VE/WM front chassis rail replacement - May 2013
VE/WM rear upper suspension control arm - August 2013
Side impart sensor location change - April 2012
Front chassis rail sectional repair - April 2012
Bodyside replacement procedure - June 2010
Bootfloor module adhesive - March 2009
Chassis rail end plate - July 2008
Repairs to spare wheel well lugs using metal brackets - July 2008


HOLDEN VE-WM SEDAN, SPORTWAGON & UTE FRONT CHASSIS RAILS NOW REPLACEABLE
MAY 2013

There is now an approved procedure to replace the front chassis rails on the Holden VE/WM series vehicles. Damage to the front chassis rail can be repaired by sectioning or replacing the complete rail if required in accordance with the Holden Body Repair manual.

Vehicles should only be repaired using the procedures outlined in the GM-Holden Body Repair information available online at;

http://www.acdelcotds.com/acdelco/action/home  

Parts numbers applicable for the front rail repair are as follow:
LHS P/N 92194474
RHS P/N 92194473

For further assistance contact the IAG Research Centre on (02) 92926840

2013 05 Holden front chasiss rail replaceable

COMMODORE VE AND STATESMAN/CAPRICE REAR SUSPENSION UPPER CONTROL ARM

AUGUST 2013

2013 08 Holden VE 3 2013 08 Holden VE 3

2013 08 Holden VE 3

2013 08 Holden VE 3

Holden has changed the material of the rear upper control arms from steel to cast aluminium.

In the case where a steel upper rear control arm requires replacement on the pre MY12 VE/WM Commodore/Statesman/Caprice range, the other side will also need to be changed if made of steel. This is a direction by GM Holden.

Holden’s direction to replace both arms is due to an updated bush that is part of the new arm assembly. This change has been implemented on the production of the MY12 VE Commodore model. If only one arm is replaced, the customer may experience some slight difference in handling from one side to side.

There is a service kit available which includes all the required components for this repair. Alternatively all the individual parts are available through Holden dealers.

For any further information please contact the IAG Research Centre on (02) 9292 6840.

2013 08 Holden VE 3

2013 08 Holden VE 3
Acknowledgement: Information supplied by GM Holden.


VE COMMODORE SIDE IMPACT SENSOR LOCATION CHANGE
APRIL 2012

  2012 04 VE side impact location change 1 2012 04 VE side impact location change 1

2012 04 VE side impact location change 1

2012 04 VE side impact location change 1

Body side assemblies for MY12 VE/WM vehicles have an internal difference compared to all production up to and including MY11.

MY 11 and prior body side assemblies cannot be used to repair a MY12 vehicle, due to changes in the side impact sensor and the sheet metal in the lower B pillar area.

When stock of the earlier body side assemblies is exhausted, repair of MY07, 08, 09, 10, 11 VE/WM vehicles will require the MY12 body side assembly plus an adaptor piece for mounting the side impact sensor. Part numbers are shown on the table below.

The original part numbers can be used for MY07 to MY11 vehicles until stock is exhausted.

Original body side part number for MY07- MY11
Ute: 92242467
Ute: 92242471
Wagon: 92198736
Wagon: 92198737
LWB: 92195896
LWB: 92195899
Sedan: 92214637
Sedan: 92214638
Replacement body side part number and adaptor part number
92420903 and 92260178
92420904 and 92260177
92420897 and 92260177
92420898 and 92260178
92420895 and 92260178
92420896 and 92260177
92420901 and 92260178
92420902 and 92260177

Note that GM-Holden does not authorise replacement of the outer quarter panel skin on VE utility by cutting the door aperture. (There is an authorised method for VE Sedan, VE Sportwagon and WM sedan.)

Holden is currently working on a solution for VE utility to contain replacement costs.

For further information please contact the IAG Research Centre on (02) 9292 6840


Acknowledgement: Information supplied by GM-Holden


HOLDEN COMMODORE VE FRONT CHASSIS RAIL SECTIONAL REPAIR

APRIL 2012

It is important to refer to the GM Holden repair manual to ensure the sectioning procedure is carried out as per GM Holden specifications.

Once the damaged front chassis rail section has been cut and removed, the new chassis rail will need to be trimmed to suit. A staggered joint repair method has to be performed between the new chassis rail section and the rear section of the existing chassis rail.

Once the new chassis rail section has been trial fitted and aligned to the existing rear section of chassis rail, welding can be carried out.

Spot welding is the preferred method for attaching panels and should be used wherever possible. A plug weld should be performed where the spot welder is unable to reach.

When performing seam-welding, care must be taken to minimize excessive heat buildup. This is to avoid distortion. Also, excessive heat can alter the structure and integrity of HSS panels.

We suggest an allowance of 4.5 hours, which includes the removal and replacing of the skirt brace.

Should you have any further enquiries regarding this bulletin please contact the IAG Research Centre (02) 9292 6843.

2012 04 VE FRONT CHASSIS RAIL SECTIONAL REPAIR 1 2012 04 VE FRONT CHASSIS RAIL SECTIONAL REPAIR 2

 


HOLDEN COMMODORE VE UTE BODY SIDE OUTER PANEL REPLACEMENT PROCEDURE
JUNE 2010

2012 04 HOLDEN COMMODORE VE BODYSIDE OUTER PANEL REPLACEMENT1

The Holden VE Commodore Ute Body side outer panel was recommended to be replaced as a whole assembly until recent revisions of the procedure.

Now there is a new recommended procedure in the replacement of the body side outer panel. If the Body side outer panel damage is from the wheel arch at a specified point rearward on vehicle, the panel can be replaced as a Quarter panel outer section (picture shown on next page).

However, if the Body side outer panel is damaged forward of the specified point the complete Body side panel assembly still requires replacement (picture shown on next page).

Holden’s procedure is to avoid the front section of the Body side outer panel replacement if not necessary. Within the front section of the Body side outer panel are sealers and panels designed to eliminate the chance of exhaust gas to enter the cabin of the vehicle (picture shown on next page). These sealers/panels should not be tampered with, or must be restored to manufacturer’s specifications if need be.
 
2012 04 HOLDEN COMMODORE VE BODYSIDE OUTER PANEL REPLACEMENT2
2012 04 HOLDEN COMMODORE VE BODYSIDE OUTER PANEL REPLACEMENT3

A Body Repair manual with the recommended replacement procedure and a Body side outer panel short section part will be available through Holden Dealers in the near future (approximately November for the part). In the meantime, Repairers and Assessors should contact the IAG Research Centre.

For any further information please contact the IAG Research Centre on (02) 9292 6840.

Acknowledgement: Information supplied by General Motors/Holden.


HOLDEN APPROVED ADHESIVE FOR SPARE WHEEL WELL
COMMODORE VE/CALAIS SEDA AND SPORTWAGON / WM STATESMAN/CAPRICE SEDAN/HSV E-SERIES SEDAN AND TOURER

MARCH 2009

A urethane adhesive is now available through Holden dealers for use when replacing spare wheel wells.

The adhesive meets GM Holden Specifications GMW3041 or Dow Betaseal 15685N as outlined in the Holden VE/WM body repair manual.

Use of the recommended urethane adhesive is crucial in maintaining the vehicle manufacturer’s design features for safety and structural integrity. Refer to the Holden VE/WM body repair manual (DVD Part Number 95710313) for the recommended replacement procedures.

The Dow Betaseal urethane adhesive 15685N is packaged and distributed in a 310ml size cartridge.

The product can be dispensed by using a general multi-purpose caulking gun. A single cartridge has sufficient material to re-bond one wheel well.

The Dow Betaseal urethane adhesive can be purchased through any Holden dealer:
Part number - 92146444
List price - $45.75 + GST

For further information please contact the IAG Research Centre on (02) 9292 6843.

 

HOLDEN COMMODORE VE SEDAN/WAGON/UTILITY, HOLDEN STATESMAN WM AND CAPRICE CHASSIS RAIL END PLATE
JULY 2008

Following discussions with the IAG Research Centre, Holden has approved the availability of end plates for the front chassis rails on VE/WM series vehicles.

The plates are now available through Holden dealers under the following part numbers:
P/N 92199226 Bracket, Front Compartment Side Rail Right Hand list price $6.85 + GST
P/N 92199227 Bracket, Front Compartment Side Rail Left Hand list price $6.50 + GST

The replacement procedure for the end plates is not in the current VE/WM body repair manual. A procedure has been produced by Holden and will be included when the next edition of the manual is released. A copy can be obtained from the IAG Research Centre.
 
2008 04 HOLDEN COMMODORE VE WM CHASSIS RAIL END PLATE 1 2008 04 HOLDEN COMMODORE VE WM CHASSIS RAIL END PLATE 2

HOLDEN VE/WM REPAIRS TO SPARE WHEEL WELL LUGS USING METAL BRACKETS
JULY 2008

2008 07 ve lugs 1  2008 07 ve lugs 1 2008 07 ve lugs 1   2008 07 ve lugs 1
Low speed rear impacts can easily damage the spare wheel wells on Holden VE/WM-series and HSV E-series sedans and sportwagons. Damage can occur to one or more of three (3) protruding lugs.
2008 07 ve lugs 5

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.

2008 07 ve lugs 6

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).

 2008 07 ve lugs 7

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.

2008 07 ve lugs 8

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.

2008 07 ve lugs 9

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.

 2008 07 ve lugs 10