SECTION 3D – BODY CONSTRUCTION – COUPE
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
2.3 BODY ASSEM BLY
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
7. REAR SEAT BACK PANEL CENTRE
EXTENSION
REMOVE
INSTALL
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
CAUTION: The rear side rail assembly (26) contains a reinforcement that is made from High Strength Low
Alloy Steel, refer to Figure 3D-1. If damaged, the reinforcement must not be heated or straightened,
therefore, as it is not serviced separately, the entire rear side rail assembly must be replaced. Refer to
Section 2, 9. SPECIAL STEEL PRECATIONS for further information.
Legend
1. Inner Rock er P anel Assembly 21. Front Wheelhouse Panel Brack et
2. Seat Inner B racket A ssem bl y 22. Rear Floor Panel Outer E xtensi on
3. Seat Outer Bracket A ssem bl y 23. Rear Suspensi on S upport Mount Plate
4. Front Floor Panel A ssem bly 24. Rear Tie Down Assembl y
5. Transm i ssion Support Bracket 25. Rear Brake Hose B racket
6. Front Floor Panel E xtens i on 26. Rear Side Rail Ass embly
7. Front Side Rail Brace 27. Rear Bumper I mpact Bar Brace Assembly, LH / RH
8. Front Wheelhous e Panel Assembly 28. Crossmember A ssem bl y No. 2
9. Horn Brack et Assembly 29. Propeller Shaf t Hanger Ass embly
10. ABS Modulator B racket A ssem bl y 30. Rear Floor Panel Reinforcement , LH
11. Battery Tray A ssem b l y 31. Rear Seat Belt Anchor P l ate Ass embly
12. Front End Panel A ssem bl y 32. Rear Floor Panel As sembly
13. Headlamp Panel 33. Rear Floor Panel Reinforcement , RH
14. Headlamp & Front Fascia Mount B racket 34. Rear Compartment Floor P anel Outer Extension, RH
15. Fender Front Lower Bracket 35. Spare Wheel Anc hor Plate As sembly
16. Radiator Lower Support As sembly 36. Fuel Tank Support Rei nforcem ent Ass embly
17. Front Side Rail Assembly 37. Rear Compartment Floor P anel A ssem bl y
18. Radiator Side Mounti ng B racket 38. Rear Compartment Floor P anel Outer Extension, LH
19. Front Wheelhouse Bracket A ssem bl y 39. Rear End Panel Assem bl y
20. Front Bum per Impac t Bar Bracket 40. Rear End Lower Panel
Figure 3D-1
2.2 UPPERBODY STRUCTURE
Legend
1. Hinge Pillar Trim Panel Bracket 17. Tail Lamp Housing
2. Hinge Pillar Inner Panel Assembly 18. Rear Wheelhouse Inner Panel Assembly
3. Front Wheelhouse Panel Upper Side Rail 19. Rear Seat Back Panel Extension
4. Front Fender 20. Rear Seat Back Panel Extension Assembly
5. Rocker Panel Moulding Bracket 21. Rear Window Panel Assembly
6. Fender Lower Rear Bracket 22. Rear Compartment Lid Strut Bracket Assembly
7. Fender Rear Bracket 23. Rear Seat Back Panel Centre Extension
8. Door Opening Frame Assembly 24. Fuel Filler Pipe Housing, RH
9. Fender Upper Rear Bracket 25. Quarter Panel Inner Assembly
10. Front Door Striker Anchor Plate 26. Hinge Pillar Upper Reinforcement
11. Body Pillar Inner Panel Reinforcement 27. Radio Quarter Speaker Bracket
12. Underbody Jacking Locator 28. Roof Bow Panel
13. Rear Quarter Panel 29. Roof Front Header Panel
14. Quarter Panel Lower Extension 30. Roof Panel
15. Bracket - rear lamp wiring harness extension 31. Roof Rear Panel
16. Quarter Panel Uppert Extension
Figure 3D-2
2.3 BODY ASSEMBLY
Legend
1. Body Assembly 8. Front Door Assembly
2. Dash Panel Assembly 9. Front Door Hinge (Body Side)
3. Rear Compartment Lid Hinge Assembly 10. Front Door Hinge (Door Side)
4. Rear Compartment Lid Assembly 11. Front Door Outer Panel
5. Rear Bumper Impact Bar 12. Hood Hinge Assembly
6. Rear Bumper Impact Bar Bracket Assembly 13. Hood assembly
7. Front Bumper Impact Bar Assembly
Figure 3D-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 3D-5.
The main datum hole (2) is a 19 mm hole on the front side rail assembly, refer to Figure 3D-5.
The dash panel assembly attaching hole (3) in Figure 3D-5 is the datum hole also depicted at View C in
Figure 3D-4.
Figure 3D-4
Figure 3D-5
3.2 UPP ERBODY DIMENSIONS – ACTUAL
FRONT
Figure 3D-6
SIDE & INTERIOR
Figure 3D-7
REAR
Figure 3-8
4. BODY M ARGINS
Figure 3D-9
Figure 3D-10
Figure 3D-11
5. BODY SEALING, ADHESIVES AND DEADENERS
This Sect ion details the s ealers, adhes ives and deadeners used in the MY 2003 V2 Series II Coupe body shell. It is
imperative that the correct materials are used and the directions on the product are always 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 ecommended f or all s er vice r epair 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 Figures 3D-12 – 3D-14.
Joint Sealer (Item 3)
Prim ar ily used f or s ealing j oints to ac hieve a watertight s eal. It s eals notc hes , c utouts and holes . J oint s ealer s hould
be applied after priming, prior to application of the top coat. Refer to Figures 3D-15 – 3D-20.
NOTE 1: Figure 3D-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.
NOTE 2: During pr oduction a heat fusible patch is applied along the joint of the back panel - upper , ref er Fig 3D-17
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 3D-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 3D-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 3D-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 3D-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 3D-24 – 3D-27 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 levelling: 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 3D-12
Legend
1. Frame Assembly - Door opening
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 3D-13
Legend
1. Side Panel - Outer
2. Frame Assembly - Door opening 3. Side Panel Assembly - Inner
ACRYLIC SPOT WELD SEALER (ITEM 2) CONTINUED
Figure 3D-14
Legend
1. Side Panel - Outer 2. Side Panel Assembly - Inner
5.2 JOINT SEALER (ITEM 3)
Figure 3D-15
JOINT SEALER (ITEM 3) CONTINUED
Figure 3D-16
JOINT SEALER (ITEM 3) CONTINUED
Figure 3D-17
JOINT SEALER (ITEM 3) CONTINUED
Figure 3D-18
JOINT SEALER (ITEM 3) CONTINUED
Figure 3D-19
JOINT SEALER (ITEM 3) CONTINUED & HAND PUTTY (ITEM 4)
Figure 3D-20
5.3 ADHESIVE – ANTI-FLUTTER (ITEM 5)
Figure 3D-21
5.4 ADHESIVE – STRUCTURAL (ITEM 6)
Figure 3D-22
Legend
1. Reinforcement - B-pillar Upper
2. Reinforcement - C-pillar 3. A-pillar - Inner
4. Side Panel - Inner
5.5 SPRAY-ON DEADENER
Figure 3D-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 3D-24
Legend
1. Deadener - Front Floor, RH
2. Deadener - Rear Floor, RH
3. Deadener - Rear Floor, Centre
4. Deadener - Floor, Rear Seat, RH
5. Deadener - Spare Wheel Well
6. Deadener - Floor, Rear Seat LH
7. Deadener - Rear Floor, LH
8. Deadener - Front Floor, LH
9. Deadener Front Floor, Centre
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 3D-25
Legend
1. Insulator - Dash Panel Upper
2. Deadener - Cockpit Module
The deadeners and insulators in Figures 3D-26 & 3D-27 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: Ens ure the notch in the rear s eat insulators (3) in Figur e 3D-27 is aligned with the slot in the rear seat ram p
as shown A.
Figure 3D-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 3D-27
Legend
1. Insulator - Rear Seat Wheelhouse, LH
2. Insulator - Rear Seat Wheelhouse, RH
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. W here poss ible, apply the patches to the new f loor
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. Us ing a heat gun or drying lam ps, etc. evenly heat
the m aterial until it sm oothes and the edges begin
to ‘soften’.
Figure 3D-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
The MY 2003 V2 Series II Coupe 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 3D-29
7. REAR SEAT BACK PANEL CENTRE EXTENSI ON
As the rear seat does not have a hatch into the rear compartment, the filler panel is fitted to provide protection
against luggage entering the passenger compartment in the event of a collision.
REMOVE
1. Remove the rear seat assembly, refer to
Section 1A7 SEAT ASSEM BLIES in the MY 2003
VY & V2 Series II Service Information.
2. Remove the four nuts (1) attaching the filler panel
(2) to the back panel assembly - upper.
3. Remove the filler panel form its mounting studs
(3).
Figure 3D-30
INSTALL
Installation is the reverse of removal. Tighten the nuts
to the specified torque.
FILLER PANEL - BACK PANEL
UPPER ATTACHING NUT
TORQUE SPECIFICATION 2.0 – 5.0Nm