3D Body Construction – Coupe Page 3D-1
Page 3D-1
Section 3D
Body Construction – Coupe
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 ...............................................................................................................................2
2 Body Structure Panels...........................................................................................................................3
2.1 Front End and Underbody..................................................................................................................................... 4
2.2 Upperbody Structure............................................................................................................................................. 6
2.3 Body Structure....................................................................................................................................................... 8
3 Body Dimensions.................................................................................................................................10
3.1 Underbody Dimensions – Projected .................................................................................................................. 10
3.2 Upperbody Dimensions – Actual........................................................................................................................ 12
Front...................................................................................................................................................................... 12
Side and Interior................................................................................................................................................... 13
Rear....................................................................................................................................................................... 14
4 Body Margins........................................................................................................................................15
5 Body Sealing, Adhesives and Deadeners..........................................................................................18
5.1 Acrylic Spot Weld Sealer (Item 2)....................................................................................................................... 20
Acrylic Spot Weld Sealer (Item 2) Continued .................................................................................................... 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.......................................................................................................................... 25
Joint Sealer (Item 3) Continued.......................................................................................................................... 26
Joint Sealer (Item 3) Continued.......................................................................................................................... 27
Joint Sealer (Item 3) Continued.......................................................................................................................... 28
Joint Sealer (Item 3) Continued and Hand Putty (Item 4) ................................................................................. 29
5.3 Adhesive – Anti Flutter (Item 5).......................................................................................................................... 30
5.4 Adhesive – Structural (Item 6) ............................................................................................................................ 31
5.5 Spray-on Deadener.............................................................................................................................................. 33
5.6 Deadener Panels and Insulators......................................................................................................................... 34
5.7 Fusible Reinforcement Patches.......................................................................................................................... 38
Replace................................................................................................................................................................. 38
6 Cavity Wax ............................................................................................................................................39
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1 General Description
This Section contains body construction information specific to Coupe 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.
3D Body Construction – Coupe Page 3D-3
Page 3D-3
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 3D – 1
3D Body Construction – Coupe Page 3D-5
Page 3D-5
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 and 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 Bumper Impact Bar Brace Assembly, Left-hand / Right-
hand
28 Propeller Shaft Hanger Assembly
29 Rear Floor Panel Reinforcement, Left-hand
30 Rear Seat Belt Anchor Plate Assembly, three places
31 Rear Underbody Assembly
32 Rear Compartment Floor Panel Outer Extension, Left-hand
33 Rear End Panel Assembly
34 Rear End Lower Panel
35 Rear Compartment Floor Panel Outer Extension, Right-hand
36 Rear Floor Panel Reinforcement, Right-hand
37 Fuel Tank Strap Bracket Assembly, Left-hand / Right-hand
38 Rear Compartment Floor Panel Assembly
39 Spare Wheel Anchor Plate Assembly
40 Fuel Tank Support Reinforcement Assembly
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2.2 Upperbody Structure
Figure 3D – 2
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Legend
1 Hinge Pillar Trim Panel Bracket, Left-hand / Right-hand
2 Hinge Pillar Inner Panel Assembly, Left-hand / Right-hand
3 Front Wheelhouse Panel Upper Side Rail, Left-hand / Right-
hand
4 Front Fender, Left-hand / Right-hand
5 Rocker Panel Moulding Bracket, Left-hand / Right-hand
6 Fender Lower Rear Bracket, Left-hand / Right-hand
7 Fender Rear Bracket, Left-hand / Right-hand
8 Door Opening Frame Assembly, Left-hand / Right-hand
9 Fender Upper Rear Bracket, Left-hand / Right-hand
10 Front Door Striker Anchor Plate, Left-hand / Right-hand
11 Body Pillar Inner Panel Reinforcement, Left-hand / Right-
hand
12 Underbody Jacking Locator, Left-hand / Right-hand
13 Rear Quarter Panel, Left-hand / Right-hand
14 Quarter Outer Panel Extension, Left-hand / Right-hand
15 Rear Lamp Wiring Harness Extension Bracket, Left-hand /
Right-hand
16 Quarter Panel Lower Extension, Left-hand / Right-hand
17 Tail Lamp Housing, Left-hand / Right-hand
18 Rear Wheelhouse Inner Panel Assembly, Left-hand / Right-
hand
19 Rear Seat Back Panel Extension, Left-hand / Right-hand
20 Rear Seat Back Panel Extension Assembly, Left-hand /
Right-hand
21 Rear Window Panel Assembly
22 Rear Compartment Lid Strut Bracket Assembly, Left-hand /
Right-hand
23 Fuel Filler Pipe Housing, Right-hand only
24 Quarter Panel Inner Assembly, Left-hand / Right-hand
25 Radio Quarter Speaker Bracket, Left-hand / Right-hand
26 Roof Bow Panel
27 Roof Front Header Panel
28 Roof Panel
29 Roof Rear Panel
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2.3 Body Structure
Figure 3D – 3
3D Body Construction – Coupe Page 3D-9
Page 3D-9
Legend
1 Body Assembly
2 Dash Panel Assembly
3 Rear Compartment Lid Hinge Assembly
4 Rear Compartment Lid Assembly
5 Rear Bumper Impact Bar
6 Rear Bumper Impact Bar Bracket Assembly
7 Front Door Assembly, Left-hand / Right-hand
8 Front Door Outer Panel, Left-hand / Right-hand
9 Front Door Hinge (Door Side), Left-hand / Right-hand
10 Front Door Hinge (Body Side), Left-hand / Right-hand
11 Hood Hinge Assembly, Left-hand / Right-hand
12 Hood Assembly
13 Front Bumper Impact Bar Assembly
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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 Figure 3D – 5.
The main datum hole (2) is a 19 mm hole on the underside of the front side rail assembly, refer to Figure 3D – 5.
The dash panel assembly attaching hole (3) in Figure 3D – 5 is the datum hole also depicted at View C in Figure 3D – 6.
Figure 3D – 4
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Figure 3D – 5
3D Body Construction – Coupe Page 3D-12
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3.2 Upperbody Dimensions – Actual
Front
Figure 3D – 6
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Side and Interior
Figure 3D – 7
3D Body Construction – Coupe Page 3D-14
Page 3D-14
Rear
Figure 3D – 8
3D Body Construction – Coupe Page 3D-15
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4 Body Margins
Figure 3D – 9
3D Body Construction – Coupe Page 3D-16
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Figure 3D – 10
3D Body Construction – Coupe Page 3D-17
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Figure 3D – 11
3D Body Construction – Coupe Page 3D-18
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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 Coupe 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 3D – 12 and Figur e 3D – 14.
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 3D – 14 – Figure 3D – 21
NOTE
• Figure 3D – 20, Views A and B illustrate the
underside of the vehicle. Following priming,
this area is sprayed with sealer (rather than
deadener) to a minimum thickness of 2.5 mm.
• During production a heat fusible patch is
applied along the joint of the back panel –
upper, refer Figure 3D – 17 Vie w E.
This patch is not serviced as the heat require d to fuse it is beyond the capabilities of the repairer. Joint sealer ma y be
applied and finished to produce a smooth surface.
3D Body Construction – Coupe Page 3D-19
Page 3D-19
Hand Putty (Item 4)
Hand putty, also known as caulking compound, is used in the areas marked * in Figure 3 D – 21.
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 3D – 22 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 3D – 23 and Figure 3D – 24 for locati ons.
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 3D – 25 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 3D – 26
– Figure 3D – 32 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 levelling: 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 your supplier for further
information.
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5.1 Acrylic Spot Weld Sealer (Item 2)
Figure 3D – 12
Legend
1 Door Opening Frame Assembly
2 Reinforcement – Hinge Pillar
3 Hinge Pillar Inner Panel Assembly
4 Closing Plate – Hinge Pillar
5 Front Wheelhouse Panel Upper Side Rail
3D Body Construction – Coupe Page 3D-21
Page 3D-21
Acrylic Spot Weld Sealer (Item 2) Continued
Figure 3D – 13
Legend
1 Rear Quarter Panel
2 Door Opening Frame Assembly 3 Quarter Panel Inner Assembly
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Acrylic Spot Weld Sealer (Item 2) Continued
Figure 3D – 14
Legend
1 Rear Quarter Panel 3 Quarter Panel Inner Assembly
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5.2 Joint Sealer (Item 3)
Figure 3D – 15
3D Body Construction – Coupe Page 3D-24
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Joint Sealer (Item 3) Continued
Figure 3D – 16
3D Body Construction – Coupe Page 3D-25
Page 3D-25
Joint Sealer (Item 3) Continued
Figure 3D – 17
3D Body Construction – Coupe Page 3D-26
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Joint Sealer (Item 3) Continued
Figure 3D – 18
3D Body Construction – Coupe Page 3D-27
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Joint Sealer (Item 3) Continued
Figure 3D – 19
3D Body Construction – Coupe Page 3D-28
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Joint Sealer (Item 3) Continued
Figure 3D – 20
3D Body Construction – Coupe Page 3D-29
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Joint Sealer (Item 3) Continued and Hand Putty (Item 4)
Figure 3D – 21
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5.3 Adhesive – Anti Flutter (Item 5)
Figure 3D – 22
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5.4 Adhesive – Structural (Item 6)
Figure 3D – 23
Legend
1 Hinge Pillar Upper Reinforcement
2 Lock Pillar Reinforcement
3 Hinge Pillar Inner
4 Quarter Panel Inner
5 Rear Compartment Floor Panel Assembly
6 Rear Side Rail Assembly
3D Body Construction – Coupe Page 3D-32
Page 3D-32
Figure 3D – 24
Legend
1 Front Door Outer Panel
2 Front Door Inner Panel 3 Rear Quarter Panel
4 Quarter Panel Inner
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Page 3D-33
5.5 Spray-on Deadener
Figure 3D – 25
3D Body Construction – Coupe Page 3D-34
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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 3D – 26
Legend
1 Deadener – Front Floor, Right-hand
2 Deadener – Rear Floor, Right-hand
3 Deadener – Rear Floor, Centre
4 Deadener – Floor, Rear Seat, Right-hand
5 Deadener – Spare Wheel Well
6 Deadener – Floor, Rear Seat Left-hand
7 Deadener – Rear Floor, Left-hand
8 Deadener – Front Floor, Left-hand
9 Deadener – Front Floor, Centre
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 3D – 27.
3D Body Construction – Coupe Page 3D-35
Page 3D-35
Figure 3D – 27
The dash panel lower insulator inner (1) is attached to the
dash panel with two retainers (2).
Figure 3D – 28
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 3D – 29
3D Body Construction – Coupe Page 3D-36
Page 3D-36
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 3D – 30
The deadeners and insulators in Figure 3D – 31 and Figure 3D – 32 are self adhesive. Re move 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 3D – 32 is aligne d with the slot in the rear
seat ramp as shown A.
Figure 3D – 31
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
3D Body Construction – Coupe Page 3D-37
Page 3D-37
Figure 3D – 32
Legend
1 Insulator – Rear Seat Wheelhouse, Right-hand
2 Insulator – Rear Seat Wheelhouse, Left-hand 3 Insulator – Rear Seat
3D Body Construction – Coupe Page 3D-38
Page 3D-38
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 3D – 33
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6 Cavity Wax
Coupe 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 3D – 34