Body Page 1A1–1

Page 1A1–1

Section 1A1

Body

ATTENTION

Before performing any service operation or other procedure described in this Section, refer to Section 00

Warnings, Cautions and Notes for correct w orkshop practices wi th regard to safety and/or property damage.

1 General Information...............................................................................................................................2

2 Body Leak Diagnosis.............................................................................................................................3

3 Body Lubrication....................................................................................................................................4

4 Lock Cylinders and Keys.......................................................................................................................5

5 Plastic Components...............................................................................................................................6

5.1 Exterior ................................................................................................................................................................... 6

5.2 Interior .................................................................................................................................................................. 10

5.3 Plastic Types........................................................................................................................................................ 13

6 Wheelhouse Liners ..............................................................................................................................14

6.1 Front Wheelhouse Liner...................................................................................................................................... 14

Remove................................................................................................................................................................. 14

Reinstall................................................................................................................................................................ 15

6.2 Rear Wheelhouse Liner....................................................................................................................................... 16

Remove................................................................................................................................................................. 16

Reinstall................................................................................................................................................................ 17

7 Fuel Filler Door Assembly and Cable Assembly...............................................................................18

7.1 Fuel Filler Door Assembly................................................................................................................................... 18

Remove................................................................................................................................................................. 18

Disassemble......................................................................................................................................................... 19

Lock Spring ...................................................................................................................................................... 19

Moulding........................................................................................................................................................... 19

Reassemble.......................................................................................................................................................... 19

Lock Spring ...................................................................................................................................................... 19

Moulding........................................................................................................................................................... 19

Reinstall................................................................................................................................................................ 20

7.2 Fuel Filler Door Lock Cable Assembly............................................................................................................... 21

Remove................................................................................................................................................................. 21

Reinstall................................................................................................................................................................ 22

8 Body Braces..........................................................................................................................................23

8.1 Front Suspension Strut Brace............................................................................................................................ 23

Remove................................................................................................................................................................. 23

Reinstall................................................................................................................................................................ 23

9 Torque Wrench Specifications ...........................................................................................................24

Techline

Body Page 1A1–2

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1 General Information

This Section contains the service procedures for body components not specific to other Sections of this Service

Information Package such as:

• Body Leak Diagnosis

• Body Lubrication

• Lock Cylinders and Keys

• Wheelhouse Liners

• Fuel Filler Door Assembly and Cable Assembly

• Body Braces

Body Page 1A1–3

Page 1A1–3

2 Body Leak Diagnosis

Diagnosis of body leaks can be complicated as the appearance of dust or water at one point within the vehicle can be

caused by seepage through any one, or more possible locations. For example the cause of wet front floor coverings

could be either water entering past the door weatherstrip, through the door inner panel, between the windshield and its

adhesive compound or through any one of the joins in the body structure. Therefore, the point or points of water or dust

entry must be established before effective resealing can be carried out.

Water leak diagnosis is usually performed by having an assistant spray a gentle fan of water from a hose around the

suspected area until the leak can be generated. Removal of various trim components from the inside may be required to

determine point of entry. Narrowing down the water spray to the point of greatest water flow will assist in determining the

point of entry.

Dust entry quite often requires the following of signs of dust entry around seals or vent inlets or outlets, etc.

Once detected, repair the area by replacing faulty components or applying the correct sealer or adhesive.

Body Page 1A1–4

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3 Body Lubrication

Careless or excessive application of body

lubricants can cause staining of the paint

finish and interior trim, damage clothing, and

become a trap for dirt. Use lubricants

sparingly and remove any excess

immediately.

The moving mechanical parts of the body which have metal to metal contact are lubricated at assembly of the vehicle.

Operating conditions, whether normal or otherwise, determine the effective life of the lubricant and for this reason

lubrication in service is important. Equally important is the type of lubricant to be used.

Listed below are the body lubrication points. For the recommended lubricants and maintenance schedule refer to

Section 0B Lubrication and Service.

Parts Readily Accessible:

• Hood Pilot Pin Assembly

• Hood Lock Assembly

• Hood Hinges Door Hinge Pins

• Door Check Assemblies

• Door Lock Cylinder

• Door Lock Striker

• Door Lock Assembly Fork

• Rear Compartment Lid Hinge

• Rear Compartment Lid Latch

• Ignition Lock Cylinder

• Instrument Panel Compartment Lock Cylinder

Parts Concealed Requirin g Disassembly:

• Door Window Regulator

• Door Window Guides and Runners

• Door Lock Mechanism

• Rear Compartment Lid Lock Mechanism

• Front Seat Adjuster

• Driver’s Seat Height Adjuster

Body Page 1A1–5

Page 1A1–5

4 Lock Cylinders and Keys

A common-key locking system operates the door and

ignition locks. A unique key is provided for the instrument

panel compartment. All vehicles have a lock cylinder on the

driver’s door handle assembly.

The door and ignition key features a remote function that

activates the central locking system and anti-theft system

from a distance of several metres. Inserting the key into the

lock cylinder incorporated in the driver’s door handle also

performs this same function.

A separate button on the remote key opens the rear

compartment lid.

Figure 1A1 – 1

NOTE

The key identification number is located on the

vehicle security card, stored with the owner’s

manual. It is essential that this key number be

available should a replacement key be required.

In the event of a key replacement, the Body Control Module (BCM) will require reprogramming to accept the new key,

refer to Section 12J Body Control Module for reprogramming and further information regarding the anti-theft system.

For service procedures for the lock cylinders:

• Driver’s door lock cylinder, refer to Section 1A5 Front and Rear Door Assemblies.

• Ignition lock cylinder, refer to Section 9 Steering.

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5 Plastic Components

Plastic components are used throughout the vehicle. The following table is included to assist with the identification and

composition of common components. refer to 5.3 Plastic Types for a description of handling procedures for each

different plastic composition.

NOTE

Most components are also identified with the

material code in an inconspicuous place.

5.1 Exterior

Front Bumper Fascia

Material: PP

Radiator Grille Assembly

Material: Painted – ABS, Unpainted – ASA

Headlamp Assembly

Material: Lens – PC, Housing – PP/T30

Tail lamp Assembly

Material: Lens - PMMA, Housing – ABS

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Wheelhouse Liner

Material: PP

Upper Radiator Air Baffle

Material: PP

Radiator Overflow Reservoir Assembly

Material: PP

Plenum Cover Assembly

Material: PP

Outside Rear View Mirror Housing

Material: Painted – ABS, Unpainted - ASA / PC

Body Page 1A1–8

Page 1A1–8

Door Handle Assembly

Material: PA 66

Body Side Moulding

Material: ASA

Rocker Panel Moulding Assembly

Material: PP

Fuel Filler Door Assembly

Material: PPE / PA

Rear Bumper Fascia

Material: PP

Body Page 1A1–9

Page 1A1–9

Rear Licence Plate Surround

Material: ABS

Roof Panel Joint Moulding Assembly

Material: PVC

Quarter Panel Belt Moulding

Material: PPE/PA-M20

Body Page 1A1–10

Page 1A1–10

5.2 Interior

Instrument Panel Pad Assembly

Material: Carrier – ABS, Pad Substrate – PP, Foam – PVC, Skin - ABS

Instrument Panel Centre Trim Assembly

Material: PC/ABS

Floor Console Cover Assembly

Material: PC/ABS

Front Floor Console

Material: PP

Instrument Panel Compartment

Material: PP

Body Page 1A1–11

Page 1A1–11

Hinge Pillar Trim

Material: PP

Windscreen Side Garnish

Material: PP

Centre Pillar Upper Trim

Material: PP

Centre Pillar Lower Trim

Material: PP

Side Sill Trim Plate

Material: PP

Body Page 1A1–12

Page 1A1–12

Side Sill Trim

Material: PP

Body Lock Pillar Garnish

Material: PP

Rear End Trim Panel

Material: PP

Body Page 1A1–13

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5.3 Plastic Types

The repair procedure for plastic body parts must conform with the type of plastic material.

Precautions to be taken with plastic parts are detailed in the following chart:

Code Material Name Heat Resisting

Temp* °C Resistance to

Alcohol or Gasoline NOTES

ABS Acrylonitrile

Butadiene Styrene

Resin

80 Alcohol is harmless if applied only

for short time in small amounts (i.e.

quick wiping to remove grease).

Avoid gasoline and organic

or aromatic solvents.

ASA Acrylate Styrene

Acrylonitrile 80 Alcohol is harmless if applied only

for short time in small amounts (i.e.

quick wiping to remove grease).

Avoid gasoline and organic

or aromatic solvents.

PC Polycarbonate 120 Alcohol is harmless. Avoid gasoline, brake fluid,

wax, wax removers and

organic solvents.

PMMA Polymethyl

Methacrylate 80 Alcohol is harmless if applied only

for short time in small amounts. Avoid dipping or immersing

in alcohol, gasoline, solvents,

etc.

PE Polyethylene 80 Alcohol and gasoline are harmless. Most solvents are harmless.

PP /

PP67 Polypropylene 80 Alcohol and gasoline are harmless. Most solvents are harmless.

PPE Polyphenylene

Ether 100 Alcohol and gasoline are harmless if

applied only for a short time in small

amounts (i.e. quick wiping to remove

grease).

Avoid dipping or immersing

in alcohol, gasoline, solvents,

etc.

PU Polyurethane

Foam 100 Alcohol and gasoline are harmless if

applied only for a short time in small

amounts (i.e. quick wiping to remove

grease).

Avoid dipping or immersing

in alcohol, gasoline, solvents,

etc.

PVC Polyvinyl Chloride 80 Alcohol and gasoline are harmless if

applied only for short time in small

amounts. (i.e. quick wiping to

remove grease).

Avoid dipping or immersing

in alcohol, gasoline, solvents,

etc.

TPO Thermoplastic

Olefin 80 Alcohol is harmless.

Gasoline is harmless if applied only

for short time in small amounts.

Most solvents are harmless

but avoid dipping or

immersing in alcohol,

gasoline, solvents, etc.

PPE/

PA-M20 Modified

Polypropylene

Ether and

Polyamide Alloy

190 Alcohol and gasoline are harmless if

applied only for a short time in small

amounts (i.e. quick wiping to remove

grease).

Avoid dipping or immersing

in alcohol, gasoline, solvents,

etc.

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6 Wheelhouse Liners

LT Section No. — 12–425

6.1 Front Wheelhouse Liner

Remove

1 Remove the front road wheel, refer to Section 10 Wheels and Tyres.

2 Depending on vehicle complete either step a or b:

a Remove the screw (1) attaching the front bumper

fascia assembly (2) to the wheelhouse liner (3).

To aid in removal of the liner remove the screw

(4) attaching the fascia assembly to the vehicle.

Figure 1A1 – 2

b Remove the screw (1) attaching the front bumper

fascia assembly (2) to the front wheelhouse liner

(3). To aid in removal of the liner remove the

screw (4) attaching the fascia assembly to the

vehicle.

Figure 1A1 – 3

3 Referring to Figure 1A1 – 4, remove the two screws (1) attaching the liner (2) to the fender.

4 Remove the four retainers (4) attaching the liner to the vehicle.

5 Remove the liner.

Body Page 1A1–15

Page 1A1–15

Figure 1A1 – 4

Reinstall

Reinstallation of the front wheelhouse liner is the reverse of the removal procedure, noting the following:

1 Ensure the wheelhouse liner is correctly positioned. Refer to Figure 1A1 – 4.

2 Tighten the screws to the correct torque specification.

Front wheelhouse liner attaching

screw torque specification...........................1.0 – 3.0 Nm

Front bumper fascia assembly attaching

screw torque specification...........................1.0 – 3.0 Nm

Body Page 1A1–16

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6.2 Rear Wheelhouse Liner

Remove

1 Remove the rear road wheel, refer to Section 10 Wheels and Tyres.

2 Remove the screw (1), two places, attaching the

rocker panel moulding assembly (2) and rear

wheelhouse liner (3).

Figure 1A1 – 5

3 Depending on vehicle complete either step a or b:

a Remove the screw (1) attaching the rear bumper

fascia assembly (2) to the rear wheelhouse

liner (3).

Remove the two screws (4) attaching the fascia

assembly to the liner and rear bumper fascia

guide.

Figure 1A1 – 6

Body Page 1A1–17

Page 1A1–17

b Remove the screw (1) attaching the rear bumper

fascia assembly (2) to the rear wheelhouse

liner (3).

Remove the two screws (4) attaching the fascia

assembly to the liner and rear bumper fascia

guide.

Figure 1A1 – 7

4 To aid removal of the wheelhouse liner partially unclip the bumper fascia from the fascia guide.

5 Referring to Figure 1A1 – 8, remove the retainer (1) and (2) attaching the liner (3) to the wheelhouse panel.

Figure 1A1 – 8

6 Manipulate the liner from behind the rocker panel moulding assembly and bumper fascia, disengage the locating

lug at the base of the liner and remove.

Reinstall

Reinstallation of the rear wheelhouse liner is the reverse of the removal procedure, noting the following:

1 Ensure the liner is correctly located behind the rocker panel moulding assembly and rear bumper fascia assembly.

Refer to Figure 1A1 – 6.

2 Tighten the screws to the correct torque specification.

Rocker panel moulding assembly

attaching screw torque specification ...........1.0 – 3.0 Nm

Rear bumper fascia assembly

attaching screw torque specification ...........1.0 – 3.0 Nm

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7 Fuel Filler Door Assembly and

Cable Assembly

LT Section No. — 03–028

If the fuel filler door assembly is being

replaced, the warning labels affixed to the

inside of the door must also be replaced.

The fuel filler door assembly is painted the vehicle body colour. A new fuel filler door assembly is supplied unpainted with

the moulding and lock spring unattached. If repainting an existing door, the moulding and lock spring will need to be

removed as described in this procedure. After painting and before reinstallation, the moulding and lock spring must be

fitted as described in this procedure.

Paint the door using the correct materials and techniques for PPE/PA resin (Polyphenylene/Polyamide). As the materials

and techniques required differ between paint brands, refer to the technical data supplied by your paint manufacturer.

7.1 Fuel Filler Door Assembly

Remove

1 Open the fuel filler door by operating the release lever.

2 Remove the fuel filler cap and cover the opening with

a clean rag as required.

3 Remove the screw (1) and two screws (2), attaching

the fuel filler door assembly (3).

4 Remove the door assembly by withdrawing it rearward,

ensuring the gasket (4) is also removed.

NOTE

When withdrawing the fuel filler door assembly

from the fuel filler pocket, a slight interference

between the rear edge of the plastic hinge

section and the fuel filler neck may occur. In this

instance it will be necessary to flex the rear edge

of the fuel filler door hinge slightly.

Figure 1A1 – 9

Body Page 1A1–19

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Disassemble

Lock Spring

Take care when removing the lock spring.

The lock spring has several barbs that will

cut into its mounting surface. Take care not

to excessively damage the surface onto

wh ich the lock spring is mounted.

Remove the lock spring (1) by inserting a small screwdriver

and levering the spring outwards.

Moulding

The moulding (2) is seated in the recess (3) around the

circumference of the door and is affixed with superglue gel.

Removal may be difficult, but by carefully peeling the

moulding from the door, it is possible to remove. It will not

be able to be reused.

NOTE

To aid removal, the moulding can be cut around

the inner (4) and outer sides (5) using a sharp

knife. Figure 1A1 – 10

Reassemble

Lock Spring

Push the spring fully onto the mounting tab.

Moulding

Use of superglue can be harmful and can

damage paintwork. Carefully read and follow

all directions and cautions with the product

prior to its use.

1 Carefully apply Loctite 454 (Superglue Gel) or equivalent into the fuel filler door recess around the complete

circumference.

2 Ensuring the moulding is correctly orientated, immediately fit it into the recess and leave the adhesive to cure.

Body Page 1A1–20

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Reinstall

Reinstallation of the fuel filler door assembly is the reverse of the removal procedure, noting the following:

1 If a new door assembly is being installed, or the door has been repainted, install the moulding and lock spring onto

the flap by following the reassemble procedure.

2 Tighten the screws to the correct torque specification.

Fuel filler door assembly attaching screw

torque specification.....................................1.0 – 3.0 Nm

3 If the door has been replaced, apply a new label in the

position shown.

NOTE

Prior to affixing the label, ensure the surface is

clean and dry. Avoid touching the back of the

label.

4 Ensure the fuel filler door closes without the need of

excess force and is flush with the surrounding panel.

Figure 1A1 – 11

Body Page 1A1–21

Page 1A1–21

7.2 Fuel Filler Door Lock Cable Assembly

LT Section No. — 03–028

Remove

1 As required, remove the following components:

a Right-hand side sill trim and quarter inner rear side carpet, refer to Section 1A8 Headlining and Interior Trim.

b Right-hand rear seat-back assembly seat cushion assembly, refer to Section 1A7 Seat Assemblies.

2 Open the fuel filler door by operating the release lever.

3 From inside the vehicle, remove the screw (1) attaching the cable assembly lever (2) to the rocker panel, refer to

Figure 1A1 – 12.

NOTE

Screw (3) and the front seat outer side cover (4)

should have been removed during step 1, they

are shown here for reference.

4 Unclip the cable from the harness formers (5), six places, and bend the retaining tab (6) to release the cable

assembly.

5 Unclip the cable from the release lever.

Figure 1A1 – 12

Body Page 1A1–22

Page 1A1–22

6 Pull the cable (1) through the back panel upper into

the rear compartment.

Figure 1A1 – 13

7 From within the fuel filler housing, remove the two

screws (1) attaching the cable assembly retainer (2).

8 Withdraw the cable assembly from the fuel filler

housing.

Figure 1A1 – 14

Reinstall

Reinstallation of the fuel filler door lock cable assembly is the reverse of the removal procedure, noting the following:

1 Tighten the screws to the correct torque specification.

Fuel filler door lock cable assembly

latch screw torque specification ..................1.9 – 2.1 Nm

Fuel filler door cable assembly

release lever attaching screw

torque specification.....................................1.0 – 3.0 Nm

2 Ensure the cable assembly is routed correctly.

3 Ensure the cable assembly operates correctly and the plunger completely retracts prior to closing the fuel filler door.

If satisfactory, close the door ensuring it does not require excess force. The door should spring ajar when the

release is operated.

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8 Body Braces

8.1 Front Suspension Strut Brace

Remove

1 Remove the nut (1), four places, attaching the front

suspension strut brace to the suspension strut towers.

2 Remove the brace.

Figure 1A1 – 15

Reinstall

Reinstallation of the front suspension strut brace is the reverse of the removal procedure. Tighten the nuts to the correct

torque specification.

Front suspension strut brace attaching

nut torque specification......................................30.0 Nm

Body Page 1A1–24

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9 Torque Wrench Specifications

Front Wheelhouse Liner Attaching Screw....................................1.0 – 3.0 Nm

Front Bumper Fascia Assembly Attaching Screw........................1.0 – 3.0 Nm

Rocker Panel Moulding Assembly Attaching Screw....................1.0 – 3.0 Nm

Rear Bumper Fascia Assembly Attaching Screw ........................1.0 – 3.0 Nm

Fuel Filler Door Assembly Attaching Screw.................................1.0 – 3.0 Nm

Fuel Filler Door Lock Cable Assembly Latch Attaching Screw.... 1.9 – 2.1 Nm

Fuel Filler Door Cable Assembly Release Lever

Attaching Screw...........................................................................1.0 – 3.0 Nm

Front Suspension Strut Brace Attaching Nut......................................30.0 Nm