3B Body Construction – Wagon Page 3B-1
Page 3B-1
Section 3B
Body Construction – Wagon
ATTENTION
Before performing any service operation or other procedure described in this Section, refer to Section 2
Precautions in this Supplement and Section 00 Warnings, Cautions and Notes in the MY2005 VZ Service
Information for correct workshop practices with regard to safety and/or property damage.
The structure of the body shell has been
developed using complex design and
development 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 here are adhered to
during all vehicle body repairs.
1 General Description ...............................................................................................................................3
2 Body Structure Panels...........................................................................................................................4
2.1 Front End and Underbody..................................................................................................................................... 5
2.2 Upperbody Structure............................................................................................................................................. 7
2.3 Body Assembly...................................................................................................................................................... 9
3 Body Dimensions.................................................................................................................................11
3.1 Underbody Dimensions – Projected .................................................................................................................. 11
3.2 Upperbody Dimensions – Actual........................................................................................................................ 13
Front...................................................................................................................................................................... 13
Side and Interior................................................................................................................................................... 14
Rear....................................................................................................................................................................... 15
4 Body Margins........................................................................................................................................16
5 Body Sealing, Adhesives and Deadeners..........................................................................................19
5.1 Acrylic Spot Weld Sealer (Item 2)....................................................................................................................... 21
Acrylic Spot Weld Sealer (Item 2) Continued .................................................................................................... 22
5.2 Joint Sealer (Item 3)............................................................................................................................................. 23
Joint Sealer (Item 3) Continued.......................................................................................................................... 24
Joint Sealer (Item 3) Continued and Hand Putty (Item 4) ................................................................................. 25
Joint Sealer (Item 3) and Hand Putty (Item 4) Continued................................................................................. 26
Joint Sealer (Item 3) and Hand Putty (Item 4) Continued................................................................................. 27
Joint Sealer (Item 3) and Hand Putty (Item 4) Continued................................................................................. 28
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5.3 Adhesive – Anti Flutter (Item 5).......................................................................................................................... 29
5.4 Adhesive – Structural (Item 6) ............................................................................................................................ 30
5.5 Spray-on Deadener.............................................................................................................................................. 31
5.6 Deadener Panels and Insulators......................................................................................................................... 32
5.7 Fusible Reinforcement Patches.......................................................................................................................... 36
Replace................................................................................................................................................................. 36
5.8 Deadener Strip and Stuffer Block....................................................................................................................... 37
Stuffer Block..................................................................................................................................................... 37
6 Cavity Wax ............................................................................................................................................38
7 Roof Joint Moulding.............................................................................................................................40
Remove................................................................................................................................................................. 40
Reinstall................................................................................................................................................................ 40
3B Body Construction – Wagon Page 3B-3
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1 General Description
This Section contains body construction information specific to Wagon vehicles. For body construction information
relevant to all models, refer to Section 3 Body Construction.
The various sealers and adhesives used throughout the body are also described as it is imperative that only the correct
materials are used for repairs.
The correct cavity wax, deadeners a nd paint refinishing techniques are also imperative if the veh icle is to be returned to
its original condition.
When replacing or repairin g a part or sub-assembly, care must be taken to ensure that correct alignment and strength of
unit as a whole is maintained. In some instances, major damage to the body or frame can be repaired more effectively
and economically by replacing a part or sub-assembly with a new one, rather than repairing the damaged part.
3B Body Construction – Wagon Page 3B-4
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2 Body Structure Panels
The following tables and illustrations describe the body structure assemblies and panels that are available for service
replacement.
NOTE
Always refer to an Authorised Retailer for spare
parts availability configurations.
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2.1 Front End and Underbody
Figure 3B – 1
3B Body Construction – Wagon Page 3B-6
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Legend
1 Inner Rocker Panel Assembly, Right-hand / Left-hand
2 Seat Inner Bracket Assembly
3 Seat Outer Bracket Assembly, Right-hand / Left-hand
4 Front Floor Panel Assembly
5 Transmission Support Bracket, Right-hand / Left-hand
6 Front Floor Panel Extension
7 Front Side Rail Brace, Right-hand / Left-hand
8 Front Wheelhouse Panel Assembly, Right-hand / Left-hand
9 Horn Bracket Assembly, Left-hand only
10 Relay Housing Bracket, Right-hand only
11 ABS Modulator Bracket Assembly, Right-hand only
12 Battery Tray Assembly, Right-hand only
13 Front End Panel Assembly
14 Headlamp Panel, Left-hand / Right-hand
15 Headlamp & Front Fascia Mount Bracket, Left-hand / Right-
hand
16 Fender Front Lower Bracket, Left-hand / Right-hand
17 Radiator Lower Support Assembly
18 Front Side Rail Assembly, Left-hand / Right-hand
19 Radiator Side Mounting Bracket, Left-hand / Right-hand
20 Front Wheelhouse Bracket Assembly, Left-hand / Right-
hand
21 Front Bumper Impact Bar Bracket, Left-hand / Right-hand
22 Front Wheelhouse Panel Bracket, Left-hand / Right-hand
23 Rear Floor Panel Outer Extension, Left-hand / Right-hand
24 Rear Suspension Support Mount Plate, Left-hand / Right-
hand
25 Rear Tie Down Assembly, Left-hand / Right-hand
26 Rear Brake Hose Bracket, Left-hand / Right-hand
27 Rear Side Rail Assembly, Left-hand / Right-hand
28 Rear Bumper Impact Bar Brace Assembly, Left-hand / Right-
hand
29 Crossmember Assembly No. 2
30 Propeller Shaft Hanger Assembly
31 Rear Seat Belt Anchor Plate Assembly, three places
32 Rear Floor Panel Assembly
33 Rear Compartment Floor Panel Assembly
34 Rear Compartment Floor Panel Outer Extension, Left-hand
35 Rear Compartment Floor Panel Outer Extension, Right-hand
36 Spare Wheel Anchor Plate Assembly
37 Fuel Tank Support Reinforcement Assembly
38 Rear End Panel Extension, Left-hand / Right-hand
39 Rear End Panel Assembly
40 Rear End Lower Panel
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2.2 Upperbody Structure
Figure 3B – 2
3B Body Construction – Wagon Page 3B-8
Page 3B-8
Legend
1 Hinge Pillar Trim Panel Bracket
2 Hinge Pillar Inner Panel Assembly
3 Front Wheelhouse Panel Upper Side Rail
4 Front Fender
5 Fender Lower Rear Bracket
6 Fender Rear Bracket
7 Door Opening Frame Assembly
8 Fender Upper Rear Bracket
9 Front Door Striker Anchor Plate
10 Rear Door Check Link Bracket
11 Rear Door Striker Anchor Plate
12 Underbody Jacking Locator
13 Rear Quarter Panel
14 Rear Bumper Fascia Side Bracket
15 Quarter Panel Extension
16 Quarter Outer Lower Rear Panel
17 Fuel Filler Pipe Housing, Right-hand
18 Quarter Inner Lower Rear Extension
19 Quarter Panel Inner Assembly
20 Cargo Screen Reinforcement Assembly
21 Quarter Panel Inner Extension
22 Rear Wheelhouse Inner Panel Assembly
23 Roof Front Header Panel
24 Roof Bow Panel No. 1
25 Roof Bow Panel No. 2
26 Roof Panel
27 Roof Bow Panel No. 3
28 Roof Bow Panel No. 2
29 Roof Rear Panel
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2.3 Body Assembly
Figure 3B – 3
3B Body Construction – Wagon Page 3B-10
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Legend
1 Body Assembly
2 Dash Panel Assembly
3 Liftgate Hinge (Liftgate Side)
4 Liftgate Assembly
5 Liftgate Outer Panel
6 5 Rear Bumper Impact Bar
7 6 Rear Bumper Impact Bar Bracket Assembly
8 Rear Door Assembly
9 Rear Door Outer Panel
10 Rear Door Hinge (Door Side)
11 Rear Door Hinge (Body Side)
12 Front Door Assembly
13 Front Door Hinge (Body Side)
14 Front Door Hinge (Door Side)
15 Front Door Outer Panel
16 Hood Hinge Assembly
17 Hood assembly
18 Front Bumper Impact Bar Assembly
3B Body Construction – Wagon Page 3B-11
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3 Body Dimensions
3.1 Underbody Dimensions – Projected
All dimensions are given in mm and are measured from the centre of hol es, on the outer side of the metal surface.
The main datum surface (1) is the underside of the front side rail assembl y, refer to Figur e 3B – 5.
The main datum hole (2) is a 19 mm hole on the underside of the front side rail assembly, refer to Figure 3B – 5.
The dash panel assembly attaching hole (3) in Figure 3B – 5 is the datum hole also depicted at View C in Figure 3B – 4.
Figure 3B – 4
3B Body Construction – Wagon Page 3B-12
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Figure 3B – 5
3B Body Construction – Wagon Page 3B-13
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3.2 Upperbody Dimensions – Actual
Front
Figure 3B – 6
3B Body Construction – Wagon Page 3B-14
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Side and Interior
Figure 3B – 7
3B Body Construction – Wagon Page 3B-15
Page 3B-15
Rear
Figure 3B – 8
3B Body Construction – Wagon Page 3B-16
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4 Body Margins
Figure 3B – 9
3B Body Construction – Wagon Page 3B-17
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Figure 3B – 10
3B Body Construction – Wagon Page 3B-18
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Figure 3B – 11
3B Body Construction – Wagon Page 3B-19
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5 Body Sealing, Adhesives and
Deadeners
The commercially available products listed
below will meet the required standards. Other
products may be available that meet the
performance characteristics, however before
their use, the product manufacturer should be
contacted to check its suitability.
This Section details the sealers, adhesives and deadeners used in the Wagon body shell. It is imperative that the correct
materials are used and the directions on the product al ways be followed.
NOTE
When replacing any sealer, adhesive or
deadener, ensure the finish meets that of the
original application.
Weld Through Primer (Item 1)
Although not used in manufacture, Weld Through Primer is recommended for all service repair lap and flange joints
where Acrylic Spot Weld Sealer (Item 2) is not used. Weld Through Primer aids in corrosion protection of the joint.
Acrylic Spot Weld Sealer (Item 2)
Used in joints that require sealing additional to Joint Sealer (Item 3). It is applied to the joint flange prior to the mating of
panels. Refer to Figure 3B – 12 and Figure 3B – 13.
Joint Sealer (Item 3)
Primarily used for sealing joints to achieve a watertig ht seal. It seals notches, cut-outs and holes. Joint se aler should be
applied after priming, prior to application of the top coat. Refer to Figure 3B – 14 – Figure 3B – 19.
NOTE
Figure 3B – 15, View E illustrates the underside
of the spare wheel-well. Following priming, this
area is sprayed with sealer (rather than
deadener) to a minimum thickness of 2.5 mm and
has a rough finish. This procedure is important
due to the mounting of the fuel tank below it.
3B Body Construction – Wagon Page 3B-20
Page 3B-20
Hand Putty (Item 4)
Hand putty, also known as caulking compound, is used in the areas marked * in Figure 3 B – 16.
Adhesive – Anti-Flutter (Item 5)
While used as a filler between an inner and outer panel to reduce panel flex, Anti-Flutter adhesive also aids rigidity and
assists in dispersing loads over a larger area. Refer to Figure 3B – 20 for locations.
Adhesive – Structural (Item 6)
Critical to the strength and rigidity of the vehicle, the correct adhesive must be used for service repairs. Using an
adhesive that is too weak will reduc e the performance of the joint. Using an adhesive that is too strong can also effect the
performance of the joint, compromising the ve hicle’s crash performance and safety system’s operation. This adhesive is
a 2-part system. Refer to Figure 3B – 21 for locations.
Spray-on Deadener (Item 7)
This deadener is spra yed onto the body shell after painting. It is used in the wheel-wells and on the under side of the
floor pan. A minimum thickness of 1.5 mm is required in these app lications. Refer to Figure 3B – 22 for locations.
Deadener Panels
Deadener panels are sold pre-cut as service parts. They are installed with the coloured side up and diamond embossed
side down. The panels are installe d prior to painting and some are heat fused to the bod y shell. Refer to Figure 3B – 23 –
Figure 3B – 29 for locations.
Commercially Available Sea ler, Adhesive and Deaden er Equivalents
Item No. Item Name Manufacturer Product Name
1 Weld Through Primer Refer to supplier –
2 Acrylic Spot Weld Sealer Lord (Fusor) Fusor #800 / #801
3 Joint Sealer Sprayable: Lord (Fusor)
Extruded beads: Lord (Fusor)
3M
Visible Seams
-self leveling: Lord (Fusor)
3M
-non sag: Lord (Fusor)
3M
Fusor #802
Fusor #800 / #801
Automix 8308
Fusor #122 / #125
Automix 8307
Fusor #123 / #126
Automix 8308
4 Hand Putty Lord (Fusor) Fusor #800 / #801
Automix 8307
5 Adhesive – Anti Flutter Lord (Fusor) Fusor #124
6 Adhesive – Structural (Two-Part) Lord (Fusor)
3M Fusor #108 B
Automix 8115
7 Spray-on Deadener Henkel Terophon 2000-13
NOTE
Special tools may be required to apply some
materials, refer to the supplier for further
information.
3B Body Construction – Wagon Page 3B-21
Page 3B-21
5.1 Acrylic Spot Weld Sealer (Item 2)
Figure 3B – 12
Legend
1 Door Opening Frame
2 Reinforcement – Hinge pillar
3 Hinge pillar inner panel
4 Closing Plate – Hinge pillar
5 Front Wheelhouse panel upper side rail
3B Body Construction – Wagon Page 3B-22
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Acrylic Spot Weld Sealer (Item 2) Continued
Figure 3B – 13
3B Body Construction – Wagon Page 3B-23
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5.2 Joint Sealer (Item 3)
Figure 3B – 14
3B Body Construction – Wagon Page 3B-24
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Joint Sealer (Item 3) Continued
Figure 3B – 15
3B Body Construction – Wagon Page 3B-25
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Joint Sealer (Item 3) Continued and Hand Putty (Item 4)
Figure 3B – 16
3B Body Construction – Wagon Page 3B-26
Page 3B-26
Joint Sealer (Item 3) and Hand Putty (Item 4) Continued
Figure 3B – 17
3B Body Construction – Wagon Page 3B-27
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Joint Sealer (Item 3) and Hand Putty (Item 4) Continued
Figure 3B – 18
3B Body Construction – Wagon Page 3B-28
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Joint Sealer (Item 3) and Hand Putty (Item 4) Continued
Figure 3B – 19
3B Body Construction – Wagon Page 3B-29
Page 3B-29
5.3 Adhesive – Anti Flutter (Item 5)
Figure 3B – 20
3B Body Construction – Wagon Page 3B-30
Page 3B-30
5.4 Adhesive – Structural (Item 6)
Figure 3B – 21
3B Body Construction – Wagon Page 3B-31
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5.5 Spray-on Deadener
Figure 3B – 22
3B Body Construction – Wagon Page 3B-32
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5.6 Deadener Panels and Insulators
The deadener panels shown are heat fusible type. They are to be installed with the di amond embossed side down. Use a
heat gun, heat lamps or such to cure each deadener sheet.
Figure 3B – 23
Legend
1 Deadener – Front Floor, Right-hand
2 Deadener – Front Floor, Centre
3 Deadener – Front Floor, Left-hand
4 Deadener – Rear Floor, Right-hand
5 Deadener – Rear Floor, Centre
6 Deadener – Floor Rear, Left-hand
7 Deadener – Floor, Rear Seat Right-hand
8 Deadener – Floor, Rear Seat Left-hand
9 Deadener – Spare Wheel Well
10 Deadener – Rear Compartment, Right-hand
11 Deadener – Rear Compartment, Left-hand
A retainer (1) is used at five places to attach the dash panel lower insulator outer (2) to the engine compartment side of
the dash panel, refer to Figure 3B – 24.
3B Body Construction – Wagon Page 3B-33
Page 3B-33
Figure 3B – 24
The dash panel lower insulator inner (1) is attached to the
dash panel with two retainers (2).
Figure 3B – 25
The dash panel upper insu lator (1) is adhered to the dash
panel and care is required during removal. If required, apply
contact adhesive to the insulator prior to affixing it to the
new dash panel and ensure it follows the form of the dash
panel.
If a new insulator is being fitted, remove the backing paper
prior to fitting and apply.
Figure 3B – 26
3B Body Construction – Wagon Page 3B-34
Page 3B-34
The dash panel lower deadener (1) is a heat-fusible type.
Install it in position with the diamond embossed side to the
panel. Use a heat gun, heat lamps or such, to cure the
deadener. Smooth the deadener with a roller or such to
expel any air bubbles a nd to maximise adhesion.
Figure 3B – 27
The deadeners and insulators in Figure 3B – 28 and Figure 3B – 29 are sel f adhesive. Remove the backing paper and
attach the insulator ensuring a ny cut-outs align with brackets etc. Smooth the insulator firmly int o position.
NOTE
Ensure the notch in the rear s eat insulators (3) in
Figure 3B – 29 is aligned with the slot in the rear
seat ramp as shown A.
Figure 3B – 28
Legend
1 Insulator – Cowl Side, Left-hand
2 Deadener – Front Floor Extension, Left-hand 3 Deadener – Front Floor Extension, Right-hand
4 Insulator – Cowl Side, Right-hand
3B Body Construction – Wagon Page 3B-35
Page 3B-35
Figure 3B – 29
Legend
1 Insulator – Rear Seat Wheelhouse, Right-hand
2 Insulator – Rear Seat Wheelhouse, Left-hand 3 Insulator – Rear Seat
3B Body Construction – Wagon Page 3B-36
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5.7 Fusible Reinforcement Patches
Two heat fusible reinforcing patches (1) are applied to the
front floor tunnel which provide stiffness and aid in the
reduction of Noise, Vibration and Harshness (NVH).
The sheets are pliable in their uncured state and ar e applied
to the vehicle prior to paint baking. The heat required to cure
and harden the sheets is approximately 120° C, and once
cured the sheets become a structural part of the vehicle.
Therefore, if the front floor assembly is replaced, the
patches must also be replaced.
Lower curing temperature replacement patches are
available from an Authorised Dealer.
Replace
1 Where possible, apply th e patches to the new floor
prior to painting.
2 Ensure the surface is clean, dry and free from weld
spatter, etc.
3 Apply the patches in the locations shown ensuring an
overlap of 5 – 10 mm (2).
4 Using a heat gun or dryi ng lamps, etc. evenly heat the
material until it smoothes and the edges begin to
‘soften’.
5 Smooth the material down with a roller or like, to
ensure no air bubbles are present and to maximise
adhesion.
6 Once cooled, the material should feel h ard.
Figure 3B – 30
3B Body Construction – Wagon Page 3B-37
Page 3B-37
5.8 Deadener Strip and Stuffer Block
To improve door operatio n sound quality, a deaden er strip
(1) is affixed within the cavity between the door opening
frame and rear quarter panel on each side of the vehicle.
Care needs to be taken when repairing or welding near
these areas, as the deadener strips are not accessible and
as they are heat cured, cannot easily be re moved.
The deadener strip requires 160° C to heat cure, therefore
service parts are not supplied. They are shown here as a
caution only.
Stuffer Block
To reduce noise transmission, a stuffer block (1) is inserted
into the cavity between the side panel – inner and rear
quarter panel on each side of the vehicle.
Made from high density foam, once install ed they expand
naturally to close the cavity. The stuffer block must be
removed when repairing or welding as it can easily ignite.
NOTE
Removal or installation of the Right-hand side A
is restricted as the fuel filler pocket interferes
with access to the cavity, therefore the block
must be compressed. When i nstalling, compress
the block, tie it with string or like, insert it in the
opening above the wheelhouse and cut the
string. The block will self expand to fill th e cavity,
refer Figure 3B – 32.
Remove or install the left-hand stuffer block through the
opening in the side panel in ner as shown B.
Figure 3B – 31
Figure 3B – 32
3B Body Construction – Wagon Page 3B-38
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6 Cavity Wax
Wagon body and structural panels are constructed from high quality corrosion resistant materials. During manufacture,
cavity wax is applied to the ar eas shown to further increase the vehicle’s anti-corrosive properties.
Following repairs, to maintain the anti-corrosive properties of the vehicle, o nce the p aint is thoroughly dry apply cavity
wax to the areas shown below, and within any repaired box sect ions or areas inaccessible to paint. Refer to the table for
equivalent products to those used in manufacture.
Cavity Wax Equivalen ts
Item No. Equivalent Manufacturer Equivalent Product Name
8 Henkel
Terotex HV 8377/65
Nox Rust Hi-Wax 100B
Terasol 800113 (Aerosol pack)
Figure 3B – 33
3B Body Construction – Wagon Page 3B-39
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Figure 3B – 34
3B Body Construction – Wagon Page 3B-40
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7 Roof Joint Moulding
A roof joint moulding is fitted to Wagon vehicles at the join of the door opening frame and r ear quarter panel. The
moulding is affixed with windscreen grade urethane adhesive, such as Beta-Seal 587.02 or equivalent.
Remove
1 Remove the roof side rails and the door opening moulding, refer to Section 1A9 Exterior Ornamentation in the
MY2005 VZ Service Information.
2 Carefully cut the adhesive (1) whil e prising the top of the moulding (2) from the vehicle as shown 3 in
Figure 3B – 35.
3 Clean off residual adhesive as requir ed.
Figure 3B – 35
Reinstall
1 The surface is to be clean and painted.
2 Apply an 8 mm bead of adhesive (4) along the back of the moulding, between the ribs.
3 Fit the moulding, ensuring the outer surface i s flush with the panel surfaces and the side gaps are even.
4 If required, temporarily secure moulding with tape.
5 Allow adhesive to cure overni ght.