General Information Page 1–1
Page 1–1
Section 1
General Information
ATTENTION
Before performing any Service Operation or other procedure described in this Section, refer to Section 2
Precautions, and Section 00 Warnings, Cautions and Notes in the MY 2004 VY Regular Cab and Crew Cab
Service Information for correct w orkshop practices with regard to safety and/or property damage.
The body structure of VY Regular Cab and
Crew Cab vehicles has been developed using
complex design and d evelopment techniques.
In addition to meeting all required standards,
the vehicle body is also a critical part of the
overall safety systems. It is therefore
imperative the repair procedures described in
this Supplement are adhered to during all
vehicle body repairs.
1 General Information ...............................................................................................................................2
1.1 General Description............................................................................................................................................... 2
2 General Index..........................................................................................................................................4
General Information Page 1–2
Page 1–2
1 General Information
With the following exception, VY Regu lar Cab and Crew Cab General Information carries over from MY 2003 VY Series
vehicles.
• General Description
• General Index
For information not contained within this Section, refer to Section 1 General Information in the MY 2003 VY and V2
Series Service Information Supplement, Body Structure Repair.
1.1 General Description
This Supplement contains body structure repair information for the following vehicles, and is to be used in conjuncti on
with the MY 2003 VY and V2 Series Service informati on Supplement, Body Structure Repair:
• MY 2003 VY Regular Cab,
• MY 2004 VY Regular Cab,
• MY 2004 VY Crew Cab, and
• MY 2004 VY AWD Crew Cab.
These vehicles are design ed to meet or exceed all frontal, offset frontal and side impact standards. It is imperative
therefore, that any repairs to the body structure do n ot compromise:
• the vehicle’s compliance with relevant statutory regulations,
• the performance of the body s tructure, or
• the vehicle’s safety systems – including the occupant protection system.
All repairs are to be performed in accord ance with this Supplement, which provides replacement procedures for the
serviced body panels and structural members. If several adjoining parts are replaced at the one time, modify the
replacement procedures acco rdingly.
Hang-on panels such as the engine hood are not covered and reference should be made to the appropriate Section in
the MY 2004 VY Series Service Information.
Prior to beginning repair work on a vehicle, the repairer should become familiar with Section 1 through Section 3 in this
Supplement and the MY 2003 VY and V2 Ser ies Service information Supplement, Body Structure Repair, Section 00 in
the MY 2004 VY Series Service Information and an y appropriate regulations covering repairs, welding and joinin g motor
vehicles and accepted industry practices.
As collision damage differs in each case, this Supplement can only be a guide for the repairer. The best repair procedure
for each vehicle will need to be determine d according to the judgements of a qualified trade’s person.
The information contained in this Sup plement is correct at the time it was approved. Ho wever, as the motor vehicle
industry is constantly updating and improving vehicle construction techniques, the repairer must use his/her acquired skill
in determining the appropriate procedure for replacing panels.
Figure 1 – 1 sho ws the Regular Cab a nd Crew Cab body structures covered b y this Supplement.
General Information Page 1–3
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Figure 1 – 1
General Information Page 1–4
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2 General Index
Section 1 General Information
Description Page
1 General Information 1–2
2 General Index 1–3
Section 2 Precautions
Description Page
1 General Information 2–2
2 Electrical Precautions 2–3
3 Jacking Precautions 2–8
4 Plastic Components 2–10
Section 3A Body Construction – Regular Cab
Description Page
1 General Information 3A–3
2 Body Structure Panels 3A–4
3 Body Dimensions 3A–11
4 Body Margins 3A–16
5 Body Sealing, Adhesives and Deadeners 3A–18
6 Cavity Wax 3A–36
Figure 1 – 2
Section 3B Body Construction – Crew Cab
Description Page
1 General Information 3B–3
2 Body Structure Panels 3B–4
3 Body Dimensions 3B–13
4 Body Margins 3B–19
5 Body Sealing, Adhesives and Deadeners 3B–21
6 Cavity Wax 3B–39
Figure 1 – 3
General Information Page 1–5
Page 1–5
Section 4 Front End
Description Page
1 General Information 4–2
Figure 1 – 4
Section 5 Cockpit Mo d ule
Description Page
1 General Information 5–2
Figure 1 – 5
Section 6A Cabin Floor – Regular Cab
Description Page
1 General Information 6A–2
2 Service Operations 6A–4
Figure 1 – 6
General Information Page 1–6
Page 1–6
Section 6B Cabin Floor – Crew Cab
Description Page
1 General Information 6B–2
2 Service Operations 6B–4
Figure 1 – 7
Section 7A Body Side – Regular Cab
Description Page
1 General Information 7A–2
2 Service Operations 7A–5
Figure 1 – 8
Section 7B Body Side – Crew Cab
Description Page
1 General Information 7B–2
2 Service Operations 7B–5
Figure 1 – 9
General Information Page 1–7
Page 1–7
Section 8 Doors and Endgate
Description Page
1 General Information 8–2
Figure 1 – 10
Section 9 Roof
Description Page
1 General Information 9–2
2 Service Operations – Crew Cab 9–4
Figure 1 – 11
Section 10A Body Rear – Regular Cab
Description Page
1 General Information 10A–2
2 Service Operations 10A–3
Figure 1 – 12
General Information Page 1–8
Page 1–8
Section 10B Body Rear – Crew Cab
Description Page
1 General Information 10B–2
2 Service Operations 10B–3
Figure 1 – 13
Section 11 Rear Tray Body Assembly – Crew Cab
Description Page
1 General Information 11–3
2 Service Operations 11–6
3 Underfloor Component Location Dimensions 11-78
Figure 1 – 14