SECTION 3C – BODY CONSTRUCTION – UTILITY
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 MY2003 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
2.3 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 DEADENERS & INSULATORS
5.7 FUSIBLE REINFORCEMENT PATCH
REPLACE
6. CAVITY WAX
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 24. Rear Tie Down Assembly
2. Seat Inner Bracket Assembly 25. Rear Brake Hose Bracket
3. Seat Outer Bracket Assembly 26. Rear Side Rail Assembly
4. Front Floor Panel Assembly 27. Crossmember Assembly No. 2
5. Transmission Support Bracket 28. Spare Wheel Support, LH
6. Front Floor Panel Extension 29. Load Floor Reinforcement Rail, LH
7. Front Side Rail Brace 30. Spare Wheel Support
8. Front Wheelhouse Panel Assembly 31. Load Floor Centre Rail Assembly
9. Horn Bracket Assembly 32. Spare Wheel Support, RH
10. ABS Modulator Bracket Assembly 33. Load Floor Reinforcement Rail, RH
11. Battery Tray Assembly 34. Rear End Panel
12. Front End Panel Assembly 35. Endgate Hinge Bracket Assembly (body side)
13. Headlamp Panel 36. Rear End Lower Panel
14. Headlamp & Front Fascia Mount Bracket 37. Load Floor Panel Reinforcement
15. Fender Front Lower Bracket 38. Load Floor Panel
16. Radiator Lower Support Assembly 39. Fuel Tank Bracket Assembly
17. Front Side Rail Assembly 40. Load Floor Front Panel Assembly
18. Radiator Side Mounting Bracket 41. Rear Floor Panel Assembly
19. Front Wheelhouse Bracket Assembly 42. Jack Stowage Bracket Assembly
20. Front Bumper Impact Bar Bracket 43. Propeller Shaft Hanger Assembly
21. Front Wheelhouse Panel Bracket 44. Front Floor Rear Extension Assembly
22. Rear Floor Panel Outer Extension 45. Front Floor Rear Extension Reinforcement
23. Rear Suspension Support Mount Plate 46. Fuel Tank Bracket Assembly
Figure 3C-1
2.2 UPPERBODY STRUCTURE
Legend
1. Roof Front Header Panel 22. Quarter Inner Lower Rear Extension
2. Roof Panel 23. Cargo Tie-Down Bracket Anchor Plate Assembly
3. Roof Rear Panel 24. Rear Wheelhouse Bracket
4. Hinge Pillar Trim Panel Bracket 25. Load Floor Panel Outer Reinforcement
5. Hinge Pillar Inner Panel Assembly 26. Load Floor Panel Outer Extension
6. Quarter Panel Inner Extension 27. Quarter Panel Inner Assembly
7. Side Inner Upper Front Panel 28. Quarter Inner & Rear Wheelhouse Brace
8. Seat Belt Guide Anchor Plate Assembly 29. Quarter Panel Upper Extension
9. Fuel Filler Pipe Housing, RH 30. Quarter Outer Lower Rear Panel
10. Rear Wheelhouse Outer Extension 31. Quarter Panel Extension
11. Front Seat Back Panel 32. Rear Quarter Panel
12. Load Compartment Extension Panel Bracket 33. Door Opening Frame Assembly
13. Load Compartment Extension Outer Panel 34. Underbody Jacking Locator
14. Front Seat Back Panel Outer 35. Fender Rear Bracket
15. Rear Inner Side Panel Cover 36. Fender Lower Rear Bracket
16. Front Inner Side Panel Cover 37. Front Door Striker Anchor Plate
17. Rear Wheelhouse Inner Panel 38. Hinge Pillar Upper Reinforcement
18. Cargo Tie-Down Bracket 39. Fender Upper Rear Bracket
19. Side Inner Upper Panel 40. Front Wheelhouse Panel Upper Side Rail
20. Endgate Striker Anchor Plate Retainer 41. Front Fender
21. Quarter Lower Rear Panel
Figure 3C-2
2.3 BODY ASSEMBLY
Legend
1. Body assembly 7. Front Door Assembly
2. Dash Panel Assembly 8. Front Door Hinge (Door Side)
3. Front Bumper Impact Bar Assembly 9. Front Door Hinge (Body Side)
4. Hood assembly 10. Endgate Outer Panel
5. Hood Hinge Assembly 11. Endgate Assembly
6. Front Door Outer Panel 12. Endgate Hinge Assembly
Figure 3C-3
3. BODY DIMENSIONS
3.1 UNDERBODY DIME NSIONS – PROJECTE D
All dimensions are given in mm and are measured from the centre of holes, on the outside of the metal surface.
The main datum surface (1) is the underside of the front side rail assembly, refer to Figure 3C-5.
The main datum hole (2) is a 19 mm hole on the underside of the front side rail assembly, refer to Figure 3C-5.
The dash panel assembly attaching hole (3) in Figure 3C-5 is the datum hole also depicted at View C in
Figure 3C-4.
Figure 3C-4
Figure 3C-5
3.2 UPP ERBODY DIMENSIONS – ACTUAL
FRONT
Figure 3C-6
SIDE & INTERIOR
Figure 3C-7
REAR
Figure 3C-8
4. BODY M ARGINS
Figure 3C-9
Figure 3C-10
Figure 3C-11
Figure 3C-12
5. BODY SEALING, ADHESIVES AND DEADENERS
This Section details the sealers, adhesives and deadeners used in the MY 2003 VY Series Utility body shell. It is
imperative that the correct materials are used and the directions on the product always are 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- Through Primer is r eco mm ended f o r all s er vice r epair 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 3C-13 – 3C-17.
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 3C-18 – 3C-24.
Hand Putty (Item 4)
Hand putty, also known as caulking compound, is used in the areas marked * in Figure 3C-24.
Adhesive - Anti-Flutter (Item 5)
W hile 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 3C-25 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 Figures 3C-26 & 3C-27 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 3C-28 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 3C-29 – 3C-31 for locations.
SEALER / ADHESIVE / DEADENER
COMMERCIA LLY 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)
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)
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 3C-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 3C-14
Legend
Section A-A
1. Side panel - outer
2. Door opening frame assembly
3. Side panel - inner
Section B-B
1. Reinforcement - B-pillar
2. Side panel - outer upper
ACRYLIC SPOT WELD SEALER (ITEM 2) CONTINUED
Figure 3C-15
Legend
Section A-A & B-B
1. Door opening frame assembly
2. Reinforcement - B-pillar
3. Side panel - outer
Section C-C
1. Side panel - outer
2. Gusset assembly - tail lamp
ACRYLIC SPOT WELD SEALER (ITEM 2) CONTINUED
Figure 3C-16
Legend
Section A-A
1. Door opening frame assembly
2. Side panel - outer
Section B-B & C-C
1. Side panel - inner
2. Side panel - outer
ACRYLIC SPOT WELD SEALER (ITEM 2) CONTINUED
Figure 3C-17
Legend
Section A-A
1. Door opening frame assembly
2. Side panel - outer
Section B-B
1. Endgate - inner
2. Endgate - outer
Section C-C & D-D
1. Side panel - outer
2. Door opening frame assembly
3. Side panel - inner
5.2 JOINT SEALER (ITEM 3)
Figure 3C-18
JOINT SEALER (ITEM 3) CONTINUED
Figure 3C19
JOINT SEALER (ITEM 3) CONTINUED
Figure 3C-20
JOINT SEALER (ITEM 3) CONTINUED
Figure 3C-21
JOINT SEALER (ITEM 3) CONTINUED
Figure 3C-22
JOINT SEALER (ITEM 3) CONTINUED
Figure 3C-23
JOINT SEALER (ITEM 3) CONTINUED & HAND PUTTY (ITEM 4)
Figure 3C-24
5.3 ADHESIVE – ANTI-FLUTTER (ITEM 5)
Figure 3C-25
5.4 ADHESIVE – STRUCTURAL (ITEM 6)
Figure 3C-26
Legend
Section A-A
1. Roof panel
2. Door opening frame assembly
Section B-B
1. Side panel - outer upper
2. Door opening frame assembly
Section C-C
1. Frame - side front roof
2. A-pillar - inner
Section D-D
1. Extension - tonneau floor side
2. Floor - tonneau rear
Section E-E
1. Floor side panel
2. Side panel - inner
3. Door opening frame assembly
4. Side panel - outer
Section F-F
1. Floor assembly - tonneau rear
2. Rear floor assembly - front
ADHESIVE – STRUCTURAL (ITEM 6) CONTINUED
Figure 3C-27
Legend
Section A-A
1. Door panel - inner
2. Door panel - outer
Section B-B
1. Wheelhouse - inner
2. Rear floor assembly - front
Section C-C
1. Endgate - inner
2. Endgate - outer
5.5 SPRAY-ON DEADENER
Figure 3C-28
5.6 DEADENERS & INSULATORS
The deadeners shown are heat fusible type. They are to be installed with the diamond embossed side down.
Use a heat gun, heat lamps or such to cure each deadener sheet.
Figure 3C-29
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
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 3C-30
Legend
1. Insulator - Dash Panel Upper
2. Deadener - Cockpit Module
The deadeners and insulators in Figure 3C-31 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.
Figure 3C-31
Legend
1. Insulator - Cowl Side, LH
2. Deadener - Front Floor Extension, LH
3. Deadener - Front Floor Extension, RH
4. Insulator - Cowl Side, RH
5.7 FUSI BLE REINFORCEMENT PATCH
A heat fusible reinforcing patch (1) is applied to the
floor panel below the fuel tank that provides stiffness
and aids in the reduction of Noise, Vibration &
Harshness (NVH).
It is pliable in its uncured state and is applied to the
vehicle prior to paint baking. The heat r equired to cure
and harden the sheet is approximately 120° C, and
once cured the sheet becomes a structural part of the
vehicle. Therefore, if the rear floor assembly is
replaced, the patch must also be replaced.
A Lower curing temperature replacement patch is
available from your Authorised Dealer.
REPLACE
1. Where possible, apply the patch to the new floor
panel prior to painting.
2. Ensure the surface is clean, dry and free from weld
spatter, etc.
3. Apply the patch in the location shown.
4. Using a heat gun or drying lamps, etc . evenly heat
the m aterial until it sm oothes and the edges begin
to ‘soften’.
Figure 3C-32
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 Utility body and structural panels are constructed from high quality corrosion resistant
materials.
Following repairs, to m aintain the anti-corrosive properties of the vehicle, once the paint is thoroughly dry apply
cavity wax within any repaired box s ections, areas inac cessible to paint, and to the areas shown below. 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 3C-33
Figure 3C-34