3G Body Construction – AWD Wagon Page 3–1
Page 3–1
Section 3G
Body Construction – AWD 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 Information ...............................................................................................................................2
2 Body Structure Panels...........................................................................................................................3
2.1 Front End and Underbody..................................................................................................................................... 4
2.2 Upperbody Structure............................................................................................................................................. 6
Roof Assembly....................................................................................................................................................... 7
2.3 Body Assembly...................................................................................................................................................... 8
3 Body Sealing, Adhesives and Deadeners..........................................................................................10
3.1 Acrylic Spot Weld Sealer (Item 2)....................................................................................................................... 12
Acrylic Spot Weld Sealer (Item 2) Continued .................................................................................................... 13
3.2 Joint Sealer (Item 3)............................................................................................................................................. 14
Joint Sealer (Item 3) Continued.......................................................................................................................... 15
Joint Sealer (Item 3) Continued and Hand Putty (Item 4) ................................................................................. 16
Joint Sealer (Item 3) Continued.......................................................................................................................... 17
Joint Sealer (Item 3) Continued.......................................................................................................................... 18
Joint Sealer (Item 3) Continued.......................................................................................................................... 19
3.3 Adhesive – Anti-flutter (Item 5)........................................................................................................................... 20
3.4 Adhesive – Structural (Item 6) ............................................................................................................................ 21
3.5 Spray-on Deadener.............................................................................................................................................. 22
3.6 Deadener Panels and Insulators......................................................................................................................... 23
3.7 Fusible Reinforcement Patches.......................................................................................................................... 27
Front Floor Tunnel............................................................................................................................................... 27
Replace............................................................................................................................................................ 27
Rear Seat Passenger Foot Well.......................................................................................................................... 27
Replace............................................................................................................................................................ 27
3.8 Deadener Strip and Stuffer Block....................................................................................................................... 29
Stuffer Block..................................................................................................................................................... 29
3G Body Construction – AWD Wagon Page 3–2
Page 3–2
1 General Information
This Section contains body construction information specific to AWD Wagon vehicles. For the following items the
information is carry over from Wagon vechic es, refer to Section 3B Bod y Construction – Wagon.
• Body Dimensions
• Body Margins
• Cavity Wax
• Roof Joint Moulding
For other 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 re placing or repairing a part or sub-assembly, care must be ta ken 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 repairin g the
damaged part.
A sunroof option is available that is fitted on the production line. To cater for this option, a new roof structure has been
introduced which features a housing assembly in place of the roof bow panel. A stainless steel front drain tube is also
fitted within the hinge pillar cavity which effects the service procedures for the hinge pillar, refer to Section 7G Body Side
and Section 9B Roof.
3G Body Construction – AWD Wagon Page 3–3
Page 3–3
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.
3G Body Construction – AWD Wagon Page 3–4
Page 3–4
2.1 Front End and Underbody
Figure 3G – 1
3G Body Construction – AWD Wagon Page 3–5
Page 3–5
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
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 Headlamp & Front Fascia Mount Bracket, Left-hand / Right-
hand
17 Fender Front Lower Bracket, Left-hand / Right-hand
18 Radiator Lower Support Assembly / 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 Rear Floor Panel Outer Extension, Left-hand / Right-hand
25 Rear Suspension Support Mount Plate, Left-hand / Right-
hand
26 Rear Tie Down Assembly, Left-hand / Right-hand
27 Rear Brake Hose Bracket, Left-hand / Right-hand
28 Rear Side Rail Assembly, Left-hand / Right-hand
29 Rear Bumper Impact Bar Brace Assembly, Left-hand / Right-
hand
30 Crossmember Assembly No. 2
31 Propeller Shaft Hanger Assembly
32 Rear Seat Belt Anchor Plate Assembly, three places
33 Rear Floor Panel Assembly
34 Rear Compartment Floor Panel Assembly
35 Rear Compartment Floor Panel Outer Extension, Left-hand
36 Rear Compartment Floor Panel Outer Extension, Right-hand
37 Spare Wheel Anchor Plate Assembly
38 Fuel Tank Support Reinforcement Assembly
39 Rear End Panel Extension, Left-hand / Right-hand
40 Rear End Panel Assembly
41 Rear End Lower Panel
3G Body Construction – AWD Wagon Page 3–6
Page 3–6
2.2 Upperbody Structure
Figure 3G – 2
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
3G Body Construction – AWD Wagon Page 3–7
Page 3–7
Roof Assembly
Figure 3G – 3
Legend
1 Roof Panel
2 Roof Front Header Panel
3 Roof Bow Panel No. 1
4 Roof Bow Panel No. 2
5 Roof Bow Panel No. 3
6 Roof Bow Panel No. 2
7 Roof Rear Panel
8 Roof Panel (with Sunroof)
3G Body Construction – AWD Wagon Page 3–8
Page 3–8
2.3 Body Assembly
Figure 3G – 4
3G Body Construction – AWD Wagon Page 3–9
Page 3–9
Legend
1 Body Assembly
2 Dash Panel Assembly
3 Liftgate Hinge (Liftgate Side)
4 Liftgate Assembly
5 Liftgate Outer Panel
6 Towbar Assembly
7 Rear Door Assembly
8 Rear Door Outer Panel
9 Rear Door Hinge (Door Side)
10 Rear Door Hinge (Body Side)
11 Front Door Assembly
12 Front Door Hinge (Body Side)
13 Front Door Hinge (Door Side)
14 Front Door Outer Panel
15 Hood Hinge Assembly
16 Hood Assembly
17 Front Bumper Impact Bar Assembly
3G Body Construction – AWD Wagon Page 3–10
Page 3–10
3 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 AWD Wagon body shell. It is imperative that the
correct materials are used and the directions on the product always 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 3G – 5 and Figure 3G – 6.
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 3G – 7 – Figure 3G – 12.
NOTE
Figure 3G – 8, Vie w E illustrates the underside of
the spare wheel- well. Following priming, this area
is sprayed with sealer (rather than de adener) 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.
Hand Putty (Item 4)
Hand putty, also known as caulking compound, is used in the areas marked * in Figure 3 G – 9.
3G Body Construction – AWD Wagon Page 3–11
Page 3–11
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 3G – 13 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 3G – 14 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 3G – 15 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 3G – 16
– Figure 3G – 22 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.
3G Body Construction – AWD Wagon Page 3–12
Page 3–12
3.1 Acrylic Spot Weld Sealer (Item 2)
Figure 3G – 5
Legend
1 Door opening frame
2 Reinforcement – Hinge pillar
3 Hinge pillar inner panel
4 Closing plate – hinge pillar
5 Pront wheelhouse panel upper side rail
3G Body Construction – AWD Wagon Page 3–13
Page 3–13
Acrylic Spot Weld Sealer (Item 2) Continued
Figure 3G – 6
3G Body Construction – AWD Wagon Page 3–14
Page 3–14
3.2 Joint Sealer (Item 3)
Figure 3G – 7
3G Body Construction – AWD Wagon Page 3–15
Page 3–15
Joint Sealer (Item 3) Continued
Figure 3G – 8
3G Body Construction – AWD Wagon Page 3–16
Page 3–16
Joint Sealer (Item 3) Continued and Hand Putty (Item 4)
Figure 3G – 9
3G Body Construction – AWD Wagon Page 3–17
Page 3–17
Joint Sealer (Item 3) Continued
Figure 3G – 10
3G Body Construction – AWD Wagon Page 3–18
Page 3–18
Joint Sealer (Item 3) Continued
Figure 3G – 11
3G Body Construction – AWD Wagon Page 3–19
Page 3–19
Joint Sealer (Item 3) Continued
Figure 3G – 12
3G Body Construction – AWD Wagon Page 3–20
Page 3–20
3.3 Adhesive – Anti-flutter (Item 5)
Figure 3G – 13
3G Body Construction – AWD Wagon Page 3–21
Page 3–21
3.4 Adhesive – Structural (Item 6)
Figure 3G – 14
3G Body Construction – AWD Wagon Page 3–22
Page 3–22
3.5 Spray-on Deadener
Figure 3G – 15
3G Body Construction – AWD Wagon Page 3–23
Page 3–23
3.6 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 3G – 16
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 3G – 17.
3G Body Construction – AWD Wagon Page 3–24
Page 3–24
Figure 3G – 17
The dash panel lower insulator inner (1) is attached to the
dash panel with two retainers (2).
Figure 3G – 18
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 3G – 19
3G Body Construction – AWD Wagon Page 3–25
Page 3–25
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 3G – 20
The deadeners and insulators in Figure 3G – 21 and Figure 3G – 22 are self adhesive. Remove the backing pa per 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 3G – 21 is ali gned with the slot in the rear
seat ramp as shown A.
Figure 3G – 21
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
3G Body Construction – AWD Wagon Page 3–26
Page 3–26
Figure 3G – 22
Legend
1 Insulator – Rear Seat Wheelhouse, Right-hand
2 Insulator – Rear Seat Wheelhouse, Left-hand 3 Insulator – Rear Seat
3G Body Construction – AWD Wagon Page 3–27
Page 3–27
3.7 Fusible Reinforcement Patches
Five heat fusible reinforcing patches are applied to the vehicle floor which provide stiffness and aid in the reduction of
Noise, Vibration and Harshness (NVH). Two patches are placed on the front floor tunnel, refer to Figure 3G – 23, one on
the rear floor tunnel and one on each rear seat passenger foot well, refer to Figure 3G – 24.
The sheets are pliable in their uncured state and are applied to the vehicle prior to paint baking. The heat required to
cure and harden the sheets is appr oximately 120° C. Once cured the sheets become a str uctural 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 Autorised Dealer.
Front Floor Tunnel
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 similar, to
ensure no air bubbles are present and to maximise
adhesion.
6 Once cooled, the material should feel h ard.
Figure 3G – 23
Rear Seat Passenger Foot Well
Replace
1 Where possible, apply th e three patches to the new floor prior to painting, refer to F igure 3G – 24.
2 Ensure the surface is clean, dry and free from weld spatter, etc.
3 Apply the patches (1) in the locations shown.
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 similar, to ensure no air bubbles are present and to maximise adhesion.
6 Once cooled, the material should feel h ard.
3G Body Construction – AWD Wagon Page 3–28
Page 3–28
Figure 3G – 24
3G Body Construction – AWD Wagon Page 3–29
Page 3–29
3.8 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.
Figure 3B – 25
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 installing, 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 the cavit y,
refer Figure 3G – 26.
Remove or install the left-hand stuffer block throu gh the opening in the side panel inner as shown B.
Figure 3G – 26