General Information Page 1–1
Page 1–1
Section 1
General Information
ATTENTION
Before performing any Service Operation or other procedure described in this Section, refer to Section 00
Warnings, Cautions And Notes for correct workshop practices with regard to safety and/or property damage.
The Structure of the MY 2004 WK Series body
shell has been developed using complex
design and development techniques. In
addition to meeting all required standards, the
vehicle 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 Information............................................................................................................................... 2
2 General Index......................................................................................................................................... 4
Section 1 General Information ..............................................................................................................................4
Section 2 Precautions............................................................................................................................................4
Section 3 Body Construction................................................................................................................................4
Section 4 Front End ...............................................................................................................................................4
Section 5 Cockpit Module......................................................................................................................................5
Section 6 Cabin Floor ............................................................................................................................................5
Section 7 Body Side...............................................................................................................................................5
Section 8 Doors................................................................................................................ ......................................6
Section 9 Roof........................................................................................................................................................6
Section 10 Body Rear ............................................................................................................................................6
General Information Page 1–2
Page 1–2
1 General Information
With the following exceptions, MY 2004 WK Series General Information carries over from MY 2003 VY Series vehicles.
For information not contained within this Section, refer to Section 1, General Information , in the MY 2003 VY and V2
Series Body Structure Repair Manual.
• General Index
MY 2004 WK Series vehicles are designed to meet or exceed all frontal, offset frontal and side impact standards. It is
imperative therefore, that any repairs to the body structure of a MY 2004 WK Series vehicle do not compromise:
• the vehicle’s compliance with relevant statutory regulations,
• the performance of the body structure, or
• the vehicle’s safety systems – including the occupant protection system.
Any repairs to the vehicle’s body structure are to be performed in accordance with this Supplement and where advised,
the MY 2003 VY and V2 Series Body Structure Repair Service Information, which provide replacement procedures for
MY 2004 WK Series body panels and structural members.
Hang-on panels such as the engine hood, rear compartment lid and front fenders are not covered and reference should
be made to the appropriate Section in the MY 2004 WK Series Service Information.
Replacement procedures for the door assemblies and outer panels, along with instructions for disassembling and
removing the glued-in dash panel assembly, are the only instructions in this Supplement that do not involve components
welded to the vehicle structure.
This Supplement has been prepared for trades persons suitably qualified in the Automotive Body Repair Industry. As
such, welding technique, panel beating or surface finishing instruction, etc. is not included. The purpose of this
Supplement is to assist the repairer to use his/her expertise in making the correct judgements to restore the vehicle to
original condition and specif ication.
Prior to beginning repair work on a vehicle, the repairer should become familiar with Section 1 through Section 3 in this
and the MY 2003 VY and V2 Series Body Structure Repair Service Information supplements, Section 00 in the MY 2004
WK Service Information and any appropriate regulations covering repairs, welding and joining motor vehicles and
accepted industry practices.
As collision damage differs in each case, this Supplement can only be a guide for the repairer. The best repair procedure
for each vehicle will need to be determined according to the judgements of a qualified trade’s person.
The Supplement describes the replacement procedures of service parts available for WK Series vehicles. If several
adjoining parts are replaced at the one time, modify the replacement procedures accordingly.
The naming of body sections and parts in this Supplement follows Global Part Description System (GPDS) naming
conventions.
The information contained in this Supplement is correct at the time it was approved for publishing. However, as the motor
vehicle industry is constantly updating and improving vehicle construction techniques, the repairer must use his/her
acquired skill in determining the appropriate procedure for replacing panels.
Figure 1 – 1 shows the MY 2004 WK body structure as covered by this Supplement.
General Information Page 1–3
Page 1–3
Figure 1 – 1
General Information Page 1–4
Page 1–4
2 General Index
Sectio n 1 Ge n e ral Info rmat io n
Description Page
1 General Information 1-2
2 General Index 1-4
Section 2 Precautions
Description Page
1 General Information 2-2
2 Electrical Precautions 2-3
3 Cavity Foam 2-10
Section 3 Body Construction
Description Page
1 General Information 3-3
2 Body Structure Panels 3-4
3 Body Dimensions 3-11
4 Body Margins 3-16
5 Body Sealing, Adhesives and Deadeners 3-19
6 Cavity Wax 3-37
Figure 1 – 2
Section 4 Front End
Description Page
1 General Information 4-2
Figure 1 – 3
General Information Page 1–6
Page 1–6
Section 8 Doors
Description Page
1 General Information 8-2
Figure 1 – 7
Section 9 Roof
Description Page
1 General Information 9-2
2 Service Operations 9-4
Figure 1 – 8
Section 10 Body Rear
Description Page
1 General Information 10-2
2 Service Operations 10-4
Figure 1 – 9