SECTION 10D – BODY REAR – 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 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 FUEL TANK SUPPORT REINFORCEMENT

ASSEMBLY – REPLACE

REMOVE

REPLACE

2.4 REAR COMPARTMENT FLOOR PANEL

OUTER EXTENSION – REPLACE

REMOVE

REPLACE

2.5 REAR COMPARTMENT FLOOR PANEL

ASSEMBLY – REPLACE

REMOVE

REPLACE

2.6 REAR WINDOW PANEL ASSEMBLY –

REPLACE

REMOVE

REPLACE

2.7 REAR SEAT BACK PANEL EXTENSION

ASSEMBLY OR REAR WHEELHOUSE

INNER PANEL ASSEMBLY – REPLACE

REMOVE

REPLACE

2.8 REAR COMPARTMENT LID STRUT

BRACKET ASSEMBLY – REPLACE

REMOVE

REPLACE

2.9 CROSSMEMBER ASSEMBLY NO. 2 –

REPLACE

REMOVE

REPLACE

2.10 REAR FLOOR PANEL OUTER

EXTENSION – REPLACE

REMOVE

REPLACE

2.11 REAR TIE DOWN HOOK ASSEMBLY –

REPLACE

REMOVE

REPLACE

2.12 REAR BUMPER IMPACT BAR BRACE

ASSEMBLY – REPLACE

REMOVE

REPLACE

2.13 REAR SIDE RAIL ASSEMBLY – REPLACE

REMOVE

REPLACE

2.14 REAR FLOOR PANEL ASSEMBLY –

REPLACE

REMOVE

REPLACE

2.15 REAR FLOOR PANEL REINFORCEMENT –

REPLACE

LEFT-HAND SIDE

RIGHT-HAND SIDE

1. GENERAL DESCRI PTI O N

This Section describes replacement procedures for the rear section components of the MY 2003 V2 Series II Coupe

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

appropriate Sections in the V2 Series 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 V2 Series II vehicles. Refer to 5. BODY SEALING, ADHESIVES &

DEADENERS and Section 6. CAVITY WAX in Section 3D for details of the cor rec t materials and their commerc ially

available equivalents.

1.1 BODY REAR COMPONENTS

The shaded components in Figure 10D-1 are those

dealt with in this Section.

The components and assemblies shown in

Figure 10D-2 are the parts serviced for MY 2003 V2

Series II Coupe 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.

CAUTION: The rear side rail assembly (18)

contains a reinforcement that is made from

High Strength Low Alloy Steel, refer to

Figure 10D-2. If damaged, the reinforcement

must not be heated or straightened, therefore,

as it is not serviced separately, the entire rear

side rail assembly must be replaced. Refer to

Section 2, 9. SPECIAL STEEL PRECATIONS for

further information.

Figure 10D-1

Figure 10D-2

Legend

1. Rear Window Panel Assembly

2. Rear Compartment Lid Strut Bracket Assembly

3. Rear Seat Back Panel Extension Assembly

4. Rear Wheelhouse Panel Assembly

5. Rear Floor Panel Reinforcement, Right-Hand

6. Rear Floor Panel Assembly

7. Rear Floor Panel Reinforcement, Left-Hand

8. Rear Compartment Floor Panel Assembly

9. Rear Compartment Floor Panel Outer Extension,

Left-Hand

10. Fuel Tank Support Reinforcement Assembly

11. Spare Wheel Anchor Plate Assembly

12. Rear Compartment Floor Panel Outer Extension,

Right-Hand

13. Rear End Panel Assembly

14. Rear End Lower panel

15. Crossmember Assembly No. 2

16. Rear Floor Panel Outer Extension

17. Rear Tie Down Assembly

18. Rear Side Rail Assembly

19. Rear Bumper Impact Bar Brace Assembly

NOTE 1: Rear Wheelhouse Panel Assembly includes part 3, which includes part 2.

NOTE 2: Rear Compartment Floor Panel Assembly includes parts 9, 10, 11 & 12.

NOTE 3: Rear Side Rail Assembly includes parts 16, 17 & 19.

2. SERVICE OPERATIONS

2.1 REAR END LOWER PANEL – REPLACE

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

to be replaced, remove the rear end panels as an

assembly. Refer to 2.2 REAR END PANEL

ASSEMBLY – REPLACE.

REMOVE

CAUTION: To avoid the possibility of fire, take

particular care when cu tt ing or welding at the rear

of the vehicle. Remove the fuel tank and plug all

fuel lines.

1. Remove the adjacent bolt-on panels and

components as described in the appropriate

Section of the MY 2003 VY & V2 Series II Service

Information.

2. Remove the rear bumper impact bar assembly,

refer to 2. BUMPER IMPACT BAR

ASSEMBLIES in Section 3.

Figure 10D-3

3. Spot cut the welds attaching the rear end lower

panel to the tail lamp housing.

4. Spot cut the welds attaching the rear end lower

panel to the rear end panel assembly, rear

quarter panel and quarter panel lower extension,

refer to Figure 10D-5.

Figure 10D-4

Figure 10D-5

5. Spot cut the welds attaching rear end lower panel to the rear end panel assembly and remove the panel,

refer to Figure 10D-6.

NOTE: If the rear quarter panel and quarter panel lower extension have not been removed, carefully bend the

flange of the rear quarter panel and lower extension to allow removal of the rear end lower panel.

Figure 10D-6

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

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 available will not access the required weld position, a plug weld should be

performed.

NOTE 2: The s ame number and pos ition of spot welds ( or plug welds) s hould be used when replac ing the panel,

as was used during manufacture, in order to maintain the original structural strength of the vehicle.

1. 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 rear end lower panel in position on the vehicle.

NOTE: If the r ear quarter panel and quar ter panel lower extension were not r em oved, ensure the r ear end lower

panel is positioned behind the flange of these panels.

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

panel lower extension, refer to Figure 10D-7.

Figure 10D-7

6. Spot or plug weld the rear end lower panel to the rear end panel assembly, refer to Figure 10D-8.

Figure 10D-8

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

tail lamp housing.

8. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

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 required to the

inside of any box sections or areas inaccessible

to paint, refer to 6. CAVITY WAX in Section 3D.

11. Install the front bumper impact bar assembly,

refer to Section 3, 2. BUMPER IMPACT BAR

ASSEMBLIES.

12. Install the rem aining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 10D-9

2.2 REAR END PANEL ASSEMBLY – REPLACE

NOTE: This procedure describes the removal of the

rear end lower panel and rear end panel assembly

together. As the panels are supplied individually, this

procedure contains the replacement of the rear end

panel assembly only. Reference should be then made

to 2.1 REAR END LOWER PANEL – REPLACE for

the relevant r eplacement proc edur es of the remaining

panel.

REMOVE

CAUTION: To avoid the possibility of fire, take

particular care when cu tt ing or welding at the rear

of the vehicle. Remove the fuel tank and plug all

fuel lines.

1. Remove the adjacent bolt-on panels and

components as described in the appropriate

Section of the MY 2003 VY & V2 Series II Service

Information.

2. Remove the rear bumper impact bar assembly,

refer to 2. BUMPER IMPACT BAR

ASSEMBLIES in Section 3.

Figure 10D-10

3. Spot cut the welds attaching the rear end panel

assembly to the tail lamp housing, rear quarter

panel and quarter panel lower extension.

4. Spot cut the welds attaching the rear side rail

assem blies to the rear end panel assem bly. Note

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

hand side, refer to Figure 10D-12.

Figure 10D-11

Figure 10D-12

5. Spot cut the welds attaching the rear end panel ass embly to the rear com partment floor panel assembly, ref er to

Figure 10D-13.

Figure 10D-13

6. Spot cut the welds attaching the fuel tank suppor t

reinforcement to the rear end panel assembly.

NOTE: As an alternative, remove the fuel

tank support reinforcement from the rear

compartment floor panel assembly, refer to

2.3 FUEL TANK SUPPORT REINFORCEMENT

ASSEMBLY – REPLACE.

7. Remove the rear end panel assembly from the

vehicle.

NOTE: If the rear quarter panel and quarter panel

lower extension have not been removed, carefully

bend the flange of the rear quarter panel and lower

extension to allow removal of the rear end panel

assembly.

8. Repair any damage to adjacent parts and check

and rec tify the alignment of the body as required,

refer to 3. BODY DIMENSIONS in Section 3D.

Figure 10D-14

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 am e num ber 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 3D.

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

3D.

4. Clamp the rear end panel assembly in position on the vehicle.

NOTE: If the rear quarter panel and quarter panel lower extension were not removed, ensure the rear end lower

panel is positioned behind the flange of these panels.

5. Spot or plug weld the rear end panel assembly to the rear compartment floor panel assembly.

Figure 10D-15

6. Spot or plug weld the rear end panel assembly to the rear side rail assembly on each side of the vehicle. The

left-hand side is different to the right-hand side, refer to Figure 10D-16.

Figure 10D-16

7. If rem oved, install the fuel tank support reinforcem ent and weld to the rear compartment floor panel assembly,

refer to 2.3 FUEL TANK SUPPORT REINFORCEMENT – REPLACE.

8. Spot or plug weld the fuel tank support

reinforcement to the rear end panel assembly.

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

grind the welds and prime any bare metal.

10. Install the rear end lower panel, refer to

2.1 REAR END LOWER PANEL – REPLACE.

11. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

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

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3D.

13. 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.

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

to 2. BUMPER IMPACT BAR ASSEMBLIES in

Section 3.

15. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 10D-17

2.3 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. Remove the deadener panels and j oint s ealer from

around the fuel tank support reinforcement

assembly as required.

Figure 10D-18

3. Spot cut the welds attaching the fuel tank support

reinforcement to the rear end panel assembly and

to the rear compartment floor assembly.

4. Remove the reinforcement and then repair any

damage to adjacent parts as required.

Figure 10D-19

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 am e num ber 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 3D.

3. Plug weld the fuel tank support reinforcement to

the rear compartment floor panel and rear end

panel assembly.

4. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

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

5. BODY SEALING, ADHESIVES & DEAD ENERS

in Section 3D.

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 3D.

7. Install the deadener panels as required, refer to

5.6 DEADENER PANELS & INSULATORS in

Section 3D.

8. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 10D-20

2.4 REAR COMPARTMENT 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,

rear quarter panel and rear wheelhouse panel as

required. Refer to Figure 10D-22.

NOTE: Also remove several welds from the left-hand

rear floor panel reinforcement.

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 3D.

Figure 10D-21

Figure 10D-22

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 am e num ber 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 3D.

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

Section 3D.

4. F it the rear compartm ent floor panel outer extension in position, ensuring the f ront edge of the left- hand side is

seated under the rear floor panel reinforcement.

5. Spot or plug weld the extension to the rear compartment floor panel, rear floor panel reinforcement, rear side rail

assembly, rear quarter panel and the rear wheelhouse panel as required, refer to Figure 10D-23.

Figure 10D-23

6. Replace any other removed panels as described 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 3D.

9. Apply Cavity W ax (Item 8) as required to the inside of any box sections or areas inaccessible to paint, refer to

6. CAVITY WAX in Section 3D.

10. Apply Spr ay-on Deadener (Item 7) where applic able, ref er to 5. BO DY SEALING, ADHESIVES & DEADENERS

in Section 3D.

11. Install the remaining components as described in the appropriate Section of the MY 2003 VY & V2 Series II

Service Information.

2.5 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) and to the rear side rail assemblies,

refer to Figure 10D-25.

Figure 10D-24

Figure 10D-25

6. As required, spot cut each rear compartment floor panel outer extension from the rear wheelhouse panel, rear

quarter panel and rear end panel assembly, refer to Figure 10D-26.

Figure 10D-26

7. Rem ove the rear compartment floor panel assembly from the vehicle and repair any damage to adjacent parts

as required.

8. Check and rectify the alignment of the body as required, refer to 3. BODY DIMENSIONS in Section 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 am e num ber 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 3D.

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

Section 3D.

4. Install rear compartment floor panel assembly (1) ensuring it is seated under the left-hand rear floor panel

reinforcement.

5. Plug weld along the join of the rear floor panel assembly (2) and to the rear side rail assemblies, refer to

Figure 10D-27.

Figure 10D-27

6. As r equired, s pot or plug weld eac h r ear c ompartment f loor panel outer ex tens ion to the rear wheelhouse panel,

rear quar ter panel, rear end panel assem bly and for the lef t-hand side, the rear f loor panel reinforcem ent, refer

to Figure 10D-28.

Figure 10D-28

7. Install the rear end panel and other panels as required, refer to the relevant procedure in this Supplement.

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 deadener panels to the rear c ompartment floor panel, ref er to 5.6 DEADENER PANEL S & INSULATORS

in Section 3D.

11. Apply Cavity W ax (Item 8) as required to the inside of any box sections or areas inaccessible to paint, refer to

6. CAVITY WAX in Section 3D.

12. Apply Spr ay-on Deadener (Item 7) where applic able, ref er to 5. BO DY SEALING, ADHESIVES & DEADENERS

in Section 3D.

13. Install the remaining components as described in the appropriate Section of the MY 2003 VY & V2 Series II

Service Information.

2.6 REAR WINDOW PANEL ASSEMBLY – REPLACE

Depending on the area of damage, it may

be advisable to include rem oval of the rear seat back

panel extension assembly or rear wheelhouse

inner panel assembly. Refer to 2.7 REAR SEAT

BACK PANEL EXTENSION ASSEMBLY or REAR

WHEELHOUSE PANEL ASSEMBLY – REPLACE.

REMOVE

CAUTION: To avoid the possibility of fire, take

particular care when cu tt ing or welding at the rear

of the vehicle. Remove the fuel tank and plug all

fuel lines.

1. Remove the adjacent bolt-on panels and

components as described in the appropriate

Section of the MY 2003 VY & V2 Series II Service

Information.

Figure 10D-29

2. Remove the rear seat back panel centre extension, refer to 7. REAR SEAT BACK PANEL CENTRE

EXTENSION in Section 3D.

3. As required, remove adjoining body structure panels, refer to the appropriate procedure in this Supplement.

4. Spot cut the welds attaching the rear window panel assembly (1) to the rear seat back panel extension

assembly (2) and the rear floor panel assembly (3), refer to Figure 10D-30.

Figure 10D-30

IMPORTANT: T he rear window panel assem bly (1) is

attached to the rear seat back extension assembly (2)

and rear quarter panel (3) with spot welding and

structural adhesive (shown shaded). The adhesive

bond is not breakable by any normal means, so spot

cutting is not a viable method of removal of the panel.

5. Cut the rear window panel assembly inboard of

the join to the rear s eat back extension assem bly

with a grinder or other cutting tool along line (4).

6. Remove the rear window panel assembly from

the vehicle.

Figure 10D-31

7. Using a grinder, remove the remaining portion of

the rear window panel assembly (1 & 2) and the

layer of adhesive below it as required.

8. 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 3D.

Figure 10D-32

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 am e num ber 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 3D.

3. Apply Structural adhesive (Item 6) to the areas

shown, refer to 5. BODY SEALING, ADHESIVES

& DEADENERS in Section 3D.

4. Clamp the rear window panel assembly in

position on the vehicle.

Figure 10D-33

5. Spot or plug weld the rear window panel

assembly to the rear quarter panel and rear seat

back extension assembly.

6. Spot or plug weld the rear window panel

assembly (1) to the rear seat back panel

extension assembly (2) and the rear floor panel

assembly (3), refer to Figure 10D-35.

Figure 10D-34

Figure 10D-35

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 3D.

9. Apply Cavity W ax (Item 8) as required to the inside of any box sections or areas inaccessible to paint, refer to

6. CAVITY WAX in Section 3D.

10. Install the rear seat bac k panel c entre extens ion, ref er to 7. REAR SEAT BACK PANEL CENTRE EXT ENSION

in Section 3D.

11. Install the remaining components as described in the appropriate Section of the MY 2003 VY & V2 Series II

Service Information.

2.7 REAR SEAT BACK PANEL EXTENSION ASSEMBLY or

REAR WHEELHOUSE INNER PANEL ASSEMBLY – REPLACE

REMOVE

1. Remove the adjacent bolt-on panels and

components as described in the appropriate

Section of the MY 2003 VY & V2 Series II Service

Information.

2. Either remove, or detach the rear window panel

assembly from the rear seat back panel

extension assembly, refer to Section 2.6 REAR

WINDOW PANEL ASSEMBLY – REPLACE.

Figure 10D-36

3. Referring to Figure 10D-37, spot cut the welds

attaching the rear seat back panel extension

assembly:

- seven places to the quarter panel inner

assembly,

- 10 places to rear wheelhouse inner panel

assembly, if required,

- five places to the rear floor panel assembly.

4. If the rear window panel assembly has not been

removed, spot cut the welds 19 places, attaching

the rear seat back panel extension assembly to

the rear window panel assembly.

Figure 10D-37

5. Spot cut the welds 15 places, attaching the rear

seat back panel extension assembly to the

quarter panel inner assembly.

6. If the rear window panel assembly has not been

removed, spot cut the welds attaching the rear

seat back panel extension assembly:

- one place to the quar ter panel inner as sembly,

rear quarter panel and rear window panel

assembly,

- five places to the rear window panel assembly,

- one place to the rear window panel assembly,

- one place to the rear window panel assembly.

Carefully cut the rear seat back panel extension

assembly around the structural adhesive (1).

NOTE: Once the panel is removed, grind off the

remaining piece and adhesive.

7. If the rear wheelhouse inner panel assembly is

not being replaced, remove the rear seat back

panel extension assembly.

8. If the rear wheelhouse inner panel assembly is

being replaced, spot cut the welds attaching the

rear wheelhouse inner panel as sem bly to the rear

floor panel assembly and rear compartment floor

panel assembly as required, refer to Figure

10D-39.

Figure 10D-38

Figure 10D-39

9. Spot cut the welds attaching the rear wheelhouse inner panel assembly to the quarter panel inner assembly,

refer to Figure 10D-40.

NOTE: The front three welds may be concealed, requiring the front of the wheelhouse to be cut to gain access.

Figure 10D-40

10. Remove the rear wheelhouse inner panel assembly.

11. Repair any damage to adjacent parts as required.

12. Check and rectify the alignment of the body as required, refer to 3. BODY DIMENSIONS in Section 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 am e num ber 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 3D.

3. If the rear wheelhouse inner panel assembly is being replaced, spot or plug weld around the wheelhouse inner

panel assembly to the quarter panel inner assembly, refer to Figure 10D-41.

Figure 10D-41

4. Spot or plug weld the rear wheelhouse inner panel assembly to the rear floor panel assembly and rear

compartment floor panel assembly, refer to Figure 10D-42.

Figure 10D-42

5. If the rear window panel assembly was not removed,

apply Structural Adhesive (1) (Item 6, refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3D) between the rear seat back panel

extension assembly and rear window panel

assembly.

6. Spot or plug weld the rear seat back panel extension

assembly to the quarter panel inner assembly and

rear window panel assembly as required.

Figure 10D-43

7. Spot or plug weld the rear seat back panel extension

assembly to the quarter panel inner assembly, rear

floor panel assembly and if required, the rear

window 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 3D.

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

of any box sections or areas inaccessible to paint,

refer to 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 10D-44

2.8 REAR COMPARTMENT LID STRUT BRACKET ASSEMBLY – REPLACE

REMOVE

1. Remove the adjacent bolt-on panels and

com ponents as desc ribed in the appropriate Section

of the MY 2003 VY & V2 Series II Service

Information.

2. Grind off the MIG weld (1) attaching the rear

compartment lid strut bracket assembly to the rear

seat back panel extension assembly.

3. Spot cut the welds attaching the bracket assembly

to and remove the rear compartment lid strut

bracket assembly from the vehicle.

4. Repair any damage to adjacent parts as required.

Figure 10D-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 am e num ber 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 3D.

3. Install the rear compartment lid strut bracket

assembly, positioning it approximately 12 mm

from the edge of the rear seat back panel

extension assembly.

4. Plug weld the bracket assembly to the rear seat

back panel extension assembly.

5. MIG weld (1) along the top edge of the bracket to

the rear seat back panel extension assembly.

6. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

7. Apply Cavity Wax (Item 8) as required to the

inside of any box sections or areas inaccessible

to paint, refer to 6. CAVITY WAX in Section 3D.

8. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 10D-46

2.9 CROSSMEMBER ASSEMBLY NO. 2 – REPLACE

REMOVE

CAUTION: To avoid the possibility of fire, take

particular care when cu tt ing or welding at the rear

of the vehicle. Remove the fuel tank and plug all

fuel lines.

1. Remove 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 10D-47

3. Spot cut the welds attaching the crossmember

No.2 to the cr ossmem ber brack et 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 10D-48

4. Spot cut the welds attaching the crossm ember 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 3D.

Figure 10D-49

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 am e num ber 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 3D.

3. Plug weld the crossmember to the crossmember

bracket and rear side rail, on each side of the

vehicle.

Figure 10D-50

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 3D.

7. Apply Cavity Wax (Item 8) as required to the inside

of any box sections or areas inaccessible to paint,

refer to 6. CAVITY WAX in Section 3D.

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

refer to 5. BODY SEALING, ADHESIVES &

DEADENERS in Section 3D.

10. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 10D-51

2.10 REAR FLOOR PANEL OUTER EXTENSION – REPLACE

REMOVE

1. Remove the adjacent components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 10D-52

2. Spot cut the welds attaching the rear floor panel

outer extension to the inner rocker panel and rear

side rail assembly and remove.

Figure 10D-53

REPLACE

NOTE 1: Spot welding is the preferred method for attaching of panels and should be used whenever possible.

Where the spot welding equipment will not access the required weld position, a plug weld should be performed.

NOTE 2: The s am e num ber 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 3D.

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 required to the

inside of any box sections or areas inaccessible

to paint, refer to 6. CAVITY WAX in Section 3D.

6. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 10D-54

2.11 REAR TIE DOWN ASSEMBLY – REPLACE

REMOVE

1. Remove the adjacent components as described

in the appropriate Section of the MY 2003 VY &

V2 Series II Service Information.

Figure 10A-55

2. Spot cut the welds attaching the tie down hook

assembly to the rear side rail assembly and

remove.

Figure 10A-56

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 am e num ber 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 3D.

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 assem bly 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 required to the

inside of any box sections or areas inaccessible

to paint, refer to 6. CAVITY WAX in Section 3D.

7. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 10A-57

2.12 REAR BUMPER IMPACT BAR BRACE ASSEMBLY – REPLACE

REMOVE

CAUTION: To avoid the possibility of fire, take

particular care when cu tt ing 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. Rem ove the adjoining panels as required, refer to

the appropriate Section of this Supplement.

4. Spot cut the 16 welds (seven on the inner side

and nine on the outer side) attaching the left-hand

or right-hand rear bumper impact bar brace

assembly to the rear side rail assembly, refer to

Figure 10D-59.

Figure 10D-58

Figure 10D-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 am e num ber 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 3D.

3. Clamp and plug weld the rear bumper impact bar br ac e ass embly in position on the rear side rail as s embly r ef er

to Figure 10D-60.

Figure 10D-60

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

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

3D.

7. Apply Cavity W ax (Item 8) as required to the inside of any box sections or areas inaccessible to paint, refer to

6. CAVITY WAX in Section 3D.

8. Install the remaining components as described in the appropriate Section of the MY 2003 VY & V2 Series II

Service Information.

2.13 REAR SIDE RAIL ASSEMBLY – REPLACE

REMOVE

CAUTION 1: The rear side rail assembly contains a reinforcement that is made from High Strength

Low Alloy Steel. If damaged, the reinforcement must not be heated or straightened, therefore, as it

is not serviced separately, the entire rear side rail assembly must be replaced. Refer to

Section 2, 9. SPECIAL STEEL PRECATIONS for further information.

CAUTION 2: To avoid the possibility of fire, take particular care when cutting or welding at the rear of the

vehicle. Remove the fuel tank and plug all fuel lines.

1. Remove the adjacent components 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 10D-61

3. Spot cut the welds attaching the crossmember

No.2 to the cr ossmem ber brack et and to the rear

side rail, on each side of the vehicle.

Figure 10D-62

4. Spot cut the welds attaching the rear side rail

assembly to the rear floor panel assembly.

Figure 10D-63

5. Spot cut the welds attaching the rear side rail

assembly to the rear floor panel assembly.

Figure 10D-64

6. Spot cut the welds attaching the rear floor panel

outer extension to the inner rocker panel

assembly.

7. Spot c ut the rear side rail ass embly f rom the rear

floor panel assembly, rear compartment floor

panel assembly and the rear end panel, refer to

Figure 10D-66.

NOTE: There are a different number of welds

between the left-hand and right-hand sides.

8. Remove the rear side rail assembly from the

vehicle.

Figure 10D-65

Figure 10D-66

9. Repair any damage to adjacent parts as required.

10. 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 am e num ber 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 3D.

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 3D.

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 10D-67.

Figure 10D-67

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

floor panel assembly.

Figure 10D-68

6. Plug weld the crossmember assembly No. 2 to the

crossmember bracket and rear side rail.

Figure 10D-69

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

floor panel assembly 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 3D.

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

of any box sections or areas inaccessible to paint,

refer to 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 10D-70

2.14 REAR FLOOR PANEL ASSEMBLY – REPLACE

REMOVE

CAUTION: To avoid the possibility of fire, take

particular care when cut t ing 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

com ponents as desc ribed 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 saf ety stands. Ensure that

the stands are clear of the sections being removed.

3. Remove the sealer and deadener panels from the

relevant areas using a scraper and heat gun.

4. Remove the adjoining panels as required, refer to

the appropriate Section of this Supplement.

Figure 10D-71

5. Spot cut the welds attaching the park brake cable

bracket to the rear floor panel assembly.

Figure 10D-72

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 10D73

8. Spot cut the welds attaching the rear floor panel

assembly to the rear window panel assembly and

the rear seat back panel extension assembly.

Figure 10D-74

9. Spot cut the welds attaching the rear floor panel

assembly and rear floor panel reinforcement to the

rear wheelhouse inner panel assembly on each of

the vehicle.

10. Spot cut the welds attaching the crossmember

assembly No. 2 to the rear floor panel assembly,

refer to 2.9 CROSSMEMBER ASSEMBLY NO. 2 –

REPLACE.

11. Spot cut the welds attaching each rear side rail

assembly to the rear floor panel assembly, refer to

2.13 REAR SIDE RAIL ASSEMBLY – REPLACE.

12. Spot cut the welds attaching the rear floor panel

assem bly and rear floor panel reinforcements to the

rear compartment floor panel assembly, refer to

Figure 10D-76.

NOTE: Also remove the welds attaching the left-hand

rear floor panel reinforcement to the rear compartment

floor panel outer extension.

13. Remove the rear floor panel assembly from the

vehicle and then repair any damage to adjacent

parts as required.

14. Check and rectify the alignment of the body

as required, refer to 3. BODY DIMENSIONS in

Section 3D.

Figure 10D-75

Figure 10D-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 s am e num ber 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 3D.

3. Clamp the new panel in position in the vehicle and plug weld to the rear floor rear. Refer to Figure 10D-77.

Figure 10D-77

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

front floor panel assembly (1).

5. Plug weld the rear floor panel assem bly to the inner

rocker panel (3) each side.

Figure 10D-78

6. Plug weld the rear floor panel assembly to the rear

window panel assembly and the rear seat back

panel extension assembly.

Figure 10D-79

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

floor panel assembly.

8. Install the rear floor panel reinforcement each side,

refer to 2.15 REAR FLOOR PANEL

REINFORCEMENT – REPLACE. Plug weld the

reinforcements on the top surface only, completing

the welds in the next step.

Figure 10D-80

9. Spot or plug weld the r ear floor panel assem bly and

rear floor panel reinforcement to the rear

wheelhouse inner panel assembly on each of the

vehicle.

10. Plug weld the crossmember assembly No.2 to

the rear floor panel assembly, refer to

2.9 CROSSMEMBER ASSEMBLY NO. 2 –

REPLACE.

11. Plug weld each rear side rail assembly to the rear

floor panel assembly, refer to 2.13 REAR SIDE

RAIL ASSEMBLY – REPLACE.

12. Replace any other removed panels as described in

the appropriate Section of this Supplement.

13. Refinish and paint panels and other components as

required. Refer to Section 3, 1.3 PAINT

REFINISHING.

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

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3D.

15. Apply Cavity Wax (Item 8) as required to the inside

of any box sections or areas inaccessible to paint,

refer to 6. CAVITY WAX in Section 3D.

Figure 10D-81

16. Apply deadener panels to the rear c ompartment floor panel, ref er to 5.6 DEADENER PANEL S & INSULATORS

in Section 3D.

17. Apply Spr ay-on Deadener (Item 7) where applic able, ref er to 5. BO DY SEALING, ADHESIVES & DEADENERS

in Section 3D.

18. Install the remaining components as described in the appropriate Section of the MY 2003 VY & V2 Series II

Service Information.

2.15 RE AR FLOOR PANEL REINFORCEMENT – REP LACE

LEFT-HAND SIDE

REMOVE

The left-hand rear floor panel reinforcement is spot

welded to the rear floor panel assembly, rear

wheelhouse panel assembly, rear compartment floor

panel assembly outer extension and rear side rail

assembly.

As required spot cut the welds and remove the

reinforcement.

REPLACE

NOTE 1: Spot welding is the preferred method for

attaching of panels and should be used whenever

possible. Where the s pot welding equipment available to

the repairer will not access the required weld position, a

plug weld should be performed.

NOTE 2: The same number and position of spot welds

(or plug welds) should be used when replacing the

panel, as was used during manufacture, in order to

maintain the original structural strength of the vehicle.

1. As required, mark the new panel with drilling

locations, in preparation for plug welding. Drill holes

as required.

2. Prepare all mating surfaces and treat with Weld

Through Primer (Item 1) as required, refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3D.

3. Spot or plug weld the rear floor panel reinforcement

to the vehicle, ensuring it is correctly located and

welded through the correct panels.

Figure 10D-82

RIGHT-HAND SIDE

REMOVE

The right-hand rear floor panel reinforcement is spot

welded to the rear floor panel assembly, rear

wheelhouse panel assembly and rear side rail assembly.

As required spot cut the welds and remove the

reinforcement.

REPLACE

NOTE 1: Spot welding is the preferred method for

attaching of panels and should be used whenever

possible. Where the s pot welding equipment available to

the repairer will not access the required weld position, a

plug weld should be performed.

NOTE 2: The same number and position of spot welds

(or plug welds) should be used when replacing the

panel, as was used during manufacture, in order to

maintain the original structural strength of the vehicle.

1. As required, mark the new panel with drilling

locations, in preparation for plug welding. Drill holes

as required.

2. Prepare all mating surfaces and treat with Weld

Through Primer (Item 1) as required, refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3D.

3. Spot or plug weld the rear floor panel reinforcement

to the vehicle, ensuring it is correctly located and

welded through the correct panels.

Figure 10D-83