2001 CIVIC Shop Manual PDF

SERVICE
MANUAL
CIVIC
CIVIC 4/5D
BODY REPAIR MANUAL 01
How to Use This Manual
This manual covers the repairs of 2001 model series 1 General Info
CIVIC that have been involved in an accident and it 2 Preparation of work
describes the work related to the replacement of 3 *Replacement
damage body parts.
Please read through instructions and familiarise 4 Body Dimensional Drawings
yourself with them before actually using this manual. 5 Rust Prevention
NOTE: Refer to the 2001 CIVIC Shop Manual (P/N. 6 Paints
60S5A00) for specifications, wire harness locations,
safety stand support points, etc.
Special Information
WARNING
Indicates a strong possibility of server
Personal Injury or death if instructions are
not followed.
CAUTION
Indicates a possibility of personal injury or
equipment damage if instructions are not
followed.
NOTE: Gives helpful information.
CAUTION
Detailed description of standard workshop
procedures, safety principles and service
operations are not included. Please note that
this manual does contain warnings and
caution against some specific service
methods which could cause PERSONAL
INJURY, damage a vehicle, or make it unsafe.
Please understand that these warning cannot
cover all conceivable ways in which service,
whether or not recommended by Honda,
might be done or of the possible hazardous
consequences of each conceivable way, nor
could Honda investigate all such ways.
Anyone using service procedures or tools,
whether or not recommended by Honda, must
satisfy himself thoroughly that neither
personal safety or vehicle safety will be
jeopardised.
All information contained in this manual is based on

the latest product information available at the time of
printing. We reserve the right to make changes at any
time without notice. No part of this publication may be
reproduced, stored in retrieval system, or transmitted,
in any form by an means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior
written permission of the publisher. This included text,
file:///C|/...EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CivBHtml/0-1.htm[8/25/2012 6:38:41 PM]

figures and tables.

Fist Edition 192 HONDA MOTOR CO., LTD.
8/2000 pages
All Rights Reserved Service Publication Office
Sections with * include SRS components; Special

Caution is required when servicing.
0-10-1home

Index - Index

Index
4-door General Information 1-3

5-door General Information 1-15

4-door General Information

Supplemental Restraint System (SRS) 1-4

Identification Number Locations 1-5
Lift and Support Points 1-6
Body Specifications/Wheel Alignment 1-7
Exterior Parts Removal/Installation 1-8
Construction 1-9
Door and Bumper Reinforcement Beams 1-10
Zinc-plated Steel Plate Repair 1-11
Colour Chart Paint Specifications 1-12
Types and Materials of Exterior Plastic Parts 1-14

Index - General Information
1-4
General Information
Supplemental Restraint System (SRS)
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. 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 212°F (100°C) 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

1-5
General Information
Identification Number Locations
1. Built Data and Vehicle

Type Except KK, KX,
KY models
2. Vehicle Identification
Number (VIN)
3. Engine Number
4. Transmission Number
(Manual)
(Automatic)
(Honda Multi Matic)

1-6
General Information
Lift and Support Points
NOTE: If you are going to remove heavy components such as Floor Jack
suspension or the fuel tank from the rear of the vehicle, first 1. 1. Set the parking brake.
support the front of the vehicle with a tall safety stands. When 2. Block the wheels that are not being lifted.
substantial weight is removed from the rear of the vehicle, the 3. When lifting the rear of the vehicle, put the gearshift
centre of gravity can change and cause the vehicle to tip lever in reverse (or automatic transmission in Park
forward on the hoist. position).
Frame Hoist 4. Position the floor jack under the front jacking bracket
Position the hoist lift blocks, or safety stands, under the or rear jacking bracket, centre the jacking bracket in
vehicle's front support points and rear support points. the jack lift platform, and jack up the vehicle high
enough to fit the safety stands under it.
1. 1. FRONT SUPPORT POINT

2. HOIST LIFT BLOCKS
3. REAR SUPPORT POINT
2. 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. 2. 1. FRONT JACKING BRACKET
Safety Stands 2. JACK LIFT PLATFORM
3. JACK LIFT PLATFORM
To support the vehicle on safety stands, use the same support
4. REAR JACKING BRACKET
points as for a frame hoist. Always use safety stands when
working on a under vehicle that is supported only by a jack. 3. 5. Position the safety stands under the support points
and adjust them so the vehicle will level.
6. Lower the vehicle onto the stands.

1-7
General Information
Body Specifications/Wheel Alignment
Unit : mm(in.)
*1: Eurpoean model
*2: Australian model
*3: Saudi Arabia model
*4: Hong Kong model
Front Wheel Alignment:

Camber 0°00'±45'
Caster 1'33'±1°
Total toe 0±3 (0±0.12)
Wheel turning in 40°00'±2° (D15B engine)
angle 38°00'±2° (D17A engine)
out 31°00' (D15B engine: Reference)
30°00' (D17A engine: Reference)
Rear Wheel Alignment:

Camber -0°45'±45'
Total toe IN 2 ±3 (0.08 ±0.12)

1-8
General Information
Exterior Parts Removal/Installation
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

1-9
General Information
Construction
Sp: Steel plateHss: High strength steel plateZn: Zinc-plated

No. Part Name No. Part Name
1 Hood (Hss, Zn) 22 Centre Pillar Stiffener (Sp)
2 Front Fender (Sp, Zn) 23 Side Sill Reinforcement (Hss, Zn)
3 Front Door (Hss, Zn) 24 Front Pillar Inner Lower (Hss)
4 Rear Door (Hss, Zn) 25 Front Pillar Inner Upper (Hss, Zn)
5 Trunk Lid (Sp, Zn) 26 Centre Inner Pillar (Hss, Zn)
6 Bulkhead Side (Sp, Zn) 27 Roof Side Rail (Hss)
7 Bulkhead Side Stray (Sp, Zn) 28 Roof Panel (Sp)
8 Bulkhead Upper Frame (Sp, Zn) 29 Rear Inner Panel (Sp, Zn)
9 Front Lower Cross-member (Hss, Zn) 30 Wheel Arch Extension (Sp, Zn)
10 Wheelhouse Upper Member (Sp) 31 Rear Wheelhouse (Sp, Zn)
11 Front Wheelhouse (Sp, Zn) 32 Inside Sill (Hss, Zn)
12 Front Damper Extension (Hss, Zn) 33 Front Floor (Sp, Zn)
13 Damper Housing (Hss, Zn) 34 Middle Floor Cross-member (Hss, Zn)
14 Front Side Frame (Hss, Zn) 35 Rear parcel Self (Sp)
15 Side Frame Extension Rear/Front Side Outrigger (Hss, Zn) 36 Rear Floor Upper Cross-member (Sp)
16 Dashboard Lower (Sp, Zn) 37 Rear Floor (Sp, Zn)
17 Dashboard Upper (Sp, Zn) 38 Rear Panel (Sp, Zn)
18 Outer Panel (Sp, Zn) 39 Rear Panel Side Stiffener (Sp)
19 Rear Combination Adaptor (Sp, Zn) 40 Rear Frame A (Sp, Zn)
20 Front Pillar Lower Stiffener (Sp, Zn) 41 Rear Frame B (Hss, Zn)

21 Front Pillar Upper Stiffener (Hss) 42 Rear Floor Cross-member (Sp, Zn)

1-10
General Information
Door and Bumper Reinforcement Beams
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
file:///C|/...U3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CivBHtml/1-10.htm[8/25/2012 6:38:41 PM]

1-11
General Information
Zinc-plated Steel Plate Repair
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. 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. 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. 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. SPECIAL BOLT
2. GROUND WIRE
3. GROUND WIRE MOUNTING HOLE
4. PLUG

1-12
General Information
Colour Chart Paint Specifications
P.: Pearl Paint / M.: Metallic Paint

NH-578 NH-623M B-92P B-96P G-95P R-81 R504P RP-32P YR-525M
Taffeta Stain Night Eternal Clover Mirano Ruby Red Vintage Titanium
White Silver M. Hawk Blue P. Green P. Red P. Plum P. M.
Black P.
KE 1.4S O O O O O O O O
1.6SE O O O O O O O O
KG 1.4S O O O O O O O O
1.6LS O O O O O O O O
1.6ES O O O O O O O O
KB 1.4S O O O O O O
1.6ES O O O O O O
KQ GLi O O O O O O
VTi O O O O O O
KY LXi O O O O O O O
EXi O O O O O O O
VTi O O O O O O O
KW EXi O O O O O O O
KT LXi O O O O O O
EXi O O O O O O
KU EXi O O O O O O O
VTi O O O O O O O
VTi-S O O O O O O O
KV LXi O O O O O O
EXi O O O O O O
VTi O O O O O O
KK DX O O O O O
LX O O O O O
EX O O O O O O
KH EXi O O O O O O
VTi O O O O O O
KF EXi O O O O O O O
LXi O O O O O O O
KN 150I O O O O O O
170I O O O O O O
KX LX O O O O O
EX O O O O O

1-13
General Information
Colour Chart Paint Specifications (cont'd)
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
(NH-70 Gloss 20)
5. DOOR OUTER
HANDLE
(NH-72 Gloss 30)
6. PROTECTER
MOULDINGS
Body colour or BP,
Dark grey (NH-533)
7. FRONT BUMPER
Body colour
8. ROOF MOULDING
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
14. FRONT UNDER
SPOILER
15. GRILLE
BP. Dark grey (NH-
533)

1-14
General Information
Type and Materials of Exterior Plastic Parts
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)


Supplemental Restraint System (SRS) 1-16

Identification Number Locations 1-17
Lift and Support Points 1-18
Body Specifications/Wheel Alignment 1-19
Exterior Parts Removal/Wheel Alignment 1-20
Construction 1-21
Door and Bumper Reinforcement Beams 1-22
Zinc-plated Steel Plate Repair 1-23
Colour Chart Paint Specifications 1-24
Types and Materials of Exterior Plastic Parts 1-26

1-16
General Information
Supplemental Restraint System (SRS)
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. 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 212°F (100°C) 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

1-17
General Information
Identification Number Locations
1. Built Data and Vehicle

Type
2. Vehicle Identification
Number (VIN)
3. Engine Number
(Manual)
(Automatic)

1-18
General Information
Lift and Support Points
NOTE: If you are going to remove heavy components such as Floor Jack
suspension or the fuel tank from the rear of the vehicle, first 1. 1. Set the parking brake.
support the front of the vehicle with a tall safety stands. When 2. Block the wheels that are not being lifted.
substantial weight is removed from the rear of the vehicle, the 3. When lifting the rear of the vehicle, put the gearshift
centre of gravity can change and cause the vehicle to tip lever in reverse (or automatic transmission in Park
forward on the hoist. position).
Frame Hoist 4. Position the floor jack under the front jacking bracket
Position the hoist lift blocks, or safety stands, under the or rear jacking bracket, centre the jacking bracket in
vehicle's front support points and rear support points. the jack lift platform, and jack up the vehicle high
enough to fit the safety stands under it.
1. 1. FRONT SUPPORT POINT

2. HOIST LIFT BLOCKS
3. REAR SUPPORT POINT
2. 1. Raise the hoist a few inches, and rock the vehicle

gently to be sure it is firmly supported. 2. 1. FRONT JACKING BRACKET
2. Raise the hoist to full height, and inspect the lift 2. JACK LIFT PLATFORM
points for solid contact with the lift blocks. 3. JACK LIFT PLATFORM
Safety Stands 4. REAR JACKING BRACKET
To support the vehicle on safety stands, use the same support 3. 5. Position the safety stands under the support points
points as for a frame hoist. Always use safety stands when and adjust them so the vehicle will level.
working on a under vehicle that is supported only by a jack. 6. Lower the vehicle onto the stands.

1-19
General Information
Body Specifications/Wheel Alignment
Unit : mm(in.)
*1: With Roof Antenna
*2: European model (MPW condition)
*3: Except European model
Front Wheel Alignment:

Camber 0°00'±45'
Caster 1'33'±1°
Total toe 0±3 (0±0.13)
Wheel turning in 40°00'±2° (D15B engine)
angle 38°00'±2° (D17A engine)
out 31°00' (D15B engine: Reference)
30°00' (D17A engine: Reference)
Rear Wheel Alignment:

Camber -0°45'±45'
Total toe IN 2 ±3 (0.08 ±0.12)

1-20
General Information
Exterior Parts Removal/Installation
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

1-21
General Information
Construction
Sp: Steel plateHss: High strength steel plateZn: Zinc-plated

No. Part Name No. Part Name
1 Hood (Hss, Zn),/p> 22 Front Pillar Upper Stiffener (Hss)
2 Front Fender (Sp, Zn) 23 Centre Pillar Stiffener (Sp)
3 Front Door (Hss, Zn) 24 Side Sill Reinforcement (Hss, Zn)
4 Rear Door (Hss, Zn) 25 Front Pillar Inner Lower (Hss)
5 Trunk Lid (Sp, Zn) 26 Front Pillar Inner Upper (Hss, Zn)
6 Bulkhead Side (Sp, Zn) 27 Centre Inner Pillar (Hss, Zn)
7 Bulkhead Side Stray (Sp, Zn) 28 Roof Side Rail (Hss)
8 Bulkhead Upper Frame (Sp, Zn) 29 Roof Panel (Sp)
9 Front Lower Cross-member (Hss, Zn) 30 Rear Inner Panel (Sp, Zn)
10 Wheelhouse Upper Member (Sp) 31 Wheel Arch Extension (Sp, Zn)
11 Front Wheelhouse (Sp, Zn) 32 Rear Wheelhouse (Sp, Zn)
12 Front Damper Extension (Hss, Zn) 33 Inside Sill (Hss, Zn)
13 Damper Housing (Hss, Zn) 34 Front Floor (Sp, Zn)
14 Front Side Frame (Hss, Zn) 35 Middle Floor Cross-member (Hss, Zn)
15 Side Frame Extension Rear/Front Side Outrigger (Hss, Zn) 36 Rear Floor Upper Cross-member (Sp)
16 Dashboard Lower (Sp, Zn) 37 Rear Floor (Sp, Zn)
17 Dashboard Upper (Sp, Zn) 38 Rear Panel (Sp, Zn)
18 Outer Panel (Sp, Zn) 39 Rear Frame A (Sp, Zn)
19 Rear Pillar Gutter Lower (Sp, Zn) 40 Rear Frame B (Hss, Zn)
20 Rear Pillar Gutter Upper (SP, Zn) 41 Rear Floor Cross-member (Sp, Zn)
21 Front Pillar Lower Stiffener (Sp, Zn)

1-22
General Information
Door and Bumper Reinforcement Beams
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

1-23
General Information
Zinc-plated Steel Plate Repair
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. 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. 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. 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. SPECIAL BOLT
2. GROUND WIRE
3. GROUND WIRE MOUNTING HOLE
4. PLUG

1-24
General Information
Colour Chart Paint Specifications
P.: Pearl Paint / M.: Metallic Paint

NH-578 NH-623M B-92P G-502M PB-77M R-81 R504P B-96P G95P
Taffeta Stain Night Aqua Lavender Mirano Ruby Eternal Clover
White Silver M. Hawk Green M. Mist M. Red Red P. Blue P. Green P.
Black P.
KE 1.4S O O O O O O O O
1.6S O O O O O O O O
1.4SE O O O O O O O O
1.6LSE O O O O O O O O
KQ Vi O O O O O O O
VTi O O O O O O
KT EXi O O O O O O

1-25
General Information
Colour Chart Paint Specifications (cont'd)
1. DOOR MIRROR BASE

2. DOOR MIRROR
(NH-70 Gloss 20)
3. CHANNEL TAPE
4. DOOR OUTER
HANDLE
(NH-72 Gloss 30)
5. CORNER TRIM
Black (NH-70 GLOSS
20)
6. ROOF MOULDING
7. LICENSE TRIM
(NH-72 Gloss 30)
8. REAR BUMPER
Body Clour
9. DOOR MOULDING
10. DOOR SASH TRIM
11. FRONT BUMPER
Body Colour
12. GRILLE
BP. Dark grey (NH-533)

1-26
General Information
Type and Materials of Exterior Plastic Parts
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 dine 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. ROOF MOULDING
Polyvinyl chloride (PVC)
5. LICENSE TRIP
Acrylonitrile butadiene styrene
(ABS)
6. REAR BUMPER
Polypropylene (PP)
7. DOOR SASH TRIM
Acrylontrile ethylene
propylene dinene rubber
styrene (A/EPDM/S)
8. FRONT BUMPER
Polypropylene (PP)

Preparation of Work - Preparation of Work

Preparation of Work
Outline of Body Repair 2-2

General Safety Precaution 2-3
Accurate Inspection of Damaged Parts (Visual)

Description 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
Installation and Inspection 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
Carbon Dioxide Arc Welder (MIG Arc Weld) 2-19
Gas Welding 2-20

Outline of Body Repair
2-2
Outline of Body Repair
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 Reference
Accurate inspection of Damaged Parts. (Visual) Wheelbase see section 1
Measurement Wheel Alignment see section 1
Body Dimensional see section 4
Drawings
Reshape 1. Remove any related parts. Shop Manual
2. Attach the frame straightener to the body. see section 1
3. Pull out and straighten the damaged
areas.
Body Dimensional see section 4
4. Check the original position.
Drawings
Replacement 1. Cut off and separate the damaged area. Mass Production Body see section 3
2. Straighten any related parts. Welding Diagram see section 3
3. Check the repair part installation and Removal
see section 4
alignment with the body. Body Dimensional
4. Clean and degrease to the welded Drawings see section 3
surfaces. Installation
5. Weld in the repair part.
6. Finish the welded areas.
Rust Prevention 1. Apply the sealer. Cross Section of Body see section 5
2. Apply the undercoating. and Sealants.
3. Apply anti-rust agent to the inside of the Soft Chipping Guard
outer panel and frames. Primer Coating
Diagram
PVC Coating Diagram
Area to be Covered by
Antirust Agents
Paint Apply the paint see section 6
Installation and 1. Adjust the hood, door, tailgate. Shop Manual
Inspection 2. Measure the wheel alignment.
3. Clean the body.
4. Install related parts.

General Safety Precaution
2-3
General Safety Precaution
Disconnect the battery to reduce the possibility Remove the fuel tank and/or fuel lines if
of damage caused by electrical shorts. welding equipment is to be used near the fuel
Check for fuel leaks and repair as necessary. system.
Use standard safety equipment when spraying
paint, welding, cutting, sanding, or grinding (see
page 2-12).
Always attach a safety cable when using a
hydraulic ram or a frame straightening table; do
not stand in direct line of the chains used on
such equipment.
1. 1. FUEL TANK
The vehicle identification number is stamped on

the dashboard upper panel and is registered
with local authorities. If the dashboard upper
1. 1. SAFETY CABLES
panel must be replaced because of damage,
Cover the exterior parts and the interior parts check with local authorities first.
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.
2. 1. VEHICLE IDENTIFICATION NUMBER (VIN)

2. DASHBOARD UPPER

Preparation of Work - Accurate Inspection of Damaged Parts (Visual)

2-4
Accurate Inspection of Damaged Parts
(Visual)
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.

Preparation of Work - Accurate Inspection of Damaged Parts (Visual)
2-5
Accurate Inspection of Damaged Parts
(Visual)
Measurement
Whenever possible, make judgements and conclusions To measure body dimensions, use a universal
based on measurements. tram gauge and convex tool.
Body Measuring Dimension/Opening Repair Chart:
Measure the wheel alignment to prevent uneven
tyre wear or incorrect steering wheel alignment.
If there are any deviations, use a tram-tracking
gauge and measure the body parts.
Frame Repair Chart:
If there is any twisting to the body, measure

with a frame centring gauge.
Diagonal measurement:

Reshape
2-6
Reshape
Correction of the Damaged Area
1. 1. Remove any related parts. 1. 4. Check that the part of the body is more or less
NOTE: See the Shop Manual. restored to its original shapes. Check the
2. 2. Connect the frame straightener to the vehicle original positions using the body dimensional
body. drawings.
The side sill is flangeless to allow reshaping
by pulling it out.
Use the horizontal pinch welds for anchoring
the vehicle.
3. 1. SUPPORT POINTS
(Jack-up stiffener)
4. 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.

Preparation of Work - Replacement
2-7
Replacement
Removal
1. 1. Decide whether to replace all the affected parts 1. 2. Peel off the undercoat.
or whether to cut the weld joint parts and
replace them. CAUTION
NOTE: When cutting the parts off, take special care Be careful not to burn the fittings inside the
that you do not damage adjacent parts on the vehicle. passenger compartment when heating.
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 2. 3. Remove the damaged parts.
welding.
Make sure that the joints are short, and that WARNING
paint repair can be performed easily. To prevent eye injury, wear goggles or safety
Make sure that locations are such that the glasses whenever sanding, cutting or
joints can be finished in a way that will not grinding.
affect the outward appearance.
Centre punch around the spot weld imprints
Make sure that the locations do not hinder
on the welded flange and drill holes using
the removing and attaching of parts.
the spot cutter.
Parts which influence wheel alignment such as damper
NOTE: Make a drill hole so that the installation of the
housing and the side frames must be examined using the
repair parts may become easy.
frame repair charts.
Remove the MIG weld flange with a disc
sander.
Pry off the welded flange with a chisel.
Cut off the outer panel with an airsaw.

NOTE: Be careful not to cut the inner section.
2. 1. DAMPER HOUSING
2. OUTER PANEL 3. 1. STIFFENER
(New part) 2. OUTER PANEL
3. FRONT SIDE FRAME
(New part)


2-8
Replacement
Installation
1. 1. Straighten any damaged parts. Where new panels cannot be spot welded,
make holes for plug welding.
WARNING Make holes to the size which corresponds to
To prevent eye injury and burns when the thickness of the welded plate (see page
welding, wear an approved welding helmet, 2-19).
gloves and safety shoes. The position and the point by which holes
are made, refer to the old parts or Mass
Fill any holes by MIG welding and even out
Production Body Welding Diagram (see
with a hammer and dolly.
section 3).
WARNING
To prevent eye injury, wear goggles or safety
glasses whenever sanding, cutting or
grinding.
Level and finish the burns on the welding
flanges with a disc sander or belt sander.
1. 1. NEW PART
2. OLD PART
3. Apply rust prevention processing on welded surface.
WARNING
To prevent eye injury, wear goggles of safety
glasses whenever sanding.
Remove the undercoat from both sides of
the areas to be spot welded with a sander
to expose the steel plate.
Apply the spot sealer to the welding surface
of the new parts and body side.
2. 2. Preparations of new parts. NOTE: Spread the spot sealer coat on the welding
Cut the new outer panel so it will overlap by surface so that there is no bare areas.
20-30mm (0.8-1.2 in.) to the panel of the
body side.
3. 1. OVERLAP


2-9
Replacement
Installation
1. 4. Check the tack weld at positions of the new Make 20% to 30% more spot welds than
parts. there were holes drilled.
Clamp the new part and check the position A new welding position should avoid an old
of it using the body dimensional drawings position as much as possible.
(see section 4). NOTE: If there is not room for spot welds, compensate
Tack weld the clamped section. by using MIG welds
The electric continuity property of zinc-
WARNING plated steel plate is different from ordinary
To prevent eye injury and burns when steel plate. When spot welding, increase the
welding, wear an approved welding helmet, current by 10-20%, or increase the
gloves and safety shoes. resistance welding line.
Fillet weld the repair outer side sill it will

overlap by 30 mm (1.2 in.) in the front and
2. 5. Check the alignment of the exterior body parts. back.
Temporary install the exterior body parts, Butt weld the front pillar, centre pillar, rear
windshield and rear window glass, and pillar and the wheel arch cut sections of the
check for differences in level and repaired outer panel.
clearances. NOTE: Attach the patches at the cut sections of the
NOTE: Check the fit of the front fender, door and the outer panel and plug weld them.
rear fender, and make sure the body lines flow
smoothly.
3. 6. Main weld the repair parts.

Use proper welding methods (see pages 2-
17, 2-18, 2-19, 2-20).
WARNING
To prevent eye injury and burns when
welding, wear an approved welding helmet,
gloves and safety shoes.
1. 1. BUTT WELD
2. PATCH
3. FILLET WELD

Rust Prevention/Paint
2-10
Replacement
Installation (cont'd)
1. 7. Finishing the welded areas. 1. 1. Applying the sealer. Seal the overlapped areas
Level the MIG welded areas with a disc of the outer panel, and the welded surfaces of
sander. the new parts. Seal gaps completely.
2. Apply the paint.
WARNING
To prevent eye injury, wear goggles or safety WARNING
glasses whenever sanding, cutting or Ventilate when spraying paint. Most
grinding. paint contains substances that are
harmful if inhaled or swallowed. Read
NOTE: Take care not to grind excessively.
the paint label before opening the
Even out high areas with a hammer. Be paint container.
careful not to deform them. Avoid contact with skin. Wear an
Smooth out welded door and tailgate areas, approved respirator, gloves, eye
and window opening flanges with a hammer protection and appropriate clothing
and dolly. when painting.
Fill the deformed area and smooth out the Paint is flammable. Store it in a safe
welded areas with body filler. place, and keep it away from sparks,
flames or cigarettes.
2. 3. Apply undercoat to the wheelhouse and under-
floor.
4. Apply the anti-rust agent to the inside of the
outer panel and welded areas.

Installation and Inspection
2-11
Installation and Inspection
1. 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. 2. Apply the sealer to the hinges of the hood, door
and tailgate.
3. 1. HOOD HINGE
2. DOOR HINGE
3. TAILGATE HINGE
4. 3. Adjust the wheel alignment.

4. Check the windows for water leaks.
5. Clean the passenger compartments.

Preparation of Work - Repair Tools
Protective Tools
2-12
Repair Tools
Measurement Equipment
TRAM TRACKING GAUGE OPERATOR:

1 Protective goggles 7 Protective apron
2 Cap 8 Welding glove
3 Ear plugs 9 Foot protector
4 Shield for eyes 10 Safety shoes
5 Overalls with long 11 Work glove
sleeves
FRAME CENTRING GAUGE 6 Dust-proof mask 12 Splatter guard
UNIVERSAL TRAM GAUGE
CONVEX TOOL
VEHICLE BODY:
Heat-resistant protective cover

Cutting Tools
2-13
Repair Tools
Processing Tools
SPOT CUTTER AIRSAW

Install the spot cutter in the air drill, and drill a hole at the Cut the outer panel.
spot weld nugget and the plug to make the hole.
AIR CHUCK GRINDER

Detaching the MIG welding part and the panel can be cut
AIR DRILL by installing cut grinding wheel in air chuck grinder.
The rotation speed can be adjusted, and an adequate
hole opening can work.
AIR IMPACT CUTTER

Cut the outer panel roughly.
PRESSURE DRILL
The depth of the hole can be adjusted, and only
necessary plate thickness can puncture.
CHISEL SET
CENTRE PUNCH
When an accurate hole opening is necessary.
SPOT WELD CUTTER

Pry off the spot welded flange.
HAND NIBBLER

Shaping Tools
2-14
Repair Tools
Cutting Tools (cont'd)
HANDSAW Skin Panel Shaping:

HAMMERS
DOLLIES
PLASMA CUTTER
Cut the thick plate.
SPOONS
GAS CUTTER
CHISEL
SNIPS/SHEARS
ACETYLENE BURNER
Peel off the undercoat.
FLANGE TOOLS
Edge preparation.
Body and Frame Shaping:

WASHER WELDER

Fixing Tools
2-15
Repair Tools
Shaping Tools (cont'd)
SLIDE HAMMER VICE GRIPS
BODY JACK
SCREW CLAMP
FRAME CORRECTOR
SCREW VICES

Sanding Tools
2-16
Repair Tools
Welders
SPOT WELDER DISC GRINDER

Grinding of welded flange.
DISC SANDER
Sand off the paint film and use to finish the welded
flanges
MIG WELDER
BELT SANDER
Finish off narrow welded flange.
DOUBLE ACTION SANDER

Featheredge and finish of putty.
GAS WELDER
LONG ORBITAL SANDER

Sanding putty within the wide range and finish.

Preparation of Work - Welding Methods
2-17
Welding Methods
Spot Welding
Spot welding is also known as resistance spot welding, and it is the most suitable method of welding for vehicles. It has 3 main
features: the welding can be performed instantaneously, it has minimal effect on the source material, and it has a minimum affect
on distortion to the absolute minimum. However, please remember to remove all paint and other impurities from the surface of the
material you intend to weld for reliable results.
Welders:
1. Spot welder
2. Timer/Transformer
Welding Conditions:
When performing spot welding, make sure that you conform to the following conditions: use the correct current, conductivity time,
welding pressure, holding time, and shutdown time recommended for the spot welder.
Please bear in mind the following points when welding:
Plate thickness and minimum welding pitch
1. Intervals
NOTE: If the welding intervals are too short, branching may occur, making it impossible to maintain the desired soldering state.
Plate thickness and tip diameter.
1. Tip diameter
Unit: mm (in.)

Plate thickness 0.6 (0.02) 0.9 (0.04) 1.2 (0.05) 1.6 (0.06)
Minimum intervals 11 (0.43) 16 (0.63) 20 (0.79) 24 (0.94)
Unit: mm (in.)
Plate thickness 0.8 (0.03) 0.9 (0.04) 1.2 (0.05) 1.6 (0.06)
Tip diameter 45 (0.12) 5.0 (0.2) 5.5 (0.22) 6.0 (0.24)

2-18
Welding Methods
Spot Welding (cont'd)
Welding Strength Test

Even if you perform the welding according to the proper conditions, the strength of the welded sections may fluctuate due to drops
in the voltage and other factors. The quality of the welding cannot be evaluated unless the welded sections are destroyed.
Provide yourself with a steel plate of the same thickness and conduct a destruction test.
If holes appear in the steel plates, this means that the welding is of standard strength.
Drive a wedge between 2 panels near the nugget. If the welded parts do not come apart and the diameter of the nugget
is more than 3 mm (0.1 in.), the welding should be satisfactory.
1. WEDGE
2. Stop inserting the
wedge when the full
size of the nugget
appears.
NOTE:
It is difficult to perform spot welding in the following circumstances:
When it is not possible to remove any rust or paint attached to the welding surfaces.
When the tip of the spot welder cannot be inserted into the welding section.
When the welding surfaces can be seen from the outside and welding will impair the exterior appearance.
In all these cases, the gas welding method should be employed. Moreover, if it is not possible to perform spot welding because of
space restrictions, plug welding using on the arc welding method may be performed instead. For plug welding, the sections to be
welded must be close together.

2-19
Welding Methods
Carbon Dioxide Arc Welder (MIG Arc Weld)
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
Disconnect the negative battery cable before arc welding.
Welding Methods:
Butt welding Fillet welding Spot welding Plug welding
Plug Welding Conditions:

Plate thickness and weld holes
Unit: mm (in.)
Plate thickness ~1.0 (0.04) 1.0 (0.04) ~ 1.5 (0.06) 1.5 (0.06)~
Weld hole diameter 5 (0.2) 6.5 (0.26) 8 (0.3)

2-20
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. Gas regulator
2. Gas regulator
3. Welder
4. Cutter
5. Oxygen/Acetylene tanks
Welding Methods:
Butt welding Fillet welding or soldering

Index - Index
Index
4-door Replacement 3-3

5-door Replacement 3-35

Index - Front Bulkhead
3-4
Front Bulkhead
Mass Production Body Welding Diagram
A. A. Front damper
extension
B. Bulkhead upper
frame
C. Bulkhead side
stay
D. Wheelhouse
upper member
E. Front wheelhouse
F. Front side frame
G. 4-Plate welding
H. Front lower
cross-member
I. Bulkhead side
J. Bulkhead bracket

3-5 Installation
Front Bulkhead
Removal
1. 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. 1. BULKHEAD UPPER FRAME

2. BULKHEAD SIDE
3. FRONT DAMPER EXTENSION
4. WHEELHOUSE UPPER MEMBER
5. FRONT WHEELHOUSE
6. FRONT SIDE FRAME
7. BULKHEAD SIDE STAY
8. FRONT LOWER CROSS-MEMBER

4. BULKHEAD SIDE
5. FRONT SIDE FRAME
7. FRONT WHEELHOUSE

9. FRONT SIDE FRAME

Index - Front Wheelhouse/Damper Housing
3-6
Front Wheelhouse/Damper Housing
a. a. Front side frame

b. Engine mount
bracket
c. Dashboard upper
d. Damper housing
extension
e. Front damper
extension
f. Wheelhouse
upper member
g. Damper housing
extension
h. Front damper
extension
i. Include (A)
j. Front side frame
k. Front wheelhouse
Passenger compartment side:

Wheelhouse upper member removed:
a. a. Dashboard upper side
member
b. Damper housing extension
c. Front damper extension
d. Damper housing
e. Front wheelhouse

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
Reused.

3-8
Removal (cont'd)
Replace the front damper extension, damper housing and damper housing extension as an assembly.
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

3-9
Installation
1. 1. Set the new damper housing assembly, front From the passenger compartment side, plug
wheelhouse and front bulkhead into position, the holes in the dashboard lower, damper
and measure the front compartment diagonally. housing extension and front damper extension.
3. Temporarily install the front sub-frame, and
check the front side frame position.
headlight and front bumper, and check for
difference in level and clearance. Make sure the
body lines flow smoothly.
Weld the damper housing and front side
frame.
Weld the front damper extension and
dashboard upper side member.
1. 1. FRONT DAMPER EXTENSION

2. DAMPER HOUSING EXTENSION
From wheelhouse side, plug weld the holes in

the dashboard upper and damper housing
extension.
2. 1. DAMPER HOUSING EXTENSION

2. DASHBOARD UPPER SIDE MEMBER
3. FRONT SIDE FRAME

4. DAMPER HOUSING

3-10
Weld the front wheelhouse, damper housing and front

side frame.
3. FRONT WHEELHOUSE
4. ENGINE MOUNT BRACKET
Weld the wheelhouse upper member.

When replacing the front wheelhouse only, butt weld
the wheelhouse upper member.

2. Butt Welding

Index - Front Side Frame/Outrigger
3-11
Front Side Frame/Outrigger

b. Sub-frame rear
bracket
c. 4-Plated welding
d. Side frame
extension rear
e. Inside sill
extension
f. Outrigger
g. Side frame
bulkhead rear
h. 4-Plate welding
i. Inside sill
extension
j. Side frame
extension rear
k. Side frame
bulkhead rear
and front side
frame
l. Front wheelhouse
VIEW (Y)
a. a. Inside sill extension
VIEW (Z)


3-12
Removal

1. FRONT SIDE FRAME
2. DAMPER HOUSING
3. FRONT WHEELHOUSE
4. FRONT SIDE FRAME
5. SIDE FRAME
BULKHEAD REAR
6. ENGINE MOUNT
BRACKET
7. SIDE FRAME
BULKHEAD REAR
8. FRONT SIDE FRAME
9. FRONT SUB-FRAME
STAY
10. FRONT SIDE FRAME
11. SIDE FRAME
EXTENSION REAR
12. SIDE FRAME
BULKHEAD REAR
13. SIDE FRAME
EXTENSION REAR

3-13
Removal (cont'd)
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.
1. OUTRIGGER
2. SUB-FRAME REAR
BRACKET
3. SIDE FRAME
EXTENSION REAR
4. OUTRIGGER
5. INSIDE SILL
EXTENSION
6. FLOOR FRAME
7. SIDE FRAME
EXTENSION REAR
8. SUB-FRAME REAR
BRACKET

3-14
Installation
1. 1. Tack weld the new side frame bulkhead rear to

the side frame extension rear.
Plug weld the inside sill extension and floor

frame.
2. 1. SIDE FRAME BULKHEAD REAR
3. 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).
4. Temporarily install the front sub-frame, and
5. Temporarily install the hood, front render,
headlights and front bumper, and check for
Make sure the body lines flow smoothly.
Plug weld the side frame extension rear,
side frame bulkhead rear and front side
frame. 1. 1. INSIDE SILL EXTENSION
2. FLOOR FRAME
From passenger compartment, plug weld the

dashboard lower and front floor.

2. FRONT SIDE FRAME
2. 1. OUTRIGGER

3-15
Weld the damper housing, front wheelhouse

and front side frame.
2. FRONT WHEELHOUSE

Index - Front Pillar Outer Panel
3-16
Front Pillar Outer Panel
a. a. Wheelhouse
upper member
(see page 3-6)
b. Inner lower
c. Front pillar lower
stiffener
d. Front pillar upper
stiffener
e. Include (A)
f. Front pillar lower
stiffener
g. Side sill
reinforcement
h. Front pillar
separator
i. Front pillar lower
stiffener

3-17
Removal
Cut the wheelhouse upper member as necessary, and cut and pry the front pillar outer panel.
Check the front pillar lower stiffener position 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. FRONT PILLAR UPPER
STIFFENER
2. FRONT PILLAR LOWER
STIFFENER
3. OUTER PANEL
4. SIDE SILL REINFORCEMENT
5. FRONT PILLAR SEPARATOR
6. INNER LOWER
STIFFENER
STIFFENER

3-18
Installation
1. 1. Glue the insulator to the inner lower at the front 1. 6. Clamp the repair part and recheck the
pillar lower separator mounted position. clearance and alignment of the front door, front
Insulator: P.N. 74416-SR1-000 fender and windshield.
Adhesive: Cemedine 366, or equivalent 7. Perform the main welding:
Attach the patch at the cut section of the
front pillar outer panel and plug weld it.
2. 1. INNER LOWER
2. INSULATOR
3. 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 difference
in level and clearance. Make sure the body
lines flow smoothly.
5. Remove the repair part, and weld the front
pillar lower stiffener, upper stiffener and side sill
reinforcement.
2. 1. Butt welding
2. PATCH
3. OUTER PANEL
4. Fillet welding
5. Overlap
30 mm (1.2 in.)
3. 8. Weld the wheelhouse upper member.
4. 1. FRONT PILLAR UPPER STIFFENER

2. FRONT PILLAR LOWER STIFFENER
3. INSULATOR
4. 1. WHEELHOUSE UPPER MEMBER

Index - Side Sill Outer Panel
3-19
Side Sill Outer Panel
a. a. Centre pillar
stiffener
b. VIEW (X)
c. Centre pillar
separator
d. Centre pillar
stiffener
reinforcement
e. 4-Plate welding
f. 4-Plate welding
g. VIEW (Y)
h. Side sill
reinforcement
i. Centre pillar
stiffener
j. VIEW (Z)
k. VIEW (W)

3-20
Removal
Cut and pry off the side sill outer panel.

Check the centre pillar stiffener and side sill reinforcement position and for damage and if necessary replace them.
When removing the centre pillar stiffener, do not cut the centre pillar stiffener reinforcement; the centre pillar stiffener
reinforcement is part of the centre pillar stiffener.
When replacing the center pillar stiffener, remove the centre pillar separator, and glue the insulator at the separator
mounted position.
1. Outer panel cut line.
2. Centre pillar stiffener
cut line.
3. CENTRE INNER
PILLAR
4. SIDE SILL
REINFORCEMENT
5. VIEW (Z)
6. INSIDE SILL
7. CENTRE PILLAR
SEPARATOR
8. SIDE SILL
REINFORCEMENT
9. OUTER PANEL
10. CENTRE PILLAR
STIFFENER
11. CENTRE PILLAR
STIFFENER
REINFORCEMENT

3-21
Installation
1. 1. Glue the insulator to the centre inner pillar at

the corner pillar separator mounted position.
Insulator: PIN. 74416-SF1-000
Adhesive: Cemedine 366, or equivalent
1. 1. NEW SIDE SILL REINFORCEMENT

2. INSIDE SILL
3. CENTRE INNER PILLAR
2. 1. CENTRE INNER PILLAR NOTE: Replace the driver side of the side sill
2. INSULATOR reinforcement with the assembly without cutting the side
sill reinforcement halfway, because there id the
3. 2. Cut and set the new centre pillar stiffener and reinforcement stiffener inside of the side sill
side sill reinforcement into position, and tack reinforcement. Therefore, cut the outer panel to under of
weld the clamped position. the front pillar.
3. Cut the repair part (outer panel), set into
position. Clamp the repair part, and check the
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.
2. 1. FRONT PILLAR OUTER PANEL

2. OUTER PANEL
4. INSIDE SILL
4. 1. Fillet welding
5. REINFORCEMENT STIFFENER
Overlap
20 mm (0.8 in.)
2. NEW CENTRE PILLAR STIFFENER

3. Fillet welding
Overlap
20 mm (0.8 in.)
4. NEW SIDE SILL REINFORCEMENT

3-22
1. 6. Clamp the repair part and recheck the clearance

and alignment of the front door, rear door and front
denser.
Attach the patch at the cut section of the centre
pillar and wheel arch and plug weld them.
2. Butt welding
3. PATCH
4. PATCH
5. Butt welding
6. Overlap
30 mm (1.2 in.)

Index - Roof Panel
3-23
Roof Panel
Without roof panel:

a. a. Front inner upper pillar
b. Front roof rail
c. Rear roof rail
d. Roof panel
e. Rear inner panel
f. Rear roof side rail
g. Outer panel
h. Front roof side rail

Index - Roof Panel
3-24
Roof Panel
Removal
1. ROOF PANEL
2. REAR INNER PANEL
3. ROOF ARCH GUSSET
4. REAR INNER PANEL
5. REAR ROOF RAIL
6. FRONT ROOF RAIL
7. FRONT INNER UPPER
PANEL
PILLAR

Index - Roof Panel
3-25
Roof Panel
Installation
1. 1. Set the new roof panel into position and clamp 1. 5. From inside the vehicle, plug weld the front
it. Check the body dimensions (see section 4), pillar inner upper, rear inner panel and front and
and check the width of the roof moulding rear roof rails.
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.
2. 1. OUTER PANEL
2. ROOF PANEL
3. ROOF SIDE RAIL
VIEW (Z)
2. 1. FRONT INNER UPPER PILLAR
2. FRONT ROOF RAIL
3. REAR INNER PANEL
4. REAR ROOF RAIL
3. 1. ROOF ARCH GUSSET

Index - Rear Side Outer Panel
3-26
Rear Side Outer Panel
a. a. Rear damper
stiffener
b. Inner panel
extension
c. Inner panel
d. Rear panel side
stiffener
e. VIEW (Z)
f. Rear combination
adaptor
g. Wheel arch
extension

3-27
Removal
Cut and pry off rear side outer panel.

Check the rear combination adaptor position for damage and if necessary, replace the rear combination adopter and rear
gutter as an assembly.
1. REAR INNER PANEL
2. REAR DAMPER
STIFFENER
3. PARCEL SHELF
4. INNER PANEL
EXTENSION
5. REAR FLOOR
6. REAR GUTTER
7. REAR PANEL
8. REAR COMBINATION
ADAPTOR
9. OUTER PANEL

3-28
Installation
1. 1. Set the new repair part (outer panel and rear Weld the rear combination adaptor and rear
combination adaptor and into position and clamp panel.
them. Check the body dimensions (see section 4).
3. Temporarily install the door, rear window, trunk lid
and rear bumper and check for difference in level
and clearance.
Attach the patch at the cut section of the rear
pillar and plug weld it.
1. 1. REAR COMBINATION ADAPTOR
2. 1. OUTER PANEL
2. PARCEL SHELF
3. REAR GUTTER
4. Butt welding
5. NEW OUTER PANEL
6. Fillet welding
7. Overlap
30 mm (1.2 in.)

8. PATCH

Index - Rear Panel
3-29
Rear Panel
a. a. Rear panel side

stiffener
b. Rear combination
adaptor
c. Trunk
compartment
side:
d. Rear panel
e. Jack-up stiffener
f. 4-Plate welding

4-door Replacement
4-door Replacement
*Front Bulkhead
Mass Production Body Welding Diagram 3-4
Removal 3-5
Installation 3-5
*Front Wheelhouse/Damper Housing

Removal 3-7
Installation 3-9
*Front Side Frame Outrigger

Removal 3-12
Installation 3-14
*Front Pillar Outer Panel

Removal 3-17
Installation 3-18
*Side Sill Outer Panel

Removal 3-20
Installation 3-21
Roof Panel
Removal 3-24
Installation 3-25

Mass Production Body Diagram 3-26
Removal 3-27
Installation 3-28
Rear Panel
Removal 3-30
Installation 3-31
Rear Floor
Removal 3-33
Installation 3-34
Items marked with and asterisk (*) include SRS components; special caution is required when servicing.

4-door Replacement

Index - Rear Panel
3-30
Rear Panel
Removal
Cut and pry off the rear panel.

NOTE: When removing the rear panel side stiffener attached to the rear combination adaptor, if possible.
Check the rear combination adaptor position and for damage and if necessary, remove the rear panel side stiffener, and
replace the rear combination adaptor and rear gutter as an assembly.
1. REAR PANEL SIDE
STIFFENER
2. REAR COMBINATION
ADAPTOR
3. REAR PANEL
4. REAR PANEL GUSSET
6. REAR FLOOR
7. REAR PANEL
8. REAR PANEL SIDE
STIFFENER
9. REAR COMBINATION
ADAPTOR

Index - Rear Panel
3-31
Rear Panel
Installation
1. 1. Set the new rear panel and rear combination In the case of leave the rear panel side
adaptor into position and clamp them. stiffener and rear combination adopter and
Check the body dimensions (see section 4). 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.
2. 1. NEW REAR COMBINATION ADAPTOR

2. NEW REAR PANEL 1. 1. REAR COMBINATION ADAPTOR
2. REAR PANEL SIDE STIFFENER
3. 2. Tack weld the clamped position. 3. REAR PANEL SIDE LOWER STIFFENER
3. Temporarily install the trunk lid, tailgate, rear (New Part)
bumper and check for difference in level and
clearance. Check for operation of the truck lid. Weld the rear panel and rear floor.
Weld the rear combination adaptor, rear
gutter, outer panel and rear panel.
2. 1. NEW REAR PANEL
4. 1. OUTER PANEL
2. NEW REAR GUTTER
3. NEW REAR COMBINATION ADAPTOR
4. NEW REAR PANEL

Index - Rear Floor
3-32
Rear Floor
a. a. Rear floor cross-

member
b. Rear floor
c. Rear panel
gusset
d. Rear frame A
e. Rear frame B
f. Rear floor
g. Include (A)

Index - Rear Floor
3-33
Rear Floor
Removal
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 CROSS-
MEMBER
2. REAR FLOOR
3. Cut line
MEMBER
5. REAR FLOOR
MEMBER
7. REAR FRAME A
8. VIEW (Z)
9. REAR FRAME B
10. REAR FRAME A
11. REAR FRAME B

Index - Rear Floor
3-34
Rear Floor
Installation
1. 1. Set the new rear cross-member and rear frame 1. 8. Set the new rear floor, and plug weld the rear
B, into position. floor cross-member, rear frame B and rear
2. Check the body dimensions (see section 4). frame A.
3. Tack weld the rear cross-member and rear
frame B.
4. 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.).
2. 1. REAR FRAME A
2. REAR FLOOR CROSS-MEMBER
3. REAR FRAME B
4. REAR FRAME A
2. 1. NEW REAR FLOOR 3. 9. Perform the main welding to the rear floor.
2. Overlap
40 mm (1.6 in.)
3. NEW REAR FLOOR
5. REAR FLOOR
(body side)
3. 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.
4. 1. Filler welding

Index - Rear Floor
4. 1. REAR FLOOR CROSS MEMBER

5-door Replacement
5-door Replacement
*Front Bulkhead
Removal 3-37
Installation 3-37
*Front Wheelhouse/Damper Housing

Mass production Body Welding Diagram 3-38
Removal 3-39
Installation 3-41
*Front Side Frame/Outrigger

Removal 3-44
Installation 3-46
*Front Pillar Outer Panel

Removal 3-49
Installation 3-50
*Side Sill Outer Panel

Removal 3-52
Installation 3-53
Roof Panel
Removal 3-56
Installation 3-57

Removal 3-59
Installation 3-60
Rear Panel
Removal 3-62
Installation 3-62
Rear Floor
Removal 3-64
Installation 3-65
Items marked with an asterisk (*) include SRS components; special caution is required when servicing.

5-door Replacement

3-36
Front Bulkhead
a. 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

3-37 Installation
Front Bulkhead
Removal
1. 1. Set the new front bulkhead into position and

Check the body dimension (see section 4).

2. BULKHEAD SIDE
3. WHEELHOUSE UPPER EXTENSION
4. FRONT WHEELHOUSE
5. FRONT SIDE FRAME

4. BULKHEAD SIDE
5. FRONT SIDE FRAME
7. FRONT WHEELHOUSE


9. FRONT SIDE FRAME

Front/Wheelhouse/Damper Housing
3-38

b. Engine mount bracket
dashboard upper
c. Damper housing extension
d. Wheelhouse upper
extension
e. Wheelhouse upper member
f. Dashboard upper side
member
g. Front wheelhouse
Wheelhouse upper member removed:

VIEW (Z)
a. a. Front wheelhouse
b. Dashboard upper
side member
c. Wheelhouse
upper extension
d. Damper housing
extension
e. Damper housing
f. Front side frame

a. a. Wheelhouse upper member

VIEW (X)

3-39
Removal
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. DAMPER HOUSING
2. WHEELHOUSE UPPER
EXTENSION
EXTENSION
Reused.

3-40
Removal (cont'd)
Replace the wheelhouse upper extension, damper housing extension as an assembly.

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

3-41
Installation
1. 1. Set the new damper housing assembly, front From passenger compartment side, plug weld
wheelhouse and front bulkhead into position the holes in the dashboard lower damper
and measure the front compartment diagonally. housing extension and wheelhouse upper
Check the body dimensions (see section 4). extension.
3. Temporarily install the front sub-frame and
headlight and front bumper, and check for
differences in level and clearance. Make sure
the lines flow smoothly.
Weld the damper housing and front side
frame.
Weld the front damper extension and
dashboard upper side member.
1. 1. WHEELHOUSE UPPER EXTENSION

2. DAMPER HOUSING EXTENSION
Weld the dashboard upper and damper

housing.
2. 1. DASHBOARD UPPER

2. DASHBOARD UPPER SIDE MEMBER
3. FRONT SIDE FRAME
4. DAMPER HOUSING

3-42
Weld the front wheelhouse, damper housing

3. FRONT WHEELHOUSE
4. ENGINE MOUNT BRACKET
Weld the wheelhouse upper member.

When replacing the front wheelhouse only, butt
weld the wheelhouse upper member.

2. WHEELHOUSE UPPER MEMBER EXTENSION
3. Butt welding

3-43

b. Sub-frame rear
bracket
c. 4-Plate welding
d. Side frame
extension rear
e. Inside sill
extension
f. Outrigger
g. Side frame
bulkhead rear
h. 4-Plate welding
inside sill
extension
i. Side frame
extension rear
j. Side frame
bulkhead rear
and front side
frame bulkhead
rear and front
side frame
k. Engine mount
bracket
a. a. Inside sill extension
VIEW (Y)

3-44
Removal

1. FRONT SIDE FRAME
2. DAMPER HOUSING
3. FRONT WHEELHOUSE
4. FRONT SIDE FRAME
5. ENGINE MOUNT
BRACKET
6. SIDE FRAME
BULKHEAD REAR
7. FRONT SIDE FRAME
8. FRONT SUB-FRAME
STAY
9. FRONT SIDE FRAME
10. SIDE FRAME
EXTENSION REAR
11. SIDE FRAME
BULKHEAD REAR
12. SIDE FRAME
BULKHEAD REAR
13. SIDE FRAME
EXTENSION REAR

3-45
Removal (cont'd)
Check the side frame bulkhead rear for position and damage. If Necessary replace it.
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.
1. OUTRIGGER
2. SUB-FRAME REAR
BRACKET
3. SIDE FRAME
EXTENSION REAR
4. OUTRIGGER
5. INSIDE SILL
EXTENSION
6. FLOOR FRAME
7. SIDE FRAME
EXTENSION REAR
8. SUB-FRAME REAR
BRACKET

3-46
Installation
1. 1. Tack weld the new side frame bulkhead rear to

the side frame extension rear.
Plug weld the inside sill extension and floor

2. 1. SIDE FRAME BULKHEAD REAR frame.
3. 2. Set the new front, side frame extension rear,
outrigger and front bulkhead into position and
4. Temporarily install the front sub-frame and
difference in level and clearance.
Plug weld the side frame extension rear,
side frame bulkhead rear and front side
frame.
1. 1. INSIDE SILL EXTENSION
2. FLOOR FRAME
From passenger compartment, plug weld the

dashboard lower and front floor.

2. FRONT SIDE FRAME
2. 1. OUTRIGGER


3-47
Weld the damper housing, front wheelhouse

2. FRONT WHEELHOUSE

3-48
a. Wheelhouse upper
member (see page
3-38)
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

3-49
Removal
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.
STIFFENER
STIFFENER
3. OUTER PANEL
5. FRONT PILLAR SEPARATOR
6. INNER LOWER
STIFFENER
STIFFENER

3-50
Installation
1. 1. Glue the insulator to the inner lower at the front 1. 6. Clamp the repair part and recheck the
pillar lower separator mounted position. clearance and alignment of the front door, front
Insulator: P/N. 74416-SF1-000 fender and windshield.
Adhesive: Cemedine 366 or equivalent 7. Perform the main welding:
Attach the patch at the cut the section of the
front pillar outer panel and plug weld it.
2. 1. INNER LOWER
2. INSULATOR
3. 2. Set the new front pillar lower stiffener into

position and tack weld the clamped position.
position. Clamp the repair part and check the
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 2. 1. Butt welding
reinforcement. 2. PATCH
3. OUTER PANEL
4. Fillet welding
5. Overlap
30 mm (1.2 in)
3. 8. Weld the wheelhouse upper member.
4. 1. FRONT PILLAR UPPER STIFFENER 4. 1. WHEELHOUSE UPPER MEMBER EXTENSION

2. FRONT PILLAR LOWER STIFFENER 2. WHEELHOUSE UPPER MEMBER
3. INSULATOR

3-51
a. 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

3-52
Removal
Cut and pry off the side sill outer panel.

Check the centre pillar stiffener and side sill reinforcement position and for damage and if necessary, replace them.
When removing the center pillar stiffener, do not cut the centre stiffener reinforcement; the centre pillar stiffener
reinforcements is part of the centre pillar stiffener.
When replacing the centre pillar stiffener, remove the centre pillar separator and glue the insulator at the separator
mounted position.
1. Outer panel cut line.
2. Centre pillar stiffener
cut line.
3. CENTRE INNER
PILLAR
4. SIDE SILL
REINFORCEMENT
5. VIEW (Z)
6. INSIDE SILL
7. CENTRE PILLAR
STIFFENER
8. CENTRE PILLAR
SEPARATOR
9. SIDE SILL
REINFORCEMENT
10. OUTER PANEL
11. CENTRE PILLAR
STIFFENER
REINFORCEMENT

3-53
Installation
1. 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
1. 1. NEW SIDE SILL REINFORCEMENT

2. INSIDE SILL
3. CENTRE INNER PILLAR
NOTE: Replace the drive side of the side sill

2. 1. CENTRE INNER PILLAR reinforcement with the assembly without cutting the side
2. INSULATOR
sill reinforcement halfway, because there is reinforcement
3. 2. Cut and set the new centre pillar stiffener and stiffener inside of the side sill reinforcement. Therefore,
side sill reinforcement into position and tack weld cut the outer panel to under of the front pillar.
the clamped position.
position. Clamp the repair part and check the
4. Temporarily install the front door, rear door and
front fender and check for differences in level
and clearance.
5. Remove the repair part and weld the centre
pillar lower stiffener and side sill reinforcement.
2. 1. FRONT PILLAR OUTER PANEL

2. OUTER PANEL
4. INSIDE SILL
5. REINFORCEMENT STIFFENER
4. 1. NEW CENTRE PILLAR STIFFENER

Filler welding

Overlap
2. 20 mm (0.8 in.)
3. NEW SIDE SILL REINFORCEMENT
4. Fillet welding
Overlap
20 mm (0.8 in.)

3-54
1. 6. Clamp the repair part and recheck the clearance

alignment of the front door, rear door and front
fender.
Attach the patches at the cut section of the
center pillar and wheel arch and plug weld
them.
2. 1. Butt welding
2. PATCH
3. PATCH
4. Butt welding
5. Overlap
30 mm (1.2 in.)
6. Fillet welding

Index - Roof Panel
3-55
Roof Panel
Without roof panel:

a. Front inner upper pillar
b. Front roof rail
c. Rear roof rail
d. Roof panel
e. Rear Pillar upper gutter
f. Rear inner panel
g. Rear roof side rail
h. Outer panel
i. Front roof side rail

Index - Roof Panel
3-56
Roof Panel
Removal
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
PILLAR
PILLAR

Index - Roof Panel
3-57
Roof Panel
Installation
1. 1. Set the new roof panel into position and clamp 1. 5. From inside the vehicle, plug weld the front
it. pillar inner upper, rear inner panel and front and
Check the body dimensions (see section 4), rear roof rail.
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.
VIEW (Z) 2. 1. FRONT INNER UPPER PILLAR

2. FRONT ROOF RAIL
1. 1. OUTER PANEL 3. REAR INNER PANEL
2. ROOF PANEL 4. REAR ROOF RAIL
3. ROOF SIDE RAIL
3. 6. Weld the roof panel and rear pillar gutter upper.
4. 1. REAR PILLAR GUTTER UPPER
2. 1. ROOF ARCH GUSSET

3-58
a. a. Quarter pillar
inner
b. Rear pillar inner
c. Rear panel
d. Rear pillar gutter
lower
e. Rear inner panel
f. Rear pillar gutter
upper
g. Rear gutter lower
stiffener
h. Rear pillar gutter
lower
i. Rear pillar lower
and Rear panel
j. VIEW (Z)
k. Wheelarch
extension

3-59
Removal
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. WHEEL ARCH
EXTENSION
2. QUARTER PILLAR
INNER
3. REAR PILLAR INNER
4. REAR PILLAR
GUTTER UPPER
5. REAR PILLAR
GUTTER LOWER
6. REAR INNER PANEL
7. REAR PILLAR
GUTTER LOWER
8. REAR PANEL
9. REAR PILLAR
GUTTER UPPER
11. VIEW (Z)
12. REAR GUTTER
LOWER STIFFENER
13. OUTER PANEL

Rear Side outer Panel
3-60
Rear Side outer Panel
Installation
1. 1. Set the new repair part (outer panel) and rear Weld the rear pillar gutter lower, gutter upper
pillar gutter lower and into position and clamp and rear panel.
them.
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.
Attach the patch at the cut section of the
quarter pillar, rear pillar and plug weld them.
1. 1. REAR GUTTER LOWER STIFFENER

2. REAR PILLAR GUTTER LOWER
2. 1. Butt welding
2. Butt welding
3. PATCH
4. NEW OUTER PANEL
5. Overlap
30 mm (1.2 in.)
Fillet welding
6. PATCH

Index - Rear Panel
3-61
Rear Panel
a. a. Rear pillar gutter

lower
b. Rear gutter lower
stiffener
c. Rear panel
d. Rear panel
e. Jack-up stiffener
f. Rear pillar gutter
lower

Index - Rear Panel
3-62 Installation
Rear Panel
Removal
Cut and pry off the rear panel. 1. 1. Set the new rear panel and check the body
Check the rear pillar gutter lower position and dimensions (see section 4).
for damage and if necessary, replace it (see 2. Tack weld the clamped position.
page 3-59). 3. Temporarily install the tailgate, tailgate, rear
bumper and check for differences in level and
clearance. Check operation of the tailgate.
2. 1. REAR PANEL
2. REAP PILLAR GUTTER LOWER
1. 1. REAR PANEL
2. REAR GUTTER LOWER STIFFENER
3. REAR PANEL
4. REAR FLOOR
5. JACK-UP STIFFENER
6. REAR PILLAR GUTTER LOWER

Index - Rear Floor
3-63
Rear Floor
a. a. Rear floor
b. Rear panel gusset
c. Rear frame B
d. Rear floor
e. Rear floor cross-member
f. Rear frame
g. Rear frame A
h. Rear floor cross-member

Index - Rear Floor
3-64
Rear Floor
Removal
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.
MEMBER
2. REAR FLOOR
3. Cut line
MEMBER
5. REAR FLOOR
MEMBER
7. REAR FRAME A
8. VIEW (Z)
9. REAR FRAME B
10. REAR FRAME A
11. REAR FRAME B

Index - Rear Floor
3-65
Rear Floor
Installation
1. 1. Set the new rear cross-member and rear frame 1. 8. Set the new rear floor and plug weld the rear
B, into position. floor cross-member, rear frame B and rear
2. Check the body dimensions (see section 4). frame A.
3. Tack weld the rear cross-member and rear
frame B.
4. 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.).
2. 1. NEW REAR FLOOR 2. 1. REAR FRAME A

2. Overlap 2. REAR FLOOR CROSS-MEMBER
40 mm (1.6 in.) 3. REAR FRAME B
3. NEW REAR FLOOR 4. REAR FRAME A
4. REAR CROSS-MEMBER 5. REAR FLOOR CROSS-MEMBER
5. REAR FLOOR
(body side) 3. 9. Perform the main welding to the rear floor.
3. 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.

Index - Rear Floor
4. 1. REAR FLOOR CROSS MEMBER

Index - Index
Index
4-door Body Dimensional Drawings 4-3

5-door Body Dimensional Drawings 4-13

4-door Body Dimensional Drawings
Upper Body Measuring Dimensions

Engine Compartment 4-4
Engine/Transmission Mount Positions and 4-5
Passenger Compartment
Under Body Measuring Dimensions

Engine Compartment and Front Floor Under 4-6
View
Middle and Rear Floor Under View 4-7
Frame Repair Chart

Top View 4-8
Side View 4-10
Opening Repair Chart 4-12

Index - Upper Body Measuring Dimensions
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)

Passenger
4-5 Compartment
Engine/Transmission Mount Positions
Unit: mm (in.) Unit: mm (in.)
1. 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:
Honda Multi Matic:
1. 1. K, k

Front Seat Rear Side Bracket Point 9 (0.35)

2. L, l
Rear Damper Mount Hole 11 (0.43)

Index - Under Body Measuring Dimensions
4-6
Engine Compartment and Front Floor Under View
Unit: mm (in.)
1. A, a
Radiator Mount Hole 15
(0.59)
2. B, b
Front Sub-frame Mount
3. C, c
Hole 15 (0.59)
Rearward
4. D, d
Front Floor Frame Point
20 (0.79)

Index - Under Body Measuring Dimensions
4-7
Middle and Rear Floor Under View
Unit: mm (in.)
1. D,d
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)

Index - Frame Repair Chart
4-8
Frame Repair Chart
Top View
Unit: mm (in.) a For sub-frame o15 (0.59) e For damper mount o 11.5 (0.45)
ø: Inner diameter b1 For engine mount o13 (0.51) f Damper centre o 78 (3.07)
b2 For engine mount o 13 (0.51) g For damper mount o 11.5 (0.45)
b3 For engine mount o 13 (0.51) h For damper mount o 11.5 (0.45)
c1 For transmission mount o13 (0.51) I For sub-frame o 11.5 (0.45)
c2 For transmission mount o13 (0.51) j For sub-frame o 11.5 (0.45)
c3 For transmission mount o13 (0.51) k Locate hole o 25 (0.98)
d1 For transmission mount o13 (0.51) l Locate hole o 50 (1.97)
d2 For transmission mount o13 (0.51)
d3 For transmission mount o13 (0.51)


4-9
Frame Repair Chart
Top View (cont'd)
m Locate hole o 25 (0.98) u For upper arm bracket center o 15 (0.59)

n For trailing arm o 13 (0.51) v1, v2 Locate hole o 13 (0.51)
o Locate hole o 25 (0.98) w For upper arm o 13 (0.51)
p Locate hole o 20 (0.79) x For rear lower arm centre
q Trailing arm centre y Locate hole o 50 (1.97)
r Rear damper center 73 x 68 (slot) z Locate hole o 20 (0.79)
s For upper arm o 13 (0.51)
t For trailing arm o 13 (0.51)

4-10
Frame Repair Chart
Side View
Unit: mm (in.) a For sub-frame o 15 (0.59) e For damper mount o 11.5 (0.45)
o: Inner diameter
b1 For engine mount o 13 (0.51) f Damper centre o 78 (3.07)
b3 For engine mount o 13 (0.51) h For damper mount o 11.5 (0.45)
c1 For transmission mount o 13 (0.51) I For sub-frame o 11.5 (0.45)
c2 For transmission mount o 13 (0.51) j For sub-frame o 11.5 (0.45)
c3 For transmission mount o 13 (0.51) k Locate hole o 25 (0.98)
d1 For transmission mount o 13 (0.51) l Locate hole o 50 (1.97)
d2 For transmission mount o 13 (0.51)
d3 For transmission mount o 13 (0.51)


4-11
Frame Repair Chart
Side View (cont'd)
m Locate hole o 25 (0.98) u For upper arm bracket center o15 (0.59)
n For trailing arm o 13 (0.51) v1, v2 Locate hole o 13 (0.51)
o Locate hole o 25 (0.98) w For upper arm o 13 (0.51)
p Locate hole o 20 (0.79) x For rear lower arm centre
q Trailing arm centre y Locate hole o 50 (1.97)
r Rear damper center 73 x 68 (slot) z Locate hole o 20 (0.79)
s For upper arm o 13 (0.51)
t For trailing arm o 13 (0.51)

Index - Opening Repair Chart
4-12
Opening Repair Chart
Door and Windshield Openings:

Unit: mm (in.)
1. 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)
Rear Window and Trunk Lip Openings:
2. 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


Engine Compartment 4-14
Engine/Transmission Mount Positions and 4-15
Passenger Compartment

Engine Compartment and Front Floor Under 4-16
View
Middle and Rear Floor Under View 4-17
Frame Repair Chart

Top View 4-18
Side View 4-20
Opening Repair Chart 4-22

4-14
Engine Compartment
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
6. B, b
Headlight Mount Hole 7
(0.3)
7. A, a
Bulkhead Upper Frame
Point 15 (0.59)

4-15 Passenger Compartment

Engine/Transmission Mount Positions
Unit: mm (in.) Unit: mm (in.)
1. 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. 1. J, j
Front seat Rear Side Bracket Point 9 (0.35)
2. K, k
Rear Damper Mount hole 11 (0.43)

4-16
Engine Compartment and Front Under View
Unit: mm (in.)
1. A, a
Radiator Mount Hole 15
(0.59)
2. B, b
3. C, c
Hole 15 (0.59)
Rearward
4. D, d
20 (0.79)

4-17
Middle and Rear Floor Under View
1. D, d
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)

4-18
Frame Repair Chart
Top View
Unit: mm (in.) a For sub-frame o 15 (0.59) e Damper centre o 78 (3.07)

ø: Inner diameter b1 For engine mount o 13 (0.51) f For damper mount o 11.5 (0.45)
b3 For engine mount o 13 (0.51) h For sub-frame o 11.5 (0.45)
c2 For transmission mount o 13 (0.51) j Locate hole o 25 (0.98)
d For damper mount o 11.5 (0.45)

4-19
Frame Repair Chart
Top View (cont'd)
l Locate hole o 25 (0.98) t For upper arm bracket center o 15 (0.59)

m For trailing arm o 13 (0.51) u1, u2 Locate hole o 13 (0.51)
n Locate hole o 25 (0.98) v For upper arm o 13 (0.51)
o Locate hole o 20 (0.79) w Locate hole o 25 (0.98)
p Trailing arm centre x For rear lower arm centre
q Rear damper center 73 x 68 (slot) y Locate hole o 50 (1.97)
r For upper arm o 13 (0.51) z Locate hole o 20 (0.79)
s For trailing arm o 13 (0.51)

4-20
Frame Repair Chart
Side View
Unit: mm (in.) a For sub-frame o 15 (0.59) e Damper centre o 78 (3.07)

ø: Inner diameter b1 For engine mount o 13 (0.51) f For damper mount o 11.5 (0.45)
b3 For engine mount o 13 (0.51) h For sub-frame o 11.5 (0.45)
c2 For transmission mount o 13 (0.51) j Locate hole o 25 (0.98)
d For damper mount o 11.5 (0.45)

4-21
Frame Repair Chart
Side View (cont'd)
l Locate hole o 25 (0.98) t For upper arm bracket center o 15 (0.59)

m For trailing arm o 13 (0.51) u1, u2 Locate hole o 13 (0.51)
n Locate hole o 25 (0.98) v For upper arm o 13 (0.51)
o Locate hole o 20 (0.79) w Locate hole o 13 (0.51)
p Trailing arm centre x For rear lower arm centre
q Rear damper center 73 x 68 (slot) y Locate hole o 50 (1.97)
r For upper arm o 13 (0.51) z Locate hole o 20 (0.79)
s For trailing arm o 13 (0.51)

4-22
Opening Repair Chart
Door and Windshield Openings:

Unit: mm (in.)
1. 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:
2. 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-door Rust Prevention 5-17

4-door Rust Prevention
Cross Section of Body and Sealants

General 5-4
Engine Compartment, Front Wheelhouse and 5-5
Damper Housing
Dashboard Upper, Dashboard Lower and Roof 5-6
Panel
Front Floor and Rear Floor 5-7
Rear Side Outer Panel and Rear Panel 5-8
Under Floor 5-9
Soft Chipping Guard Primer Coat

General 5-10
Coating Diagram 5-11
Rust-preventive Treatments
General 5-12
Undercoating Diagram 5-13
Area to be Covered by Anti-rust Agents 5-14
Materials and Tools 5-15

Index - Cross Section of Body and Sealants
5-4
General
NOTE: Following the sealer manufacturer's instructions. 1. 5. Apply sealer on any area that the replacement
part will cover. Smooth the sealer with a brush
1. 1. Clean the areas to be sealed with the white
is necessary.
gasoline.
2. Wipe off any excess spot sealer with thinner.
After the primer is sprayed, sealer will fill to the
area where spot sealer was wiped off.
3. Make sure you can see the sealant when the
sealed part is in its proper location. See page
5-5 to page 5-9 of this manual.
2. 4. Finish sealing the engine compartment, the

door opening, the truck gutter and the tailgate
gutter. Wipe of the excess sealer.

5-5
Engine Compartment, Front Wheelhouse and
Damper Housing
1. Bulkhead Upper Frame

2. Fender Bracket
3. Damper Housing
4. Front Damper
Extension
5. Front Damper Base
6. Front Damper
Extension
9. Dashboard Upper
10. Steering Joint Cover
11. Dashboard Lower
12. Dash Board Lower
Extension
13. Dashboard Lower
14. Windshield Lower
15. Outer Panel
16. Front Pillar Inner Upper
17. Dashboard Upper
18. Inner Lower
19. Outer Panel
20. Front Pillar Lower
Stiffener
21. Outrigger
22. Side Sill Extension
23. Outer Panel
24. Dashboard Lower
25. Dashboard Extension
26. VIEW (Z)
27. Damper Housing
28. Front Damper
Extension
30. Front Damper Housing
Extension
31. Dashboard Lower
32. Front Side Frame
33. Front Side Back Plate
34. Damper Housing

5-6
Dashboard Upper, Dashboard Lower and Roof
Panel
1. Dashboard Upper
2. Windshield Lower
3. Dashboard Lower
4. Front Pillar Inner Lower
5. Dashboard Lower
Extension
7. Front Side Outrigger
8. Front Pillar Inner Upper
11. Dashboard Lower
12. From Floor
13. Floor Cap
14. VIEW (Z)
15. Dashboard Upper
16. Dashboard Lower
17. Outer Panel
18. Roof Panel
19. Front Pillar Inner Lower
20. Dashboard Upper
21. Dashboard Lower
22. Front Floor
23. Dashboard Lower
Extension
24. Floor Cap
25. Inner Lower Extension
26. Dashboard Upper

5-7
Front Floor and Rear Floor
1. Front Floor
2. Inside Sill
3. Outer Panel
5. Inside Sill
6. Middle Floor Cross-
member Stiffener
8. Rear Frame
9. Rear Floor
10. Wheelhouse
11. Rear Panel
12. Rear Floor
13. Rear Floor
14. Rear Panel
15. Jack Up Stiffener
16. Rear Panel
17. Outer Panel
18. Rear Floor
19. Floor Cap
20. Front Floor
21. Floor Cap
member
23. Rear Floor
member
member
26. Front Floor
member Stiffener
member
29. Front Floor
member Stiffener
31. Floor Cap
32. Front Floor

5-8
Rear Side Outer Panel and Rear Panel
1. Rear Floor
2. Wheelhouse
3. Outer Panel
4. Rear Floor Outer Panel
5. Outer Panel
6. Parcel Shelf
7. VIEW (Z)
8. Outer Panel
9. Rear Gutter
10. Outer Panel
11. Rear Panel
12. Rear Gutter
13. Combination Adaptor
15. Rear Panel
16. VIEW (X)
18. Rear Panel
19. Outer Panel
21. Outer Panel
24. Side Sill Extension End
Flange
25. Outer Panel
26. Wheel Arch Extension
28. End Flange
29. Outer Panel
30. Fuel Door Adaptor
31. Outer Panel
32. Rear Inner
33. Outer Panel
34. Rear Inner

5-9
Under Floor
1. Wheelhouse Stiffener
2. Damper Base
3. Rear Inner Panel
5. Inner Panel
6. Wheelhouse
7. Outer Panel
9. Rear Wheelhouse
10. Upper Arm Bracket
11. Rear Frame
12. Damper Base
13. Rear Frame
14. Damper Base
16. VIEW (X)
17. Lower Arm Bracket B
18. Lower Arm Bracket A
19. Rear Floor Cross-
member
20. Rear Floor
21. VIEW (Z)
member
25. Rear Floor
26. Front Floor
27. Front Floor Centre
Cross-member
(A): No need seal areas.

(B): No need seal areas.
30 mm (1.2 in.)

Index - Soft Chipping Guard Primer Coat
5-10
General
The removal of paint and undercoating by stones chips 1. 2. Air blowing/degreasing

immediately exposes metal to the atmosphere, causing Use alcohol, wax and grease remover.
it to oxidise. The thickness of this oxidation increases if 3. Making
the process continues unchecked. The soft chipping Use masking tape and paper.
guard primer protects against damage due to the 4. Spraying primer surface
impact of such objects. Spray 4~5 coats to get 20 microns of
Sectional View of Paint Coats: thickness.
Top coat One coat deposits 5~7 microns
Do not try to cover the surface with one heavy
Intermediate coat
coat.
+
Apply several thin coats.
Chipping guard primer
Use a 2-part urethane primer surface
Electrodeposition of primer and a spray gun.
Base metal Mix the primer surface with the
additive and solvent, and in the
The soft chipping guard primer coat is applied correct ratio.
over the E.D. (Electrostatically Despotised) Follow the primer surface
primer. It is followed by guide coating and top manufacturer's instructions.
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:
Soft chipping guard primer coat is then
applied to the most susceptible area (see
page 5-11).
Spray the primer surface (2-part urethane
primer surface) on the soft chipping guard
primer coating areas when you replaced parts 2. 5. Drying
using soft chipping guard primer coat. After spraying primer surface, allow 7~10 minutes
of drying time, then force dry it with infrared lamps
WARNING or an industrial dryer.
Wear goggles or safety glasses to 6. Polishing
prevent eye injury. Check the primer surface has dried thoroughly,
Ventilate when spraying undercoat. then sand the primer surface.
1. 1. Sanding the replacement part. Use a double action sander and #400~#600
NOTE: disc sandpaper.
Do not oversand the edges or corners of 7. Intermediate coating and top coating
the part. Refer to pages 6-8 to 6-10 of this manual for the
Do not expose base metal. painting procedure.
Use a double action sander and #400 disc
sandpaper.

5-11
Coating Diagram
Indicates chipping guard primer coating area.

NOTE: Make sure to coat the flange on front wheel arch.
Unit: mm (in.)
1. HOOD SKIN
2. OUTER PANEL
3. INNER PANEL
4. OUTER PANEL
5. FRONT FENDER
6. FRONT FENDER

Index - Rust-preventive Treatments
5-12
General
Undercoat: Anti-rust Agents:
WARNING WARNING
Wear goggles or safety glasses to Anti-rust agents contain substances
prevent eye injury. that are harmful if you breathe or
Ventilate when spraying undercoat. swallow them, or get them on your
NOTE: skin. Wear overalls, gloves, eye
protection and an aspproved
Mask the exhaust system, oxygen sensors and
respirator while using such agents.
suspension mount area to prevent overspread
Ventilate when spraying an anti-rust
from the undercoat.
agent since it contains a small
Follow the undercoating manufacturer's
amount of organic solvent. Keep
instructions.
sparks, flames and cigarettes away.
1. 1. Clean the body with wax and grease remover
before the undercoat is sprayed. NOTE:
2. Apply the undercoat to the front wheelhouse, Do not spray an anti-rust agent on the brake
rear wheelhouse and undersides of the front system, exhaust system and its related parts,
floor and rear floor (see page 5-13). emission control devices in the engine
3. Coat the bottom of the fuel tank. 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. 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 anti-
rust agent sufficiently unit the excess amount
oozes out when filling the side sill.

5-13
Undercoating Diagram
Indicated PVC coating area.

NOTE:
Coating thickness 0.4mm (0.16 in.) MIN.
Front wheelhouse, rear wheelhouse and dashboard lower on the imported control area, and coating thickness 0.5 mm
(0.2 in.).
1. FRONT SIDE DAMPER
2. DAMPER HOUSING
3. OUTER PANEL
4. FRONT FLOOR
CENTRE CROSS-
MEMBER
SECTION AA SECTION BB SECTION CC SECTION DD
SECTION EE
1. Dashboard Lower
2. Front Floor
3. Middle Floor Cross-member
4. Rear Floor
5. Rear Floor Cross-member
SECTION FF
1. <Front Wheelhouse>
2. <Rear Wheelhouse>
3. OUTER PANEL
4. FUEL DOOR
ADAPTOR SECTION
5. FUEL DOOR
ADAPTOR
6. No Coating Area.
VIEW (Z)

Index - Rust-prevention Treatments
5-14
Rust-prevention Treatments
Area to be Covered by Anti-rust Agents
Indicates anti-rust agents.

1. HOOD FRAME (inside)
2. HOOD HINGE
3. MIDDLE FLOOR
CROSS-MEMBER
(inside)
4. REAR FRAME (inside)
5. TRUNK LID FRAME
(inside)
MEMBER (inside)
(inside)
8. FUEL DOOR (inside)
9. REAR WHEEL ARCH
(inside)
10. SIDE SILL (inside)
11. REAR DOOR PANEL
(inside)
12. DOOR HINGE
13. FRONT DOOR PANEL
(inside)
14. DOOR HINGE
15. FRONT FENDER
(inside)
16. WHEELHOUSE UPPER
MEMBER (inside)
17. OUTRIGGER (inside)
18. FRONT LOWER
CROSS-MEMBER
(inside)
19. SUB-FRAME REAR
BRACKET (inside)
(inside)
21. DASHBOARD UPPER
22. FLOOR FRAME (inside)
23. FLOOR CENTRE
FRAME (inside)

Index - Materials and Tools
5-15
Materials and Tools
SEALER SPRAY GUNS

Use urethane sealer. Use the correct gun toe the agent being
3m #08892 (internal) used.
3m #08893 (external) Use of a pressure type spray gun is
or equivalents. recommended when work involves a
TOOLS considerable number of vehicles.
For nox-rust 409-20S/solton
Cartridge type Tube type
1000S
Sealing gun
For rustop
UNDERCOAT
To be applied to under-floor and wheelhouse.
Nox-rust 409-20S
Solton 1000S
or equivalent.
For deox #100
ANTI-RUST AGENT
For waxoyl
To be applied to weld joints inside the body panel.
Rustop
Deox #100
Waxoyl
or equivalent.


General 5-18
Engine Compartment, Front Wheelhouse and 5-19
Damper Housing
Dashboard Upper, Dashboard Lower and Roof 5-20
Panel
Front Floor and Rear Floor 5-21
Rear Side Outer Panel and Rear Panel 5-22
Under Floor 5-23

General 5-24
Coating Diagram 5-25
General 5-26
Undercoating Diagram 5-27
Area to be Covered by Anti-rust Agents 5-28
Materials and Tools 5-29

5-18
General
NOTE: Following the sealer manufacturer's instructions. 1. 5. Apply sealer on any area that the replacement
part will cover. Smooth the sealer with a brush
1. 1. Clean the areas to be sealed with the white
is necessary.
gasoline.
2. Wipe off any excess spot sealer with thinner.
After the primer is sprayed, sealer will fill to the
area where spot sealer was wiped off.
3. Make sure you can see the sealant when the
sealed part is in its proper location. See page
5-19 to page 5-23 of this manual.
2. 4. Finish sealing the engine compartment, the

door opening, the truck gutter and the tailgate
gutter. Wipe of the excess sealer.

5-19
Engine Compartment, Front Wheelhouse and
Damper Housing
1. Bulkhead Upper Frame

2. Fender Bracket
3. Damper Housing
4. Wheelhouse Upper
Extension
6. Wheelhouse Upper
Extension
8. Steering Joint Cover
9. Dashboard Lower
10. Dashboard Lower
11. Dashboard Lower
Extension
13. Outer Panel
14. Inner Lower
15. Dashboard Upper
16. Dashboard Lower
17. Dashboard Lower
extension
19. Inner Lower
20. Dashboard Lower
21. Outer Panel
22. Inner Lower
23. VIEW (Z)
24. Dashboard Lower
25. Dashboard Extension
26. Damper Housing
27. Wheelhouse Upper
Extension
Extension Lower
30. Dashboard Lower
33. Damper Housing

5-20
Dashboard Upper, Dashboard Lower and Roof
Panel
1. Dashboard Upper
2. Windshield Lower
3. Windshield Lower
4. Dashboard Upper
5. Inner Lower
6. Dashboard Lower
7. Dashboard Lower
Extension
9. Outrigger
10. Inner Lower
13. Dashboard Lower
14. VIEW (Z)
15. Dashboard Upper
16. Inner Lower
17. Dashboard Upper
18. Dashboard Lower
19. Outer Panel
20. Roof Panel
21. Front Floor
22. Floor Cap
23. Front Floor
24. Dashboard Lower
25. Dashboard Lower
Extension
26. Floor Cap
27. Side Frame Extension
28. Dashboard Lower
Extension
29. Inner Lower Extension
30. Dashboard Upper

5-21
Front Floor and Rear Floor
1. Front Floor
2. Inside Sill
3. Outer Panel
5. Inside Sill
member Stiffener
8. Rear Frame
9. Rear Floor
10. Wheelhouse
11. Outer Panel
12. Inner Panel
13. Rear Floor
14. Gutter lower
15. Rear Floor
16. Rear Panel
17. Rear Floor
18. Rear Panel
19. Rear Panel
20. Jack-up Stiffener
21. Rear Floor
22. Floor Cap
23. Rear Floor
24. Floor Cap
member Stiffener
26. Rear Floor
member
member
29. Front Floor
member Stiffener
member
32. Front Floor
member
34. Front Floor
35. Floor Cap

5-22
Rear Side Outer Panel and Rear Panel
1. Outer Panel
3. Outer Panel
4. Inner Panel
5. Tailgate Hinge
6. Roof Panel
7. Gutter Upper
8. Gutter Upper
9. Outer Panel
10. Outer Panel
11. Gutter Upper
12. Gutter Upper
13. Gutter Lower
14. Outer Panel
15. Rear Floor
16. Gutter Lower
17. Rear Panel
18. VIEW (Z)
19. Rear Panel
20. Rear Panel Lower
21. Rear Floor
22. Gutter Lower
23. Gutter Lower
24. Outer Panel
26. Side Sill Extension End
Flange
27. Outer Panel
30. End Flange
31. Outer Panel
32. Fuel Door Adaptor
33. Outer Panel
34. Gutter Lower
35. Outer Panel
36. Inner Panel

5-23
Under Floor
2. Damper Base
3. Rear Inner Panel
5. Inner Panel
6. Wheelhouse
7. Outer Panel
9. Rear Wheelhouse
10. Rear Frame
12. Damper Base
13. Rear Frame
14. Damper Base
15. VIEW (X)
member
20. Rear Floor
21. VIEW (Z)
member
25. Rear Floor
26. Front Floor
27. Front Floor Centre
Cross-member
(A): No need seal areas.

(B): No need seal areas.
30 mm (1.2 in.)

5-24
General
The removal of paint and undercoating by stones chips 1. 2. Air blowing/degreasing

immediately exposes metal to the atmosphere, causing Use alcohol, wax and grease remover.
it to oxidise. The thickness of this oxidation increases if 3. Making
the process continues unchecked. The soft chipping Use masking tape and paper.
guard primer protects against damage due to the 4. Spraying primer surface
impact of such objects. Spray 4~5 coats to get 20 microns of thickness.
Sectional View of Paint Coats:
Top coat One coat deposits 5~7 microns
Do not try to cover the surface with one heavy
Intermediate coat
coat.
+
Chipping guard primer
Use a 2-part urethane primer surface
Electrodeposition of primer and a spray gun.
Base metal Mix the primer surface with the
additive and solvent, and in the
The soft chipping guard primer coat is correct ratio.
applied over the E.D. (Electrostatically Follow the primer surface
Despotised) primer. It is followed by guide manufacturer's instructions.
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:
Soft chipping guard primer coat is then
applied to the most susceptible area (see
page 5-25).
Spray the primer surface (2-part urethane
primer surfacer) on the soft chipping guard
primer coating areas when you replaced 2. 5. Drying
parts using soft chipping guard primer coat. After spraying primer surface, allow 7~10 minutes
of drying time, then force dry it with infrared lamps
WARNING or an industrial dryer.
Wear goggles or safety glasses to 6. Polishing
prevent eye injury. Check the primer surface has dried thoroughly,
Ventilate when spraying undercoat. then sand the primer surface.
1. 1. Sanding the replacement part. Use a double action sander and #400~#600
NOTE: disc sandpaper.
7. Intermediate coating and top coating
Do not oversand the edges or cornres of
Refer to pages 6-8 to 6-10 of this manual for the
the part.
painting procedure.
Do not expose base metal.
Use a double action sander and #400 disc
sandpaper.

5-25
Coating Diagram
Indicates chipping guard primer coating area.
NOTE: Make sure to coat the flange on front wheel arch.

Unit: mm (in.)
1. HOOD SKIN
2. OUTER PANEL
3. INNER PANEL
4. OUTER PANEL
5. FRONT FENDER
6. FRONT FENDER

Index - Rust-preventive Treatments
5-26
General
Undercoat: Anti-rust Agents:
WARNING WARNING
Wear goggles or safety glasses to Anti-rust agents contain substances
prevent eye injury. that are harmful if you breathe or
Ventilate when spraying undercoat. swallow them, or get them on your
NOTE: skin. Wear overalls, gloves, eye
protection and an approved respirator
Mask the exhaust system, oxygen sensors and
while using such agents.
suspension mount area to prevent overspread
Ventilate when spraying an anti-rust
from the undercoat.
agent since it contains a small
Follow the undercoating manufacturer's
amount of organic solvent. Keep
instructions.
sparks, flames and cigarettes away.
1. 1. Clean the body with wax and grease remover
before the undercoat is sprayed. NOTE:
2. Apply the undercoat to the front wheelhouse, Do not spray an anti-rust agent on the brake
rear wheelhouse and undersides of the front system, exhaust system and its related parts,
floor and rear floor (see page 5-27). emission control devices in the engine
3. Coat the bottom of the fuel tank. 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. 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 anti-
rust agent sufficiently unit the excess amount
oozes out when filling the side sill.

5-27
Undercoating Diagram
Indicated PVC coating area.

NOTE:
Coating thickness 0.4mm (0.16 in.) MIN.
Front wheelhouse, rear wheelhouse and dashboard lower on the imported control area, and coating thickness 0.5 mm
(0.2 in.).
1. FRONT SIDE DAMPER
2. DAMPER HOUSING
3. OUTER PANEL
4. FRONT FLOOR
CENTRE CROSS-
MEMBER
SECTION AA SECTION BB SECTION CC SECTION DD
SECTION EE
1. Dashboard Lower
2. Front Floor
3. Middle Floor Cross-member
4. Rear Floor Cross-member
SECTION FF
1. <Front Wheelhouse>
2. <Rear Wheelhouse>
3. OUTER PANEL
4. FUEL DOOR
ADAPTOR SECTION
5. FUEL DOOR
ADAPTOR
6. No Coating Area.
VIEW (Z)

Index - Rust-prevention Treatments
5-28
Rust-prevention Treatments
Area to be Covered by Anti-rust Agents
Indicates anti-rust agents.

1. HOOD FRAME (inside)
2. HOOD HINGE
3. FLOOR CENTRE
FRAME (inside)
4. MIDDLE FLOOR
CROSS-MEMBER
(inside)
5. REAR FRAME (inside)
6. TAILGATE FRAME
(inside)
MEMBER (inside)
(inside)
9. FUEL DOOR (inside)
10. SIDE SILL (inside)
11. REAR DOOR PANEL
(inside)
12. DOOR HINGE
13. FRONT DOOR PANEL
(inside)
14. DOOR HINGE
15. FRONT FENDER
(inside)
16. OUTRIGGER (inside)
17. WHEELHOUSE UPPER
MEMBER (inside)
18. FRONT LOWER
CROSS-MEMBER
(inside)
19. SUB-FRAME
BRACKET (inside)
(inside)
21. DASHBOARD FRAME
(inside)
22. FLOOR FRAME (inside)

Index - Materials and Tools
5-29
Materials and Tools
SEALER SPRAY GUNS

Use urethane sealer. Use the correct gun toe the agent being used.
3m #08892 (internal) Use of a pressure type spray gun is recommended when
3m #08893 (external) work involves a considerable number of vehicles.
or equivalents. For nox-rust 409-20S/solton 1000S
TOOLS
Cartridge type Tube type
Sealing gun
For rustop
UNDERCOAT
To be applied to under-floor and wheelhouse.
Nox-rust 409-20S
Solton 1000S
or equivalent. For deox #100
For waxoyl
ANTI-RUST AGENT
To be applied to weld joints inside the body panel.
Rustop
Deox #100
Waxoyl
or equivalent.

Paints - Paints
Paints
General Safety Precautions 6-2
Body Paint
General 6-3
Refinishing Processes 6-4
Pre-processing of Painting 6-5
Treatment of Metal Surface 6-6
Undercoating 6-7
Intermediate Coating 6-8
Top Coating 6-9
Plastic Parts Paint

Features of Plastic Material 6-11
Use of the Repair Material (reference) 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

General Safety Precautions
6-2
General Safety Precautions
Most paints contain substances that are harmful 1. 4. Read the paint label before opening the
if inhaled or swallowed. container. Cover spilled paint with sand, or wipe
The following precautions are important items in it up at once.
order to maintain safe painting work.
1. 1. Wear an approved respirator and eye protection
when painting.
2. 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. 2. Wear approved gloves, appropriate clothing
when painting. Avoid contact with skin.
3. 6. After the painting work is finished, wash face

and gargle with water.
3. 3. Spray paint only in a well ventilated area.
4. 7. Paint is flammable. Store it in a safe place, and

keep it away from sparks, flames or cigarettes.

Paints - Body Paint
6-3
Body Paint
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.
Basic Rules for Repairing a Paint Finish
To repair paint damage, always use the 2-part acrylic urethane paints designated: polish and bake each of the three coats, as in
production, to maintain the original film thickness, and to assure the same quality as the original finish.
Outline of Factory Painting Process:
Features in Each Work Process

1. 1. Pre-treatment and Electrodeposition
In the pre-treatment process, the entire body is degreased, cleaned and coated with zinc phosphate by dipping.
After the body has been cleaned with pure water, it is placed in an electrolytic bath of soluble primer (Cationic
Electrodeposition). This produces a thorough corrosion inhibiting coating on the inner surface and corners of the body,
pillars, sills and panel joints. Chipping primer is then applied to the most susceptible areas (see page 5-11, 5-25).
2. Intermediate coat
The intermediate coat is applied to the prepared surface for further protection against damage.
3. Top Coat
Enamel paint and either polyester or acrylic resin paint are used in the top coat for higher solidity, smoothness,
brightness and weather resistance.
Sectional View of Paint Coats:
3-Coat Pearl (White Pearl) Paint

Paints - Body Paint
6-4
Body Paint
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.
: Indicates the best method depending on the degree of damage.

Paints - Body Paint
6-5
Body Paint
Pre-processing of Painting
1. 1. Featheredging If double action sander is not available, use a

NOTE rubber pad and wet or dry sandpaper.
The paint film damaged area should be Use the flexible block and #280, #340, #400, #600
sanded flat and smooth. sandpaper.
If this is not done correctly the end results Damage to undercoat, intermediate coat and
will not be acceptable. top coat:
Sand the damage area flat and smooth
Use the double action sander and #180~#240~#320 disc
paper.
Damage to metal surface:

1. 2. Preparation of metal surface
Sand the damaged area flat and smooth.
Remove all corrosion from the damaged area.
Use the disc sander and #60~#80 disc paper.
Use a product that removes corrosion.
2. 3. Air blowing/degreasing
Use alcohol, wax and grease remover.
2. 1. Top coat
2. Intermediate coat
3. Undercoat
4. Metal surface
Use the double action sander and #60~#80 disc paper.
Sand the area larger than the damaged

area.
Use the double action sander and #180~#240 disc
paper.

Paints - Body Paint
6-6
Body Paint
Treatment of Metal Surface
1. 1. Filling/drying After applying the body filler, allow 5~6 minutes

Small cracks or pinholes in the sheet metal should be of normal drying time, then force dry it with
repaired with a body filler and sanded flat and smooth. infrared lamps or other industrial dryer at 50°C
Use the 2-part polyester resin putty. (122°F)~60°C (140°F).
Mix the putty with the hardener in the correct NOTE: Follow the body filler manufacturer's instructions
ratio. for drying time.
Follow the body filler manufacturer's 1. 2. Polishing
instructions. When the body filler is dry a white mark appears when
the surface is scratched with your finger nail.
Mix the body filler and hardener quickly. 1. Thoroughly sand the body filler surface.
Use the double action sander and #80~#120 disc paper.
Apply the body filler in several thin coats, 2. Sand the surface evenly, particularly the
without air bubbles. area that was filled.
Do not try to cover the surface with one Use the flexible block and #120~#180 sandpaper.
heavy coat.
Apply the body filler over the damaged area
with a putty knife using light pressure.
2. 1. Body Filler

Paints - Body Paint
6-7Undercoating
Body Paint
Treatment of Metal Surface (cont'd)
3. Featheredge the paint coat. 1. 1. Masking

Mask the area surrounding the damage to prevent
Sand the body filler surface until the proper dimensions
over spray from the primer surfacer.
are met.
Use the masking tape and paper.
Use the double action sander and #240~#320#~400 disc
papers. 2. 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.
Use the 2-part urethane primer surfacer and a
spray gun.
Mix the primer surfacer with the additive and
solvent, and in the correct ratio.
Follow the primer surfacer manufacturer's
instructions.
1. 1. Body Filler
2. Featheredging
Use the alcohol, wax and grease remover.
Also clean and degrease the surfaces where masking

tape will be attached.
3. 1. Primer Surfacer
4. 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.

Paints - Body Paint
6-8Intermediate Coating
Body Paint
Undercoating (cont'd)
1. 4. Polishing 1. 1. Masking
Check that the primer surfacer has dried thoroughly, Mask the area surrounding the damage to prevent
then sand the primer surfacer. over spray from the intermediate coat.
Use the double action sander and #320~#400~#600 disc Use masking tape and paper.
papers. 2. 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.
Use the 2-part polyester urethane top coat
enamel and a spray gun.
Mix the top coat enamel with the additive and
Follow the top coat manufacturer's instructions.
Use the alcohol, wax and grease remover.
Also clean and degrease the surfaces where the

masking tape will be attached.
3. 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.

Paints - Body Paint
6-9Top Coating
Body Paint
Intermediate Coating (cont'd)
1. 4. Polishing 1. 1. Masking
Check that the top coat enamel has dried thoroughly, Mask the area surrounding the damage to prevent
then sand the top coat enamel. over spray from the top coat.
Use the double action sander and #600~#800 disc Use masking tape and paper.
papers. 2. 2. Spraying top coat enamel/clear coat
Spray 2~3 double coat until the intermediate coat is
NOTE: Be careful not to polish down to the primer fully covered.
surfacer. NOTE: See pages 6-11, 6-12 for the painting repair
(gradation) of the 3-coat pearl paint.
enamel and spray gun.
When the painting repair (gradation) is almost done,

polish the area that will be top coated.
Use the #2000 sandpaper and compound.
2. 5. Air blowing/degreasing Drying

Use alcohol, wax and grease remover. After spraying the top coat enamel, allow it to air dry,
then force dry it with infrared lamps or other industrial
Also clean and degrease surfaces where the masking dryer.
tap will be attached. NOTE: Follow the top coat manufacturer's instructions
NOTE: See pages 6-11, 6-12 for the painting repair for drying time.
(gradation) of the 3-coat pearl paint. 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.

Paints - Body Paint
6-10
Body Paint
Top Coating (cont'd)
Drying 4. After buffing, remove the masking paper and

After spraying the clear coat, allow it to dry for 10 tape, and thoroughly wash the entire
minutes, then force dry it with infrared lamps or other vehicle.
industrial dryer.
NOTE: Follow the top coat manufacturer's instructions
for drying times.
1. 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.
2. Polish any roughness caused by sanding.

NOTE: Clean the top coat surface frequently so you do
not damage the clear coat with the polishing particles.
Use a buffing towel, buffing wool and
compound.
2. 2. Finishes up with buffing.
NOTE:
Do not use a power buffer.

Do not polish too much; use light hand pressure.
Use the buffing sponge, fine compound, very

fine compound, then ultra fine compound.

Paints - Plastic Parts Paint
6-11
Plastic Parts Paint
Features of Plastic Material
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 Name Heat Solvent Resistance Note
Symbol Resistance
Temperature
°C (°F)
AAS Acrylonitrile acrylic 80 A small amount of alcohol is An organic solvent such as gasoline is not
styrene (176) acceptable for a short time. recommended.
(Degreasing) An aroma product is not recommended.
ABS Acrylonitrile 80 A small amount of alcohol is An organic solvent such as gasoline is not
butadiene styrene (176) acceptable for a short time. recommended.
AES Acrylonitrile ethylene 80 A small amount of alcohol is An organic solvent such as gasoline is not
styrene (176) acceptable for a short time. recommended.
A/EPDM/S Acrylonitrile / 80 A small amount of alcohol is An organic solvent such as gasoline is not
ethylene propylene (176) acceptable for a short time. recommended.
diene rubber / (Degreasing) An aroma product is not recommended.
styrene
ASA Acrylonitrile styrene 80 A small amount of alcohol is An organic solvent such as gasoline is not
acrylate (176) acceptable for a short time. recommended.
CAB Cellulose acetate 80 A small amount of alcohol is An organic solvent such as gasoline is not
butylate (176) acceptable for a short time. recommended.
E/VAC Ethylene-vinyl 80 A small amount of alcohol and Soaking with an organic solvent such as
acetate (176) gasoline are acceptable for a gasoline and alcohol is not recommended.
short time. (Degreasing)
PA Polyamide 80 Alcohol and gasoline are Battery acid (sulphuric acid) is not
(176) acceptable. recommended.
PBT Polybutylene 160 Alcohol and gasoline are Solvent is not recommended.
terephtalate (320) acceptable.
PC Polycarbonate 120 A small amount of alcohol is Brake fluid, and wax and grease remover not
plastics (248) acceptable for a short time. recommended.
PE Polyethylene 80 Alcohol and gasoline are Solvent is not recommended.
(176) acceptable.
PF Phenol formaldehyde 80 A small amount of alcohol is Soaking with an organic solvent such as
(176) acceptable for a short time. gasoline and alcohol, is not recommended.
(Degreasing)
PMMA Polymethyl 80 A small amount of alcohol is Soaking with an organic solvent such as
methacrylate (176) acceptable for a short time. gasoline and alcohol, is not recommended.
(Degreasing) Wash remover off with water thoroughly.
POM Polyoxymethylene 100 Alcohol and gasoline are Solvent is not recommended.
polyacetal (212) acceptable.

6-12
Plastic Parts Paint
Features of Plastic Material (cont'd)
Standard Name Heat Solvent Resistance Note

Symbol Resistance
Temperature
°C (°F)
PP Polypropylene 80 Alcohol and gasoline are Solvent is not recommended.
(176) acceptable.
PPO Polyphenylene 100 A small amount of alcohol is Soaking with an organic solvent such as
(PPE) oxide (212) acceptable for a short time. gasoline and alcohol is not recommended.
PS Polystyrene 60 A small amount of alcohol is Soaking with an organic solvent such as

(140) acceptable for a short time. gasoline and alcohol is not recommended.
PUR Polyurethane 80 A small amount of alcohol is Soaking with an organic solvent such as
(176) acceptable for a short time. gasoline and alcohol is not recommended.
(Degreasing)
PVC Polyvinylchloride 80 A small amount of alcohol and Soaking with an organic solvent such as
(176) gasoline are acceptable for a gasoline and alcohol is not recommended.
short time. (Degreasing)
SAN Styrene acrylonitrile 80 Wiping alcohol off in a short time Soaking with an organic solvent such as
(176) can be allowed. gasoline and alcohol is not recommended.
SMC Sheet moulding 180 Alcohol and gasoline are Solvent is not recommended.
compound (356) acceptable.
TPE Thermoplastic 80 Alcohol is acceptable and Soaking with an organic solvent such as
polyester elastomer (176) wiping gasoline for a short time gasoline and alcohol is not recommended.
can be allowed. (Degreasing) Wash remover off with water thoroughly.
TPS Thermoplastic 80 A small amount of alcohol and Soaking with an organic solvent such as
styrene elastomer (176) gasoline are acceptable for a gasoline and alcohol is not recommended.
short time. (Degreasing) Wash remover off with water thoroughly.
TPO Thermoplastic 80 Alcohol is acceptable and Soaking with an organic solvent such as
olefin / elastomer (176) wiping gasoline for a short time gasoline and alcohol is not recommended.
can be allowed. (Degreasing) Wash remover off with water thoroughly.
TPU Thermoplastic / 80 A small amount of alcohol and Soaking with an organic solvent such as
urethane / (176) gasoline are acceptable for a gasoline and alcohol is not recommended.
elastomer short time. (Degreasing) Wash remover off with water thoroughly.
UP Polyester 110 Alcohol and gasoline are Alkali is not recommended.
(230) acceptable.

6-13
Plastic Parts Paint
Use of the Repair Material (reference)
NOTE: Follow the materials manufacturer's instructions. Mixing Ratio:

The use of a special polyester putty for PP bumper is
described here:
1. 1. Filler
Mixing Ratio:
1. 4. Intermediate coat and top coat

Use the 2-part polyester urethane top coat.
Top coat is also used for an intermediate coat.
Mixing Ratio:
NOTE: Be sure to mix the correct amount of the
hardener and softener.
2. 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. NOTE: Use a spray gun to apply the paint. Do not use
Use the 2-component type primer surfacer (grey). a brush.
Drying time:
Air dry 20°C (68°F) 6~10 minutes Touch dry
Almost hardened 12~24 hours
Thoroughly hardened 96 hours
Force dry the intermediate coat and top coat.

NOTE: Mix only an amount that can be used before it
hardens.

6-14
Plastic Parts Paint
Refinishing Processes
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: Deep Abrasion 3 mm (0.12 in.) approx.
C: Shallow Scratch 1 mm (0.04 in.) approx.

Undercoating
6-15
Plastic Parts Paint
Pre-processing of Painting
1. 1. Sanding 1. 1. Spraying primer

Sand the damage area flat and smooth. Primer is used to fill cavities in the putty and primer
Shallow Scratch: surfacer.
Use a flexible block and #240~#400~#600 sandpaper. Spray primer on the exposed area.
Spray the 2~3 coats of primer on 2~3 coats
over the area you applied putty.
Apply primer to the back of the bumper if
the damage is a tear or hole.
Bumper primer (Reference)
Warm the primer if the ambient temperature is
below 10°C (50°F).
Follow the bumper primer manufacturer's
instructions.
Use the spray gun and brush.
Hole/Deep Gouge:
Cut out and make any torn or burred area flat.
Use a knife, flexible block and #180~#240 sandpapers.
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 20°C (68°F) 20 minutes
Force dry 60°C (140°F) 10 minutes

6-16
Plastic Parts Paint
Undercoating (cont'd)
1. 2. Filing/Sanding 1. 5. Spraying primer surfacer

Apply putty to repair any holes or deep gouges. NOTE: Spray the bumper primer (see page 6-17) on
Apply the putty on the damaged are in 2~3 the area where the PP material was exposed and
steps. around the putty.
Glue aluminium tape on the outside of the Spray the primer surface wider than the
bumper, and apply putty from the other side putty and painted surfaces of bumper
of the bumper. primer.
Remove the aluminium tape after the putty Spray 2~3 coats to get 20~30 microns of
dries, apply putty from the outside, and fill thickness.
the hole. Use the 2-component type primer surfacer
Use a special polyester putty (Reference) and a putty (grey) and a spray gun.
knife. Follow the materials manufacturer's
instructions.
Drying
2. 1. Aluminium Tape
2. Outside bumper during the drying process.
2. 6. Sanding
3. 3. Sanding
After drying, wet sand the area of the intermediate
Sand the surface evenly, particularly at the area where
coat.
the PP material and putty meet.
Use the #600 sandpaper.
Use a flexible block and #240~#400~#600 sandpaper.
NOTE: Do not use less than #600.
4. 1. Featheredging 3. 7. Air blowing/degreasing

Use alcohol, a tack cloth, and wax and grease remover.
Use alcohol, a tack cloth, and wax and grease remover. Also clean and degrease the surfaces where the
masking tape will be attached.

6-17
Plastic Parts Paint
Intermediate Coating
NOTE: You must do this procedure on the PP parts of 1. 3. Polishing

the bumper and side sill panel. Check the top coat enamel has dried thoroughly, then
sand the top coat enamel.
1. 1. Masking
Mask the area surrounding the damage to prevent Use a flexible block and #600~#800~#1000 sandpapers.
overspray from the intermediate coat.
Use masking tape and paper. NOTE: Be careful not to sand down to the primer
surfacer.
2. 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.
When the painting repair is almost complete, polish

the top coat.
Use #1500 sandpaper and compound.
Drying
After spraying the top coat enamel, allow for 5~10 2. 1. Material
minutes of normal drying, then force dry it with infrared 2. Putty
lamps or other industrial dryer. 3. Intermediate Coat
4. Sanding
5. Paint Coat
Use alcohol, a tack cloth, and wax and grease remover.
Clean and degrease the surfaces where the masking

tape will be attached.

6-18
Plastic Parts Paint
Top Coating
1. 1. Masking Using a buffer and compound, remove any

Mask the area surrounding the damage to prevent polishing marks made from the sandpaper.
overspray of the top coat Use a buffing sponge, and buffing wool and
Use masking tape and paper. compounds.
2. 2. Spraying top coat enamel / clear coat Finish up with buffing:
Spray 2~3 coats in double coat until the intermediate coat 1. 1. Wet sands with #2000 sandpaper and soapy
is fully covered. water.
NOTE:
Do not cover the surface with one heavy coat.
solvent, and in the correct ratio. 2. 2. Remove moisture using compressed air.
Follow the top coat manufacturer's instructions. 3. Finish using fine compound and very fine
After spraying the top coat enamel, allow for 5~10 compound. Do not polish with an electric
minutes drying time before you spray the clear coat. polisher.
NOTE: Polish lightly.
3. 4. Check the finished area at an angle, and

Drying make sure there are no polishing marks.
5. Polish with ultra fine compound and a
buffing sponge.
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. 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.
4. 6. Wax the finished area.

Paints - Glossary
6-19
Glossary
All paint Painting of complete surface.

Compressed air Use compressed air to blow away dust and debris.
Block paint Painting a section only, such as a door
Clear paint (clear coat) Clear paint without dye (pigment).
Double coat Application of two paint coats.
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 Electrostatic discharge painting.
Enamel Finishing paint pigmented with dye.
Featheredging Smoothing out the edges of painted surface.
Flash off Evaporation of the pain solvent. (Flash off time is the period between pain coat applications.)
Ford cup A type of viscosity meter.
Gun stroke Movement of the paint gun.
Hardener Harding agent of two-liquid type paint or fillers.
Polycyanated and oxides are used for hardeners.
Heat-hardening acrylic resin Composed of acrylic resin and meramine resin and hardener (forms a paint film) by banking.
paint

Paints - Glossary
6-20
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 Paint with aluminium power for metallic tone.
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/cm², 21.3-28.4 psi)
Mixing scale Colour mixing device.

Overlap Blending of spray patterns.
Overspray Spraying other than the area that needs painting.
Paddle A tool to mix paint.
Paint dust Dust of paint formed by spraying.
Paper dispenser A paper posting device (masker) that combines tape and paper.
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 Application of paint in single layer.
Spot paint Painting of small section, such as for touch-up.
Undercoat Undercoat paint (such as primer and surface).
May be applied to lower section of car for moist prevention and rust proofing.

Paints - Glossary
6-21
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 Paint which has not dried completely.
Wet on wet Application of the next coat of paint before the previous layer has dried completely.
Wool bonnet Wood grinder for compound polishing.

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SERVICE

How to Use This Manual

NOTE: Gives helpful information.

All information contained in this manual is based on

file:///C|/...EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CivBHtml/0-1.htm[8/25/2012 6:38:41 PM]

figures and tables.

Sections with * include SRS components; Special

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4-door General Information 1-3

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Supplemental Restraint System (SRS) 1-4

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1. Built Data and Vehicle

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1. 1. FRONT SUPPORT POINT

2. 1. Raise the hoist a few inches, and rock the vehicle

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Front Wheel Alignment:

Rear Wheel Alignment:

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Sp: Steel plateHss: High strength steel plateZn: Zinc-plated

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P.: Pearl Paint / M.: Metallic Paint

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Supplemental Restraint System (SRS) 1-16

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1. Built Data and Vehicle

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1. 1. FRONT SUPPORT POINT

2. 1. Raise the hoist a few inches, and rock the vehicle

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Front Wheel Alignment:

Rear Wheel Alignment:

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Sp: Steel plateHss: High strength steel plateZn: Zinc-plated

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P.: Pearl Paint / M.: Metallic Paint

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1. DOOR MIRROR BASE

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Outline of Body Repair 2-2

Accurate Inspection of Damaged Parts (Visual)

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The vehicle identification number is stamped on

2. 1. VEHICLE IDENTIFICATION NUMBER (VIN)

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Frame Repair Chart:

If there is any twisting to the body, measure

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