SECTION 3A – BODY CONSTRUCTION – SEDAN

IMPORTANT

Before performing any Service Operation or other procedure described in this 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

2. BODY STRUCTURE PANELS

2.1 FRONT END & UNDERBODY

2.2 UPPERBODY STRUCTURE,

EXCLUDING ROOF STRUCTURE

2.3 ROOF STRUCTURE

2.4 BODY ASSEMBLY

3. BODY DIMENSIONS

3.1 UNDERBODY DIMENSIONS –

PROJECTED

3.2 UPPERBODY DIMENSIONS – ACTUAL

FRONT

SIDE & INTERIOR

REAR

4. BODY MARGINS

5. BODY SEALING, ADHESIVES & DEADENERS

5.1 ACRYLIC SPOTWELD SEALER

5.2 JOINT SEALER

5.3 ADHESIVE – ANTI-FLUTTER

5.4 ADHESIVE – STRUCTURAL

5.5 SPRAY-ON DEADENER

5.6 DEADENER PANELS & INSULATORS

5.7 FUSIBLE REINFORCEMENT PATCHES

REPLACE

6. CAVITY WAX

1. GENERAL DESCRI PTI O N

This Section contains body construction information specific to MY 2003 VY Series Sedan vehicles. For body

construction information relevant to all models, refer to Section 3, GENERAL BODY CONSTRUCTION.

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 f eatures a hous ing assem bly in place of the roof bow panel. A stainless steel f ront drain

tube is also fitted within the hinge pillar cavity which effects the service procedures for the hinge pillar, refer to

Section 7A BODY SIDE – SEDAN and Section 9 ROOF.

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 your authorised Retailer for spare parts availability configurations.

2.1 FRONT END & UNDERBODY

Legend

1. Inner Rocker Panel Assembly 22. Rear Floor Panel Outer Extension

2. Seat Inner Bracket Assembly 23. Rear Suspension Support Mount Plate

3. Seat Outer Bracket Assembly 24. Rear Tie Down Assembly

4. Front Floor Panel Assembly 25. Rear Brake Hose Bracket

5. Transmission Support Bracket 26. Rear Side Rail Assembly

6. Front Floor Panel Extension 27. Rear Bumper Impact Bar Brace Assembly, LH / RH

7. Front Side Rail Brace 28. Crossmember Assembly No. 2

8. Front Wheelhouse Panel Assembly 29. Propeller Shaft Hanger Assembly

9. Horn Bracket Assembly 30. Rear Floor Panel Reinforcement, LH

10. ABS Modulator Bracket Assembly 31. Rear Seat Belt Anchor Plate Assembly

11. Battery Tray Assembly 32. Rear Floor Panel Assembly

12. Front End Panel Assembly 33. Rear Floor Panel Reinforcement, RH

13. Headlamp Panel 34. Rear Compartment Floor Panel Outer Extension, RH

14. Headlamp & Front Fascia Mount Bracket 35. Spare Wheel Anchor Plate Assembly

15. Fender Front Lower Bracket 36. Fuel Tank Support Reinforcement Assembly

16. Radiator Lower Support Assembly 37. Rear Compartment Floor Panel Assembly

17. Front Side Rail Assembly 38. Rear Compartment Floor Panel Outer Extension, LH

18. Radiator Side Mounting Bracket 39. Rear End Panel Assembly

19. Front Wheelhouse Bracket Assembly 40. Rear End Panel Extension, LH

20. Front Bumper Impact Bar Bracket 41. Rear End Panel Extension, RH

21. Front Wheelhouse Panel Bracket 42. Rear End Lower Panel

Figure 3A-1

2.2 UPPERBODY STRUCTURE, EXCLUDING ROOF STRUCTURE

Legend

1. Hinge Pillar Trim Panel Bracket 17. Tail Lamp Housing

2. Hinge Pillar Inner Panel Assembly 18. Wiring Harness Bracket

3. Front Wheelhouse Panel Upper Side Rail 19. Quarter Panel Upper Extension

4. Front Fender 20. Rear Wheelhouse Inner Panel Assembly

5. Fender Lower Rear Bracket 21. Rear Seat Back Panel Extension

6. Fender Rear Bracket 22. Rear Seat Back Panel Extension Assembly

7. Door Opening Frame Assembly 23. Rear Window Panel Assembly

8. Fender Upper Rear Bracket 24. Rear Compartment Lid Strut Bracket Assembly

9. Front Door Striker Anchor Plate 25. Tail Lamp Housing Brace

10. Rear Door Check Link Bracket 26. Fuel Filler Pipe Housing, RH

11. Rear Door Striker Anchor Plate 27. Quarter Panel Inner Assembly

12. Underbody Jacking Locator 28. Sunroof front drain tube*

13. Rear Quarter Panel 29. Hinge Pillar Upper Reinforcement

14. Quarter Panel Lower Extension 30. Quarter Panel Inner Extension

* Shown for reference only, not serviced individually

Figure 3A-2

2.3 ROOF STRUCTURE

1. Roof Panel 4. Roof Rear Panel

2. Roof Front Header Panel 5. Roof Panel As sembly (with S unroof)

3. Roof Bow Panel

Figure 3A-3

2.4 BODY ASSEMBLY

Legend

1. Body assembly 10. Rear Door Hinge (body side)

2. Dash Panel Assembly 11. Front Door Assembly

3. Rear Compartment Lid Hinge Assembly 12. Front Door Hinge (body side)

4. Rear Compartment Lid Assembly 13. Front Door Hinge (door side)

5. Rear Bumper Impact Bar 14. Front Door Outer Panel

6. Rear Bumper Impact Bar Bracket Assembly 15. Hood Hinge Assembly

7. Rear Door Assembly 16. Hood assembly

8. Rear Door Outer Panel 17. Front Bumper Impact Bar Assembly

9. Rear Door Hinge (Door Side)

Figure 3A-4

3. BODY DIMENSIO NS

3.1 UNDERBODY DIME NSIONS – PROJECTE D

All dimensions are given in mm and are measured from the centre of holes, on the outer side of the metal surface.

The main datum surface (1) is the underside of the front side rail assembly, refer to Figure 3A-6

The main datum hole (2) is a 19 mm hole on the underside of the front side rail assembly, refer to Figure 3A-6.

The dash panel assembly attaching hole (3) in Figure 3A- is the datum hole also depicted at View C in

Figure 3A-5.

Figure 3A-5

Figure 3A-6

3.2 UPP ERBODY DIMENSIONS – ACTUAL

FRONT

Figure 3A-7

SIDE & INTERIOR

Figure 3A-8

REAR

Figure 3A-9

4. BODY M ARGINS

Figure 3A-10

Figure 3A-11

Figure 3A-12

5. BODY SEALING, ADHESIVES AND DEADENERS

This Section details the sealers, adhesives and deadeners used in the MY 2003 VY Series Sedan 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.

IMPORTANT: 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.

Weld Through Primer (Item 1)

Although not us ed in manuf ac ture , Weld T hr ough Pr imer is r ec ommended for all s ervic e repair lap and f lange j oints

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 Figures 3A-13 & 3A-14.

Joint Sealer (Item 3)

Primarily used for sealing joints to achieve a watertight seal. It seals notches, cut-outs and holes. Joint sealer

should be applied after priming, prior to application of the top coat. Refer to Figures 3A-15 – 3A-20

NOTE 1: Figure 3A-16, 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.

NOTE 2: During production a heat fusible patch is applied along the joint of the back panel - upper, refer Figure

3A-18 View E.

This patch is not serviced as the heat required to fuse it is beyond the capabilities of the repairer. Joint sealer may

be applied and finished to produce a smooth surface.

Hand Putty (Item 4)

Hand putty, also known as caulking compound, is used in the areas marked * in Figure 3A-20.

Adhesive - Anti-Flutter (Item 5)

W hile used as a filler between an inner and outer panel to reduce panel f lex, Anti-Flutter adhesive also aids rigidity

and assists in dispersing loads over a larger area. Refer to Figure 3A-21 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 reduce the performance of the joint. Using an adhesive that is too strong can also

effect the performance of the joint, compromising the vehicle’s crash performance and safety system’s operation.

This adhesive is a 2-part system. Refer to Figure 3A-22 for locations.

Spray-on Deadener (Item 7)

This deadener is sprayed 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 applications. Refer to Figure 3A-23 for locations.

Deadener Panels

Deadener panels are sold pre-cut as Service Parts. They are installed with the coloured side up and diamond

embos sed side down. The panels are installed pr ior to painting and som e ar e heat fused to the body shell. Refer to

Figures 3A-24 – 3A-27 for locations.

SEALER / ADHESIVE / DEADENER

COMMERCIALLY AVAILABLE 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)

Visible Seams

-self leveling: Lord (Fusor)

-non sag: Lord (Fusor)

Fusor #802

Fusor #800 / #801

Automix 8308

Fusor #122 / #125

Automix 8307

Fusor #123 / #126

Automix 8308

4 Hand Putty Lord (Fusor)

3M 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.

5.1 ACRYLIC SPOT WELD SEALER (ITEM 2)

Figure 3A-13

Legend

1. Door Opening Frame

2. Reinforcement - Hinge A-pillar

3. Shroud Side Panel

4. Closing Plate - A-pillar

5. Brace - Front Wheelhouse

ACRYLIC SPOT WELD SEALER (ITEM 2) CONTINUED

Figure 3A-14

5.2 JOINT SEALER (ITEM 3)

Figure 3A-15

JOINT SEALER (ITEM 3) CONTINUED

Figure 3A-16

JOINT SEALER (ITEM 3) CONTINUED

Figure 3A-17

JOINT SEALER (ITEM 3) CONTINUED

Figure 3A-18

JOINT SEALER (ITEM 3) CONTINUED

Figure 3A-19

JOINT SEALER (ITEM 3) CONTINUED & HAND PUTTY (ITEM 4)

Figure 3A-20

5.3 ADHESIVE – ANTI-FLUTTER (ITEM 5)

Figure 3A-21

5.4 ADHESIVE – STRUCTURAL (ITEM 6)

Figure 3A-22

5.5 SPRAY-ON DEADENER

Figure 3A-23

5.6 DEADENER PANELS & INSULATORS

The deadener panels shown are heat fusible type. They are to be ins talled with the diamond em bossed side down.

Use a heat gun, heat lamps or such to cure each deadener sheet.

Figure 3A-24

Legend

1. Deadener - Front Floor, RH

2. Deadener - Front Floor, Centre

3. Deadener - Front Floor, LH

4. Deadener - Rear Floor, RH

5. Deadener - Rear Floor, Centre

6. Deadener - Floor Rear, LH

7. Deadener - Floor, Rear Seat RH

8. Deadener - Floor, Rear Seat LH

9. Deadener - Spare Wheel Well

The insulator (1) is self adhesive. To install, remove the backing paper and attach the insulator ensuring any cut-

outs align with brackets etc. Smooth the insulator firmly into position. The deadener (2) is a heat cure type and is

attached as previously described.

Figure 3A-25

Legend

1. Insulator - Dash Panel Upper

2. Deadener - Cockpit Module

The deadeners and insulators in Figures 3A- & 3A- are self adhesive. Remove the backing paper and attach the

insulator ensuring any cut-outs align with brackets etc. Smooth the insulator firmly into position.

NOTE: Ensure the notc h in the rear s eat insulators (3) in Figur e 3A- is aligned with the slot in the rear seat ramp as

shown A.

Figure 3A-26

Legend

1. Insulator - Cowl Side, LH

2. Deadener - Front Floor Extension, LH

3. Deadener - Front Floor Extension, RH

4. Insulator - Cowl Side, RH

Figure 3A-27

Legend

1. Insulator - Rear Seat Wheelhouse, RH

2. Insulator - Rear Seat Wheelhouse, LH

3. Insulator - Rear Seat

5.7 FUSI BLE REINFORCEMENT PATCHES

Two heat fusible reinforcing patches (1) are applied to

the front floor tunnel which provide stiff ness and aid in

the reduction of Noise, Vibration & Harshness (NVH).

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

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 your Authorised Dealer.

REPLACE

1. Where possible, apply the 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 drying lam ps, etc. evenly heat

the m aterial until it sm oothes and the edges begin

to ‘soften’.

Figure 3A-28

4. Smooth the material down with a roller or like, to

ensure no air bubbles are present and to maximise

adhesion.

5. Once cooled, the material should feel hard.

6. CAVITY WAX

MY 2003 VY Series Sedan body and structural panels are constructed from high quality corrosion resistant

materials. During manufacture, cavity wax is applied to the areas shown to further increase the vehicle’s anti-

corrosive properties.

Following repairs, to m aintain the anti-corrosive properties of the vehicle, once the paint is thoroughly dry apply

cavity wax to the areas shown below, and within any repaired box sections or areas inaccess ible to paint. Refer

to the table for equivalent products to those used in manufacture.

CAVITY WAX EQUIVALENTS

Item No. Equivalent Manufacturer Equivalent Product Name

8 Henkel Terotex HV 8377/65

Nox Rust Hi-Wax 100B

Terasol 800113 (Aerosol pack)

Figure 3A-29

Figure 3A-30