SECTION 4 – FRONT END

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 FRONT END COMPONENTS

2. SERVICE OPERATIONS

2.1 FRONT END PANEL ASSEMBLY – REPLACE

REMOVE

REPLACE

2.2 HEADLAMP PANEL – REPLACE

REMOVE

REPLACE

2.3 FRONT WHEELHOUSE BRACKET

ASSEMBLY, FRONT WHEELHOUSE

BRACKET & FRONT BUMPER IMPACT BAR

BRACKET ASSEMBLY – REPLACE

REMOVE

REPLACE

2.4 RADIATOR LOWER SUPPORT ASSEMBLY –

REPLACE

REMOVE

REPLACE

2.5 FRONT WHEELHOUSE PANEL UPPER

SIDE RAIL – REPLACE

REMOVE

REPLACE

2.6 FRONT WHEELHOUSE PANEL ASSEMBLY –

REPLACE

REMOVE

REPLACE

2.7 FRONT WHEELHOUSE PANEL & FRONT

SIDE RAIL – PARTIAL REPLACE*

REMOVE

REPLACE

* Includes Hydraulic Modulator Bracket

2.8 FRONT SIDE RAIL ASSEMBLY – REPLACE

REMOVE

REPLACE

1. GENERAL DESCRI PTI O N

This Sect ion desc r ibes the replacement pr ocedur es f or the front-end c omponents of the MY 2003 VY & V2 Series II

body s tructur e. Rem oval of bolt- on panels and m echanic al com ponents is not c overed. Referenc e mus t be made to

the appropriate Section of the MY 2003 VY & V2 Series II Service Information.

When repairing the front end of the vehicle, care must be taken to ensure the structure is returned to its original

production configuration for the occupant protection system to operate correctly. This is especially important with

repairs to the front side rails.

Incorrect repair of the front side rails could cause the seatbelt pretensioners and airbag(s) to operate incorrectly,

affecting the timing of deployment during a collision.

The following strategy must be used when repairing the front side rails of a MY 2003 VY & V2 Series II vehicle:

1. If minor damage has occurred to the front section of the front side rail, which does not involve significant

creasing or crumple of the rail, it may be straightened.

2. If significant creasing or crumple of the rail has occurred, but is restricted to the area forward of the front

suspension crossmember, the front side rail may be cut at a point between the two crossmember mounting

bolts and a partial section welded in place as described in this Section.

3. If significant creasing or crumple of the rail has occurred and continues rearward of the front suspension

crossmember, the full front side rail assembly must be replaced.

NOTE: It is imperative that the correct body adhesives, sealers, deadeners and cavity waxes are used when

repairing the body structure of MY 2003 VY & V2 Series II vehicle. Refer to 5. BODY SEALING, ADHESIVES &

DEADENERS and 6. CAVITY W AX in Section 3A (Sedan), 3B (Wagon), 3C (Utility) or 3D (Coupe) for details of

the correct materials and their commercially available equivalents.

1.1 FRONT END COMPONENTS

The shaded components in Figure 4-1 are those dealt

with in this Section.

The components and assemblies shown in Figure 4-2

are the parts serviced for MY 2003 VY & V2 Series II

vehicles which form the basis of the repair procedures

in this Section. For a detailed view of the MY 2003 VY

& V2 Series II body components, refer to Section

3A (Sedan), 3B (Wagon), 3C (Utility) or 3D (Coupe).

NOTE: Always refer to your Authorised Retailer for

latest spare parts availability configurations.

Figure 4-1

Figure 4-2

Legend

1. Front End Panel Assembly

2. Headlamp Panel

3. Headlamp & Front Fascia Mount Bracket

4. Radiator Side Mounting Bracket

5. Front Wheelhouse Bracket Assembly

6. Front Bumper Impact Bar Bracket

7. Front Wheelhouse Panel Bracket

8. Radiator Lower Support Assembly

9. ABS Modulator Bracket Assembly

10. Horn Bracket Assembly

11. Front Wheelhouse Panel Assembly

12. Front Side Rail Assembly

13. Front Wheelhouse Panel Upper Side Rail

NOTE 1: Front end panel assembly (1) includes parts 2 & 3.

NOTE 2: Front side rail assembly (12) includes parts 4, 5, 6 and 7.

2. SERVICE OPERATIONS

2.1 FRONT END PANEL ASSEMBLY – REPLACE

REMOVE

1. Remove the adjacent bolt-on panels and

components as described in the appropriate

Section of the MY 2003 VY & V2 Series II Service

Information.

2. Remove the front bumper impact bar assembly,

refer to Section 3, 2. BUMPER IMPACT BAR

ASSEMBLIES.

3. If required, mount the vehicle on a suitable jig or

secure an appropriate tool between the two front

wheelhouse panels to maintain correct body

alignment when the front panel is removed.

Figure 4-3

4. On each side of the vehicle, spot cut the welds

attaching the front end panel upper (1) to the front

wheelhouse panel (2). Four welds are on the

horizontal surface and two on the vertical flange.

Refer to weld group A.

5. Spot cut a total of 10 welds on each side of the

vehicle, attaching the headlamp panel (3) to the

front wheelhouse panel (2) and to the wheelhouse

upper side rail (4). Refer to weld group B.

Figure 4-4

6. On each side of the vehicle, spot cut the welds

attaching the front wheelhouse bracket assembly

(1) to the front end panel upper (2) and headlamp

panel (3). Refer to weld group A.

7. On each side of the vehicle, spot cut the three

welds on the vertical flange attaching the

headlamp panel and front end panel upper to the

front wheelhouse bracket assem bly. Refer to weld

group B.

Figure 4-5

8. On each side of the vehicle, spot cut the welds

attaching the front wheelhouse bracket assembly

(1) to the front end panel upper (2) and headlamp

panel (3).

Figure 4-6

9. On each side of the vehicle, spot cut the welds

attaching the headlamp & front fascia mount

bracket (1) and headlamp panel (2) to the front

wheelhouse panel. Refer to weld group A.

10. Spot cut the two welds on each side of the vehicle

attaching the headlamp & front fascia mount

bracket to the front wheelhouse panel bracket (3).

Refer to weld group B.

11. Remove the complete front end panel assembly

from the vehicle and then repair any damage to

the adjacent parts as required.

12. Check and rectify the alignment of the body as

required, refer to 3. BODY DIMENSIONS in

Section 3A (Sedan), 3B (Wagon), 3C (Utility) or

3D (Coupe).

Figure 4-7

REPLACE

NOTE 1: Spot welding is the preferred method for attaching of panels and should be used whenever possible.

Where the spot welding equipment will not access the required weld position, a plug weld should be performed.

NOTE 2: The s ame number and pos ition of s pot welds (or plug welds) should be used when replac ing the panel,

as was used during manufacture, in order to maintain the original structural strength of the vehicle.

1. As required, mark the new panel with drilling locations in preparation for plug welding. Drill holes as required.

2. Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to 5. BODY

SEALING, ADHESIVES & DEADENERS in Section 3A (Sedan), 3B (Wagon), 3C (Utility) or 3D (Coupe).

3. Install the panel in position and secure with clamps.

4. Temporarily install the fenders and hood and

check the alignment and margins. Refer to

4. BODY MARGINS in Section 3A (Sedan),

3B (Wagon), 3C (Utility) or 3D (Coupe). Adjust

where necessary, and then remove fenders and

hood.

Figure 4-8

5. Spot weld the headlamp & front fascia mount

bracket (1) and headlamp panel (2) to the front

wheelhouse panel. Refer to weld group A.

6. Spot weld the headlamp & front fascia mount

bracket to the front wheelhouse panel bracket (3).

Refer to weld group B.

Figure 4-9

7. On each side of the vehicle, spot weld the front

wheelhouse bracket assembly (1) to the front end

panel upper (2) and headlamp panel (3).

Figure 4-10

8. Spot weld in two places on each side of vehicle,

the front wheelhouse bracket assembly (1) to the

front end panel upper (2) and headlamp panel (3).

Refer to weld group A.

9. On each side of the vehicle, spot weld the

headlamp panel and the front end panel upper to

the front wheelhouse bracket assembly. Refer to

weld group B.

Figure 4-11

10. On each side of the vehicle, spot or plug weld

the front end panel upper (1) to the front

wheelhouse panel (2). Four welds are on the

horizontal surface and two on the vertical flange.

Refer to weld group A.

11. Weld a total of 10 places on each side of vehicle,

the headlamp panel (3) to the front wheelhouse

panel and the f ront wheelhouse upper side r ail (4).

Refer to weld group B.

12. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

13. Apply Joint Sealer (Item 3) as required. Refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3A (Sedan), 3B (Wagon), 3C (Utility)

or 3D (Coupe).

14. Apply Cavity Wax ( Item 8) as requir ed to the inside

of any box sections or areas inaccessible to paint,

refer to 6. CAVITY WAX in Section 3A (Sedan),

3B (Wagon), 3C (Utility) or 3D (Coupe).

15. Install the fr ont bumper impact bar assemb ly, refer

to Section 3, 2. BUMPER IMPACT BAR

ASSEMBLIES.

16. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 4-12

2.2 HEADLAMP PANEL – REPLACE

REMOVE

1. Remove the adjacent bolt-on panels and

components as described in the appropriate

Section of the MY 2003 VY & V2 Series II Service

Information.

2. Remove the front bumper impact bar assembly,

refer to Section 3, 2. BUMPER IMPACT BAR

ASSEMBLIES.

Figure 4-13

3. Spot cut a total of 12 welds attaching the

headlamp panel (1) to the front wheelhouse panel

(2) and to the wheelhouse upper side rail (3).

Figure 4-14

4. Spot cut the welds attaching the front wheelhouse

bracket assembly (1) to the front end panel upper

(2) and headlamp panel (3). Refer to weld group A.

5. Spot cut the two welds on the vertical flange

attaching the headlamp panel to the front end

panel upper and front wheelhouse bracket

assembly. Refer to weld group B.

Figure 4-15

6. Spot cut the welds attaching the headlamp & front

fascia mount bracket (1) and headlamp panel (2)

to the front wheelhouse panel.

Figure 4-16

7. Spot cut the welds attaching the front end panel

upper (1) to the headlamp panel (2).

8. Remove the headlam p panel from the vehicle and

then repair any damage to the adjacent parts as

required.

9. Check and rectify the alignment of the body as

required, refer to 3. BODY DIMENSIONS in

Section 3A (Sedan), 3B (Wagon), 3C (Utility) or

3D (Coupe). Repair any damage to adjacent

panels.

Figure 4-17

REPLACE

NOTE 1: Spot welding is the preferred method for attaching of panels and should be used whenever possible.

Where the spot welding equipment available will not access the required weld position, a plug weld should be

performed.

NOTE 2: The s ame number and pos ition of s pot welds (or plug welds) should be used when replac ing the panel,

as was used during manufacture, in order to maintain the original structural strength of the vehicle.

1. As required, mark the new panels with drilling locations in preparation for plug welding. Drill holes as

required.

2. Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to 5. BODY

SEALING, ADHESIVES & DEADENERS in Section 3A (Sedan), 3B (Wagon), 3C (Utility) or 3D (Coupe).

3. Clamp the headlamp panel in position.

4. Spot or plug weld the front panel upper (1) to the

headlamp panel (2) and to the front fender skirt

(3).

Figure 4-18

5. Spot weld the headlamp & front fascia mount

bracket (1) and headlamp panel (2) to the front

wheelhouse panel.

Figure 4-19

6. Spot weld in two places, the front wheelhouse

bracket assembly (1) to the front end panel upper

(2) and headlamp panel (3). Refer to weld group A.

7. Spot weld the headlamp panel and the front end

panel upper to the front wheelhouse bracket

assembly. Refer to weld group B.

Figure 4-20

8. Spot weld a total of 12 places, the headlam p panel

(1) to the front wheelhouse panel (2) and the front

wheelhouse upper side rail (3).

9. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

10. Apply Joint Sealer (Item 3) as required. Refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3A (Sedan), 3B (Wagon), 3C (Utility)

or 3D (Coupe).

11. Apply Cavity Wax (Item 8) as r equired to the inside

of any box sections or areas inaccessible to paint,

refer to 6. CAVITY WAX in Section 3A (Sedan),

3B (Wagon), 3C (Utility) or 3D (Coupe).

12. Install the fr ont bumper impact bar assemb ly, refer

to Section 3, 2. BUMPER IMPACT BAR

ASSEMBLIES.

13. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 4-21

2.3 FRONT WHEELHOUSE BRACKET ASSEMBLY, FRONT WHEELHOUSE BRACKET &

FRONT BUMPER IMPACT BAR BRACKET ASSEMBLY – REPLACE

REMOVE

1. Remove the adjacent bolt-on panels and

components as described in the appropriate

Section of the MY 2003 VY & V2 Series II Service

Information.

2. Remove the front bumper impact bar assembly,

refer to Section 3, 2. BUMPER IMPACT BAR

ASSEMBLIES.

3. Remove the adjoining panels as required.

Figure 4-22

4. Spot cut the six welds attaching the front

wheelhouse bracket assembly (1) to the front side

rail (2). Refer to weld group A.

5. Spot cut the three welds attaching the front

wheelhouse bracket assembly (1) to the front

bumper impact bar bracket (3). Refer to weld

group B.

6. Remove the front wheelhouse bracket assembly.

Figure 4-23

7. Spot cut the welds attaching the front wheelhouse

panel bracket (1) to the front side rail (3). Refer to

weld group A.

8. Spot cut the welds attaching the front wheelhouse

panel bracket to the radiator lower support

assembly (2). Refer to weld group B.

9. Spot cut the three welds attaching the front

wheelhouse panel brack et to the front wheelhouse

panel (4). Refer to weld group C.

10. Remove the front wheelhouse panel bracket.

Figure 4-24

11. Spot cut the welds attac hing each side of the front

bumper im pact bar brac ket (1) to the f ront side rail

(2).

12. Prise front bumper impact bar bracket out from

between the front side rail and the front side rail

closing plate (3).

13. Repair any damage to adjacent panels.

14. Check and rectify the alignment of the body as

required, refer to 3. BODY DIMENSIONS in

Section 3A (Sedan), 3B (Wagon), 3C (Utility) or

3D (Coupe).

Figure 4-25

REPLACE

NOTE 1: Spot welding is the preferred method for attaching of panels and should be used whenever possible.

Where the spot welding equipment available will not access the required weld position, a plug weld should be

performed.

NOTE 2: The s ame number and pos ition of s pot welds (or plug welds) should be used when replac ing the panel,

as was used during manufacture, in order to maintain the original structural strength of the vehicle.

1. As required, mark the new panel with drilling locations in preparation for plug welding. Drill holes as required.

2. Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to 5. BODY

SEALING, ADHESIVES & DEADENERS in Section 3A (Sedan), 3B (Wagon), 3C (Utility) or 3D (Coupe).

3. Clamp the panels in position and test fit the front bumper impact bar.

4. Spot weld each side of the front bumper impact

bar mounting bracket (1) to front side rail (2).

Figure 4-26

5. Spot weld the front wheelhouse panel bracket (1)

to the front side rail (3). Refer to weld group A.

6. Spot weld the front wheelhouse panel bracket to

the radiator lower support assembly (2). Refer to

weld group B.

7. Spot weld the front wheelhouse panel bracket to

the front wheelhouse panel (4). Refer to weld

group C.

Figure 4-27

8. Plug weld the front wheelhouse bracket assembly

(1) to the front side rail (2). Refer to weld group A.

9. Spot weld the front wheelhouse bracket assembly

to the front bumper impact bar bracket (3). Refer

to weld group B.

10. Replace the any removed panels as required.

11. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

12. Apply Joint Sealer (Item 3) as required. Refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3A (Sedan), 3B (Wagon), 3C (Utility)

or 3D (Coupe).

13. Apply Cavity Wax ( Item 8) as requir ed to the inside

of any box sections or areas inaccessible to paint,

refer to 6. CAVITY WAX in Section 3A (Sedan),

3B (Wagon), 3C (Utility) or 3D (Coupe).

14. Install the fr ont bumper impact bar assemb ly, refer

to Section 3, 2. BUMPER IMPACT BAR

ASSEMBLIES.

15. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 4-28

2.4 RADIATOR LOWER SUPPORT ASSEMBLY – REPLACE

REMOVE

1. Remove the adjacent bolt-on panels and

components as described in the appropriate

Section of the MY 2003 VY & V2 Series II Service

Information.

2. Remove the front bumper impact bar assembly,

refer to Section 3, 2. BUMPER IMPACT BAR

ASSEMBLIES.

3. If required, mount the vehicle on a suitable jig or

secure an appropriate tool between the two front

side rails to m aintain correct body alignment when

the radiator lower support assembly is removed.

Figure 4-29

4. On both sides of the vehicle, spot cut nine welds

attaching the fr ont wheelhouse panel brac ket (1) to

the radiator lower support assembly (2).

Figure 4-30

5. From underneath the vehicle, spot cut the six

welds attaching the radiator lower support

assembly (1) to each front side rail (2).

NOTE: Access is available to the two centre spot

welds through the hole on the underside of the

support.

6. Remove the radiator lower support assembly from

the vehicle.

Figure 4-31

REPLACE

NOTE 1: Spot welding is the preferred method for attaching of panels and should be used whenever possible.

Where the spot welding equipment available will not access the required weld position, a plug weld should be

performed.

NOTE 2: The s ame number and pos ition of s pot welds (or plug welds) should be used when replac ing the panel,

as was used during manufacture, in order to maintain the original structural strength of the vehicle.

1. As required, mark the new panel with drilling locations in preparation for plug welding. Drill holes as required.

2. Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to 5. BODY

SEALING, ADHESIVES & DEADENERS in Section 3A (Sedan), 3B (Wagon), 3C (Utility) or 3D (Coupe).

3. Clamp the radiator lower support assembly (1) in

position on the front side rails (2) and spot or plug

weld in place.

Figure 4-32

4. Spot weld nine places , the front wheelhouse panel

bracket (1) to the radiator lower support assembly

(2).

5. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

6. Apply Joint Sealer (Item 3) as required. Refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3A (Sedan), 3B (Wagon), 3C (Utility)

or 3D (Coupe).

7. Apply Cavity Wax (Item 8) as r equired to the inside

of any box sections or areas inaccessible to paint,

refer to 6. CAVITY WAX in Section 3A (Sedan),

3B (Wagon), 3C (Utility) or 3D (Coupe).

8. Install the fr ont bumper impact bar assembly, refer

to Section 3, 2. BUMPER IMPACT BAR

ASSEMBLIES.

9. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 4-33

2.5 FRONT WHEELHOUSE PANEL UPPER SIDE RAIL – REPLACE

REMOVE

1. Remove the adjacent bolt-on panels and

components as described in the appropriate

Section of the MY 2003 VY & V2 Series II Service

Information.

2. Remove the front bumper impact bar assembly,

refer to Section 3, 2. BUMPER IMPACT BAR

ASSEMBLIES.

3. As required, remove front end panel assembly or

spot cut the welds attaching the side rail to the

front end panel assembly, refer to 2.1 FRONT

END PANEL ASSEMBLY – REPLACE.

Figure 4-34

4. Spot cut the welds attaching the front wheelhouse

panel upper s ide rail (1) to the door opening f ram e

assem bly (2), hinge pillar inner panel assem bly (3)

and front wheelhouse panel assembly (4) and

remove the upper side rail.

Figure 4-35

REPLACE

NOTE 1: Spot welding is the preferred method for attaching of panels and should be used whenever possible.

Where the spot welding equipment available will not access the required weld position, a plug weld should be

performed.

NOTE 2: The s ame number and pos ition of s pot welds (or plug welds) should be used when replac ing the panel,

as was used during manufacture, in order to maintain the original structural strength of the vehicle.

1. As required, mark the new panel with drilling locations in preparation for plug welding. Drill holes as required.

2. Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to 5. BODY

SEALING, ADHESIVES & DEADENERS in Section 3A (Sedan), 3B (Wagon), 3C (Utility) or 3D (Coupe).

3. Clamp the front wheelhouse panel upper side rail in position.

4. Spot or plug weld the front wheelhouse panel

upper side rail (1) to the door opening frame

assem bly (2), hinge pillar inner panel assem bly (3)

and front wheelhouse panel assembly (4).

5. As required, replace the front end panel assembly

or spot or plug weld the side rail to the front end

panel assembly, refer to 2.1 FRONT END PANEL

ASSEMBLY – REPLACE.

6. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

7. Apply Joint Sealer (Item 3) as required. Refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3A (Sedan), 3B (Wagon), 3C (Utility)

or 3D (Coupe).

8. Apply Cavity Wax ( Item 8) as requir ed to the inside

of any box sections or areas inaccessible to paint,

refer to 6. CAVITY WAX in Section 3A (Sedan),

3B (Wagon), 3C (Utility) or 3D (Coupe).

Figure 4-36

9. Apply Spray-on Deadener (Item 7) to the wheel

side of front wheelhouse panel assem bly. Refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3A (Sedan), 3B (Wagon), 3C (Utility)

or 3D (Coupe).

NOTE: Keep the area around brake pipe holes (1)

clear of deadener. Over spray of deadener is

permissible on the strut tower reinforcement and front

suspension strut tower (2).

10. Install the fr ont bumper impact bar assemb ly, refer

to Section 3, 2. BUMPER IMPACT BAR

ASSEMBLIES.

11. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 4-37

2.6 FRONT WHEELHOUSE PANEL ASSEMBLY – REPLACE

REMOVE

1. Remove the adjacent bolt-on panels and

components as described in the appropriate

Section of the MY 2003 VY & V2 Series II Service

Information.

2. Remove the front bumper impact bar assembly,

refer to Section 3, 2. BUMPER IMPACT BAR

ASSEMBLIES.

3. If required, mount the vehicle on a suitable jig or

secure an appropriate tool between the front side

rails to maintain correct body alignment when the

front end panel assembly is removed.

4. Remove front end panel assembly, refer to

2.1 FRONT END PANEL ASSEMBLY –

REPLACE.

5. Remove the welds attaching the front wheelhouse

panel bracket to the front wheelhouse, refer to

2.3 FRONT WHEELHOUSE BRACKET

ASSEMBLY, FRONT WHEELHOUSE BRACKET

& FRONT BUMPER IMPACR BAR BRACKET

ASSEMBLY – REPLACE.

6. Remove the front wheelhouse panel upper side

rail, refer to 2.5 FRONT WHEELHOUSE PANEL

UPPER SIDE RAIL – REPLACE.

Figure 4-38

7. Spot cut the welds attaching the front wheelhouse

panel assembly (1) to the hinge pillar inner panel

assembly (2).

Figure 4-39

8. Spot cut the welds attaching the front wheelhouse

panel assembly (1) to the front floor panel

extension (2).

NOTE: The dash panel assembly is not shown for

clarity.

9. Spot cut the weld attaching the front wheelhouse

panel assembly (1) to the hinge pillar inner panel

assembly.

Figure 4-40

10. Spot cut the welds attaching the front wheelhouse

panel assembly (1) to the front side rail (2).

11. Remove front wheelhouse panel assembly and

repair any adjacent damaged panels as required.

12. Check and rectify the alignment of the body as

required, refer to 3. BODY DIMENSIONS in

Section 3A (Sedan), 3B (Wagon), 3C (Utility) or

3D (Coupe).

Figure 4-41

REPLACE

NOTE 1: Spot welding is the preferred method for attaching of panels and should be used whenever possible.

Where the spot welding equipment available will not access the required weld position, a plug weld should be

performed.

NOTE 2: The s ame number and pos ition of s pot welds (or plug welds) should be used when replac ing the panel,

as was used during manufacture, in order to maintain the original structural strength of the vehicle.

1. As required, mark the new panel with drilling locations in preparation for plug welding. Drill holes as required.

2. Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to 5. BODY

SEALING, ADHESIVES & DEADENERS in Section 3A (Sedan), 3B (Wagon), 3C (Utility) or 3D (Coupe).

3. Clamp the front wheelhouse panel assembly in position and confirm its location by checking the vehicle body

dimensions, refer to 3. BODY DIMENSIONS in Section 3A (Sedan), 3B (Wagon), 3C (Utility) or

3D (Coupe). Additionally, the front fender and engine hood may be fitted to confirm margins.

4. Plug weld the front wheelhouse panel assembly (1)

to the front side rail (2).

Figure 4-42

5. Plug weld the front wheelhouse panel assembly (1)

to the f ront floor panel extens ion (2) and the hinge

pillar inner panel assembly.

Figure 4-43

6. Spot weld the front wheelhouse panel assembly

(1) to the hinge pillar inner panel assembly (2).

7. Replace the front wheelhouse panel upper side

rail, refer to 2.5 FRONT WHEELHOUSE PANEL

UPPER SIDE RAIL.

8. Replace the front end panel assembly, refer to

2.1 FRONT END PANEL ASSEMBLY –

REPLACE.

9. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

10. Apply J oint Sealer (Item 3) as required. Ref er to 5.

BODY SEALING, ADHESIVES & DEADENERS in

Section 3A (Sedan), 3B (Wagon), 3C (Utility) or

3D (Coupe).

11. Apply Cavity Wax ( Item 8) as requir ed to the inside

of any box sections or areas inaccessible to paint,

refer to 6. CAVITY WAX in Section 3A (Sedan),

3B (Wagon), 3C (Utility) or 3D (Coupe).

Figure 4-44

12. Apply Spray-on Deadener (Item 7) to the wheel

side of front wheelhouse panel assem bly. Refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3A (Sedan), 3B (Wagon), 3C (Utility)

or 3D (Coupe).

NOTE: Keep the area around brake pipe holes (1)

clear of deadener. Over spray of deadener is

permissible on the strut tower reinforcement and front

suspension strut tower (2).

12. Install the fr ont bumper impact bar assemb ly, refer

to Section 3, 2. BUMPER IMPACT BAR

ASSEMBLIES.

13. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 4-45

2.7 FRONT WHEELHOUSE PANEL & FRONT SIDE RAIL – PARTIAL REPLACE

REMOVE

NOTE: The integrity of the front side rails is critical to

the function of the occupant protection system. If the

rails are incorrectly repaired following damage, it is

possible the seatbelt pretensioner and airbag system

will not function as intended, allowing incorrect

deployment.

IMPORTANT: If significant creasing or crumple of the

front side rail has occurred and continues rearward of

the front suspension crossmember, the full front side

rail as sem bly m ust be replac ed. Refer to 1. GENERAL

DESCRIPTION for further information.

1. Remove the adjacent bolt-on panels and

components as described in the appropriate

Section of the MY 2003 VY & V2 Series II Service

Information.

2. Remove the front bumper impact bar assembly,

refer to Section 3, 2. BUMPER IMPACT BAR

ASSEMBLIES.

Figure 4-46

3. Either m ount the vehic le on a suitable jig or secure

an appropriate tool between the front side rails to

maintain correct body alignment when the front

end panel assembly is removed.

4. Remove the front end panel assembly, refer to

2.1 FRONT PANEL – REPLACE.

5. Remove the front wheelhouse panel upper

side rail on the damaged side, refer to

2.5 FRONT WHEEL HOUSE PANEL UPPER SIDE

RAIL – REPLACE .

6. Either detach one side, or remove completely, the

radiator lower support assembly, refer to

2.4 RADIATOR LOWER SUPPORT ASSEMBLY

– REPLACE.

7. If the damage is on the right-hand side of the

vehicle, the front wheelhouse panel will be cut

through the position of the ABS m odulator bracket

assembly. In this cas e, r emove the brac ket by spot

cutting the welds attaching it to the front

wheelhouse panel.

Figure 4-47

8. Rough cut the damaged front wheelhouse panel

and f ront s ide rail, leaving enough mater ial to allow

the final cut lines to be completed.

9. Cut the front side rail half way through its depth,

mid way between the two crossmember mounting

bolt holes shown A.

10. Step the cut forward by 50 mm as shown, so that

the load is not concentrated through a single line.

11. Ac c ur ately trim the f r ont wheelhouse panel, 50 mm

rearward of the top front side rail cut.

12. Repair any damage to adjacent areas.

13. Check and rectify the alignment of the body as

required, refer to 3. BODY DIMENSIONS in

Section 3A (Sedan), 3B (Wagon), 3C (Utility) or

3D (Coupe).

Figure 4-48

REPLACE

NOTE 1: Spot welding is the preferred method for attaching of panels and should be used whenever possible.

Where the spot welding equipment available will not access the required weld position, a plug weld should be

performed.

NOTE 2: The s ame number and pos ition of s pot welds (or plug welds) should be used when replac ing the panel,

as was used during manufacture, in order to maintain the original structural strength of the vehicle.

1. Using a suitable tool, modify the edge of the

rem aining section of the front wheelhouse panel to

form a joggle, to facilitate lap jointing. The joggle

should be towards the outside of the vehicle (1).

2. Accurately step cut the required section (2) from a

new front side rail assembly and clamp or tack

weld the new section in position.

3. Clamp the radiator lower support (3) in position.

Ensure the alignment of the front side rail

and lower support is correct, refer to

3. BODY DIMENSIONS in Section 3A (Sedan),

3B (Wagon), 3C (Utility) or 3D (Coupe).

4. Butt-weld the stepped longitudinal sections

together. The weld should extend around the

entire periphery of the cut.

5. Spot or plug weld the radiator lower support (3) in

place. Refer to 2.4 RADIATOR LOWER

SUPPORT ASSEMBLY – REPLACE.

Figure 4-49

6. Accurately cut the required section (1) from a new

front wheelhouse panel assembly to replace the

removed section.

7. Drill the required holes in the lower edge of the

front wheelhouse panel to permit plug welding to

the front side rail.

8. Drill holes along the lap joint approximately every

25 mm, to accommodate plug welding of the joint.

9. Prepare all mating surfaces and treat with Weld

Through Primer (Item 1) as required, refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3A (Sedan), 3B (Wagon), 3C (Utility)

or 3D (Coupe).

10. Clamp the modified front wheelhouse panel in

position and plug weld (2) to the front side rail.

11. Plug weld along the lap joint (3) through the

previously drilled holes.

12. Additionally, MIG (fillet) weld the front wheelhouse

panel sections together on the engine

compartment side (4).

13. Dress the welds on the engine compartment side

with a suitable grinder or sander, removing the

minimum amount of weld consis tent with achieving

an acceptable surface finish.

Figure 4-50

14. Reattach the ABS modulator bracket assembly, if

removed, in the position shown on the front

wheelhouse panel, by spot or plug welding.

15. Install the front wheelhouse panel upper side rail,

refer to 2.5 FRONT WHEELHOUSE PANEL

UPPER SIDE RAIL – REPLACE.

16. Install the front end panel assembly, refer to

2.1 FRONT END PANEL ASSEMBLY –

REPLACE.

Figure 4-51

17. Seal the wheel side of the seam with Joint Sealer

(Item 3) (1) and apply Spray-on Deadener (Item 7)

(2) to the wheel side of the f ront wheelhouse panel

assembly, refer to 5. BODY SEALING,

ADHESIVES & DEADENERS in Section

3A (Sedan), 3B (Wagon), 3C (Utility) or

3D (Coupe).

18. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

19. Apply Joint Sealer (Item 3) as required. Refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3A (Sedan), 3B (Wagon), 3C (Utility)

or 3D (Coupe).

20. Apply Cavity Wax ( Item 8) as requir ed to the inside

of any box sections or areas inaccessible to paint,

refer to 6. CAVITY WAX in Section 3A (Sedan),

3B (Wagon), 3C (Utility) or 3D (Coupe).

21. Install the fr ont bumper impact bar assemb ly, refer

to Section 3, 2. BUMPER IMPACT BAR

ASSEMBLIES.

22. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 4-52

2.8 FRONT SIDE RAIL ASSEMBLY – REPLACE

REMOVE

IMPORTANT: The integrity of the front side rails is

critical to the function of the occupant protection

system. If the rails are incorrectly repaired following

damage, it is possible the seatbelt pretensioner and

airbag system will not function as intended, allowing

incorrect deployment. Refer to 1. GENERAL

DESCRIPTION for further information.

1. Remove the adjacent bolt-on panels and

components as described in the appropriate

Section of the MY 2003 VY & V2 Series II Service

Information.

2. Remove the front bumper impact bar assembly,

refer to Section 3, 2. BUMPER IMPACT BAR

ASSEMBLIES.

3. Secure the vehicle on a suitable fixture ensuring

that it is mounted without relying on support from

the front side rail assembly(s) being replaced.

Figure 4-53

4. Rem ove the f ront end panel ass em bly as required,

refer to 2.1 FRONT END PANEL ASSEMBLY.

5. Remove the radiator lower support assembly as

required, refer to 2.4 RADIATOR LOWER

SUPPORT ASSEMBLY – REPLACE.

6. Remove the front wheelhouse panel assembly as

required, refer to 2.6 FRONT WHEELHOUSE

PANEL ASSEMBLY – REPLA CE.

7. Using a scraper and heat gun, remove the body

sealer and deadener from the front floor and floor

extension in the front side rail attaching areas.

8. Spot cut the welds attaching the front floor panel

support ass embly to the front f loor panel and inner

rocker panel.

9. Spot cut the welds attaching the front side rail

assembly to the front floor extension panel and

front floor panel, refer to Figure 4-55.

Figure 4-54

Figure 4-55

10. Spot cut four welds attaching the centre

crossmember to the inner rocker panel. Refer to

weld group A.

11. Spot cut the welds attaching the centre

crossmember to the front floor panel and seat

inner bracket assembly.

Figure 4-56

12. Spot cut five welds attaching the right-hand centre

crossmember to the left-hand centre

crossmember.

13. Remove the longitudinal assembly from the vehicle

and repair any damage to adjoining areas.

14. Check and rectify the alignment of the body as

required, refer to 3. BODY DIMENSIONS in

Section 3A (Sedan), 3B (Wagon), 3C (Utility) or

3D (Coupe).

Figure 4-57

REPLACE

NOTE 1: Spot welding is the preferred method for attaching of panels and should be used whenever possible.

Where the spot welding equipment available will not access the required weld position, a plug weld should be

performed.

NOTE 2: The s ame number and pos ition of s pot welds (or plug welds) should be used when replac ing the panel,

as was used during manufacture, in order to maintain the original structural strength of the vehicle.

1. Dress the floor in the areas where the front side rail assembly will attach and mark the new assembly with

drilling locations in preparation for plug welding. Drill holes as required.

2. Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to 5. BODY

SEALING, ADHESIVES & DEADENERS in Section 3A (Sedan), 3B (Wagon), 3C (Utility) or 3D (Coupe).

3. Secure the new front side rail assembly in position on the vehicle and clamp the radiator lower support

assembly in place.

4. Check the alignm ent of the front side r ail assem bly, ref er to 3. BODY DIMENSIONS in Section 3A (Sedan),

3B (Wagon), 3C (Utility) or 3D (Coupe).

5. Lightly tack weld the f ront side rail ass embly to the

floor in a few places, then recheck the alignment

as above. Correct as required.

Figure 4-58

6. Plug weld the front side rail assembly to the front

floor panel extension and front floor panel.

Figure 4-59

7. Plug weld the centre crossmember to the inner

rock er panel, ref er to weld group A and to the front

floor panel.

Figure 4-60

8. Plug weld in four places, the right-hand centre

crossmember to the left-hand centre

crossmember.

Figure 4-61

9. Plug or spot weld the front floor panel support

assembly to the front floor panel and inner rocker

panel.

10. Reinstall the radiator lower support assembly, refer

to 2.4 RADIATOR LOWER SUPPORT

ASSEMBLY – REPLACE.

11. Install the front wheelhouse panel assembly, refer

to 2.6 FRONT WHEELHOUSE PANEL

ASSEMBLY – REPLACE.

12. Install the front end panel assembly, refer to

2.1 FRONT END PANEL ASSEMBLY –

REPLACE.

13. Refinish and paint panels and other components

as required. Refer to Section 3, 1.3 PAINT

REFINISHING.

14. Apply Joint Sealer (Item 3) as required. Refer to

5. BODY SEALING, ADHESIVES & DEADENERS

in Section 3A (Sedan), 3B (Wagon), 3C (Utility)

or 3D (Coupe).

15. Apply Cavity Wax ( Item 8) as requir ed to the inside

of any box sections or areas inaccessible to paint,

refer to 6. CAVITY WAX in Section 3A (Sedan),

3B (Wagon), 3C (Utility) or 3D (Coupe).

16. Apply Spray-on Deadener (Item 7), after the

application of body colour. Refer to 5. BODY

SEALING, ADHESIVES & DEADENERS in

Section 3A (Sedan), 3B (Wagon), 3C (Utility) or

3D (Coupe).

17. Install the fr ont bumper impact bar assemb ly, refer

to Section 3, 2. BUMPER IMPACT BAR

ASSEMBLIES.

18. Install the remaining components as described in

the appropriate Section of the MY 2003 VY & V2

Series II Service Information.

Figure 4-62