket to

the quarter panel inner assembly on the relevant

side of the vehicle.

6. Replace the adjoining panels as required, refer to

the appropriate Section in this Supplement.

7. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

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

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3B.

9. Apply Spray-on Deadener (Item 7) where

applicable, refer to 5. BODY SEALING,

ADHESIVES & DEADENERS in Section 3B.

10. 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.

11. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 10B-40

2.8 REAR FLOOR PANEL ASSEMBLY – 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. Secure the vehicle on a suitable fixture. As a

minimum, support the appropriate structural

sections of the vehicle on safety stands. Ensure

that the stands are clear of the sections being

removed.

3. Remove the sealer and floor deadener panels

from the relevant areas using a scraper and heat

gun.

4. Remove the adjoining panels as required, refer to

the appropriate Section in this Supplement.

Figure 10B-41

5. Spot cut the welds attaching the park brake cable

bracket to the rear floor panel assembly.

Figure 10B-42

6. Spot cut the welds joining the front floor panel

assembly (1) and rear floor panel assembly (2).

7. Spot cut the welds attaching the rear floor panel

assembly to the inner rocker panel (3) each side.

Figure 10B-43

8. Spot cut the welds attaching the rear floor panel

assembly to the rear wheelhouse inner panel

assembly on both sides of the vehicle.

9. Spot cut the welds attaching the rear floor panel

assembly to the rear compartment floor panel

assem bly and crossm em ber assem bly No. 2, refer

to Figure 10B-45.

10. Spot cut the welds attaching the rear floor panel

assembly to the rear side rail assemblies, refer to

2.13 REAR SIDE RAIL ASSEMBLY – REPLACE.

11. Remove the rear floor panel assembly from the

vehicle and then repair any damage to adjacent

parts.

12. Check and rectify the alignment of the body as

required, refer to 3. BODY DIMENSIONS in

Section 3B.

Figure 10B-44

Figure 10B-45

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 s pot 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. Clam p the new rear floor panel assembly in position and plug weld to the rear compartm ent floor assem bly

and crossmember assembly No 2, refer to Figure 10B-46.

Figure 10B-46

4. Spot weld the rear floor assembly to the rear

wheelhouse inner panel assem bly on both sides of

the vehicle.

5. Plug weld the rear floor panel ass embly to the rear

side rail assemblies, refer to 2.13 REAR SIDE

RAIL ASSEMBLY – REPLACE.

Figure 10B-47

6. Plug weld the rear floor panel assembly (2) to the

front floor panel assembly (1).

7. Plug weld the rear floor panel assembly to the

inner rocker panel (3) each side.

Figure 10B-48

8. Plug weld the park brake cable bracket to the rear

floor panel assembly.

9. Replac e any other rem oved panels as desc r ibed in

the appropriate Section in this Supplement.

10. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

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

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3B.

12. 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.

13. Apply Spray-on Deadener (Item 7) where

applicable, refer to 5. BODY SEALING,

ADHESIVES & DEADENERS in Section 3B.

14. Apply deadener panels to the rear compartment

floor panel, refer to 5.6 DEADENER PANELS &

INSULATORS in Section 3B.

15. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 10B-49

2.9 REAR BUMPER IMPACT BAR BRACE ASSEMBLY – 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 the

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. Secure the vehicle on a suitable fixture. As a

minimum, support the appropriate structural

sections of the vehicle on safety stands. Ensure

that the stands are clear of the sections being

removed.

3. Remove the adjoining panels as required, refer to

the appropriate Section of this Supplement.

4. Spot cut the welds attaching the left-hand (1) or

right-hand (2) rear bumper impact bar brace

assembly to the rear side rail ass embly (3), refer to

Figure 10B-51.

5. If required, for the right-hand rear bumper impact

bar brace assembly, remove the closing plate (4).

Figure 10B-50

Figure 10B-51

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 s pot 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 and plug weld the rear bumper impact bar brace assembly (1 or 2) in position on the rear side rail

assembly (3).

4. If required, for the right-hand side clamp and plug weld the closing plate (4) in position, refer to Figure

10B-52.

Figure 10B-52

5. Install other panels as required, refer to the appropriate Section in this Supplement.

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

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

Section 3B.

8. Apply Cavity Wax (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.

9. Ins tall the remaining c omponents as des cribed in the appropriate Section of the MY 2003 VY & V2 Series II

Service Information.

2.10 CROSSMEMBER ASSEMBLY NO. 2 – 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. Rem ove the adjacent 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.

Figure 10B-53

3. Spot cut the welds attaching the crossmember

No.2 to the crossmember bracket and to the rear

side rail, on each side of the vehicle.

NOTE: Take care not to damage the crossmember

brackets when removing the crossmember, as these

parts are only serviced as part of the rear side rail

assemblies.

Figure 10B-54

4. Spot cut the welds attaching the crossmember to

the rear compartment floor panel assembly.

5. Remove the crossmember from the vehicle, and

then repair any damage to adjacent parts as

required.

6. Check and rectify the alignment of the body as

required, refer to 3. BODY DIMENSIONS in

Section 3B.

Figure 10B-55

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 s pot 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. Plug weld the crossmember to the crossmember

bracket and rear side rail, on each side of the

vehicle.

Figure 10B-56

4. Plug weld the crossmember to the rear

compartment floor panel assembly.

5. Refinish and paint panels and other components

as required. Refer to Section 3, 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. Apply Spray-on Deadener (Item 7) where

applicable, refer to 5. BODY SEALING,

ADHESIVES & DEADENERS in Section 3B.

9. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 10B-57

2.11 REAR TIE DOWN ASSEMBLY – REPLACE

REMOVE

1. Rem ove the adjacent components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 10B-58

2. Spot cut the welds attaching the tie down hook

assembly to the rear side rail assembly and

remove.

Figure 10B-59

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 s pot 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. Install the tie down hook assembly onto the rear

side rail assembly, approximately 9 mm rearward

of the join.

4. Plug weld the tie down hook assembly to the rear

side rail assembly, eight places.

5. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

6. 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.

7. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 10B-60

2.12 REAR FLOOR PANEL OUTER EXTENSION – REPLACE

REMOVE

1. Rem ove the adjacent components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 10B-61

2. Spot cut the welds attaching the rear floor panel

outer extension to the inner rocker panel and rear

side rail assembly and remove.

Figure 10B-62

REPLACE

NOTE 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 s pot 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. Install and plug weld the rear floor panel outer

extension to the inner rocker panel and rear side

rail assembly.

4. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

5. 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.

6. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 10B-63

2.13 REAR SIDE RAIL ASSEMBLY – 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. Rem ove the adjacent 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. Ensure

that the stands are clear of the rear side rail

assembly(s) being removed.

Figure 10B-64

3. Spot cut the welds attaching the crossmember

No.2 to the crossmember bracket and to the rear

side rail, on each side of the vehicle.

Figure 10A-1

4. Spot cut the welds attaching the rear side rail

assembly to the rear floor panel assembly.

Figure 10B-65

5. Spot cut the welds attaching the rear side rail

assembly to the rear floor panel assembly.

Figure 10B-66

6. Spot cut the welds attaching the rear floor panel

outer extension to the inner rocker panel

assembly.

7. Spot cut the rear side rail assembly from the rear

floor panel assembly, rear compartment floor

panel assembly and the rear end panel, refer to

Figure 10B-68.

NOTE: Ther e are a dif f erent num ber of welds between

the left-hand and right-hand sides.

8. Remove the rear side rail assembly from the

vehicle.

Figure 10B-67

Figure 10B-68

9. Repair damage to adjacent parts as required.

10. 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 s ame number and pos ition of s pot 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.

CAUTION: Prior to plug welding in this region, remove the deadener from the inside floor to remove the

risk of fire.

3. Locate and clamp the new rear side rail assembly in position and check and adjust its alignment, refer to

3. BODY DIMENSIONS in Section 3B.

4. Plug weld the rear side rail assembly to the rear floor panel assembly, rear compartment floor panel

assembly and the rear end panel, refer to Figure 10B-69.

Figure 10B-69

5. Plug weld the rear side rail assembly to the rear

floor panel assembly.

Figure 10B-70

6. Plug weld the crossm em ber assem bly No. 2 to the

crossmember bracket and rear side rail.

Figure 10B-71

7. Plug weld the rear side rail assembly to the rear

floor panel ass embly and the rear floor panel outer

extension to the inner rocker panel assembly.

8. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

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

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3B.

10. 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.

11. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 10B-72