Professional Documents
Culture Documents
1 General Info
2 Preparation of work
3 *Replacement
4 Body Dimensional Drawings
5 Rust Prevention
6 Paints
Special Information
WARNING
CAUTION
CAUTION
Fist Edition
8/2000
Index - Index
Index
4-door General Information
1-3
1-15
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1-4
1-5
1-6
1-7
1-8
Construction
1-9
1-10
1-11
1-12
1-14
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General Information
1-4
This model has an SRS which includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above the glove box, seat belt tensions in the front seat
belt retractors and side airbags in the front seat backs. The SRS unit is separate from the airbag assembly and has built-in sensors. The following precautions should be observed
when performing sheet metal work, paint work and repair work around the locations of the SRS components.
1. The SRS unit (including the safing sensor and the impact is located under the dashboard and the side impact sensors are located in each side still. Avoid any strong Impact with
a hammer or other tools when repairing the front side frame, the lower part of the dashboard and the side sill. Do not apply heat to these areas with a torch, etc.
2. Take extra care when painting or doing body work in the area below the centre pillar. Avoid direct exposure of the seat belt retractor with tensioner to heat guns, welding or
spraying equipment.
3. SRS electrical wiring harness are identified with yellow colour coding. Care should be taken not to damage the harness when repairing this area.
4. Do not apply heat of more than 212F (100C) when drying painted surfaces anywhere around the locations of SRS components.
5. If strong impact or high temperature needs to be applied to the areas around the locations of SRS components, remove the Components before performing the repair work.
6. If any of the SRS related components are damaged or deformed, be sure to replace them.
NOTE: Refer to the Restraints section of the Shop Manual for after deployment, and removal and replacement of SRS related components.
1. DRIVER'S AIRBAG
ASSEMBLY
2. CABLE REEL
3. FRONT PASSENGER'S
AIRBAG ASSEMBLY
4. SIDE AIRBAG
5. SEAT BELT TENSIONERS
6. SIDE IMPACT SENSOR
7. SIDE IMPACT SENSOR
8. SIDE AIRBAG
9. SRS UNIT
(with built-in sensor)
10. UNDER-DASH FUSE/
RELAY BOX
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General Information
15
1. Built Data and Vehicle Type
Except KK, KX, KY models
2. Vehicle Identification
Number (VIN)
3. Engine Number
4. Transmission Number
(Manual)
5. Transmission Number
(Automatic)
6. Transmission Number
(Honda Multi Matic)
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General Information
1-6
NOTE: If you are going to remove heavy components such as suspension or the fuel
tank from the rear of the vehicle, first support the front of the vehicle with a tall safety
stands. When substantial weight is removed from the rear of the vehicle, the centre of
gravity can change and cause the vehicle to tip forward on the hoist.
Frame Hoist
Position the hoist lift blocks, or safety stands, under the vehicle's front support points
and rear support points.
Floor Jack
1. Set the parking brake.
2. Block the wheels that are not being lifted.
3. When lifting the rear of the vehicle, put the gearshift lever in reverse (or automatic
transmission in Park position).
4. Position the floor jack under the front jacking bracket or rear jacking bracket, centre
the jacking bracket in the jack lift platform, and jack up the vehicle high enough to
fit the safety stands under it.
1. Raise the hoist a few inches, and rock the vehicle gently to be sure it is firmly
supported.
2. Raise the hoist to full height, and inspect the lift points for solid contact with the lift
blocks.
Safety Stands
To support the vehicle on safety stands, use the same support points as for a frame
hoist. Always use safety stands when working on a under vehicle that is supported
only by a jack.
1.
2.
3.
4.
5. Position the safety stands under the support points and adjust them so the vehicle
will level.
6. Lower the vehicle onto the stands.
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General Information
1-7
000'45'
Caster
1'33'1
Total toe
03 (00.12)
in
out
-045'45'
Total toe
IN 2 3 (0.08 0.12)
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General Information
1-8
NOTE: To adjust the alignment of the hood, the front door, rear door and trunk lid, refer to the CIVIC Shop Manual.
Mounting bolts/nuts torque:
6X1.0 mm: 9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
*6X1.0 mm: 1.8 Nm (1.8 kgf/m, 13 lbf/ft)
8X1.0 mm: 22 Nm (2.2 kgf/m, 16 lbf/ft)
*8X1.25 mm: 29 Nm (3.0 kgf/m, 22 lbf/ft)
1. HOOD
2. HOOD HINGE
3. REAR BUMPER SIDE
BRACKET
4. TRUNK LID HINGE
5. TRUNK LID
6. REAR BUMPER BEAM
7. FUEL DOOR
8. REAR BULKHEAD GUSSET
9. REAR DOOR
10. REAR DOOR HINGE
11. FRONT DOOR
12. FRONT DOOR HINGE
13. FRONT FENDER
14. CORNER UPPER BEAM
15. FRONT BUMPER BEAM
16. BATTERY SET BASE
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1-9
General Information
Construction
Part Name
No.
Part Name
22
23
24
25
26
27
28
29
30
10
31
11
32
12
33
13
34
14
35
15
36
16
37
17
38
18
39
19
40
20
41
21
42
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General Information
110
Door and bumper reinforcement beams used on Honda vehicles are made from a metal equivalent to High Strength Steel.
If High Strength Steel is heated, the strength of the steel will b e reduced. If High Strength Steel is damaged, as in a vehicle accident, where the door and bumper reinforcement
beams are bent, the beams may crack if an attempt is made to straighten them.
For this reason, the door and bumper reinforcement beams should NEVER be repaired; they should be replaced if they are damaged.
NOTE: If a door beam is damaged, the whole door panel assembly should be replaced.
1. REAR BUMPER REINFORCEMENT
BEAM
2. REAR DOOR REINFORCEMENT
BEAM
3. FRONT DOOR REINFORCEMENT
BEAMS
4. FRONT BUMPER
REINFORCEMENT BEAM
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111
General Information
The Zinc-plated steel plate used in some panels of the CIVIC 4-door requires different repair techniques than ordinary steel plate. Refer to "Body Construction" (see page 1-9) for the
location of the Zinc-plated panels.
1. ZINC-PLATED (5-6 microns)
2. Steel plate
1. Before spot welding the zinc-plated steel plate, remove the paint from both sides of the flange to be welded. Apply sealer to the flange after welding.
WARNING
To prevent eye injury, wear goggles or safety glassed whenever sanding, cutting or grinding.
NOTE: Seal the sanded surface thoroughly to prevent rust.
2. The electric continuity properties of zinc-plated steel plate is different from the ordinary steel plate. When spot welding, increase the current by 10-20%.
NOTE: The MIG welding procedures for Zinc-plated steel plate are the same an for ordinary steel plate.
WARNING
To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.
3. Before applying putty or body filler to the Zinc-plated steel plate, sand the zinc plating thoroughly to promote adhesion and to prevent blistering.
NOTE: Use only epoxy-based putties and fillers on zinc-plated steel plate, following the manufacture's specifications.
4. When performing pain work, protect the ground wire and ground wire mounting hole threads with a bolt or a plug.
1.
2.
3.
4.
SPECIAL BOLT
GROUND WIRE
GROUND WIRE MOUNTING HOLE
PLUG
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General Information
KB
KQ
KY
NH623M
Stain
Silver M.
B-92P
Night
Hawk
Black P.
B-96P
Eternal
Blue P.
G-95P
Clover
Green P.
R-81
Mirano
Red
R504P
RP-32P
Ruby Red Vintage
P.
Plum P.
YR-525M
Titanium
M.
1.4S
1.6SE
1.4S
1.6LS
1.6ES
1.4S
1.6ES
GLi
VTi
LXi
EXi
VTi
KW
EXi
KT
LXi
EXi
EXi
VTi
VTi-S
LXi
EXi
VTi
DX
LX
EX
EXi
VTi
EXi
LXi
150I
170I
LX
EX
KU
KV
KK
KH
KF
KN
KX
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General Information
113
1. FRONT GRILLE
Body Colour
2. HOOD MOLDING BASE
Chrome plated or body
colour
3. DOOR MIRROR BASE
Black (NH-70 Gloss 20)
4. DOOR MIRROR
Body colour or black (NH70 Gloss 20)
5. DOOR OUTER HANDLE
Body colour or black (NH72 Gloss 30)
6. PROTECTER
MOULDINGS
Body colour or BP, Dark
grey (NH-533)
7. FRONT BUMPER
Body colour
8. ROOF MOULDING
Black (NH-70 Gloss 20)
9. DRIP MOULDING
Chrome plated or black
(NH-70 Gloss 20)
10. LICENSE TRIM
Chrome plated or body
colour
11. REAR BUMPER
Body Colour
12. DOOR MOULDING
Chrome plated or black
(NH-70 Gloss 20)
13. DOOR SASH TRIM
Black (NH-70 Gloss 20)
14. FRONT UNDER SPOILER
Black (NH-68 Gloss 10)
15. GRILLE
BP. Dark grey (NH-533)
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General Information
114
NOTE: A standard symbol is stamped on the underside of each resin part to show the type of material of used.
Example:
1. FRONT GRILLE
Polypropylene (PP)
2. HOOD MOULDING
Acrylonitrile butadiene
styrene (ABS)
3. FRONT WINDSHIELD
MOULDING
Acrylonitrile ethylene
propylene dine rubber
styrene (A/EPDM/S)
4. DOOR OUTER HANDLE
Polycarbonate (PC)
5. DOOR MIRROR
Painted: Acrylonitrile
butadiene styrene (ABS)
Unpainted: Acrylonitrile
styrene acrylate (ASA)
6. FRONT BUMPER
Polypropylene (PP)
7. ROOF MOULDING
Polyvinyl chloride (PVC)
8. LICENSE TRIP
Acrylonitrile butadiene
styrene (ABS)
9. REAR BUMPER
Polypropylene (PP)
10. PROTECTOR MOULDING
Polypropylene (PP)
11. DOOR SASH TRIM
Acrylontrile ethylene
propylene dinene rubber
styrene (A/EPDM/S)
12. FRONT UNDER SPOILER
Ethylene propylene dinene
rubber (EPDM)
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1-16
1-17
1-18
1-19
1-20
Construction
1-21
1-22
1-23
1-24
1-26
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General Information
116
This model has an SRS which includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above the glove box, seat belt tensioners in the front seat
belt retractors and side airbags in the front seat backs. The SRS unit is separated from the airbag assembly and has built-in sensors. The following precautions should be observed
when performing sheet metal work, paint work and repair work around the location of the SRS components.
1. The SRS unit (including the safing sensor and the impact sensor) is located under the dashboard and the side impact sensors are located in each side sill. Avoid any strong
impact with a hammer or other tools when repairing the front side frame, the lower part of the dashboard and side sill. Do not apply heat to these areas with a torch, etc.
2. Take extra care when painting or doing body work in the area below the centre pillar. Avoid direct exposure of the seat belt retractor with tensioner to heat guns, welding, or
spraying equipment.
3. SRS electrical wiring harnesses are identified with yellow colour coding. Care should be taken not to damage the harness when repairing this area.
4. Do not apply heat of more than 212F (100C) when drying painted surfaces anywhere around the locations of SRS components.
5. If strong impact or high temperature needs to be applied to the areas around the locations of SRS components, remove the components before performing the repair work.
6. If any of the SRS related components are damaged or deformed, be sure to replace them.
NOTE: Refer to the restraints section of the Shop Manual for after deployment and remove and replacement of SRS related components.
1. SIDE AIRBAG
2. FRONT PASSENGER'S
AIRBAG ASSEMBLY
3. DRIVER'S AIRBAG
ASSEMBLY
4. CABLE REEL
5. UNDER-DASH FUSE/
RELAY BOX
6. SRS UNIT
(with built-in sensor)
7. SIDE IMPACT SENSOR
8. SIDE AIRBAG
9. SIDE IMPACT SENSOR
10. SEAT BELT TENSIONERS
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General Information
117
1. Built Data and Vehicle Type
2. Vehicle Identification
Number (VIN)
3. Engine Number
4. Transmission Number
(Manual)
5. Transmission Number
(Automatic)
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General Information
Lift and Support Points
NOTE: If you are going to remove heavy components such as suspension or the fuel
tank from the rear of the vehicle, first support the front of the vehicle with a tall safety
stands. When substantial weight is removed from the rear of the vehicle, the centre of
gravity can change and cause the vehicle to tip forward on the hoist.
Frame Hoist
Position the hoist lift blocks, or safety stands, under the vehicle's front support points
and rear support points.
118
Floor Jack
1. Set the parking brake.
2. Block the wheels that are not being lifted.
3. When lifting the rear of the vehicle, put the gearshift lever in reverse (or automatic
transmission in Park position).
4. Position the floor jack under the front jacking bracket or rear jacking bracket, centre
the jacking bracket in the jack lift platform, and jack up the vehicle high enough to fit
the safety stands under it.
1. Raise the hoist a few inches, and rock the vehicle gently to be sure it is firmly
supported.
2. Raise the hoist to full height, and inspect the lift points for solid contact with the lift
blocks.
Safety Stands
To support the vehicle on safety stands, use the same support points as for a frame
hoist. Always use safety stands when working on a under vehicle that is supported only
by a jack.
1.
2.
3.
4.
5. Position the safety stands under the support points and adjust them so the vehicle
will level.
6. Lower the vehicle onto the stands.
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General Information
119
Unit : mm(in.)
000'45'
Caster
1'33'1
Total toe
03 (00.13)
in
out
-045'45'
Total toe
IN 2 3 (0.08 0.12)
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General Information
120
NOTE: To adjust the alignment of the hood, the front door, rear door and trunk lid, refer to the CIVIC Shop Manual.
Mounting bolts/nuts torque:
6X1.0 mm: 9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
*6X1.0 mm: 1.8 Nm (1.8 kgf/m, 13 lbf/ft)
8X1.0 mm: 22 Nm (2.2 kgf/m, 16 lbf/ft)
*8X1.25 mm: 29 Nm (3.0 kgf/m, 22 lbf/ft)
1. HOOD
2. HOOD HINGE
3. REAR BUMPER SIDE
BRACKET
4. TAILGATE HINGE
5. TAILGATE
6. REAR BUMPER BEAM
7. FUEL DOOR
8. REAR BULKHEAD GUSSET
9. REAR DOOR
10. REAR DOOR HINGE
11. FRONT DOOR
12. FRONT DOOR HINGE
13. FRONT FENDER
14. CORNER UPPER BEAM
15. FRONT BUMPER BEAM
16. FRONT BUMPER LOWER
STIFFENER
17. BATTERY SET BASE
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121
General Information
Construction
Part Name
No.
Part Name
22
23
24
25
26
27
28
29
30
10
31
11
32
12
33
13
34
14
35
15
36
16
37
17
38
18
39
19
40
20
41
21
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General Information
122
Door and bumper reinforcement beams used on Honda vehicles are made from a metal equivalent to High Strength Steel.
If High Strength Steel is heated, the strength of the steel will b e reduced. If High Strength Steel is damaged, as in a vehicle accident, where the door and bumper reinforcement
beams are bent, the beams may crack if an attempt is made to straighten them.
For this reason, the door and bumper reinforcement beams should NEVER be repaired; they should be replaced if they are damaged.
NOTE: If a door beam is damaged, the whole door panel assembly should be replaced.
1. REAR BUMPER
REINFORCEMENT BEAM
2. REAR DOOR
REINFORCEMENT BEAM
3. FRONT DOOR
REINFORCEMENT BEAMS
4. FRONT BUMPER
REINFORCEMENT BEAM
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123
General Information
The Zinc-plated steel plate used in some panels of the CIVIC 5-door requires different repair techniques than ordinary steel plate. Refer to "Body Construction" (see page 1-21) for
the location of the Zinc-plated panels.
1. ZINC-PLATED (5-6 microns)
2. Steel plate
1. Before spot welding the zinc-plated steel plate, remove the paint from both sides of the flange to be welded. Apply sealer to the flange after welding.
WARNING
To prevent eye injury, wear goggles or safety glassed whenever sanding, cutting or grinding.
NOTE: Seal the sanded surface thoroughly to prevent rust.
2. The electric continuity properties of zinc-plated steel plate is different from the ordinary steel plate. When spot welding, increase the current by 10-20% or increase the resistance
welding time.Also increase the number of weld spots by 10-20%.
NOTE: The MIG welding procedures for Zinc-plated steel plate are the same an for ordinary steel plate.
WARNING
To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.
3. Before applying putty or body filler to the Zinc-plated steel plate, sand the zinc plating thoroughly to promote adhesion and to prevent blistering.
NOTE: Use only epoxy-based putties and fillers on zinc-plated steel plate, following the manufacture's specifications.
4. When performing pain work, protect the ground wire and ground wire mounting hole threads with a bolt or a plug.
1.
2.
3.
4.
SPECIAL BOLT
GROUND WIRE
GROUND WIRE MOUNTING HOLE
PLUG
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124
General Information
KQ
KT
B-92P
Night
Hawk
Black P.
G-502M
Aqua
Green M.
PB-77M
Lavender
Mist M.
R-81
Mirano
Red
R504P
Ruby
Red P.
B-96P
Eternal
Blue P.
G95P
Clover
Green P.
1.4S
1.6S
1.4SE
1.6LSE
Vi
VTi
EXi
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General Information
125
1. DOOR MIRROR BASE
Black (NH-70 Gloss 20)
2. DOOR MIRROR
Body colour or black (NH-70
Gloss 20)
3. CHANNEL TAPE
Black (NH-70 Gloss 20)
4. DOOR OUTER HANDLE
Body colour or black (NH-72
Gloss 30)
5. CORNER TRIM
Black (NH-70 GLOSS 20)
6. ROOF MOULDING
Black (NH-70 Gloss 20)
7. LICENSE TRIM
Body colour or black (NH-72
Gloss 30)
8. REAR BUMPER
Body Clour
9. DOOR MOULDING
Black (NH-70 Gloss 20)
10. DOOR SASH TRIM
Black (NH-70 Gloss 20)
11. FRONT BUMPER
Body Colour
12. GRILLE
BP. Dark grey (NH-533)
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General Information
126
NOTE: A standard symbol is stamped on the underside of each resin part to show the type of material of used.
Example:
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Preparation of Work
General Safety Precaution
2-3
2-4
Measurement
2-5
Reshaping
Correction of the Damaged Area
2-6
Replacement
Removal
2-7
Installation
2-8
Rust Prevention/Paint
2-10
2-11
Repair Tools
Measurement Equipment
2-12
Protective Tools
2-12
Processing Tools
2-13
Cutting Tools
2-13
Shaping Tools
2-14
Fixing Tools
2-15
Welders
2-16
Sanding Tools
2-16
Welding Methods
Spot Welding
2-17
2-19
Gas Welding
2-20
2-2
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2-2
The contents described in this section are the basic processes of repair procedures needed to cut and replace welded parts. Reshape the light damage, outer panel with filler after
repair by the washer welder, the hammer and dolly.
The table below shows information to this model.
Processes
Repair Procedures
Information
Reshape
1.
2.
3.
4.
Rust Prevention
Installation and
Inspection
see section 1
see section 4
see section 1
Paint
see section 1
Shop Manual
Replacement
Wheelbase
Wheel Alignment
Body Dimensional Drawings
Reference
see section 4
see section 3
see section 3
see section 4
see section 3
see section 6
1.
2.
3.
4.
Shop Manual
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2-3
1. FUEL TANK
1. SAFETY CABLES
Cover the exterior parts and the interior parts with a fireproof cover
and protect the vehicle when welding.
Do not damage the passenger compartment parts when you heat the
undercoat of the welded flange with a torch.
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2-4
Description
Most monocoque bodies are composed as a single until by welding together pressed parts made of steel plates, which come in a variety of different shapes and sizes. Each part is
responsible for displaying a certain strength and durability in order that it may play its role in meeting the functions of the body.
Damage to the exterior of the body can be visually inspected, but where there has been external impact, it is necessary to inspect the extent of the damage. In some cases, the
deformation may have spread beyond the actual areas that were in the collision so the deformation must be closely inspected.
Distortion to the vehicle, bends, inclines and gaps between parts should be thoroughly checked. Also, check for paint peeling at welded areas, corners and the sealing coat.
: Carefully checked.
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2-5
Diagonal measurement:
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Reshape
Reshape
2-6
4. Check that the part of the body is more or less restored to its original
shapes. Check the original positions using the body dimensional
drawings.
1. SUPPORT POINTS
(Jack-up stiffener)
3. Pull out and straighten damaged areas. Apply load to the damaged
section, and pull on it until the section is almost restored to its original
shape. Do not pull out more than necessary.
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2-7
Replacement
Removal
1. Decide whether to replace all the affected parts or whether to cut the
weld joint parts and replace them.
NOTE: When cutting the parts off, take special care that you do not
damage adjacent parts on the vehicle.
Setting Condition for Replacement Parts Joint Sections:
Make sure that you can perform straightening work after welding.
Make sure that the locations will not be susceptible to distortion
caused by other parts.
Make sure that there are few removable parts and that the location
allows for safe welding.
Make sure that the joints are short, and that paint repair can be
performed easily.
Make sure that locations are such that the joints can be finished in
a way that will not affect the outward appearance.
Make sure that the locations do not hinder the removing and
attaching of parts.
Parts which influence wheel alignment such as damper housing and the
side frames must be examined using the frame repair charts.
CAUTION
WARNING
1. DAMPER HOUSING
2. OUTER PANEL
(New part)
3. FRONT SIDE FRAME
(New part)
1. STIFFENER
2. OUTER PANEL
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2-8
Replacement
Installation
WARNING
Where new panels cannot be spot welded, make holes for plug
welding.
Make holes to the size which corresponds to the thickness of the
welded plate (see page 2-19).
The position and the point by which holes are made, refer to the old
parts or Mass Production Body Welding Diagram (see section 3).
Fill any holes by MIG welding and even out with a hammer and
dolly.
WARNING
Level and finish the burns on the welding flanges with a disc sander
or belt sander.
1. NEW PART
2. OLD PART
3. Apply rust prevention processing on welded surface.
WARNING
1. OVERLAP
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2-9
Replacement
Installation
WARNING
Make 20% to 30% more spot welds than there were holes drilled.
A new welding position should avoid an old position as much as
possible.
NOTE: If there is not room for spot welds, compensate by using MIG
welds
Fillet weld the repair outer side sill it will overlap by 30 mm (1.2 in.)
in the front and back.
Butt weld the front pillar, centre pillar, rear pillar and the wheel arch
cut sections of the repaired outer panel.
NOTE: Attach the patches at the cut sections of the outer panel and
plug weld them.
WARNING
1. BUTT WELD
2. PATCH
3. FILLET WELD
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210
Replacement
Installation (cont'd)
WARNING
1. Applying the sealer. Seal the overlapped areas of the outer panel, and
the welded surfaces of the new parts. Seal gaps completely.
2. Apply the paint.
WARNING
Even out high areas with a hammer. Be careful not to deform them.
Smooth out welded door and tailgate areas, and window opening
flanges with a hammer and dolly.
Fill the deformed area and smooth out the welded areas with body
filler.
Rust Prevention/Paint
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211
1. Check the clearance of the door, hood, tailgate and adjust if necessary.
Check the operation of the parts and make sure the doors lock
securely.
2. Apply the sealer to the hinges of the hood, door and tailgate.
1. HOOD HINGE
2. DOOR HINGE
3. TAILGATE HINGE
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212
Repair Tools
Measurement Equipment
Protective Tools
OPERATOR:
1
Protective goggles
Protective apron
Cap
Welding glove
Ear plugs
Foot protector
10
Safety shoes
11
Work glove
Dust-proof mask
12
Splatter guard
CONVEX TOOL
VEHICLE BODY:
Heat-resistant protective cover
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Repair Tools
Processing Tools
213
SPOT CUTTER
AIRSAW
Install the spot cutter in the air drill, and drill a hole at the spot weld
nugget and the plug to make the hole.
Cutting Tools
Detaching the MIG welding part and the panel can be cut by installing cut
grinding wheel in air chuck grinder.
CHISEL SET
CENTRE PUNCH
When an accurate hole opening is necessary.
HAND NIBBLER
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219
Welding Methods
This welding process uses inexpensive carbon dioxide instead of expensive inert gases as a shielding means. Consumable metal electrodes are employed. It has a wide range of
applications, including butt welding of a thin plate, fillet welding, plug welding and MIG spot welding. In terms of the weld strength, it is also highly stable.
Welders:
1. Single-phase 110V
Three-phase 200-240V
2. Gas hose
3. Input cable
4. Gas regulator
5. Carbon dioxide or Argon +
Carbon dioxide
6. Welding power supply
(built-in wire feed
mechanism)
7. Welding torch
8. Workpiece
9. Work cable
10. Ground wire
CAUTION
Fillet welding
Spot welding
Plug welding
~1.0 (0.04)
1.5 (0.06)~
5 (0.2)
6.5 (0.26)
8 (0.3)
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220
Welding Methods
Gas Welding
Gas welding is indispensable for body repair because of the broad range of its applications to join the body panels, cut the materials that construct the body, apply heat to reform
panels, and also because it is easy to get hold of the tools.
However, this method requires experience.
Welders:
1.
2.
3.
4.
5.
Gas regulator
Gas regulator
Welder
Cutter
Oxygen/Acetylene tanks
Welding Methods:
Butt welding
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Index - Index
Index
4-door Replacement
3-3
5-door Replacement
3-35
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4-door Replacement
4-door Replacement
*Front Bulkhead
Mass Production Body Welding Diagram
3-4
Removal
3-5
Installation
3-5
3-6
Removal
3-7
Installation
3-9
3-11
Removal
3-12
Installation
3-14
3-16
Removal
3-17
Installation
3-18
3-19
Removal
3-20
Installation
3-21
Roof Panel
Mass Production Body Welding Diagram
3-24
Removal
3-24
Installation
3-25
3-26
Removal
3-27
Installation
3-28
Rear Panel
Mass Production Body Welding Diagram
3-29
Removal
3-30
Installation
3-31
Rear Floor
Mass Production Body Welding Diagram
3-32
Removal
3-33
Installation
3-34
Items marked with and asterisk (*) include SRS components; special caution is required when servicing.
4-door Replacement
Front Bulkhead
34
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
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Front Bulkhead
3-5
Installation
Removal
1. Set the new front bulkhead into position and measure the front
compartment diagonally. Check the body dimensions (see section 4).
2. Tack weld the clamped position.
3. Temporarily install the hood, front fender, headlight and front bumper
and check for differences in level and clearance.
4. Perform the main welding:
1.
2.
3.
4.
5.
6.
7.
8.
1.
2.
3.
4.
5.
6.
7.
8.
9.
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36
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
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3-7
Removal
Cut and remove the wheelhouse upper member, and replace the front wheelhouse.
1. DAMPER HOUSING
2. FRONT DAMPER
EXTENSION
3. WHEELHOUSE UPPER
MEMBER Reused.
4. FRONT WHEELHOUSE
5. ENGINE MOUNT BRACKET
6. FRONT SIDE FRAME
Check the front damper extension and damper housing for position and damage. If necessary, remove the wheelhouse upper member and replace the damper housing and
front damper extension as an assembly, if possible.
1. DAMPER HOUSING
2. FRONT DAMPER EXTENSION
3. WHEELHOUSE UPPER MEMBER Reused.
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3-8
Removal (cont'd)
Replace the front damper extension, damper housing and damper housing extension as an assembly.
Passenger compartment side:
1. FRONT DAMPER
EXTENSION
2. DASHBOARD UPPER
SIDE MEMBER
3. DAMPER HOUSING
4. FRONT DAMPER
EXTENSION
5. ENGINE MOUNT BRACKET
6. FRONT SIDE FRAME
7. DAMPER HOUSING
EXTENSION
8. DAMPER HOUSING
EXTENSION
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3-9
1. Set the new damper housing assembly, front wheelhouse and front
bulkhead into position, and measure the front compartment diagonally.
Check the body dimensions (see section 4).
From wheelhouse side, plug weld the holes in the dashboard upper
and damper housing extension.
1.
2.
3.
4.
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Weld the front wheelhouse, damper housing and front side frame.
1.
2.
3.
4.
310
DAMPER HOUSING
FRONT DAMPER EXTENSION
FRONT WHEELHOUSE
ENGINE MOUNT BRACKET
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311
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
VIEW (Y)
a. Inside sill extension
VIEW (Z)
312
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313
Check the side frame bulkhead rear for position and damage. If necessary replace it.
1. SUB-FRAME REAR BRACKET
2. SIDE FRAME BULKHEAD REAR
3. SIDE FRAME EXTENSION REAR
If necessary, replace the side frame extension rear, outrigger and sub-frame rear bracket as an assembly.
NOTE: When removing the outrigger, leave the inside sill extension attached to the inside sill, if possible.
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314
1. Tack weld the new side frame bulkhead rear to the side frame
extension rear.
2. Set the new front side frame, side frame extension rear, outrigger and
front bulkhead into position and measure the front compartment
diagonally. Check the body dimensions (see section 4).
3. Tack weld the clamped position.
4. Temporarily install the front sub-frame, and check the front side frame
position.
5. Temporarily install the hood, front render, headlights and front bumper,
and check for differences in level and clearance.
Make sure the body lines flow smoothly.
6. Perform the main welding:
Plug weld the side frame extension rear, side frame bulkhead rear
and front side frame.
1. OUTRIGGER
2. SUB-FRAME REAR BRACKET
3. SIDE FRAME EXTENSION REAR
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Roof Panel
Removal
324
1.
2.
3.
4.
5.
6.
7.
ROOF PANEL
REAR INNER PANEL
ROOF ARCH GUSSET
REAR INNER PANEL
REAR ROOF RAIL
FRONT ROOF RAIL
FRONT INNER UPPER
PANEL
8. FRONT INNER UPPER
PILLAR
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Roof Panel
Installation
1. Set the new roof panel into position and clamp it. Check the body
dimensions (see section 4), and check the width of the roof moulding
installation.
2. Install the roof arch gusset, and tack weld the roof panel.
3. Temporarily install the windshield, door and rear window and check for
difference in level and clearance.
4. Perform the main welding.
325
5. From inside the vehicle, plug weld the front pillar inner upper, rear
inner panel and front and rear roof rails.
1. OUTER PANEL
2. ROOF PANEL
3. ROOF SIDE RAIL
VIEW (Z)
1.
2.
3.
4.
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326
a.
b.
c.
d.
e.
f.
g.
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327
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1. Set the new repair part (outer panel and rear combination adaptor and into
position and clamp them. Check the body dimensions (see section 4).
2. Tack weld the clamped position.
3. Temporarily install the door, rear window, trunk lid and rear bumper and check
for difference in level and clearance.
Make sure the body lines flow smoothly.
4. Perform the main welding:
Attach the patch at the cut section of the rear pillar and plug weld it.
328
1.
2.
3.
4.
5.
6.
7.
OUTER PANEL
PARCEL SHELF
REAR GUTTER
Butt welding
NEW OUTER PANEL
Fillet welding
Overlap
30 mm (1.2 in.)
8. PATCH
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Rear Panel
329
a.
b.
c.
d.
e.
f.
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Rear Panel
Removal
330
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331
Rear Panel
Installation
1. Set the new rear panel and rear combination adaptor into position and
clamp them.
Check the body dimensions (see section 4).
In the case of leave the rear panel side stiffener and rear combination
adopter and replace rear panel.
Remove the new panel side stiffener from the new rear panel.
Weld the rear panel side lower stiffener and rear panel side stiffener.
1.
2.
3.
4.
OUTER PANEL
NEW REAR GUTTER
NEW REAR COMBINATION ADAPTOR
NEW REAR PANEL
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Rear Floor
332
a.
b.
c.
d.
e.
f.
g.
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Rear Floor
Removal
333
Cut the rear floor 15 mm (0.6 in.) from the welded flange of the rear cross-member.
If necessary, replace the rear frame B.
Check the rear floor cross-member position for damage.
If necessary, replace the rear floor cross-member.
1. REAR FLOOR CROSSMEMBER
2. REAR FLOOR
3. Cut line
4. REAR FLOOR CROSSMEMBER
5. REAR FLOOR
6. REAR FLOOR CROSSMEMBER
7. REAR FRAME A
8. VIEW (Z)
9. REAR FRAME B
10. REAR FRAME A
11. REAR FRAME B
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Rear Floor
Installation
1.
2.
3.
4.
Set the new rear cross-member and rear frame B, into position.
Check the body dimensions (see section 4).
Tack weld the rear cross-member and rear frame B.
Set the new rear floor to align it with the body.
Cut the new rear floor so it overlaps the body side floor by about 40
mm (1.6 in.).
334
8. Set the new rear floor, and plug weld the rear floor cross-member, rear
frame B and rear frame A.
1.
2.
3.
4.
5.
REAR FRAME A
REAR FLOOR CROSS-MEMBER
REAR FRAME B
REAR FRAME A
REAR FLOOR CROSS-MEMBER
5. Check the position of the rear inner panel and rear panel.
6. Remove the new rear floor and plug weld the rear floor cross-member.
7. Finish plug welding the area, and take not to grind excessively.
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5-door Replacement
5-door Replacement
*Front Bulkhead
Mass Production Body Welding Diagram
3-36
Removal
3-37
Installation
3-37
3-38
Removal
3-39
Installation
3-41
3-43
Removal
3-44
Installation
3-46
3-48
Removal
3-49
Installation
3-50
3-51
Removal
3-52
Installation
3-53
Roof Panel
Mass Production Body Welding Diagram
3-55
Removal
3-56
Installation
3-57
3-58
Removal
3-59
Installation
3-60
Rear Panel
Mass Production Body Welding Diagram
3-61
Removal
3-62
Installation
3-62
Rear Floor
Mass Production Body Welding Diagram
3-63
Removal
3-64
Installation
3-65
Items marked with an asterisk (*) include SRS components; special caution is required when servicing.
5-door Replacement
Front Bulkhead
336
a. Front wheelhouse
b. Wheelhouse upper
extension
c. Front side frame
d. Wheelhouse upper
member
e. Front lower cross-member
f. Bulkhead side
g. Front side frame
h. 4-Plate welding
i. 4-Plate welding
j. Front lower cross-member
k. Bulkhead side stay
l. Bulkhead centre stay
m. Bulkhead upper frame
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Front Bulkhead
Removal
337
Installation
1. Set the new front bulkhead into position and measure the front
compartment diagonally. Check the body dimension (see section 4).
2. Tack weld the clamped position.
3. Temporarily install the hood, front fender, headlight and front bumper
and check for differences in level and clearance.
4. Perform the main welding:
1.
2.
3.
4.
5.
6.
7.
1.
2.
3.
4.
5.
6.
7.
8.
9.
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Front/Wheelhouse/Damper Housing
Front/Wheelhouse/Damper Housing
Mass Production Body Welding Diagram
338
a.
b.
c.
d.
e.
f.
g.
Front/Wheelhouse/Damper Housing
VIEW (X)
339
Cut and remove the wheelhouse upper member, and replace the front wheelhouse.
1. DAMPER HOUSING
2. WHEELHOUSE UPPER
EXTENSION
3. WHEELHOUSE UPPER
MEMBER Reused.
4. FRONT WHEELHOUSE
5. ENGINE MOUNT BRACKET
6. FRONT SIDE FRAME
Check the wheelhouse upper extension and damper housing for position and damage. If Necessary, remove the wheelhouse upper member and replace the damper housing and
wheelhouse upper extension as an assembly. If possible.
1.
2.
3.
4.
DAMPER HOUSING
WHEELHOUSE UPPER EXTENSION
WHEELHOUSE UPPER MEMBER EXTENSION
WHEELHOUSE UPPER MEMBER Reused.
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340
1. WHEELHOUSE UPPER
EXTENSION
2. DASHBOARD UPPER
SIDE MEMBER
3. DAMPER HOUSING
4. WHEELHOUSE UPPER
EXTENSION
5. ENGINE MOUNT BRACKET
6. FRONT SIDE FRAME
7. DASHBOARD UPPER
8. MOUNTING BOLT
9. DAMPER HOUSING
EXTENSION
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341
1. Set the new damper housing assembly, front wheelhouse and front
bulkhead into position and measure the front compartment diagonally.
Check the body dimensions (see section 4).
2. Tack weld the clamped position.
3. Temporarily install the front sub-frame and check the front side frame
position.
4. Temporarily install the hood, front fender, headlight and front bumper,
and check for differences in level and clearance. Make sure the lines
flow smoothly.
5. Perform the main welding:
Weld the damper housing and front side frame.
Weld the front damper extension and dashboard upper side
member.
1. DASHBOARD UPPER
1.
2.
3.
4.
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Weld the front wheelhouse, damper housing and front side frame.
1.
2.
3.
4.
342
DAMPER HOUSING
WHEELHOUSE UPPER EXTENSION
FRONT WHEELHOUSE
ENGINE MOUNT BRACKET
1.
2.
3.
4.
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343
a.
b.
c.
d.
e.
f.
g.
h.
VIEW (Y)
Passenger compartment side:
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344
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345
Check the side frame bulkhead rear for position and damage. If Necessary replace it.
1. SUB-FRAME REAR BRACKET
2. SIDE FRAME BULKHEAD REAR
3. SIDE FRAME EXTENSION
If necessary, replace the side frame extension rear, outrigger and sub-frame rear bracket as an assembly.
NOTE: When removing the outrigger, leave the inside sill extension attached to the inside sill, if possible.
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346
1. Tack weld the new side frame bulkhead rear to the side frame
extension rear.
2. Set the new front, side frame extension rear, outrigger and front
bulkhead into position and measure the front compartment diagonally.
Check the body dimensions (see section 4).
3. Tack weld the clamped position.
4. Temporarily install the front sub-frame and check the front side frame
position.
5. Temporarily install the hood, front fender, headlight and front bumper
and check for difference in level and clearance.
Make sure the body lines flow smoothly.
6. Perform the main welding:
Plug weld the side frame extension rear, side frame bulkhead rear
and front side frame.
1. OUTRIGGER
2. SUB-FRAME REAR BRACKET
3. SIDE FRAME EXTENSION REAR
347
Weld the damper housing, front wheelhouse and front side frame.
1. DAMPER HOUSING
2. FRONT WHEELHOUSE
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348
a. Wheelhouse upper
member (see page 338)
b. Front pillar lower
stiffener
c. Inner lower
d. Front pillar upper
stiffener
e. VIEW (Z)
f. Side sill reinforcement
g. Front pillar stiffener
h. 4-Plate welding
i. Front pillar separator
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349
Cut the wheelhouse upper member as necessary pry off the front pillar outer panel.
Check the front pillar lower stiffener position and for damage and replace it if necessary.
When replacing the front pillar lower stiffener, remove the front pillar separator and glue the insulator at the separator mounted position.
1.
2.
3.
4.
5.
6.
7.
8.
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1. Glue the insulator to the inner lower at the front pillar lower separator
mounted position.
Insulator: P/N. 74416-SF1-000
Adhesive: Cemedine 366 or equivalent
350
6. Clamp the repair part and recheck the clearance and alignment of the
front door, front fender and windshield.
7. Perform the main welding:
Attach the patch at the cut the section of the front pillar outer panel
and plug weld it.
1. INNER LOWER
2. INSULATOR
2. Set the new front pillar lower stiffener into position and tack weld the
clamped position.
3. Cut the repair part (outer panel), set it into position. Clamp the repair
part and check the body dimensions (see section 4).
4. Temporarily install the windshield, front door, hood and front fender
and check for differences in level and clearance. Make sure the body
lines flow smoothly.
5. Removal the repair part and weld the front pillar lower stiffener, upper
stiffener and side sill reinforcement.
1.
2.
3.
4.
5.
Butt welding
PATCH
OUTER PANEL
Fillet welding
Overlap
30 mm (1.2 in)
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351
a. Center pillar stiffener
reinforcement
b. Centre pillar stiffener
c. 4-Plate welding
d. Centre pillar separator
e. VIEW (Y)
f. Side sill reinforcement
g. VIEW (Z)
h. Centre pillar stiffener
i. VIEW (W)
j. VIEW (Y)
k. 4-Plate welding
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352
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353
1. Glue the insulator to the center inner pillar at the centre pillar separator
mounted position.
Insulator: PIN. 774416-SF1-000
Adhesive: Cemedine 366, or equivalent
2. Cut and set the new centre pillar stiffener and side sill reinforcement into
position and tack weld the clamped position.
3. Cut the repair part (outer panel), set it into position. Clamp the repair part
and check the body dimensions (see section 4).
4. Temporarily install the front door, rear door and front fender and check for
differences in level and clearance.
Make sure the body lines flow smoothly.
5. Remove the repair part and weld the centre pillar lower stiffener and side
sill reinforcement.
NOTE: Replace the drive side of the side sill reinforcement with the
assembly without cutting the side sill reinforcement halfway, because there
is reinforcement stiffener inside of the side sill reinforcement. Therefore, cut
the outer panel to under of the front pillar.
1.
2.
3.
4.
5.
354
6. Clamp the repair part and recheck the clearance alignment of the front door,
rear door and front fender.
7. Perform the main welding:
Attach the patches at the cut section of the center pillar and wheel arch and
plug weld them.
1.
2.
3.
4.
5.
Butt welding
PATCH
PATCH
Butt welding
Overlap
30 mm (1.2 in.)
6. Fillet welding
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Roof Panel
355
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Roof Panel
Removal
356
1. ROOF PANEL
2. REAR INNER PANEL
3. REAR PILLAR GUTTER
UPPER
4. ROOF ARCH GUSSET
5. REAR INNER PANEL
6. REAR ROOF RAIL
7. FRONT ROOF RAIL
8. FRONT INNER UPPER
PILLAR
9. FRONT INNER UPPER
PILLAR
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Roof Panel
Installation
1. Set the new roof panel into position and clamp it.
Check the body dimensions (see section 4), and check the width of the
roof moulding installation.
2. Install the roof arch gusset, rear roof rail mounting bolts and tack weld
the roof panel.
3. Temporarily install the windshield, door and tailgate, check for
difference in level and clearance.
4. Perform the main welding.
357
5. From inside the vehicle, plug weld the front pillar inner upper, rear
inner panel and front and rear roof rail.
VIEW (Z)
1. OUTER PANEL
2. ROOF PANEL
3. ROOF SIDE RAIL
1.
2.
3.
4.
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358
a.
b.
c.
d.
e.
f.
g.
h.
i.
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359
Cut and pry off the rear side sill outer panel.
Check the rear pillar gutter lower and gutter upper position and for damage and if necessary, replace the rear pillar gutter lower.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
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360
1. Set the new repair part (outer panel) and rear pillar gutter lower and into
position and clamp them.
Check the body dimensions (see section 4).
2. Tack weld the clamped position.
3. Temporarily install the door, tailgate, tailgate and rear bumper and check
for differences in the level and clearance. Make sure the body lines flow
smoothly.
4. Perform the main welding:
Attach the patch at the cut section of the quarter pillar, rear pillar and
plug weld them.
Weld the rear pillar gutter lower, gutter upper and rear panel.
1.
2.
3.
4.
5.
Butt welding
Butt welding
PATCH
NEW OUTER PANEL
Overlap
30 mm (1.2 in.)
Fillet welding
6. PATCH
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Rear Panel
361
a.
b.
c.
d.
e.
f.
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Rear Panel
Removal
362
Installation
1. Set the new rear panel and check the body dimensions (see section 4).
2. Tack weld the clamped position.
3. Temporarily install the tailgate, tailgate, rear bumper and check for
differences in level and clearance. Check operation of the tailgate.
4. Perform the main welding:
1. REAR PANEL
2. REAP PILLAR GUTTER LOWER
1.
2.
3.
4.
5.
6.
REAR PANEL
REAR GUTTER LOWER STIFFENER
REAR PANEL
REAR FLOOR
JACK-UP STIFFENER
REAR PILLAR GUTTER LOWER
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Rear Floor
363
a.
b.
c.
d.
e.
f.
g.
h.
Rear floor
Rear panel gusset
Rear frame B
Rear floor
Rear floor cross-member
Rear frame
Rear frame A
Rear floor cross-member
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Rear Floor
Removal
364
Cut the rear floor 15 mm (0.6 in.) from the welded flange of the rear floor cross-member.
Id necessary, replace the rear frame B.
Check the rear floor cross-member position and for damage.
If necessary, replace the rear floor cross-member.
1. REAR FLOOR CROSSMEMBER
2. REAR FLOOR
3. Cut line
4. REAR FLOOR CROSSMEMBER
5. REAR FLOOR
6. REAR FLOOR CROSSMEMBER
7. REAR FRAME A
8. VIEW (Z)
9. REAR FRAME B
10. REAR FRAME A
11. REAR FRAME B
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Rear Floor
Installation
1.
2.
3.
4.
Set the new rear cross-member and rear frame B, into position.
Check the body dimensions (see section 4).
Tack weld the rear cross-member and rear frame B.
Set the new floor to align it with the body.
Cut the new rear floor so it overlaps the body side floor by about 40
mm (1.6 in.).
5. Check the position of the rear inner panel and rear panel.
6. Removal the new rear floor and plug weld the rear floor cross-member.
7. Finish plug welding the area and take care not to grind excessively.
365
8. Set the new rear floor and plug weld the rear floor cross-member, rear
frame B and rear frame A.
1.
2.
3.
4.
5.
REAR FRAME A
REAR FLOOR CROSS-MEMBER
REAR FRAME B
REAR FRAME A
REAR FLOOR CROSS-MEMBER
1. Fillet welding
Index - Index
Index
4-door Body Dimensional Drawings
4-3
4-13
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4-4
4-5
4-7
4-8
Side View
4-10
4-12
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4-4
Engine Compartment
Unit: mm (in.)
1. E, e
Front Damper Mount Hole
11.5 (0.45)
2. F, f
Front Fender Mount Hole 7
(0.3) Rearward
3. G, g
Hood Hinge Mount Hole 7
(0.3) Forward
4. D, d
Front Bumper Beam Mount
Hole 9 (0.35)
5. C, c
Front Fender Mount Hole 7
(0.3) Forward
6. B, b
Headlight Mount Hole 7 (0.3)
7. A, a
Bulkhead Upper Frame
Point 15 (0.59)
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4-5
Passenger Compartment
Unit: mm (in.)
Unit: mm (in.)
1. E
Front Damper Mount Hole 11.5 (0.45)
2. H
AT/MT Transmission Bracket Mount Holed 13 (0.51)
3. I
Engine Bracket Mount Hole 13 (0.51)
4. J
Honda Multi Matic Transmission Bracket Mount Hole 13 (0.51)
AT/MT:
1. K, k
Front Seat Rear Side Bracket Point 9 (0.35)
2. L, l
Rear Damper Mount Hole 11 (0.43)
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46
Unit: mm (in.)
1. A, a
Radiator Mount Hole 15
(0.59)
2. B, b
Front Sub-frame Mount
Hole 15 (0.59) Forward
3. C, c
Front Sub-frame Mount
Hole 15 (0.59) Rearward
4. D, d
Front Floor Frame Point 20
(0.79)
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4-7
Unit: mm (in.)
1. D,d
Front Floor Frame Point 20
(0.79)
2. E, e
Front Floor Point 25 (0.98)
3. F, f
Rear Frame Extension Point
20 (0.79)
4. G, g
Trailing arm Mount Holed 14
(0.55)
5. H, h
Upper Arm Mount Hole 15
(0.59)
6. I, I
Lower Arm Mount Hole 12.8
(0.5)
7. J, j
Rear Frame A Point 20
(0.79)
8. K, k
Rear Frame B Pint 15 (0.59)
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48
Unit: mm (in.)
: Inner diameter
b1
b2
b3
c1
c2
c3
d1
d2
d3
49
v1, v2
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410
Unit: mm (in.)
o: Inner diameter
b1
b2
b3
c1
c2
c3
d1
d2
d3
411
v1, v2
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412
1. A
Windshield lower dashboard guide pin
2. B, C
Windshield opening flange notch (2 places)
3. D, E, F, G, H, I, J, K,
Door opening flange notch (16 places)
1. L, M
Rear window opening flange notch (3 places)
2. N
Trunk gutter area convex bead
3. O
Outer panel range end (2 places)
4. P
Trunk seal flange water drain notch
4-14
4-15
4-17
4-18
Side View
4-20
4-22
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414
Unit: mm (in.)
1. E, e
Front Damper Mount Hole
11.5 (0.45)
2. G, g
Hood Hinge Mount Hole 7
(0.3) Forward
3. F, f
Front Fender Mount Hole 7
(0.3) middle
4. D, d
Front Bumper Beam Mount
Hole 9 (0.35)
5. C, c
Front Fender Mount Hole 7
(0.3) Forward
6. B, b
Headlight Mount Hole 7 (0.3)
7. A, a
Bulkhead Upper Frame
Point 15 (0.59)
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Unit: mm (in.)
415
Passenger Compartment
Unit: mm (in.)
1. E
Front Damper Mount Hole 11.5 (0.45)
2. H
AT/MT Transmission bracket Mount Hole 13 (0.51)
3. I
Engine Bracket Mount Hole 13 (0.51)
1. J, j
Front seat Rear Side Bracket Point 9 (0.35)
2. K, k
416
Unit: mm (in.)
1. A, a
Radiator Mount Hole 15
(0.59)
2. B, b
Front Sub-frame Mount
Hole 15 (0.59) Forward
3. C, c
Front Sub-frame Mount
Hole 15 (0.59) Rearward
4. D, d
Front Floor Frame Point 20
(0.79)
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417
1. D, d
Front Floor Frame Point 20
(0.79)
2. E, e
Front Floor Point 25 (0.98)
3. F, f
Rear Frame Extension Point
20 (0.79)
4. G, g
Trailing arm Mount Hole 14
(0.55)
5. H, h
Upper Arm Mount Hole 15
(0.59)
6. I, I
Lower Arm Mount Hole 12.8
(0.5)
7. J, j
Rear Frame A Point 20
(0.79)
8. K, k
Rear Frame B Point 25 (1.0)
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418
Unit: mm (in.)
: Inner diameter
b1
b2
b3
c1
c2
c3
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419
u1, u2
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420
Unit: mm (in.)
: Inner diameter
b1
b2
b3
c1
c2
c3
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421
u1, u2
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422
1. A
Windshield lower dashboard guide pin
2. B, C
Windshield opening flange notch (3 places)
3. D, E, F, G, H, I, J, K,
Door opening flange notch (16 places)
Tailgate Opening:
1. L
Roof lower Rail Flange notch
2. M
Rear Gutter Lower Stiffener flange end (2 places)
3. N
Rear panel upper stiffener water drain notch
Index - Index
Index
4-door Rust Prevention
5-3
5-17
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5-4
5-5
5-6
5-7
5-8
Under Floor
5-9
5-10
Coating Diagram
5-11
Rust-preventive Treatments
General
5-12
Undercoating Diagram
5-13
5-14
5-15
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5-4
General
5. Apply sealer on any area that the replacement part will cover. Smooth
the sealer with a brush is necessary.
4. Finish sealing the engine compartment, the door opening, the truck
gutter and the tailgate gutter. Wipe of the excess sealer.
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55
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
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56
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
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Dashboard Upper
Windshield Lower
Dashboard Lower
Front Pillar Inner Lower
Dashboard Lower Extension
Side Sill Extension
Front Side Outrigger
Front Pillar Inner Upper
Side Sill Extension
Side Sill Extension
Dashboard Lower
From Floor
Floor Cap
VIEW (Z)
Dashboard Upper
Dashboard Lower
Outer Panel
Roof Panel
Front Pillar Inner Lower
Dashboard Upper
Dashboard Lower
Front Floor
Dashboard Lower Extension
Floor Cap
Inner Lower Extension
Dashboard Upper
Windshield Lower
57
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
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Front Floor
Inside Sill
Outer Panel
Side Sill Extension
Inside Sill
Middle Floor Cross-member
Stiffener
Side Sill Extension
Rear Frame
Rear Floor
Wheelhouse
Rear Panel
Rear Floor
Rear Floor
Rear Panel
Jack Up Stiffener
Rear Panel
Outer Panel
Rear Floor
Floor Cap
Front Floor
Floor Cap
Middle Floor Cross-member
Rear Floor
Middle Floor Cross-member
Middle Floor Cross-member
Front Floor
Middle Floor Cross-member
Stiffener
Middle Floor Cross-member
Front Floor
Middle Floor Cross-member
Stiffener
Floor Cap
Front Floor
58
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
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Rear Floor
Wheelhouse
Outer Panel
Rear Floor Outer Panel
Outer Panel
Parcel Shelf
VIEW (Z)
Outer Panel
Rear Gutter
Outer Panel
Rear Panel
Rear Gutter
Combination Adaptor
Combination Adaptor
Rear Panel
VIEW (X)
Combination Adaptor
Rear Panel
Outer Panel
Combination Adaptor
Outer Panel
Combination Adaptor
Side Sill Extension
Side Sill Extension End
Flange
Outer Panel
Wheel Arch Extension
Wheel Arch Extension
End Flange
Outer Panel
Fuel Door Adaptor
Outer Panel
Rear Inner
Outer Panel
Rear Inner
59
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
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Wheelhouse Stiffener
Damper Base
Rear Inner Panel
Wheel Arch Extension
Inner Panel
Wheelhouse
Outer Panel
Wheelhouse Stiffener
Rear Wheelhouse
Upper Arm Bracket
Rear Frame
Damper Base
Rear Frame
Damper Base
Upper Arm Bracket
VIEW (X)
Lower Arm Bracket B
Lower Arm Bracket A
Rear Floor Cross-member
Rear Floor
VIEW (Z)
Lower Arm Bracket B
Lower Arm Bracket A
Rear Floor Cross-member
Rear Floor
Front Floor
Front Floor Centre Crossmember
510
2. Air blowing/degreasing
Top coat
Intermediate coat
The soft chipping guard primer coat is applied over the E.D.
(Electrostatically Despotised) primer. It is followed by guide
coating and top coating.
The soft chipping guard primer produces a smooth surface
when dry. It should be sprayed so the thickness of the
protective film is 20 microns.
Basic Rules for Repairing a Soft Chipping
Guard Primer Coat:
WARNING
5. Drying
After spraying primer surface, allow 7~10 minutes of drying time, then force
dry it with infrared lamps or an industrial dryer.
6. Polishing
Check the primer surface has dried thoroughly, then sand the primer surface.
Use a double action sander and #400~#600 disc
sandpaper.
7. Intermediate coating and top coating
Refer to pages 6-8 to 6-10 of this manual for the painting procedure.
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511
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HOOD SKIN
OUTER PANEL
INNER PANEL
OUTER PANEL
FRONT FENDER
FRONT FENDER
512
Rust-preventive Treatments
General
Anti-rust Agents:
Undercoat:
WARNING
WARNING
NOTE:
Mask the exhaust system, oxygen sensors and suspension mount
area to prevent overspread from the undercoat.
Follow the undercoating manufacturer's instructions.
1. Clean the body with wax and grease remover before the undercoat is
sprayed.
2. Apply the undercoat to the front wheelhouse, rear wheelhouse and
undersides of the front floor and rear floor (see page 5-13).
3. Coat the bottom of the fuel tank.
NOTE:
Do not spray an anti-rust agent on the brake system, exhaust system
and its related parts, emission control devices in the engine
compartment, ball joint cover, fuel strainer and exterior and interior
parts.
Wipe the excess agent with a clean rag dampened with light oil.
Follow the anti-rust agent manufacturer's instructions.
1. Before applying an anti-rust agent, thoroughly clean the area to be
coated with a steam cleaner, etc., and let it dry. Waxoyl may be
applied to wet surface.
2. Apply anti-rust agent from the installation hole and the access hole of
parts in the outer panel and the frame (see page 5-14). Spray an antirust agent sufficiently unit the excess amount oozes out when filling
the side sill.
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513
SECTION AA
SECTION BB
SECTION CC
SECTION DD
SECTION EE
1.
2.
3.
4.
5.
Dashboard Lower
Front Floor
Middle Floor Cross-member
Rear Floor
Rear Floor Cross-member
SECTION FF
1.
2.
3.
4.
<Front Wheelhouse>
<Rear Wheelhouse>
OUTER PANEL
FUEL DOOR ADAPTOR
SECTION
5. FUEL DOOR ADAPTOR
6. No Coating Area.
VIEW (Z)
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Rust-prevention Treatments
514
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515
SEALER
SPRAY GUNS
3m #08892 (internal)
3m #08893 (external)
or equivalents.
TOOLS
Cartridge type
For rustop
For waxoyl
Tube type
Sealing gun
UNDERCOAT
To be applied to under-floor and wheelhouse.
Nox-rust 409-20S
Solton 1000S
or equivalent.
ANTI-RUST AGENT
To be applied to weld joints inside the body panel.
Rustop
Deox #100
Waxoyl
or equivalent.
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5-18
5-19
5-20
5-21
5-22
Under Floor
5-23
5-24
Coating Diagram
5-25
Rust-preventive Treatments
General
5-26
Undercoating Diagram
5-27
5-28
5-29
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518
5. Apply sealer on any area that the replacement part will cover. Smooth
the sealer with a brush is necessary.
4. Finish sealing the engine compartment, the door opening, the truck
gutter and the tailgate gutter. Wipe of the excess sealer.
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519
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
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520
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
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Dashboard Upper
Windshield Lower
Windshield Lower
Dashboard Upper
Inner Lower
Dashboard Lower
Dashboard Lower Extension
Side Sill Extension
Outrigger
Inner Lower
Side Sill Extension
Side Sill Extension
Dashboard Lower
VIEW (Z)
Dashboard Upper
Inner Lower
Dashboard Upper
Dashboard Lower
Outer Panel
Roof Panel
Front Floor
Floor Cap
Front Floor
Dashboard Lower
Dashboard Lower Extension
Floor Cap
Side Frame Extension
Dashboard Lower Extension
Inner Lower Extension
Dashboard Upper
Windshield Lower
521
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
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Front Floor
Inside Sill
Outer Panel
Side Sill Extension
Inside Sill
Middle Floor Cross-member
Stiffener
Side Sill Extension
Rear Frame
Rear Floor
Wheelhouse
Outer Panel
Inner Panel
Rear Floor
Gutter lower
Rear Floor
Rear Panel
Rear Floor
Rear Panel
Rear Panel
Jack-up Stiffener
Rear Floor
Floor Cap
Rear Floor
Floor Cap
Middle Floor Cross-member
Stiffener
Rear Floor
Middle Floor Cross-member
Middle Floor Cross-member
Front Floor
Middle Floor Cross-member
Stiffener
Middle Floor Cross-member
Front Floor
Middle Floor Cross-member
Front Floor
Floor Cap
522
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
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Outer Panel
Wheel Arch Extension
Outer Panel
Inner Panel
Tailgate Hinge
Roof Panel
Gutter Upper
Gutter Upper
Outer Panel
Outer Panel
Gutter Upper
Gutter Upper
Gutter Lower
Outer Panel
Rear Floor
Gutter Lower
Rear Panel
VIEW (Z)
Rear Panel
Rear Panel Lower
Rear Floor
Gutter Lower
Gutter Lower
Outer Panel
Side Sill Extension
Side Sill Extension End
Flange
Outer Panel
Wheel Arch Extension
Wheel Arch Extension
End Flange
Outer Panel
Fuel Door Adaptor
Outer Panel
Gutter Lower
Outer Panel
Inner Panel
523
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
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Wheelhouse Stiffener
Damper Base
Rear Inner Panel
Wheel Arch Extension
Inner Panel
Wheelhouse
Outer Panel
Wheelhouse Stiffener
Rear Wheelhouse
Rear Frame
Upper Arm Bracket
Damper Base
Rear Frame
Damper Base
VIEW (X)
Upper Arm Bracket
Lower Arm Bracket B
Lower Arm Bracket A
Rear Floor Cross-member
Rear Floor
VIEW (Z)
Lower Arm Bracket B
Lower Arm Bracket A
Rear Floor Cross-member
Rear Floor
Front Floor
Front Floor Centre Crossmember
524
2. Air blowing/degreasing
Top coat
Intermediate coat
The soft chipping guard primer coat is applied over the E.D.
(Electrostatically Despotised) primer. It is followed by guide
coating and top coating.
The soft chipping guard primer produces a smooth surface
when dry. It should be sprayed so the thickness of the
protective film is 20 microns.
Basic Rules for Repairing a Soft Chipping
Guard Primer Coat:
WARNING
5. Drying
After spraying primer surface, allow 7~10 minutes of drying time, then force
dry it with infrared lamps or an industrial dryer.
6. Polishing
Check the primer surface has dried thoroughly, then sand the primer surface.
Use a double action sander and #400~#600 disc
sandpaper.
7. Intermediate coating and top coating
Refer to pages 6-8 to 6-10 of this manual for the painting procedure.
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525
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HOOD SKIN
OUTER PANEL
INNER PANEL
OUTER PANEL
FRONT FENDER
FRONT FENDER
526
Rust-preventive Treatments
General
Anti-rust Agents:
Undercoat:
WARNING
WARNING
NOTE:
Mask the exhaust system, oxygen sensors and suspension mount
area to prevent overspread from the undercoat.
Follow the undercoating manufacturer's instructions.
1. Clean the body with wax and grease remover before the undercoat is
sprayed.
2. Apply the undercoat to the front wheelhouse, rear wheelhouse and
undersides of the front floor and rear floor (see page 5-27).
3. Coat the bottom of the fuel tank.
NOTE:
Do not spray an anti-rust agent on the brake system, exhaust system
and its related parts, emission control devices in the engine
compartment, ball joint cover, fuel strainer and exterior and interior
parts.
Wipe the excess agent with a clean rag dampened with light oil.
Follow the anti-rust agent manufacturer's instructions.
1. Before applying an anti-rust agent, thoroughly clean the area to be
coated with a steam cleaner, etc., and let it dry. Waxoyl may be
applied to wet surface.
2. Apply anti-rust agent from the installation hole and the access hole of
parts in the outer panel and the frame (see page 5-28). Spray an antirust agent sufficiently unit the excess amount oozes out when filling
the side sill.
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527
SECTION AA
SECTION BB
SECTION CC
SECTION DD
SECTION EE
1.
2.
3.
4.
Dashboard Lower
Front Floor
Middle Floor Cross-member
Rear Floor Cross-member
SECTION FF
1.
2.
3.
4.
<Front Wheelhouse>
<Rear Wheelhouse>
OUTER PANEL
FUEL DOOR ADAPTOR
SECTION
5. FUEL DOOR ADAPTOR
6. No Coating Area.
VIEW (Z)
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Rust-prevention Treatments
528
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529
SEALER
SPRAY GUNS
3m #08892 (internal)
3m #08893 (external)
or equivalents.
For rustop
For waxoyl
TOOLS
Cartridge type
Tube type
Sealing gun
UNDERCOAT
To be applied to under-floor and wheelhouse.
Nox-rust 409-20S
Solton 1000S
or equivalent.
ANTI-RUST AGENT
To be applied to weld joints inside the body panel.
Rustop
Deox #100
Waxoyl
or equivalent.
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Paints - Paints
Paints
General Safety Precautions
6-2
Body Paint
General
6-3
Refinishing Processes
6-4
Pre-processing of Painting
6-5
6-6
Undercoating
6-7
Intermediate Coating
6-8
Top Coating
6-9
6-11
6-13
Refinishing Processes
6-14
Pre-processing of Painting
6-15
Undercoating
6-15
Intermediate Coating
6-17
Top Coating
6-18
Glossary
6-19
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6-2
4. Read the paint label before opening the container. Cover spilled paint
with sand, or wipe it up at once.
5. If paint gets in your mouth or your skin, rinse or wash thoroughly with
water. If paint gets in your eyes, flush with water and get prompt
medical attention.
2. Wear approved gloves, appropriate clothing when painting. Avoid
contact with skin.
6. After the painting work is finished, wash face and gargle with water.
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Body Paint
6-3
General
The 3-coat/3-bake (3C/3B) paint finishes give the Odyssey a deep gloss and stunning finish. This manual provides information on paint defect, repair and refinishing. Throughout,
the objective is to explain in a simple yet comprehensive manner the basic items you should know about paint repairs. Select the correct material for the defect and repaint or
refinish in the correct manner as described in this manual.
WARNING
Most paints contain substances that are harmful if inhaled or swallowed. Read the paint label
before opening the container. Spray paint only in a well ventilated area.
Cover spilled paint with sand, or wipe it up at once.
Wear an approved respirator, gloves, eye protection and appropriate clothing when painting.
Avoid contact with skin.
If paint gets in your mouth or on your skin, rinse or wash thoroughly with water. If paint gets in
your eyes, flush with water and get prompt medical attention.
Paint is flammable. Store it in a safe place, and keep it away from sparks, flames or cigarettes.
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Body Paint
6-4
Refinishing Processes
Paint damage can appear in any form. Before making a repair, check the damaged area carefully, and determine the best procedure for repairing the damage. The following shows
you refinishing methods for various types of paint damage or defects.
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6-5
Body Paint
Pre-processing of Painting
1. Featheredging
NOTE
The paint film damaged area should be sanded flat and smooth.
If this is not done correctly the end results will not be acceptable.
If double action sander is not available, use a rubber pad and wet or
dry sandpaper.
1.
2.
3.
4.
Top coat
Intermediate coat
Undercoat
Metal surface
3. Air blowing/degreasing
Use alcohol, wax and grease
remover.
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6-6
Body Paint
1. Filling/drying
Small cracks or pinholes in the sheet metal should be repaired with a
body filler and sanded flat and smooth.
After applying the body filler, allow 5~6 minutes of normal drying time,
then force dry it with infrared lamps or other industrial dryer at 50C
(122F)~60C (140F).
NOTE: Follow the body filler manufacturer's instructions for drying time.
2. Polishing
When the body filler is dry a white mark appears when the surface is
scratched with your finger nail.
1. Thoroughly sand the body filler surface.
Use the double action sander and
#80~#120 disc paper.
2. Sand the surface evenly, particularly the area that was filled.
Apply the body filler in several thin coats, without air bubbles.
Do not try to cover the surface with one heavy coat.
Apply the body filler over the damaged area with a putty knife
using light pressure.
1. Body Filler
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6-7
Body Paint
Undercoating
Sand the body filler surface until the proper dimensions are met.
Use the double action sander and
#240~#320#~400 disc papers.
1. Masking
Mask the area surrounding the damage to prevent over spray from the
primer surfacer.
Use the masking tape and paper.
2. Spraying primer surfacer
Spray the primer surfacer over a wider area than the body filler and
the exposed surface of the paint film.
Spray 2~3 coats to get 30 microns of thickness.
1. Body Filler
2. Featheredging
3. Air blowing/degreasing
Use the alcohol, wax and grease remover.
Also clean and degrease the surfaces where masking tape will be
attached.
1. Primer Surfacer
3. Drying
After spraying primer surfacer, allow for 5~10 minutes of normal drying
time, then force dry it with infrared lamps or other industrial dryer.
NOTE: Follow the primer surfacer manufacturer's instructions for
drying time.
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6-8
Body Paint
Intermediate Coating
Undercoating (cont'd)
4. Polishing
Check that the primer surfacer has dried thoroughly, then sand the
primer surfacer.
Use the double action sander and
#320~#400~#600 disc papers.
1. Masking
Mask the area surrounding the damage to prevent over spray from the
intermediate coat.
Use masking tape and paper.
2. Spraying top coat enamel
Spray the top coat enamel over the surface until the primer surfacer is
fully covered.
NOTE: For the 3-coat pearl paint, spray the colour base over the
surface.
5. Air blowing/degreasing
Use the alcohol, wax and grease
remover.
Also clean and degrease the surfaces where the masking tape will be
attached.
3. Drying
After spraying top coat enamel or colour base (3-coat pearl paint),
allow 5~10 minutes of normal drying time, then force dry it with infrared
lamps or other industrial dryer.
NOTE: Follow the top coat manufacturer's instructions for drying time.
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6-9
Body Paint
Top Coating
4. Polishing
Check that the top coat enamel has dried thoroughly, then sand the
top coat enamel.
Use the double action sander and
#600~#800 disc papers.
NOTE: Be careful not to polish down to the primer surfacer.
1. Masking
Mask the area surrounding the damage to prevent over spray from the
top coat.
Use masking tape and paper.
2. Spraying top coat enamel/clear coat
Spray 2~3 double coat until the intermediate coat is fully covered.
NOTE: See pages 6-11, 6-12 for the painting repair (gradation) of the
3-coat pearl paint.
When the painting repair (gradation) is almost done, polish the area
that will be top coated.
Use the #2000 sandpaper and
compound.
5. Air blowing/degreasing
Use alcohol, wax and grease
remover.
Also clean and degrease surfaces where the masking tap will be
attached.
NOTE: See pages 6-11, 6-12 for the painting repair (gradation) of the
3-coat pearl paint.
Drying
After spraying the top coat enamel, allow it to air dry, then force dry it
with infrared lamps or other industrial dryer.
NOTE: Follow the top coat manufacturer's instructions for drying time.
Spraying clear coat
Spray the top clear coat evenly over the surface of the top coat
enamel. Do not try to cover the surface with one heavy coat.
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Body Paint
610
4. After buffing, remove the masking paper and tape, and thoroughly
wash the entire vehicle.
NOTE: Follow the top coat manufacturer's instructions for drying times.
3. Polishing/buffing
Check that the clear coat has dried thoroughly.
The clear coat is cooled.
1. Any adhesion or roughness on the top coat should be wet sanded
and repaired.
Use the #1200~#2000 and crystal block.
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611
Check each of the plastic parts for solvent resistance and heat resistance temperatures before you do any repair work.
Select the repair material according to materials of the plastic parts.
Standard
Symbol
Name
Heat Resistance
Temperature C (
F)
AAS
80
(176)
Acrylonitrile butadiene
styrene
80
(176)
Acrylonitrile ethylene
styrene
80
(176)
Acrylonitrile / ethylene
propylene diene rubber /
styrene
80
(176)
Acrylonitrile styrene
acrylate
80
(176)
80
(176)
Ethylene-vinyl acetate
80
(176)
PA
Polyamide
80
(176)
PBT
Polybutylene terephtalate
160
(320)
PC
Polycarbonate plastics
120
(248)
PE
Polyethylene
80
(176)
PF
Phenol formaldehyde
80
(176)
PMMA
Polymethyl methacrylate
80
(176)
POM
Polyoxymethylene
polyacetal
100
(212)
ABS
AES
A/EPDM/S
ASA
CAB
E/VAC
Solvent Resistance
Note
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612
Standard
Symbol
PP
Name
Heat Resistance
Temperature C (
F)
Solvent Resistance
Note
Polypropylene
80
(176)
Polyphenylene oxide
100
(212)
PS
Polystyrene
60
(140)
PUR
Polyurethane
80
(176)
PVC
Polyvinylchloride
80
(176)
SAN
Styrene acrylonitrile
80
(176)
SMC
Sheet moulding
compound
180
(356)
TPE
Thermoplastic polyester
elastomer
80
(176)
Alcohol is acceptable and wiping gasoline Soaking with an organic solvent such as gasoline and
for a short time can be allowed.
alcohol is not recommended. Wash remover off with
(Degreasing)
water thoroughly.
TPS
Thermoplastic styrene
elastomer
80
(176)
TPO
Thermoplastic olefin /
elastomer
80
(176)
Alcohol is acceptable and wiping gasoline Soaking with an organic solvent such as gasoline and
for a short time can be allowed.
alcohol is not recommended. Wash remover off with
(Degreasing)
water thoroughly.
TPU
Thermoplastic /
urethane / elastomer
80
(176)
UP
Polyester
110
(230)
PPO
(PPE)
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613
Mixing Ratio:
2. Sanding filler
Spray bumper primer (see page 6-19) on the area where the PP
material was used.
3. Primer surfacer
The primer surfacer is used to protect the PP resin surface and fill
cavities or flaws before the intermediate coat and top coat.
Use the 2-component type primer surfacer (grey).
NOTE: Use a spray gun to apply the paint. Do not use a brush.
Drying time:
Air dry 20C (68F)
Almost hardened
12~24 hours
Thoroughly hardened
96 hours
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Refinishing Processes
614
The following shows refinishing methods to various types of paint damage or defects.
Be careful not to deform and damage the parts when force drying.
A:
Hole/Deep Gouge
B:
C:
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615
Pre-processing of Painting
1. Sanding
Sand the damage area flat and smooth.
Undercoating
1. Spraying primer
Primer is used to fill cavities in the putty and primer surfacer.
Shallow Scratch:
Hole/Deep Gouge:
Cut out and make any torn or burred area flat.
Use a knife, flexible block and
#180~#240 sandpapers.
2. Air blowing/degreasing
Clean the damaged area thoroughly.
Use alcohol, and wax and grease
remover.
Drying
NOTE: Take care not to let the heat lamp deform the bumper during
the drying process.
Dry the bumper primer thoroughly with an infrared dryer or other
suitable method.
Drying Time:
Air dry 20C (68 20 minutes
F)
Force dry 60C
(140F)
10 minutes
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616
Undercoating (cont'd)
2. Filing/Sanding
Apply putty to repair any holes or deep gouges.
Spray the primer surface wider than the putty and painted surfaces
of bumper primer.
Spray 2~3 coats to get 20~30 microns of thickness.
Drying
1. Aluminium Tape
2. Outside
3. Sanding
Sand the surface evenly, particularly at the area where the PP material
and putty meet.
Use a flexible block and
#240~#400~#600 sandpaper.
NOTE: Take care not to let the heat lamp deform the bumper during
the drying process.
6. Sanding
After drying, wet sand the area of the intermediate coat.
Use the #600 sandpaper.
NOTE: Do not use less than #600.
7. Air blowing/degreasing
1. Featheredging
4. Air blowing/degreasing
Use alcohol, a tack cloth, and wax
and grease remover.
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NOTE: You must do this procedure on the PP parts of the bumper and
side sill panel.
1. Masking
Mask the area surrounding the damage to prevent overspray from the
intermediate coat.
Use masking tape and paper.
2. Spraying top coat enamel
Spray the top coat enamel over the surface until the primer surfacer
is fully covered.
Spray 2~3 coats to get 15~25 microns of thickness.
617
3. Polishing
Check the top coat enamel has dried thoroughly, then sand the top
coat enamel.
Use a flexible block and
#600~#800~#1000 sandpapers.
NOTE: Be careful not to sand down to the primer surfacer.
Drying
NOTE: Take care not to let the heat lamp deform the bumper during
the drying process.
After spraying the top coat enamel, allow for 5~10 minutes of normal
drying, then force dry it with infrared lamps or other industrial dryer.
1.
2.
3.
4.
5.
Material
Putty
Intermediate Coat
Sanding
Paint Coat
4. Air blowing/degreasing
Use alcohol, a tack cloth, and wax
and grease remover.
Clean and degrease the surfaces where the masking tape will be
attached.
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1. Masking
Mask the area surrounding the damage to prevent overspray of the top coat
Use masking tape and paper.
2. Spraying top coat enamel / clear coat
Spray 2~3 coats in double coat until the intermediate coat is fully covered.
NOTE:
618
Use the 2-part polyester urethane top coat enamel and a spray gun.
Mix the top coat enamel with the additive and solvent, and in the correct
ratio.
Follow the top coat manufacturer's instructions.
After spraying the top coat enamel, allow for 5~10 minutes drying time before
you spray the clear coat.
Drying
4. Check the finished area at an angle, and make sure there are
no polishing marks.
5. Polish with ultra fine compound and a buffing sponge.
NOTE: Take care not to let the heat lamp deform the bumper during the drying
process.
After spraying the clear coat, allow for 5~10 minutes drying time before you
force dry it with infrared lamps or other industrial dryer.
3. Polishing/buffing
Check that the clear coat has dried thoroughly.
Wet sand to remove any imperfections.
Use a flexible block soap and #2000 sandpaper.
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Paints - Glossary
619
Glossary
All paint
Compressed air
Block paint
Double coat
Dry film
Pain which left the spray gun and fried partially before it reached the surface, thereby making the painted surface rough. Dry
coating is caused by too little paint being fed, too high an air pressure, too much distance between the painted surface and
the gun, or moving the gun too fast.
Dust coat
Paint is applied thinner than the dry coat. Painted surface becomes rough.
ED painting
Enamel
Featheredging
Flash off
Evaporation of the pain solvent. (Flash off time is the period between pain coat applications.)
Ford cup
Gun stroke
Hardener
Composed of acrylic resin and meramine resin and hardener (forms a paint film) by banking.
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Paints - Glossary
620
Glossary
Cont'd
Lacquer
A type of pain that uses cellulose nitrate or other chemicals and dries by evaporation of its solvent agent.
Meramine resin
Used as component for aminoalkyd resin paint and heat-hardening acrylic resin paint.
Metallic-base paint
Mist coat
Painting for fade-in sections. A small amount of paint may be dissolved with slow-evaporating thinner, or thinner alone may
be applied with low pressure.
150-200kPa (1.5-2.0kgf/cm, 21.3-28.4 psi)
Mixing scale
Overlap
Overspray
Paddle
Paint dust
Paper dispenser
Scrapes
Traces of scratches.
Scuffing
Particles on the painted surface are lightly polished with fine emery paper (#600 or over).
Set (setting)
Evaporation time of solvent in the paint, before drying the layer forcefully or by banking. (May be considered the same as
flash-off time).
Single coat
Spot paint
Undercoat
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Paints - Glossary
621
Glossary
cont'd
Wet coat
Paint is applied with an excess of solvent, thereby producing a painted surface that's smooth, glossy and has a wet look.
Wet film
Wet on wet
Application of the next coat of paint before the previous layer has dried completely.
Wool bonnet
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Introduction
Introduction
This manual covers the repairs of 2001 model series CIVIC 3-door that
have been involved in an accident and it describes the work related to the
replacement of damage body parts.
Please read through these instructions and familiarise yourself with them
before actually using this manual.
NOTE: Refer to the 2001 CIVIC 4-door/CIVIC 5-door Body Repair Manual
(P/N. 62S5A30), CIVIC Shop Manual (P/N. 62S5A00) and CIVIC Shop
Manual supplement (P/N. 62S5A20) on this CD for specifications, wire
harness locations, safety stand support points, etc.
1 General Info
3 *Replacement
4 Body Dimensional Drawings
5 Rust Prevention
Sections with an * include SRS
components; special caution is
required when servicing.
Special Information
WARNING
CAUTION
CAUTION
1-1
General Information
Supplemental Restraint System (SRS)
1-2
1-3
Body Construction
1-4
1-5
1-7
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1-2
General Information
1-2
This model has an SRS which includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above the glove box, seat belt tensions in the front seat
belt retractors and side airbags in the front seat backs. The SRS unit is separate from the airbag assembly and has built-in sensors. The following precautions should be observed
when performing sheet metal work, paint work and repair work around the locations of the SRS components.
1. The SRS unit is located under the dashboard and the side impact sensors are located in each side sill. The front sensors are located behind the right and left end of the front
bumper. Avoid any strong Impact with a hammer or other tools when repairing the front side frame, the lower part of the dashboard and the side sill. Do not apply heat to these
areas with a torch, etc.
2. Take extra care when painting or doing body work in the area below the centre pillar. Avoid direct exposure of the seat belt retractor and tensioner to heat guns, welding or
spraying equipment.
3. SRS electrical wiring harnesses and connectors are identified with yellow colour coding. Care should be taken not to damage the harness when repairing this area.
4. Do not apply heat of more than 100C (212F) when drying painted surfaces anywhere around the locations of SRS components.
5. If strong impact or high temperature needs to be applied to the areas around the locations of SRS components, remove the components before performing the repair work.
6. If any of the SRS related components are damaged or deformed, be sure to replace them.
NOTE: Refer to the Restraints section of the Shop Manual for after deployment procedures, and removal and replacement of SRS related components.
1. FRONT SENSOR
2. DRIVER'S AIRBAG
ASSEMBLY
3. FRONT SENSOR
4. CABLE REEL
5. FRONT PASSENGER'S
AIRBAG
6. SIDE AIRBAG
7. SIDE IMPACT SENSOR
8. SEAT BELT TENSIONERS
9. SIDE IMPACT SENSOR
10. SIDE AIRBAG
11. SRS UNIT
12. UNDER-DASH FUSE/RELAY
BOX
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1-3
1-3
General Information
000' 45'
Caster
133' 1
Total toe
0 3 (0 0.12)
in
4000' 2
out
3100' (Reference)
-045' 45'
Total toe
IN 2 3 (0.08 0.12)
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1-4
1-4
General Information
Body Construction
No.
Zn: Zinc-plated
Part Name
No.
Part Name
23
24
25
26
27
28
29
30
31
10
32
11
33
12
34
13
35
14
36
15
37
16
38
17
39
18
40
19
41
20
42
21
43
22
44
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1-5
1-5
General Information
1.4 B
B-92P Night
Hawk Black P.
B-94 Midnight
Blue
B-96P Eternal
Blue P.
R-81 Mirano
Red
R-504P Ruby
Red P.
G-503P
Amazon
Green P.
YR-62 Corona
Gold P.
1.4 S
1.4 SE
1.6 S
1.6 SE
1.6 SEE
KG
1.4 S
1.4 LS
1.6 S
1.6 LS
1.6 ES
KR
1.4 S
1.4 LS
1.6 S
1.6 LS
1.6 ES
KS
1.4 S
1.4 LS
1.6 LS
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1-6
General Information
1-6
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1-7
General Information
1-7
NOTE: A standard symbol is stamped on the underside of each resin part to show the type of material of used.
Example:
1. FRONT WINDSHIELD
MOULDING
Acrylonitrile ethylene
propylene diene rubber
styrene (A/EPDM/S)
2. DOOR OUTER HANDLE
Polycarbonate (PC)
3. DOOR MIRROR
Painted: Acrylonitrile
butadiene styrene (ABS)
Unpainted: Acrylonitrile
styrene acrylate (ASA)
4. TAILGATE SPOILER
Acrylonitrile butadiene styrene
(ABS)
5. LICENSE TRIM
Painted: Acrylonitrile
butadiene styrene (ABS)
Unpainted: Acrylontirile
ethylene styrene (AES)
6. REAR BUMPER
Polypropylene (PP)
7. DOOR SASH TRIM
Acrylontrile styrene acrylate
(ASA)
8. ROOF MOULDING
Polyvinyl chloride (PVC)
9. FRONT BUMPER
Polypropylene (PP)
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3-2
3-2
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3-3
3-3
Removal
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3-4
3-4
Installation
1. Cut and set the new side sill reinforcement into position and tack weld the clamped
position.
2. Cut the repair part (outer panel) and set it into position. Clamp the repair part and
check the body dimensions (see section 4).
3. Temporarily install the door and front fender and check for differences in level and
clearance. Make sure the body lines flow smoothly.
4. Remove the repair part and weld the center pillar stiffener, lower side sill
reinforcement and front pillar lower stiffener (driver's side).
Driver's side
Passenger's side
When replacing the side sill reinforcement, cut the new side sill reinforcement so it
overlaps the body side reinforcement by 20 mm (1.8 in.) and fillet weld it.
VIEW (Z)
5. Clamp the repair part and recheck the clearance and alignment of the door and
front fender.
6. Perform the main welding:
Attach a patch at the cut section of the front pillar (driver's side), side sill
(passenger's side) and wheel arch and plug weld them.
Driver's side
1.
2.
3.
4.
5.
PATCH
Butt welding
Butt welding
PATCH
OUTER PANEL
Passenger's side:
1. PATCH
2. Butt welding
3. OUTER PANEL
3-5
Roof Panel
3-5
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3-6
3-6
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3-7
3-7
Removal
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3-8
3-8
Installation
3. Set the new repair part (outer panel) and rear pillar gutter lower into position and
clamp them.
Check the body dimensions (see section 4).
Remove the repair part (outer panel) and weld the centre pillar stiffener lower.
2. Set the new centre pillar stiffener lower into position and install the middle floor
gusset.
4. Tack weld the outer panel and rear pillar gutter lower.
5. Temporarily install the door, tailgate and rear bumper and check for differences in
level and clearance.
Make sure the body lines flow smoothly.
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3-9
3-9
Installation (cont'd)
VIEW (Z)
1.
2.
3.
4.
5.
6.
7.
8.
Butt welding
PATCH
Butt welding
PATCH
Butt welding
NEW OUTER PANEL
PATCH
NEW REAR GUTTER LOWER
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3-10
Rear Panel
310
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3-11
Rear Panel
Removal
311
Installation
1. Set the new rear panel and check the body dimensions (see section 4).
2. Tack weld the clamped position.
3. Temporarily install the tailgate, taillight, rear bumper and check for differences in
level and clearance. Check for operation of the tailgate.
4. Do the main welding.
1.
2.
3.
4.
5.
6.
REAR PANEL
REAR GUTTER LOWER STIFFENER
REAR PANEL
REAR FLOOR
JACK-UP STIFFENER
REAR PILLAR GUTTER LOWER
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4-1
4-2
4-3
4-4
Side View
4-6
4-8
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4-2
4-2
Passenger Compartment
Unit: mm (in.)
Unit: mm (in.)
AT/MT:
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4-3
4-3
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4-4
4-4
Top View
Unit: mm (in.)
: Inner diameter
b1
b2
b3
c1
c2
c3
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4-5
4-5
u1, u2
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4-6
4-6
Unit: mm (in.)
: Inner diameter
b1
b2
b3
c1
c2
c3
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4-7
4-7
u1, u2
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file:///C|/Users/Navindra/Desktop/ManualSpace.com_Honda_Civic_2001...anual%20Honda%20Civic%202001-2005(english)/EngCivic/CBHtml/0-1.htm
1 General Info
5 Rust Prevention
3 *Replacement
4 Body Dimensional Drawings
Sections with * include SRS
components; special caution is
required when servicing.
Special Information
WARNING
CAUTION
CAUTION
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32 pages
General Information
Supplemental Restraint System (SRS)
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1-3
Construction
1-4
1-5
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General Information
1-2
This model has an SRS which includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above the glove box, seat belt tensioners in the front seat
belt retractors and side airbags in the front seat backs. The SRS unit is separate from the airbag assembly and has built-in sensors. The following precautions should be observed
when performing sheet metal work, paint work and repair work around the locations of the SRS components.
1. The SRS unit (including the safing sensor and the impact sensor) is located under the dashboard and the side impact sensors are located in each side sill. The front impact
sensors are located behind the right and left end of the front bumper. Avoid any strong impact with a hammer or other tools when repairing the front side frame, the lower part of
the dashboard and the side sill. Do not apply heat to these areas with a torch, etc.
2. Take extra care when painting or doing body work in the area below the centre pillar. Avoid direct exposure of the seat belt retractor and tensioner to heat guns, welding or
spraying equipment.
3. SRS electrical wiring harnesses and connectors are identified with yellow colour coding. Care should be taken not to damage the harness when repairing this area.
4. Do not apply heat of more than 100C (212F) when drying painted surfaces anywhere around the locations of SRS components.
5. If strong impact or high temperature needs to be applied to the areas around the locations of SRS components, remove the components before performing the repair work.
6. If any of the SRS related components are damaged or deformed, be sure to replace them.
NOTE: Refer to the Restraints section of the Shop Manual for after deployment procedures, and removal and replacement of SRS related components.
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General Information
1-3
000' 45'
Caster
133' 1
Total toe
0 2 (0 1/16)
4000' 2
out
3100' (Reference)
-045' 45'
Total toe
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General Information
Construction
Sp: Steel plate / Hss: High strength steel plate / Zn: Zinc-plating
No.
Part Name
No.
Part Name
(1)
(22)
(2)
(23)
(3)
(24)
(4)
(25)
(5)
(26)
(6)
(27)
(7)
(28)
(8)
(29)
(9)
(30)
(10)
(31)
(11)
(32)
(12)
(33)
(13)
(34)
(14)
(35)
(15)
(36)
(16)
(37)
(17)
(38)
(18)
(39)
(19)
(40)
(20)
(41)
(21)
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General Information
NH-578
NH-623M Stain
Taffeta White
Silver M.
B-92P Night
Hawk Black P.
B-96P Eternal
Blue P.
G-95P Clover
Green P.
R-513 Rallye
Red
Y-61P Inca P.
YR-525M
Titanium M.
SE
SE EXEC
LS
LSG
ES
ESG
KK
EX
KY
VTi
KX
EX
KB
LS
ES
KG
NOTE: In case of vehicles painted with NH-578, NH-623M, Y-61P and YR-525M and apply black (NH-70 Gloss 20) to the lower surface of the side sill (A) section.
1. FRONT BUMPER
Body colour
2. FRONT GRILLE
Body colour
3. HOOD MOULDING
Body colour
4. DOOR MIRROR
Body colour or black (NH-72 Gloss 30)
5. DOOR OUTER HANDLE
Body colour or black (NH-72 Gloss 30)
6. SIDE SILL
7. ROOF MOULDING
Black (NH-70 Gloss 20)
8. LICENSE PLATE TRIM
Body colour or black (NH-70 Gloss 20)
9. REAR BUMPER
Body colour
10. DOOR MOULDING
Black (NH-70 Gloss 20)
11. DOOR SASH TRIM
Black (NH-70 Gloss 20)
12. FRONT UNDER SPOILER
Black (NH-68 Gloss 10)
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Replacement - Replacement
Replacement
*Side Sill Outer Panel
Mass Production Body Welding Diagram
3-2
Removal
3-3
Installation
3-4
Roof Panel
Mass Production Body Welding Diagram
3-5
3-6
Removal
3-7
Installation
3-8
Rear Panel
Mass Production Body Welding Diagram
3-9
Items marked with and asterisk (*) include SRS components; special caution is required when servicing.
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a.
b.
c.
d.
e.
VIEW (Y)
Centre pillar stiffener
Outer panel stiffener
Side sill reinforcement
VIEW (Z)
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3-3
Removal
OUTER PANEL
SIDE SILL REINFORCEMENT
REINFORCEMENT STIFFENER (Driver side)
INSIDE SILL
REAR INNER PANEL
SIDE SILL REINFORCEMENT
VIEW (Z)
CENTRE PILLAR STIFFENER
OUTER PANEL STIFFENER
WHEEL ARCH EXTENSION
SIDE SILL REINFORCEMENT
OUTER PANEL
FRONT PILLAR LOWER STIFFENER
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3-4
Installation
1. Cut and set the new side sill reinforcement into position, and tack weld the
clamped position.
2. Cut the repaired part (outer panel) and set it into position. Clamp the repair part
and check the body dimensions (see section 4).
3. Temporarily install the door and front fender and check for differences in level and
clearance. Make sure the body lines flow smoothly.
4. Remove the repaired part and weld the centre pillar stiffener, side sill reinforcement
and front pillar lower stiffener (driver's side).
Driver's side
Passenger's side
When replacing the side sill reinforcement, cut the new side sill reinforcement so it
overlaps the body side reinforcement by 20 mm (1.8 in.), and fillet weld it.
1. Fillet welding
Overlap
20 mm (1.8 in.)
VIEW (Z)
5. Clamp the repair part and recheck the clearance and alignment of the door and
front fender.
6. Perform the main welding:
Attach a patch at the cut section of the front pillar (driver's side) center pillar and
wheel arch and plug weld them.
Driver's side
PATCH
Butt welding
Butt welding
PATCH
OUTER PANEL
Passenger's side:
1. Fillet welding
Overlap
30 mm (1.2 in.)
2. OUTER PANEL
Roof Panel
Roof Panel
3-5
Outer panel
Roof panel
Front roof rail
Rear roof rail
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a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
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3-7
Removal
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Installation
1. Cut and set the new centre pillar stiffener into position, and install the middle floor
gusset.
8. Temporarily install the door, rear window, trunk lid and rear bumper, and check for
differences in level and clearance.
Make sure the body lines flow smoothly.
9. Do the main welding:
Attach a patch at the cut section of the rear pillar and plug weld it.
2. Set the new repaired part (outer panel) and rear combination adaptor into position
and clamp them.
Check the body dimensions (see section 4).
Remove the repaired part (outer panel) and weld the centre pillar stiffener.
1.
2.
3.
4.
5.
6.
7.
8.
OUTER PANEL
PARCEL SHELF
REAR GUTTER
Butt welding
PATCH
Butt welding
NEW OUTER PANEL
Fillet welding
Overlap
30 mm (1.2 in.)
9. PATCH
1. Fillet welding
Overlap
20 mm (0.8 in.)
2. NEW CENTRE PILLAR STIFFENER
Rear Panel
Rear Panel
39
a.
b.
c.
d.
e.
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4-2
4-3
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4-2
Passenger Compartment
Unit: mm (in.)
1. K, k
Front Seat Rear Side Bracket Point 7 (0.3)
2. L, l
Rear Damper Mount Hole 11 (0.43)
4-3
Unit: mm (in.)
Door and Windshield Openings:
1. A
Windshield lower dashboard guide pin
2. B, C
Windshield opening flange notch (2 places)
3. D, E, F, G
Door opening flange notch (8 places)
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Rust Prevention
Cross Section of Body and Sealants
General
5-2
5-3
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5-2
General
5. Apply sealer on any area that the replacement part will cover. Smooth the sealer
with a brush is necessary.
4. Finish sealing the engine compartment, the door opening, the truck gutter and the
tailgate gutter. Wipe of the excess sealer.
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20.
Rear gutter
Outer Panel
Outer Panel
Parcel Shelf
Rear combination adaptor
Outer Panel
Rear gutter
Rear combination adaptor
Rear combination adaptor
Rear panel
Rear combination adaptor
Outer Panel
Rear combination adaptor
Rear gutter extension
Rear combination adaptor
Rear gutter
Gutter extension
Rear gutter
Quarter lower extension
Outer panel
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