SECTION 3 - BODY CONSTRUCTION

IMPORTANT

Before perfo rming any Service O perat ion or o th er pro cedu re describ ed in th is Section, refer to Section

00 CAUTIONS AND NOTES and Section 2 PRECAUTIONS in this Supplement for correct workshop

practices with regard to safety and/or property damage.

CAUTION

The Structure of the M Y 2003 VY & V2 Series II body shell has been developed using complex design

and development techniques. In addition to meeting all required standards, the v ehicle 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

1.1 BODY STRUCTURE PART REFINISHING

1.2 ANTI-CORROSIVE TREATMENT

1.3 PAINT REFINISHING

PANEL REFINISHING

PAINT CODE

2. BUMPER IMPACT BAR ASSEMBLIES

2.1 FRONT

REMOVE

REINSTALL

2.2 REAR

REMOVE

REINSTALL

3. SPECIAL TOOLS

1. GENERAL DESCRI PTI O N

Section 3, Body Construction, has been divided into five sub-sections. This sub-section contains the general

information relative to all body styles. Sub-section 3A contains information specific to Sedan vehicles, sub-section

3B is specific to Wagon, 3C for Utility and 3D for Coupe.

Each sub-s ection descr ibes the body s tructure as a whole and provides a detailed breakdown of the body structure

components, key body dimensional measurements and body margin tolerances.

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 and paint refinishing techniques are also imperative if the vehicle is to be

returned to its original condition.

When replacing or repairing 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.

1.1 BODY STRUCTURE P ART REFINISHING

The vehicle body structure is designed to meet or exceed many regulations, including crash performance and

occupant protection, etc. When replacing or repairing 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 structure can be repaired more effectively and economically by

replacing a part or sub-assembly with a new one, rather than repairing the damaged part.

Spot welding is used extensively for joining panels or assemblies, however special adhesives are playing an ever

increasing role in the joining of body structure components, either on their own or together with spot welds. W here

repairs are performed, it is imperative that effective rust proofing techniques, as outlined in the following

paragraphs, be observed.

It is for these reasons that qualified persons with suitable training and qualifications only perform the repair or

replacement of body structure components.

1.2 ANTI-CORROSIVE TREATMENT

Precoated and galvanised steel is used extensively for various body structure components for increased corrosion

protection. Body panels such as the engine hood, door and deck lid outer panels ar e precoated on the inner surf ace

of the metal to improve corrosion protection. Other body structure members have complete double-sided galvanised

protection.

In addition, a rust preventative material (cavity wax) is sprayed after paint application to areas such as the interior

surfaces of doors, etc. Refer to 6. CAVITY WAX in Section, 3A – Sedan, 3B – Wagon, 3C – Utility or 3D – Coupe.

Any repair or replacement of panels, assemblies, etc. that disturb this anti-corrosive treatment must be resealed

and should be included as part of the repair or replacement operation.

Anti-corrosive compounds used for repairs should be light bodied materials designed to penetrate between metal-

to-metal surfaces such as pinch weld flanges and integral panel attaching points.

All bare metal sur f ac es must be tr eated with metal conditioner and pr imed. T hes e operations need to be c arr ied out

prior to the application of sealer s, waxes and s ound deadeners. Attac hing points of new replacem ent panels s hould

be resealed. T he hemm ing flanges of replacem ent doors, lif tgates, endgates and r ear compartm ent lids will require

resealing.

Open joins that require bridging of the sealer to close a gap should be sealed with a heavy-bodied caulking material.

When colour application is required to restore repaired areas to original appearance, conventional refinishing

preparation, undercoat build-up and colour application techniques should be employed.

When deadeners are disturbed during damage repair, or a panel has been replaced, the deadener material must be

replaced with an equivalent material. The location and pattern for replacement material can be determined by

observing the original deadener application outlines. Refer to 5. BODY SEALING, ADHESIVES & DEADENERS, in

Section, 3A – Sedan, 3B – Wagon, 3C – Utility or 3D – Coupe.

1.3 PAINT REFINISHING

PANEL REFINISHING

Metal service replacement parts (or assemblies) are painted with a black, high bake factory primer. To ensure

sound adhesion of colour coats in service, the following refinish steps are necessary.

1. Clean part with a wax and grease removing solvent such as Prepsol.

2. Scuff-sand panel lightly with wet and dry number 400 paper and water. Avoid cut throughs. Reclean part, and

then apply sealer to entire part.

3. If the factory prim er coat has been cut through, apply metal conditioner to the exposed bare metal. Follow the

directions on container label.

4. Apply primer-surfacer to the entire part; allow to dry thoroughly before sanding.

5. Sand primer-surfacer using wet and dry number 400 paper and water. Do not sand sealer.

6. Re-clean part.

7. Apply colour coats to parts as directed on the container label.

8. Follow directions on container label for drying time before compounding.

9. Compound part by hand or with power equipment.

10. Non-sealing polish may be applied after rub- out if des ired. Waxes however, should not be applied until the paint

finish has aged for at least two months.

NOTE: Always follow the paint manufacturer’s recommendations to ensure a high quality durable finish is achieved.

PAINT CODE

The Paint Code for the vehicle can be found on the

Body and Option Identification Plate (1).

Figure 3-1

The Paint Code enables a ref inish paint to be m atc hed

with the original paint colour.

NOTE: The paint on the vehic le m ay not exactly m atch

the original colour due to fade, in which case paint

colour m atching will be required. As this is an acquir ed

skill, it is a task that must be performed by qualified

individuals.

Figure 3-2

Export vehicles for Brazil also have a paint label that is

located on the left-hand B-pillar and contains the paint

colour (1), paint code (2) and repair paint (3) for the

vehicle.

Figure 3-3

2. BUMPER IMPACT BAR ASSEM BLIES

2.1 FRONT

The front bumper impact bar assembly not only acts as a m ount and support for the bum per fascia, but is also

critical in the dispersion of crash energy. Hence, it plays an integral role in the operation of the vehicle’s safety

systems.

Repair of the bar assembly should be limited to replacement, as straightening and/or heating can weaken the

bar assembly, resulting in incorrect airbag and seatbelt pretensioner operation.

REMOVE

1. Remove the f ront bumper f as c ia assembly, r ef er to

2.2 FRONT BUMPER FASCIA ASSEM BLY in the

MY 2003 VY & V2 Series II Service Information.

2. If fitted, remove the radiator air lower baffle, refer

to Section 6B1 or Section 6B3 in the MY 2003 VY

& V2 Series II Service Information.

3. Remove the nuts (1), three places each side,

attaching the bar assembly (2) to the vehicle.

4. Remove the bar assembly.

Figure 3-4

REINSTALL

NOTE: Check the vehicle’s front body dimensions

as required to ensure correct alignment, refer to

Section 1A2 BODY DIMENSIONS.

1. Fit the bar assembly in position and attach each

nut. Do not tighten.

2. Ensure the bar assembly is correctly positioned

centrally and tighten the nuts to the specified

torque.

3. Refit the front bumper fascia assembly, refer to

2.2 FRONT BUMPER FASCIA ASSEM BLY in the

MY 2003 VY & V2 Series II Service Information.

FRONT BUMPER IMPACT BAR

ASSEMBLY ATTACHING NUT

TORQUE SPECIFICATION 20.0 – 30.0 Nm

2.2 REAR

REMOVE

1. Remove the rear bumper f ascia ass embly, refer to

2.5 REAR BUMPER FASCIA ASSEMBLY,

SEDAN & COUPE or 2.6 REAR BUMPER

FASCIA ASSEMBL Y , W AGON in the MY 2003 VY

& V2 Series II Service Information.

2. Remove the screws (1), two places each side,

attaching the rear bumper impact bar (2) to the

rear bumper impact bar bracket assembly (3).

3. Remove the bar.

4. If required, remove the two nuts (4), attaching the

bracket assembly to the vehicle and remove the

bracket.

Figure 3-5

REINSTALL

1. Fit the bracket assemblies in position and attach

the nuts. Tighten to the specified torque.

2. Fit the bar to the bracket assemblies and fit each

screw. Do not tighten.

3. When all screws are installed, check the bar is

centralised. Tighten the bolts to the specified

torque.

4. Refit the rear bumper fascia, refer to

2.5 REAR BUMPER FASCIA ASSEMBLY,

SEDAN & COUPE or 2.6 REAR BUMPER

FASCIA ASSEMBL Y , W AGON in the MY 2003 VY

& V2 Series II Service Information.

REAR BUMPER IMPACT BAR BRACKET

ASSEMBLY ATTACHING NUT

TORQUE SPECIFICATION 49.0 – 65.0 Nm

REAR BUMPER IMPACT

BAR ATTACHING SCREW

TORQUE SPECIFICATION 35.0 – 52.0 Nm

3. SPECIAL TOOLS

TOOL NO REF IN TEXT TOOL DESCRIPTION COMMENTS

AU170 DOOR HINGE SLEEVE

REMOVER

Used for removing door hinge pivot

sleeves

AU184 DOOR HINGE SETTING TOOL

Used to adjust door alignment.

AU303 DOOR HINGE SLEEVE

INSTALLER

Used to install door hinge pivot

sleeves

AU458 REAR CROSSMEMBER

CENTERING TOOL

Used when any service operation

requires removal / reinstallation of

rear suspension frame assembly,

or when checking rear end

alignment.

N/A SPOT CUTTING TOOL

Commercially available

Used for separating spot welds

N/A FLANGING TOOL

Commercially available

Used for making a joggle to form a

lap joint on overlapping panels.

TOOL NO REF IN TEXT TOOL DESCRIPTION COMMENTS

N/A TRACKING GAUGE

Commercially available

Used for measuring body

dimensions.

N/A POWER SAW

Commercially available

Used for cutting panels. An angle

grinder may also be used when

deemed more appropriate for the

task.