Holden - Sportwagon - Workshop Manual - 2008 - 2008

TECHNICAL BULLETIN B32 HOLDEN COMMODORE VE/ CALAIS SEDAN AND SPORTWAGON/ STATESMAN AND CAPRICE WM SEDAN HSV E-SERIES SEDAN AND SPORTWAGON REPAIRS TO SPARE WHEEL WELL LUGS USING METAL BRACKETS JULY 2008 Insurance Australia Limited Disclaimer: The information contained herein is for general information purposes only. Users should be aware that (to the maximum permitted by law) we accept no responsibility for the accuracy or completeness of any material contained herein and exclude all liability to any person arising directly or indirectly from using the information or material. We recommend users confirm the accuracy and appropriateness of the information from another source if necessary, and to exercise their own skill and care with respect to its use. Copyright Copyright © 2007 Insurance Australia Limited ABN 11 000 016 722. All content included herein, such as text, documents, graphics, logos and images are the property of Insurance Australia Limited or its content suppliers and protected by Australian copyright laws. Third party copyright and trade marks appearing herein are reproduced with permission. No part of the content may be reproduced, transmitted, distributed, commercialised or re-used for any purpose whatsoever without written permission of Insurance Australia Limited (contact IAG Research Centre for more information). ABN 11 000 016 722 AFS Licence No. 227681 IAG Research Centre Unit One/ No. 2 Holker Street Newington NSW 2127 Australia T +61 (0)2 9292 6840 F +61 (0)2 9737 9860 E [email protected] W www.iagresearch.com.au Low speed rear impacts can easily damage the spare wheel wells on Holden VE/WMseries and HSV E-series sedans and sportwagons. Damage can occur to one or more of three (3) protruding lugs. The lower edge of the rear bumper fascia is attached to these lugs with plastic retainers. Minor rear impacts can transfer high loadings to the lugs, which will then typically fail. The lugs cannot be plastic welded because they are fibre-reinforced composite. The wheel well itself is bonded into the rear of the body shell. It is difficult and time consuming to remove and replace. The IAG Research Centre has designed metal brackets which can be fitted over the damaged lugs to avoid having to remove and replace the entire wheel-well. These brackets reduce the cost of repairs enormously and also preserve the integrity of the original factory wheel well installation. Left side bracket Centre bracket Right side bracket The following steps outline the method developed at the IAG Research Centre to restore damaged lugs to their original strength and function. These steps should be followed closely to ensure similar future impact performance is achieved. Note: • Latex gloves should be worn during this operation • The work can be done with the vehicle at ground level, or raised on a hoist There are 14 steps: 1. Detach the rear bumper bar plastic facia and the plastic clips from the lug(s) to be repaired. 2. Remove any broken or hanging debris from the damaged lug(s). Right side lug Right side bracket 3. Using a panel file or similar, carefully remove the ‘lip’ on the back edge of the lug(s). Ensure that the lug itself is not filed. Left side lug Lip to be removed with the panel file 4. Using 180-200 grit abrasive paper, scuff each exterior surface of the damaged lug(s). 5. Clean the exterior of the damaged lug(s) with Prepsol or similar solvent to remove dust, grease or fibres. 6. Using a 180-200 grit abrasive paper, scuff each interior surface of the replacement bracket(s). 7. Clean the interior of the replacement bracket(s) with Prepsol or similar solvent to remove dust, grease and paint powder. 8. Check-fit the lug(s) to the appropriate bracket(s). To achieve a better fit with the lug(s), bend the sides of the bracket(s) in or out, as required. There should be a 1-2mm gap between the bracket and the lug surfaces for adhesive. 9. Apply Sika® Sikaflex-206 G&P surface primer to the interior surfaces of bracket(s) and exterior surfaces of lug(s) and allow to dry, according to product instructions. 10. Apply Sika® Sikaflex-206 adhesive to the interior bracket bonding surface. 11. Push bracket(s) onto lug(s) and remove excess adhesive. 12. Insert a plastic fascia fastener into the lug, to hold the bracket in place. 13. Apply the adhesive tape over the bracket(s) whilst Sika flex is curing. Allow the adhesive 48 hours to cure completely. Repaired lug curing (centre) Damaged lug Replacement bracket (centre) Plastic fastener Adhesive tape 14. After the adhesive has completely cured, remove the adhesive tape and plastic fastener. Inspect the repair by checking for movement of the bracket. The bracket should feel quite rigid, but with a very small amount of flex (from the adhesive). The rear bar can now be reattached to the vehicle in the normal manner. Repaired lug (centre) Replacement bracket (centre) Plastic fastener