Body Page B-1
Page B-1
Section B
Body
ATTENTION
HSV vehicles are equipped with a Supplemental Restraint System (SRS). An SRS consists of seat belt pre-
tensioners (fitted to all front seats), a d river’s-side air bag, a passeng er’s-side air bag and left and right h and
side air bags. Refer to CAUTIONS, Section 12M Occupant Protection System in th e MY 2005 VZ Series Ser vice
Information before performing any service operation on or around SRS components, the steering mechanism
or wiring. Failure to follow the CAUTIONS could result in personal injury or unnecessary SRS system repairs.
1 Purpose...................................................................................................................................................2
2 Body Ornamentation..............................................................................................................................3
3 Seats........................................................................................................................................................4
3.1 HSV Trim Cover Assembly Matrix...................................................................................................................... 11
3.2 HSV Seat Pad Assembly Matrix.......................................................................................................................... 12
3.3 HSV Seat Assembly Matrix ................................................................................................................................. 13
3.4 HSV Frame Assembly Matrix .............................................................................................................................. 14
4 Body Styling..........................................................................................................................................15
4.1 Clubsport Sedan.................................................................................................................................................. 15
Body Styling Package ......................................................................................................................................... 15
Service Operations.............................................................................................................................................. 15
4.2 Clubsport Sedan R8............................................................................................................................................. 17
Body Styling Package ......................................................................................................................................... 17
Service Operations.............................................................................................................................................. 17
4.3 Senator Sedan...................................................................................................................................................... 19
Body Styling Package ......................................................................................................................................... 19
Service Operations.............................................................................................................................................. 19
4.4 Maloo Utility (With Tonneau Soft Cover) ........................................................................................................... 21
Body Styling Package ......................................................................................................................................... 21
Service Operations.............................................................................................................................................. 21
4.5 Maloo R8 Utility (With Tonneau Hard Cover)..................................................................................................... 23
Body Styling Package ......................................................................................................................................... 23
Service Operations.............................................................................................................................................. 23
5 Fender Vent...........................................................................................................................................71
5.1 Service Procedures. ............................................................................................................................................ 71
Removal................................................................................................................................................................ 71
Globe................................................................................................................................................................ 71
Vent.................................................................................................................................................................. 71
Installation............................................................................................................................................................ 71
Heat Staking Procedure ...................................................................................................................................... 73
Techline
Body Page B-2
Page B-2
1 Purpose
The purpose of this section is to provide information on the body and body components fitted to HSV VZ vehicles. The
information is designed to supplement the information contained in the Holden VZ series Service Manuals, and details
are given where differenc es occur between the HSV models and stan dard Holden models. A series of instruction
drawings describe the design changes and indicate specific part numbers, fitting instructions and relevant notes for
vehicle servicing.
NOTE:
If specific technical data on a HSV model is not
contained in this supplement, obtain data for that
model from the relevant Holden VZ series
Service Manual Supplement. References are
made throughout this section to Holden Service
Manuals, to assist in providing information for
specific service operations.
When hoisting (or jacking) HSV models,
ensure that the lifting h ead o f th e hoist lifts on
the chassis before the arm of the hoist
contacts the side-skirt
Body Page B-3
Page B-3
2 Body Ornamentation
HSV models are fitted with HSV specific deca ls and badges to ide ntify eac h model an d po wer train optio n. T he exclusiv e
HSV ornamentation is positi oned in exact locations on each HSV model. The ornament ation for each model is specified
by part number in this section.
Body Page B-4
Page B-4
3 Seats
HSV VZ models are fitted with exclusive seat designs to compliment the Sport, Performance or Luxury ride packages of
each vehicle. A full range of replacement parts is available for each specific HSV seat item and these p arts are listed in
Tables attached.
Body Page B-5
Page B-5
13/10/04
1
1
1
3
3
2
6
5
6
4
6
6
2
DATE SYM REVISION RECORD
RELEASE
DATE:
DR.
AUTH'YCK.
DWG.
INSTRUCTION DRAWING.
NT
GD
BG
VZ
-
-
DRF03026.01
CLUBSPORT & MALOO
SPORTS SEATS
J0I-030010
CLOTH ‘MICROCHECK’
CLOTH ‘ORBIT’
EMBROIDERY
VINYL
COMP PLASTICS
M20
ITEM PART NAME MATERIAL COLOUR
1
2
3
4
5
6
BLACK ANTHRACITE
RED
RED
ANTHRACITE
ANTHRACITE
RED
27
(CLUBSPORT
ONLY)
7
MAP POCKET NETTING ANTHRACITE
(CLUBSPORTONLY)
Body Page B-6
Page B-6
13/10/04
1
1
1
3
3
2
6
5
6
4
6
6
2
DATE SYM REVISION RECORD
RELEASE
DATE:
DR.
AUTH'Y CK.
DWG.
INSTRUCTION DRAWING.
NT
GD
BG
VZ
-
-
DRF03026.01
CLUBSPORT & MALOO
SPORTS SEATS
J0I-030011
CLOTH ‘MICROCHECK’
CLOTH ‘ORBIT’
EMBROIDERY
VINYL
COMP PLASTICS
M20
ITEM PART NAME MATERIAL COLOUR
1
2
3
4
5
6
BLACK ANTHRACITE
GREY
SILVER GREY
ANTHRACITE
ANTHRACITE
2
SILVER GREY
7 (CLUBSPORT
ONLY)
(CLUBSPORT ONLY)
NETTING
7
MAP POCKET ANTHRACITE
Body Page B-7
Page B-7
13/10/04
1
1
1
3
3
2
6
5
6
4
6
6
2
DATE SYM REVISION RECORD
RELEASE
DATE:
DR.
AUTH'Y CK.
DWG
.
INSTRUCTION DRAWING.
NT
GD
BG
VZ
-
-
DRF03026.01
CLUBSPORT
SPORTS SEATS
J0I-030012
LEATHER
LEATHER PERFORATED
EMBOSSED
VINYL
COMP PLASTICS
M20
ITEM PART NAME MATERIAL COLOUR
1
2
3
4
5
6
BLACK ANTHRACITE
ANTHRACITE
ANTHRACITE
2
SILVER GREY
BLACK ANTHRACITE
BLACK ANTHRACITE
7
MAP POCKET NETTING ANTHRACITE
7
Body Page B-8
Page B-8
13/10/04
DATE SYM REVISION RECORD
RELEASE
DATE:
DR.
AUTH'YCK.
DWG.
INSTRUCTION DRAWING.
NT
GD
BG
VZ
-
-
DRF03026.01
CLUBSPORT R8 & MALOO R8
PERFORMANCE LEATHER SEAT
J0I-030013
LEATHER
EMBROIDERY
VINYL
COMP PLASTICS
M20
ITEM PART NAME MATERIAL COLOUR
1
2
3
4
5
6
BLACK ANTHRACITE
ANTHRACITE
ANTHRACITE
SILVER GREY
BLACK ANTHRACITE
1
3
2
6
5
2
1
6
4
13
6
6
2
PERFORATED LEATHER
SILVER GREY
MAP POCKET
7
NETTING ANTHRACITE
7
(CLUBSPORT
ONLY)
(CLUBSPORTONLY)
Body Page B-9
Page B-9
13/10/04
DATE SYM REVISION RECORD
RELEASE
DATE:
DR.
AUTH'YCK.
DWG.
INSTRUCTION DRAWING.
NT
GD
BG
VZ
-
-
DRF03026.01
SENATOR PERFORMANCE
LEATHER SEAT
J0I-030014
LEATHER
EMBROIDERY
COMP PLASTICS
M20
ITEM PART NAME MATERIAL COLOUR
1
2
3
4
5
6
LIGHT REED
1
3
2
6
5
1
6
4
13
6
6
2
LISMORE S. PERFORATED
LOGOLIGHT REED
LIGHT REED
LISMORE SUEDE LIGHT REED
LIGHT REED
LIGHT REED
7
MAP POCKET NETTING LIGHT REED
Body Page B-10
Page B-10
13/10/04
DATE SYM REVISION RECORD
RELEASE
DATE:
DR.
AUTH'Y CK.
DWG.
INSTRUCTION DRAWING.
NT
GD
BG
VZ
-
-
DRF03026.01
SENATOR PERFORMANCE
LEATHER SEAT
J0I-030015
LEATHER
EMBROIDERY
COMP PLASTICS
M20
ITEM PART NAME MATERIAL COLOUR
1
2
3
4
5
6
1
3
2
6
5
1
6
4
13
6
6
2
LISMORE S. PERFORATED
LOGO
LISMORE SUEDE
BLACK ANTHRACITE
ANTHRACITE
ANTHRACITE
ANTHRACITE
7
7MAP POCKET NETTING ANTHRACITE
BLACK ANTHRACITE
BLACK ANTHRACITE
Body Page B-11
Page B-11
3.1 HSV Trim Cover Assembly Matrix
HSV Trim Cover Assemblies
# Seat Kit # Description
T CVR FSC
T CVR FSB RH
T CVR FSB LH
T CVR FRT
H/REST
T CVR RSC
T CVR RSB RH
T CVR RSB LH
T CVR RSB FLAP
T CVR REAR
H/REST
T CVR REAR
ARMREST
T CVR FLAP
H/REST
92176448
1 4106448 Clubsport, Sport Cloth PR 4102104PR 4102106PR 4102105PR 4101103PR 4102108PR 4102110PR 4102109PR 4101046PR N/A 4101047NK N/A
92176447
2 4106447 Clubsport, Sport Cloth NG 4102104NG 4102106NG 4102105NG 4101103NG 4102108NG 4102110NG 4102109NG 4101046NG N/A 4101047NK N/A
92176449
3 4106449 Clubsport, Sport Leather NK 4102112NK 4102114NK 4102113NK 4101176NK 4102116NK 4102118NK 4102117NK 4102115NK 4102120NK 4004700NK N/A
92176456
4 4106456 Maloo, Sport Cloth PR 4102104PR 4102106PR 4102105PR 4101103PR N/A N/A N/A N/A N/A N/A N/A
92176457
5 4106457 Maloo, Sport Cloth NG 4102104NG 4102106NG 4102105NG 4101103NG N/A N/A N/A N/A N/A N/A N/A
92176450
6 4106450 Clubsport R8, Perf Lthr NK 4102121NK 4102122NK 4102123NK 4101176NK 4102116NK 4102124NK 4102125NK 4102115NK 4102120NK 4004700NK N/A
92176458
7 4106458 Maloo R8, Perf. Lthr NK 4102121NK 4102122NK 4102123NK 4101176NK N/A N/A N/A N/A N/A N/A N/A
92176459
8 4106459 Senator, Perf. Soft Lthr NK 4102131NK 4102132NK 4102133NK 4102134NK 4102135NK 4102136NK 4102137NK 4102138NK 4102139NK 4102140NK 4102141NK
92176460
9 4106460 Senator, Perf. Soft Lthr LR 4102131LR 4102132LR 4102133LR 4102134LR 4102135LR 4102136LR 4102137LR 4102138LR 4102139LR 4102140LR 4102141LR
COLOUR LEGEND LEATHER CLOTH
K = BLACK ANTHRACITE NG = NELSON GREY
LR = LIGHT REED PR = POPPY RED
ID = INDIANA RED
MU = DEVIL YELLOW
Body Page B-12
Page B-12
3.2 HSV Seat Pad Assembly Matrix
HSV Seat Pad Assemblies
# Seat Kit # Description
FSC PAD
FSB PAD
FRT H/REST PAD
ASS.
RSC PAD
RSB PAD ASS.
RH
RSB PAD ASS. lH
RSB FLAP PAD
REAR H/REST
PAD ASS.
REAR ARMREST
PAD ASS.
FLAP H/REST
PAD ASS.
92176448
1 4106448 Clubsport, Sport Cloth PR 4003487 4101034 4100976 4005233 403506 4003505 4003565 N/A 4002236 N/A
92176447
2 4106447 Clubsport, Sport Cloth NG 4003487 4101034 4100976 4005233 403506 4003505 4003565 N/A 4002236 N/A
92176449
3 4106449 Clubsport, Sport Leather NK 4003487 4101034 4100976 4100980 400974 4003975 4003565 4002948 4002236 N/A
92176456
4 4106456 Maloo, Sport Cloth PR 4003487 4101034 4100976 N/A N/A N/A N/A N/A N/A N/A
92176457
5 4106457 Malo o, Sport Cloth NG 4003487 4101034 4100976 N/A N/A N/A N/A N/A N/A N/A
92176450
6 4106450 Clubsport R8, Perf Lthr NK 4100974 4100975 4100976 4100980 4003974 4003975 4003565 4002948 4002236 N/A
92176458
7 4106458 Maloo R8, Perf. Lthr NK 4100974 4100975 4100976 N/A N/A N/A N/A N/A N/A N/A
92176459
8 4106459 Senator, Perf. Soft Lthr NK 4100974 4100975 4100976 4102272 4003974 4003975 4005253 4002948 4002236 4001884
92176460
9 4106460 Senator, Perf. Soft Lthr LR 4100974 4100975 4100976 4102272 4003974 4003975 4005253 4002948 4002236 4001884
Body Page B-13
Page B-13
3.3 HSV Seat Assembly Matrix
HSV Seat Assemblies
# Seat Kit # Description
FS ASS. RH
FS ASS. LH
RSC ASS.
RSB ASS. RH
RSB ASS. LH
RSB FLAP ASS.
92176448
1 4106448 Clubsport, Sport Cloth PR 4102178 4102179 4102180 4102182 4102181 4102183
92176447
2 4106447 Clubsport, Sport Cloth NG 4102184 4102185 4102186 4102188 4102187 4102189
92176449
3 4106449 Clubsport, Sport Leather NK 4102194 4102195 4102172 4102196 4102197 4102175
92176456
4 4106456 Maloo, Sport Cloth PR 4102190 4102191 N/A N/A N/A N/A
92176457
5 4106457 Maloo, Sport Cloth NG 4102192 4102193 N/A N/A N/A N/A
92176450
6 4106450 Clubsport R8, Perf Lthr NK 4102170 4102171 4102172 4102174 4102173 4102175
92176458
7 4106458 Maloo R8, Perf. Lthr NK 4102176 4102177 N/A N/A N/A N/A
92176459
8 4106459 Senator, Perf. Soft Lthr NK 4102226 4102227 4102228 4102230 4102229 4102231
92176460
9 4106460 Senator, Perf. Soft Lthr LR 4102232 4102233 4102234 4102236 4102235 4102237
Body Page B-14
Page B-14
3.4 HSV Frame Assembly Matrix
HSV Frame Assemblies
# Seat Kit # Description
FSC FRAME ASM
FSB FRAME ASM
RH
FSB FRAME ASM
LH
RSC FRAME ASM
RSB FLAP
FRAME ASM
RSB FRAME ASM
REAR ARMREST
ASM
92176448
1 4106448 Clubsport, Sport Cloth PR 4004611 4004419 4004420 4002223 N/A N/A N/A
92176447
2 4106447 Clubsport, Sport Cloth NG 4004611 4004419 4004420 4002223 N/A N/A N/A
92176449
3 4106449 Clubsport, Sport Leather NK 4004611 4004419 4004420 4002223 N/A N/A N/A
92176456
4 4106456 Maloo, Sport Cloth PR 40046 11 4004419 4004420 N/A N/A N/A N/A
92176457
5 4106457 Maloo, Sport Cloth NG 4004611 4004419 4004420 N/A N/A N/A N/A
92176450
6 4106450 Clubsport R8, Perf Lthr NK 4100979 4004419 4004420 4002223 N/A N/A N/A
92176458
7 4106458 Maloo R8, Perf. Lthr NK 4100979 4004419 4004420 N/A N/A N/A N/A
92176459
8 4106459 Senator, Perf. Soft Lthr NK 4100979 4005733 4005731 4002223 4002085 N/A N/A
92176460
9 4106460 Senator, Perf. Soft Lthr LR 4100979 4005733 4005731 4002223 4002085 N/A N/A
Body Page B-15
Page B-15
4 Body Styling
4.1 Clubsport Sedan
Body Styling Package
PART No QTY DESCRIPTIONS REF
A08-020701 1 SIDE SKIRT – ASSEMBLY – RH 1
A08-020702 1 SIDE SKIRT – ASSEMBLY – LH 2
14A2020601 1 REAR FACIA – HSV VZ 3
14A1040602 1 FRONT FACIA - LEVEL 1 – HSV VZ 4
B08-040607 1 HEADER – HOOD 5
E08-040601 1 SPOILER - LEVEL 1 - HSV VZ 6
12E-970301 1 LAMP ASM – HIGH MOUNT STOP LAMP 7
E08-020603B8 1 BADGE - CLUBSPORT LH 8
E08-020604B8 1 BADGE - CLUBSPORT RH 9
A08-040601B8 2 BADGE – CORPORATE LOGO - RH 10
E08-040603 1 BADGE – ENG ID – 297 11
B08-040601B8 2 BADGE – LION & HELMET (CHROME) 12
E08-020602 1 APPLIQUE – REAR 13
E08-040602 1 BADGE - LS2 – 6.0 14
14A1040607 1 FOG LAMP SURROUND - LH 15
14A1040608 1 FOG LAMP SURROUND - RH 16
12C-020601 1 FOG LAMP 17
14A1040610 1 MESH-BUMPER BAR OPENING UPPER 18
14A1040611 1 MESH-BUMPER BAR OPENING LOWER 19
B08-040811/13/15 1 SIDE VENT LH 20
B08-040812/14/16 1 SIDE VENT RH 21
Service Operations
When servicing the VZ body components, refer to drawings in this section obtai n the necessary information on the
correct location of each component.
For badge information and locations refer to drawings at the end of this section.
Body Page B-16
Page B-16
12.10.04
DP
BG
BODY EXTERIOR ORNAMENTATON
ADVANCED AUTOMOTIVE DESIGN AND ENGINEERING
CLUBSPORT
1A2F040043
VZ
6
8
2
10
5
12
18
19
15 17 4
7
14
12
313 11
9
1
10
16
20
21
Body Page B-17
Page B-17
4.2 Clubsport Sedan R8
Body Styling Package
PART No QTY DESCRIPTIONS REF
A08-020701 1 SIDE SKIRT – ASSEMBLY – RH 1
A08-020702 1 SIDE SKIRT – ASSEMBLY – LH 2
14A2020601 1 REAR FACIA – HSV VZ 3
14A1040602 1 FRONT FACIA - LEVEL 1 – HSV VZ 4
B08-040607 1 HEADER – HOOD 5
E08-040601 1 SPOILER - LEVEL 1 - HSV VZ 6
12E-970301 1 LAMP ASM – HIGH MOUNT STOP LAMP 7
E08-020603B8 1 BADGE - CLUBSPORT LH 8
E08-020604B8 1 BADGE - CLUBSPORT RH 9
A08-040601B8 2 BADGE – CORPORATE LOGO - RH 10
E08-040603 1 BADGE – ENG ID – 297 11
B08-040601B8 2 BADGE – LION & HELMET (CHROME) 12
E08-020602 1 APPLIQUE – REAR 13
E08-040602 1 BADGE - LS2 – 6.0 14
14A1040607 1 FOG LAMP SURROUND - LH 15
14A1040608 1 FOG LAMP SURROUND - RH 16
12C-020601 1 FOG LAMP 17
14A1040610 1 MESH-BUMPER BAR OPENING UPPER 18
14A1040611 1 MESH-BUMPER BAR OPENING LOWER 19
E08-020606B8 1 BADGE – R8 20
B08-040811/13/15 1 SIDE VENT LH 21
B08-040812/14/16 1 SIDE VENT RH 22
Service Operations
When servicing the VZ body components, refer to drawings in this section obtai n the necessary information on the
correct location of each component.
For badge information and locations refer to drawings at the end of this section.
Body Page B-18
Page B-18
05.09.04
DP
BG
BODY EXTERIOR ORNAMENTATON
ADVANCED AUTOMOTIVE DESIGN AND ENGINEERING
CLUBSPORT R8
1A2F040045
VZ
6
8
2
10
5
12
18
19
15 17 4
7
14
12
313 11
9
1
10
16
20
21
22
Body Page B-19
Page B-19
4.3 Senator Sedan
Body Styling Package
PART No QTY DESCRIPTIONS REF
A08-020702 1 SIDE SKIRT – ASSEMLBY – RH 1
A08-020701 1 SIDE SKIRT – ASSEMBLY – LH 2
14A2020901 1 REAR FACIA – HSV VY 3
E08-020602 1 APPLIQUE – REAR 4
14A1040802 1 FRONT FACIA – LEVEL 2 HSV VY 5
B08-040801 1 HEADER – HOOD 6
E08-020801 1 SPOILER – LEVEL 2 HSV VY 7
12E-170301 1 LAMP ASM – HIGH MOUNT STOP LAMP 8
E08-040603 1 BADGE ENG ID -297 9
E08-020802B8 1 BADGE – SENATOR – RH 10
E08-020801B8 1 BADGE – SENATOR – LH 11
E08-020803B8 1 BADGE – SENATOR REAR 12
A08-040601B8 2 BADGE – CORPORATE LOGO 13
B08-040601B8 2 BADGE – LION & HELMET 14
14A1040808 1 MESH – BUMPER OPENING LOWER 15
14A1040807 1 GRILL FRONT FASCIA 16
E08-040602 1 BADGE – LS2 – 6.0 17
B08-040811 1 SIDE VENT LH 18
B08-040813B8/15B8 1 UPPER AND LOWER VENT BARS (CHROME) 18
B08-040812 1 SIDE VENT RH 19
B08-040814B8/16B8 1 UPPER AND LOWER VENT BARS (CHROME) 19
12C-020901 2 FOG LAMP 20
Service Operations
When servicing the VZ body components, refer to drawings in this section obtai n the necessary information on the
correct location of each component.
For badge information and locations refer to drawings at the end of this section.
Body Page B-20
Page B-20
18.10.04
DP
BG
BODY EXTERIOR ORNAMENTATON
ADVANCED AUTOMOTIVE DESIGN AND ENGINEERING
SENATOR
1A2F040046
VZ
7
11
2
18
12
20
5
15
16
13
6
8
9
3
12
14
17
4
10
1
13
19
Body Page B-21
Page B-21
4.4 Maloo Utility (With Tonneau Soft Cover)
Body Styling Package
PART No QTY DESCRIPTIONS REF
A08-040502 1 SIDE SKIRT – ASSEMBLY – RH 1
A08-040501 1 SIDE SKIRT – ASSEMBLY – LH 2
14A1040602 1 FACIA – FRONT BUMPER BAR 3
14A2040501 1 FACIA – REAR BUMPER BAR ASSEMBLY 4
12C-020501 1 LAMP ASM – HI MOUNT STOP LIGHT 5
22C-028008 1 SAIL PLANE ASSEMBLY 6
B08-040609 1 HEADER – HOOD 7
A08-040601B8 2 BADGE – CORPORATE LOGO - RH 8
E08-040603 1 BADGE – ENG ID – 297 9
B08-040601B8 1 BADGE – LION & HELMET (CHROME) 10
22H-018004 1 LICENCE PLATE SURROUND 11
E08-040602 1 BADGE - LS2 – 6.0 12
14A1040607 1 FOG LAMP SURROUND - LH 13
14A1040608 1 FOG LAMP SURROUND - RH 14
12C-020601 1 FOG LAMP 15
14A1040610 1 MESH-BUMPER BAR OPENING UPPER 16
14A1040611 1 MESH-BUMPER BAR OPENING LOWER 17
B08-040811/13/15 1 SIDE VENT LH 18
B08-040812/14/16 1 SIDE VENT RH 19
E08-020506B8 1 BADGE – MALOO RH 20
E08-020505B8 1 BADGE – MALOO LH 21
22E-028001 1 TONNEAU – SOFT COVER 22
H08-020504 1 BADGE – LION & HELMET (CHROME) 23
Service Operations
When servicing the VZ body components, refer to drawings in this section obtai n the necessary information on the
correct location of each component.
For badge information and locations refer to drawings at the end of this section.
Body Page B-22
Page B-22
19.10.04
DP
BG
BODY EXTERIOR ORNAMENTATON
ADVANCED AUTOMOTIVE DESIGN AND ENGINEERING
MALOO
1A2F040047
VZ
1
2
3
4
5
6
7
8
9
23
10
11
12
14
13 15
16
17
20
21
8
22
18
19
Body Page B-23
Page B-23
4.5 Maloo R8 Utility (With Tonneau Hard
Cover)
Body Styling Package
PART No QTY DESCRIPTIONS REF
A08-040502 1 SIDE SKIRT – ASSEMBLY – RH 1
A08-040501 1 SIDE SKIRT – ASSEMBLY – LH 2
14A1040602 1 FACIA – FRONT BUMPER BAR 3
14A2040501 1 FACIA – REAR BUMPER BAR ASSEMBLY 4
12C-020501 1 LAMP ASM – HI MOUNT STOP LIGHT 5
22C-028008 1 SAIL PLANE ASSEMBLY 6
B08-040609 1 HEADER – HOOD 7
A08-040601B8 2 BADGE – CORPORATE LOGO - RH 8
E08-040603 1 BADGE – ENG ID – 297 9
B08-040601B8 1 BADGE – LION & HELMET (CHROME) 10
22H-018004 1 LICENCE PLA TE SURROUND 11
E08-040602 1 BADGE - LS2 – 6.0 12
14A1040607 1 FOG LAMP SURROUND - LH 13
14A1040608 1 FOG LAMP SURROUND - RH 14
12C-020601 1 FOG LAMP 15
14A1040610 1 MESH-BUMPER BAR OPENING UPPER 16
14A1040611 1 MESH-BUMPER BAR OPENING LOWER 17
B08-040811/13/15 1 SIDE VENT LH 18
B08-040812/14/16 1 SIDE VENT RH 19
E08-020506B8 1 BADGE – MALOO RH 20
E08-020505B8 1 BADGE – MALOO LH 21
H08-020515 1 TO NNEAU – HARD COVER 22
H08-010510 1 REAR SPOILER 23
E08-020606B8 1 BADGE – R8 24
H08-020504 1 BADGE – LION & HELMET (CHROME) 25
Service Operations
When servicing the VZ body components, refer to drawings in this section obtai n the necessary information on the
correct location of each component.
For badge information and locations refer to drawings at the end of this section.
Body Page B-24
Page B-24
19.10.04
DP
BG
BODY EXTERIOR ORNAMENTATON
ADVANCED AUTOMOTIVE DESIGN AND ENGINEERING
MALOO R8
1A2F040048
VZ
2
3
7
10
14
13 15
16
17
21
8
18
1
4
5
6
8
9
25
11
12
20
22
19
24
23
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SIZE
A4
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SIZE
A4
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advanced automotive design and engineering
DATE SYM
RELEASE
REVISION RECORD
advanced automotive design and engineering
-
REFERENCE :
VY
17.05.02
T.K
D.P
J.D
DR.
AUTH'Y
APPR
CK.
-
DR.
APPR
CK.
DWG.
MODEL :
DATE:
SIGNATURES ON
ISSUE DATED
ORIGINAL APPROVAL
NAME
PART NO.
INSTRUCTION DRAWING.
14I-020005
SIZE
A4
FRONT BUMPER ASSEMBLY
SENATOR
VIEW B
72D-97060
SCREWS
(6 PLACES)
SCREW
4 PLACES
FOGLAMP BRACKET
(2 PLACES)
14A1020803 - LH
14A1020804 - RH
FOG LAMP
(2 PLACES)
12C - 020901
APPLY LOCTITE "242"
LH SHOWN
RH OPPOSITE EXCEPT
WHERE SHOWN
3-5Nm
1
1
1-2Nm
2
2
Body Page B-51
Page B-51
REVISION RECORD
SYM
DATE
INSTRUCTION DRAWING.
-
AUTH'Y CK.
DR.
-
VY2
T.K
T.B
25.06.03
DWG.
DATE:
HID-0306-1
-
CLUBSPORT
HID ASSEMBLY
INITIAL RELEASE
A
77C-030001
SPRING LAMP
ADJUSTER
12C-030603 - LH REAR
12C-030604 - RH REAR
BRACKET LAMP
12C-030605 - LH FRONT (HID)
12C-030606 - RH FRONT (HID)
BRACKET LAMP
72H-062002
SCREWLAMP
ADJUSTER - HID
72A-970301
77B-030002
SCRIVET
SCREW PANHEAD M5 x 10mm
(2 PLACES)
12C-030607
KIT - HID LAMP
(NARVA80mm OVAL)
WASHER AND SCREW
PARTOF 12C-030607
HID LAMP KIT
SCREW PARTOF
12C-030607
HID LAMP KIT
B
HID LAMP
ADJUSTMENT
HOLE
Body Page B-52
Page B-52
RELEASE
REVISION RECORD
SYM
DATE
INSTRUCTION DRAWING.
M.B
AUTH'Y CK.
DR.
-
VY
L.H
D.P
23.04.03
DWG.
DATE:
14I-020008
-
FASCIA - REAR BUMPER - MALOO
VIEW A
A
VIEW B
Body Page B-53
Page B-53
PAINT PROTECTOR
RHS
14A2020507
14I-050002
REAR BUMPER BAR
VZ MALOO
19/04/05
DP
AP
DP
AP D.P
PAINT PROTECTOR
LHS
14A2020508
Body Page B-54
Page B-54
DETAIL A
15.04.03
D.P
L.H
VY REAR FASCIA
NODS SENSOR
14I-020013
A
REAR PARKING SENSOR
CONNECTED ONTO 4 CLIPS
12F-020601
RING - DE-COUPLING
PARK SENSOR (VY)
12F-020602
HOUSING -
PARKING
SENSOR (VY)
12H-020602
HARNESS
(PARK SENSOR VY)
VIEW A
A
12F-021605
SENSOR PARKING(VY)
Body Page B-55
Page B-55
A
SCRIVET
77B-970601
(5 PLACES)
VIEW A
SCREW
72D-041901
( 4 PLACES)
SCREW
72G-970302
( 6 PLACES)
T213021102 SINGLE
SIDED GASKET
TAPE. PART OF
MOULDING
ASSEMBLY
VIEW B
B
CLIP
75F-970302
( 6 PLACES)
DATE SYM REVISION RECORD
RELEASE
DATE:
DR.
AUTH'Y CK.
DWG.
A0I-040008
INSTRUCTION DRAWING.
SIDE SKIRT
ASSEMBLY - MALOO
DP
LH
05.11.04
VZ
-
Body Page B-56
Page B-56
VIEW A
LH SHOWN
RH OPPOSITE
EXCEPT AS SHOWN
WEATHERSTRIP
F09-020602 RH
F09-020601 LH
SCRIVET
77B-970601
(9 PLACES)
CLIP
75F-970302
(6 PLACES)
SCREW
72D-041901
(4 PLACES)
SCREW - SIDE
SKIRT LWR
72G-970302
(6 PLACES)
DATE SYM REVISION RECORD
RELEASE
DATE:
DR.
AUTH'Y CK.
DWG.
A0I-040007
INSTRUCTION DRAWING.
SIDE SKIRT ASSEMBLY
DP
LH
05.11.04
VZ
-
A
Body Page B-57
Page B-57
77A-020402
TEXTRON STUD
M5 x 12mm
(4 PLACES)
E09-020603
SEAL FOAM
WASHER
GARDINER
(4 PLACES)
VIEW A
URETHANE
ADHESIVE
92108365
LAMP & HARNESS ASM
REAR LICENSE PLATE
A
DATE SYM REVISION RECORD
RELEASE
DATE:
DR.
AUTH'Y CK.
DWG.
E08-040001
INSTRUCTION DRAWING.
REAR APLIQUE
DP
LH
05.11.04
VZ
-
Body Page B-58
Page B-58
A
VIEW A
AREA TO BE
PAINTED BLACK
1015.0
85.0
DATE SYM REVISION RECORD
RELEASE
DATE:
DR.
AUTH'Y CK.
DWG.
E0I-040003
INSTRUCTION DRAWING.
REAR MESH BLACKOUT
CLUBSPORT / R8
DP
LH
04.11.04
VZ
-
Body Page B-59
Page B-59
A
J.D
-
10.09.02
J.D
T.K
VY
-
REAR MESH
BLACKOUT
E0I-020006
VIEW A
(REAR FASCIA
NOT SHOWN)
AREA TOBE
PAINTED BLACK 1015.0
85.0
Body Page B-60
Page B-60
79A-851901
CONNECTOR &
79B-851901
TERMINAL
-REAR SPOILER
RETAINER
79A-020801
E09-000801
GASKET - SPOILER
MOUNTING WIRING
0 15.0 ID. x 0 25.0 OD.
(2 PLACES)
E09-970301
SINGLE SIDED
ADHESIVE
FOAM TAPE
E08-020801
SPOILER REAR DECKLID
12E-021101
LAMP ASM. -HI MOUNT
STOP LIGHT
E08-020404
SEAL -
RUBBER
(5 PLACES)
70A-970101
NUT
72G-062501
STUD
GASKET - PART
OF LAMP
ASSEMBLY
SECTION C -C
SECTION THROUGH
TYPICAL SPOILER
ATTACHMENT
GASKET
RUBBER
SEAL
FLAT
WASHER
NUT
(350mm)
72D-021105
SCREW
(2 PLACES)
VIEW A
E09-970602
GASKET
(5 PLACES)
71A-020001
WASHER
(4 PLACES)
77A-020401
STUD
(4 PLACES)
70A-991301
NUT
(4 PLACES)
VIEW B
SPOILER NOT
SHOWN FOR CLARITY
C
C
A
DATE SYM REVISION RECORD
RELEASE
DATE:
DR.
AUTH'Y CK.
DWG.
E0I-040002
INSTRUCTION DRAWING.
REAR DECKLID
SPOILER - SENATOR
DP
LH
04.11.04
VZ
-
Body Page B-61
Page B-61
FOAM TAPE
06M-3990609
VIEW A
PART No.
22C-020501
(2 PLACES)
PART No.
70M-010502
(2 PLACES)
PART No.
72D-991301
(4 PLACES)
SECTION B-B
SAIL PLANE
REAR WINDOW
ROOF PANEL
(2 PLACES)
A
BB
DATE SYM REVISION RECORD
RELEASE
DATE:
DR.
AUTH'Y CK.
DWG.
22I-040004
INSTRUCTION DRAWING.
SAIL PLANE MALOO
DP
LH
04.08.04
VZ
-
Body Page B-62
Page B-62
72D-001002
(2 PLACES)
ROLL PIN
77E-738001
REMOVE FLUSH WHEN INSTALLED
LICENCE PLATE SURROUND INNER
22H-018003
LICENCE PLATE SURROUND OUTER
22H-018004
LICENCE PLATE HOLDER
HU8-738005
B
GAS STRUT
H08-738002
VIEW A
VIEW B
A
DATE
PARTNO.
NAME
REVISION RECORD
SYM
ORIGINAL APPROVAL
ISSUE DATED
SIGNATURES ON
DR.
AUTH'YCK.
APPR
APPR
MODEL :
REFERENCE :
DWG.
CK.
DATE:
DR.
25/10/04
DP
HL
VZ
-
LICENCE PLATE - SURROUND
12I-040002
INSTRUCTION DRAWING.
A4
SIZE
RELEASE
H08-020504
Body Page B-63
Page B-63
22mm
37mm
DATE SYM REVISION RECORD
RELEASE
DATE:
DR.
AUTH'Y CK.
DWG.
1A2F040053
INSTRUCTION DRAWING.
BADGE - VZ CLUBSPORT/R8
, MALOO/R8 & SENATOR
DP
BG
10.11.04
VZ
-
B08-040601B8
H08-020504
B08-040601B8
(HOOD ONLY)
(ALL MODELS)
Body Page B-64
Page B-64
CAD FILE NO.
E08-040501.dwgfmt.000.prt
Body Page B-65
Page B-65
Body Page B-66
Page B-66
DATE
PARTNO.
NAME
REVISION RECORD
SYM
ORIGINAL APPROVAL
ISSUE DATED
SIGNATURES ON
DR.
AUTH'YCK.
APPR
APPR
MODEL :
REFERENCE :
DWG.
CK.
DATE:
DR.
25/10/04
GD
BG
VZ
-
MALOO
BADGE LOCATION
1A2F-040053
INSTRUCTION DRAWING.
A4
SIZE
RELEASE
(LHS & RHS MALOO BADGE LOCATION)
Body Page B-67
Page B-67
DATE
PARTNO.
NAME
REVISION RECORD
SYM
ORIGINAL APPROVAL
ISSUE DATED
SIGNATURES ON
DR.
AUTH'YCK.
APPR
APPR
MODEL :
REFERENCE :
DWG.
CK.
DATE:
DR.
25/10/04
GD
BG
VZ
-
LS2 - 6.0L
BADGE LOCATION
1A2F-040049
INSTRUCTION DRAWING.
A4
SIZE
RELEASE
25
50
23
27
Clubsport / R8 / Senator Maloo / R8
Body Page B-68
Page B-68
DATE
PARTNO.
NAME
REVISION RECORD
SYM
ORIGINAL APPROVAL
ISSUE DATED
SIGNATURES ON
DR.
AUTH'YCK.
APPR
APPR
MODEL :
REFERENCE :
DWG.
CK.
DATE:
DR.
25/10/04
GD
BG
VZ
-
CLUBSPORT
BADGE LOCATION
1A2F-040050
INSTRUCTION DRAWING.
A4
SIZE
RELEASE
APPLICATION
PAPER
(LHS & RHS CLUBSPORT BADGE LOCATION)
Body Page B-69
Page B-69
DATE
PARTNO.
NAME
REVISION RECORD
SYM
ORIGINAL APPROVAL
ISSUE DATED
SIGNATURES ON
DR.
AUTH'YCK.
APPR
APPR
MODEL :
REFERENCE :
DWG.
CK.
DATE:
DR.
25/10/04
GD
BG
VZ
-
CLUBSPORT
BADGE LOCATION
1A2F-040051
INSTRUCTION DRAWING.
A4
SIZE
RELEASE
25
40
APPLICATION PAPER
40
175
68
25
Body Page B-70
Page B-70
DATE
PARTNO.
NAME
REVISION RECORD
SYM
ORIGINAL APPROVAL
ISSUE DATED
SIGNATURES ON
DR.
AUTH'YCK.
APPR
APPR
MODEL :
REFERENCE :
DWG.
CK.
DATE:
DR.
25/10/04
GD
BG
VZ
-
SENATOR
BADGE LOCATION
1A2F-040052
INSTRUCTION DRAWING.
A4
SIZE
RELEASE
(LHS & RHS SENATOR BADGE LOCATION)
Body Page B-71
Page B-71
5 Fender Vent
5.1 Service Procedures.
Removal
1. Raise the vehicle on a suitable Hoist taking care not to damage the Side Skirts and also allowing access to the
lower Side Skirt attaching Screws.
2. Remove Side Skirt. - Refer to Side Skirt Drawing A0I-040007 (Sedan) or A0I-040008 (Utility).
3. Remove Front Fender Liner attaching Scrivets and Screws. Pull the Liner downwards to remove it from the
Wheelhouse.
Globe
1. From inside the Fender wheelhouse the globe socket can be removed by turning anti-clockwise and withdrawing it
inboard. Installation is the reverse of the removal procedure.
Vent
1. From inside the Fender wheelhouse the vent can be removed by depressing the attaching Clips legs (2 per clip and
2 clips per vent) toward each other using a set of “pointy nosed” pliers or similar. At the same time gently pull the
lower edge of the Vent away from the Fender. On the Left side the rear clip may not be accessible because of the
power antenna. In this case, after disengaging the front clip, pull the forward end of the vent down and forward
leaving the rear clip in the fender.
Installation
The Installation of the Fender Vent is the rev erse of the removal procedure with the follo wing e xceptions.
1. Ensure that the 3 rubber strips and 2 clips are attached to the vent.
2. Slide the vent in and up over the 3 metal tabs at the top of the fend er opening and rotate it inboard at the bottom
until the clips are engaged.
3. Install the Side Skirt if it has been removed but Do Not install the 2 Side Skirt front attaching Screws.
4. Install the front Fender liners by first feeding the rear edge of the Fender Liner in bet ween the Side Skirt front
flange and the Side Skirt body attaching bracket. Then push the remainder of the Fender Liner into position ensure
the Fender Liner is pulled toward the outside of the vehicle and its outside edge is ab ove and overlapping the
Fender Flange before installing the attaching Screws and Scrivets.
5. Install the Side Skirt Front attaching Screws.
NOTE
If the Vent is to be replaced with a new one, the
individual items must be assembled in the
following sequence:
6. Paint the Vent body B08-040811/12 L/RH, Upper bar B08-040813/14 L/RH and Lower bar B08-040815/6 L/RH as
required. (Bars for Senator and Grange B08-040813/4/5/6B8, are chrome plated and don’t require painting)
7. Assemble the Turn Signal Lamp 92175662/3 L/RH to the Vent body. Sn aps in from outside.
8. Snap the bars into the slots in the base over the lamp and heat stake tabs from behind usi ng a hot soldering iron or
equivalent. Take care not to damage the e xternal finish and ensure slots are not visible from the outside. Push tabs
to the outside of the slots if necessary before staking. Clamp or hold together until plastic has sol idified.
9. Install new vent as above.
Body Page B-72
Page B-72
Body Page B-73
Page B-73
Heat Staking Procedure
Step 1 Step 2
Finished
Soldering Iron and
movement direction
Melt material across blade
and into base in leav ing
material several places
taking care not to distort
outer visible surface
Smooth and fill initial cuts
proud of base to avoid
excess thinning over joint.