3E Body Construction – Regular Cab Page 3E–1
Page 3E–1
Section 3E
Body Construction – Regular Cab
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 Information ...............................................................................................................................2
2 Body Structure Panels...........................................................................................................................3
2.1 Front End and Underbody..................................................................................................................................... 4
2.2 Upperbody Structure............................................................................................................................................. 6
2.3 Body Assembly...................................................................................................................................................... 8
3 Body Dimensions.................................................................................................................................10
3.1 Underbody Dimensions – Projected .................................................................................................................. 10
3.2 Upperbody Dimensions – Actual........................................................................................................................ 13
Front...................................................................................................................................................................... 13
Side and Interior................................................................................................................................................... 14
4 Body Margins........................................................................................................................................15
5 Body Sealing, Adhesives and Deadeners..........................................................................................17
5.1 Acrylic Spot Weld Sealer (Item 2)....................................................................................................................... 19
Acrylic Spot Weld Sealer (Item 2) Continued .................................................................................................... 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 and Hand Putty (Item 4) ................................................................................. 28
5.3 Adhesive – Anti-Flutter (Item 5).......................................................................................................................... 29
5.4 Adhesive – Structural (Item 6) ............................................................................................................................ 30
Adhesive – Structural (Item 6) Continued.......................................................................................................... 31
5.5 Spray-on Deadener.............................................................................................................................................. 32
5.6 Deadeners and Insulators................................................................................................................................... 33
6 Cavity Wax ............................................................................................................................................36
3E Body Construction – Regular Cab Page 3E–2
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1 General Information
This Section contains body construction information specific to Regular Cab vehicles. For bod y 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
the unit as a whole is maintained. In some instances, major damage to the body or frame can be repaired more
effectively and economica lly by replacing a part or sub-assembly with a new one, rather than repairing the damaged part.
3E Body Construction – Regular Cab Page 3E–3
Page 3E–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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Page 3E–4
2.1 Front End and Underbody
Figure 3E – 1
3E Body Construction – Regular Cab Page 3E–5
Page 3E–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
6 Transmission Support Bracket, Left-hand, AWD Only
7 Front Floor Panel Extension
8 Front Side Rail Brace, Right-hand / Left-hand
9 Front Wheelhouse Panel Assembly, Right-hand / Left-hand
10 Horn Bracket Assembly, Left-hand only
11 Relay Housing Bracket, Right-hand only
12 ABS Modulator Bracket Assembly, Right-hand only
13 Battery Tray Assembly, Right-hand only
14 Front End Panel Assembly
15 Headlamp Panel, Left-hand / Right-hand
16 Radiator Lower Support Assembly
17 Headlamp and Front Fascia Mount Bracket, Left-hand /
Right-hand
18 Fender Front Lower Bracket, Left-hand / Right-hand
19 Front Side Rail Assembly, Left-hand / Right-hand
20 Radiator Side Mounting Bracket, Left-hand / Right-hand
21 Front Wheelhouse Bracket Assembly, Left-hand / Right-
hand
22 Front Bumper Impact Bar Bracket, Left-hand / Right-hand
23 Front Wheelhouse Panel Bracket, Left-hand / Right-hand
24 Inner Rocker Panel Filler, Left-hand / Right-hand
25 Jack Stowage Bracket, Left-hand only
26 Floor Panel Plate Assembly (2 places), Left-hand / Right-
hand
27 Propeller Shaft Hanger Assembly
28 Front Floor Panel Extension, Left-hand
29 Front Floor Panel Extension, Right-hand
30 Rear Lower Body Panel
31 Rear Lower Body Panel Assembly, Left-hand / Right-hand
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2.2 Upperbody Structure
Figure 3E – 2
3E Body Construction – Regular Cab Page 3E–7
Page 3E–7
Legend
1 Roof Front Header Panel
2 Roof Panel
3 Roof Rear Header Panel
4 Rear Body Upper Outer Panel Assembly
5 Rear Body Upper Inner Panel Assembly
6 Rear Body Lower Panel
7 Quarter Panel Inner Assembly, Right-hand / Left-hand
8 Quarter Panel Inner Extension, Right-hand / Left-hand
9 Hinge Pillar Trim Panel Bracket, Right-hand / Left-hand
10 Hinge Pillar Inner Panel Assembly, Right-hand / Left-hand
11 Front Wheelhouse Panel Upper Side Rail, Right-hand / Left-
hand
12 Fender Upper Rear Bracket, Right-hand / Left-hand
13 Door Opening Frame Assembly, Right-hand / Left-hand
14 Front Door Striker Anchor Plate, Right-hand / Left-hand
15 Fender Lower Rear Bracket, Right-hand / Left-hand
16 Fender Rear Bracket, Right-hand / Left-hand
17 Underbody Jacking Locator, Right-hand / Left-hand
18 Quarter Panel Reinforcement, Right-hand / Left-hand
19 Rear Quarter Panel Assembly, Right-hand / Left-hand
20 Front Fender, Right-hand / Left-hand
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Page 3E–8
2.3 Body Assembly
Figure 3E – 3
3E Body Construction – Regular Cab Page 3E–9
Page 3E–9
Legend
1 Body Assembly
2 Dash Panel Assembly
3 Front Bumper Impact Bar Assembly
4 Hood Assembly
5 Hood Hinge Assembly, Right-hand / Left-hand
6 Front Door Outer Panel, Right-hand / Left-hand
7 Front Door Assembly, Right-hand / Left-hand
8 Front Door Hinge (door side), Right-hand / Left-hand
9 Front Door Hinge (body side), Right-hand / Left-hand
10 Subframe Assembly
3E Body Construction – Regular Cab Page 3E–10
Page 3E–10
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 3E – 5.
The main datum hole (2) is a 19 mm hole on the underside of the front side rail assembly, refer to Figure 3E – 5.
The dash panel assembly attaching hole (3) in Figure 3E – 5 is also the same datum hole depicted at View C in
Figure 3E – 4.
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Figure 3E – 4
3E Body Construction – Regular Cab Page 3E–12
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Figure 3E – 5
3E Body Construction – Regular Cab Page 3E–13
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3.2 Upperbody Dimensions – Actual
Front
Figure 3E – 6
3E Body Construction – Regular Cab Page 3E–14
Page 3E–14
Side and Interior
Figure 3E – 7
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Page 3E–15
4 Body Margins
Figure 3E – 8
3E Body Construction – Regular Cab Page 3E–16
Page 3E–16
Figure 3E – 9
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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 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 3E – 10 to Figure 3E – 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 3E – 14 to Figure 3E – 19.
Hand Putty (Item 4)
Hand putty, also known as caulking compound, is used in the areas marked * in Figure 3 E – 19.
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 3E – 20 for locations.
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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 3E – 21 and Figure 3E – 22 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 3E – 23 for locations.
Floor 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 installed prior to painting. Some are heat fused to the body shell. Refer to Figure 3E – 24 –
Figure 3E – 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
NOTE
Special tools may be required to apply some
materials, refer to the supplier for further
information.
3E Body Construction – Regular Cab Page 3E–19
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5.1 Acrylic Spot Weld Sealer (Item 2)
Figure 3E – 10
Legend
1 Door Opening Frame
2 Hinge Pillar Reinforcement
3 Hinge Pillar Inner Panel
4 Hinge Pillar Closing Plate
5 Front Wheelhouse Panel Upper Side Rail
3E Body Construction – Regular Cab Page 3E–20
Page 3E–20
Acrylic Spot Weld Sealer (Item 2) Continued
Figure 3E – 11
3E Body Construction – Regular Cab Page 3E–21
Page 3E–21
Acrylic Spot Weld Sealer (Item 2) Continued
Figure 3E – 12
3E Body Construction – Regular Cab Page 3E–22
Page 3E–22
Acrylic Spot Weld Sealer (Item 2) Continued
Figure 3E – 13
3E Body Construction – Regular Cab Page 3E–23
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5.2 Joint Sealer (Item 3)
Figure 3E – 14
3E Body Construction – Regular Cab Page 3E–24
Page 3E–24
Joint Sealer (Item 3) Continued
Figure 3E – 15
3E Body Construction – Regular Cab Page 3E–25
Page 3E–25
Joint Sealer (Item 3) Continued
Figure 3E – 16
3E Body Construction – Regular Cab Page 3E–26
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Joint Sealer (Item 3) Continued
Figure 3E – 17
3E Body Construction – Regular Cab Page 3E–27
Page 3E–27
Joint Sealer (Item 3) Continued
Figure 3E – 18
NOTE
When the inner rear body panel is installed, joint
sealer is applied around its perimeter between
the panel and body.
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Page 3E–28
Joint Sealer (Item 3) Continued and Hand Putty (Item 4)
Figure 3E – 19
3E Body Construction – Regular Cab Page 3E–29
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5.3 Adhesive – Anti-Flutter (Item 5)
Figure 3E – 20
3E Body Construction – Regular Cab Page 3E–30
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5.4 Adhesive – Structural (Item 6)
Figure 3E – 21
3E Body Construction – Regular Cab Page 3E–31
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Adhesive – Structural (Item 6) Continued
Figure 3E – 22
3E Body Construction – Regular Cab Page 3E–32
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5.5 Spray-on Deadener
Figure 3E – 23
3E Body Construction – Regular Cab Page 3E–33
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5.6 Deadeners and Insulators
The deadeners shown are heat fusible type. They are to be installed with the diamon d embossed side do wn. Use a heat
gun, heat lamps or such to cure each deadener sheet.
Figure 3E – 24
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
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 3E – 25.
3E Body Construction – Regular Cab Page 3E–34
Page 3E–34
Figure 3E – 25
The dash panel lower insulator inner (1) is attached to the
dash panel with two retainers (2).
Figure 3E – 26
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 3E – 27
3E Body Construction – Regular Cab Page 3E–35
Page 3E–35
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 3E – 28
The deadeners and insulators in Figure 3E – 29 are self-ad hesive. Remove the backing paper an d attach the insulator
ensuring any cut-outs align with brackets, etc. Smooth the insulator firmly into position.
Figure 3E – 29
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
3E Body Construction – Regular Cab Page 3E–36
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6 Cavity Wax
Regular Cab body and structural panels are constructed from high quality corrosion resistant materials.
Following repairs, to maintain the anti-corrosive properties of the vehicle, o nce the p aint is thoroughly dry apply cavity
wax within any repaired b ox sections, areas inaccessible to paint, and to the areas shown below. 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 3E – 30
3E Body Construction – Regular Cab Page 3E–37
Page 3E–37
Figure 3E – 31