Civic Shop Manual PDF

How to Use This Manual
This manual covers the repairs of 2001 model series CIVIC that 1 General Info
have been involved in an accident and it describes the work related 2 Preparation of work
to the replacement of damage body parts.
Please read through instructions and familiarise yourself with them 3 *Replacement
before actually using this manual. 4 Body Dimensional Drawings
NOTE: Refer to the 2001 CIVIC Shop Manual (P/N. 60S5A00) for
specifications, wire harness locations, safety stand support points, 5 Rust Prevention
etc. 6 Paints
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, figures and tables.
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Fist Edition 192 pages HONDA MOTOR CO., LTD.

8/2000
All Rights Reserved Service Publication Office
Sections with * include SRS components; Special Caution is required

when servicing.

Index - Index
Index
4-door General Information 1-3

5-door General Information 1-15
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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
General Information 1-4

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. The SRS unit (including the safing sensor and the impact is located under the dashboard and the side impact sensors are located in each side still. Avoid any strong Impact with
a hammer or other tools when repairing the front side frame, the lower part of the dashboard and the side sill. Do not apply heat to these areas with a torch, etc.
2. Take extra care when painting or doing body work in the area below the centre pillar. Avoid direct exposure of the seat belt retractor with tensioner to heat guns, welding or
spraying equipment.
3. SRS electrical wiring harness are identified with yellow colour coding. Care should be taken not to damage the harness when repairing this area.
4. Do not apply heat of more than 212F (100C) when drying painted surfaces anywhere around the locations of SRS components.
5. If strong impact or high temperature needs to be applied to the areas around the locations of SRS components, remove the Components before performing the repair work.
6. If any of the SRS related components are damaged or deformed, be sure to replace them.
NOTE: Refer to the Restraints section of the Shop Manual for after deployment, and removal and replacement of SRS related components.
1. DRIVER'S AIRBAG
ASSEMBLY
2. CABLE REEL
3. FRONT PASSENGER'S
AIRBAG ASSEMBLY
4. SIDE AIRBAG
5. SEAT BELT TENSIONERS
6. SIDE IMPACT SENSOR
8. SIDE AIRBAG
9. SRS UNIT
(with built-in sensor)
10. UNDER-DASH FUSE/
RELAY BOX
General Information 1-
Identification Number Locations
5
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)

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

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

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 000'45'
Caster 1'33'1
Total toe 03 (00.12)
Wheel turning angle in 4000'2 (D15B engine)
3800'2 (D17A engine)
out 3100' (D15B engine: Reference)

3000' (D17A engine: Reference)
Rear Wheel Alignment:

Camber -045'45'
Total toe IN 2 3 (0.08 0.12)

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

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)
Door and Bumper Reinforcement Beams
10
Door and bumper reinforcement beams used on Honda vehicles are made from a metal equivalent to High Strength Steel.
If High Strength Steel is heated, the strength of the steel will b e reduced. If High Strength Steel is damaged, as in a vehicle accident, where the door and bumper reinforcement
beams are bent, the beams may crack if an attempt is made to straighten them.
For this reason, the door and bumper reinforcement beams should NEVER be repaired; they should be replaced if they are damaged.
NOTE: If a door beam is damaged, the whole door panel assembly should be replaced.
1. REAR BUMPER REINFORCEMENT
BEAM
2. REAR DOOR REINFORCEMENT
BEAM
3. FRONT DOOR REINFORCEMENT
BEAMS
4. FRONT BUMPER
REINFORCEMENT BEAM
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Zinc-plated Steel Plate Repair
11
The Zinc-plated steel plate used in some panels of the CIVIC 4-door requires different repair techniques than ordinary steel plate. Refer to "Body Construction" (see page 1-9) for the
location of the Zinc-plated panels.
1. ZINC-PLATED (5-6 microns)
2. Steel plate
1. Before spot welding the zinc-plated steel plate, remove the paint from both sides of the flange to be welded. Apply sealer to the flange after welding.
WARNING
To prevent eye injury, wear goggles or safety glassed whenever sanding, cutting or grinding.
NOTE: Seal the sanded surface thoroughly to prevent rust.
2. The electric continuity properties of zinc-plated steel plate is different from the ordinary steel plate. When spot welding, increase the current by 10-20%.
NOTE: The MIG welding procedures for Zinc-plated steel plate are the same an for ordinary steel plate.
WARNING
To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.
3. Before applying putty or body filler to the Zinc-plated steel plate, sand the zinc plating thoroughly to promote adhesion and to prevent blistering.
NOTE: Use only epoxy-based putties and fillers on zinc-plated steel plate, following the manufacture's specifications.
4. When performing pain work, protect the ground wire and ground wire mounting hole threads with a bolt or a plug.
1. SPECIAL BOLT
2. GROUND WIRE
3. GROUND WIRE MOUNTING HOLE
4. PLUG
Colour Chart Paint Specifications
12
P.: Pearl Paint / M.: Metallic Paint
NH-578 NH- B-92P B-96P G-95P R-81 R504P RP-32P YR-525M
Taffeta 623M Night Eternal Clover Mirano Ruby Red Vintage Titanium
White Stain Hawk Blue P. Green P. Red P. Plum P. M.
Silver 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
Colour Chart Paint Specifications (cont'd)
13
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
Body colour or black (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)
Type and Materials of Exterior Plastic Parts
14
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)
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)
Ethylene propylene dinene
rubber (EPDM)

Identification Number Locations 1-17
Lift and Support Points 1-18
Exterior Parts Removal/Wheel Alignment 1-20
Construction 1-21
Door and Bumper Reinforcement Beams 1-22
Zinc-plated Steel Plate Repair 1-23
16
This model has an SRS which includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above the glove box, seat belt tensioners in the front seat
belt retractors and side airbags in the front seat backs. The SRS unit is separated from the airbag assembly and has built-in sensors. The following precautions should be observed
when performing sheet metal work, paint work and repair work around the location of the SRS components.
1. The SRS unit (including the safing sensor and the impact sensor) is located under the dashboard and the side impact sensors are located in each side sill. Avoid any strong
impact with a hammer or other tools when repairing the front side frame, the lower part of the dashboard and side sill. Do not apply heat to these areas with a torch, etc.
2. Take extra care when painting or doing body work in the area below the centre pillar. Avoid direct exposure of the seat belt retractor with tensioner to heat guns, welding, or
spraying equipment.
3. SRS electrical wiring harnesses are identified with yellow colour coding. Care should be taken not to damage the harness when repairing this area.
4. Do not apply heat of more than 212F (100C) when drying painted surfaces anywhere around the locations of SRS components.
5. If strong impact or high temperature needs to be applied to the areas around the locations of SRS components, remove the components before performing the repair work.
NOTE: Refer to the restraints section of the Shop Manual for after deployment and remove and replacement of SRS related components.
1. SIDE AIRBAG
AIRBAG ASSEMBLY
3. DRIVER'S AIRBAG
ASSEMBLY
4. CABLE REEL
5. UNDER-DASH FUSE/
RELAY BOX
6. SRS UNIT
8. SIDE AIRBAG
Identification Number Locations
17
1. Built Data and Vehicle Type
2. Vehicle Identification
Number (VIN)
3. Engine Number
(Manual)
(Automatic)
Lift and Support Points 18
NOTE: If you are going to remove heavy components such as suspension or the fuel Floor Jack
tank from the rear of the vehicle, first support the front of the vehicle with a tall safety 1. Set the parking brake.
stands. When substantial weight is removed from the rear of the vehicle, the centre of 2. Block the wheels that are not being lifted.
gravity can change and cause the vehicle to tip forward on the hoist. 3. When lifting the rear of the vehicle, put the gearshift lever in reverse (or automatic
Frame Hoist transmission in Park position).
Position the hoist lift blocks, or safety stands, under the vehicle's front support points 4. Position the floor jack under the front jacking bracket or rear jacking bracket, centre
and rear support points. the jacking bracket in the jack lift platform, and jack up the vehicle high enough to fit
the safety stands under it.
1. FRONT SUPPORT POINT

2. HOIST LIFT BLOCKS
3. REAR SUPPORT POINT
1. Raise the hoist a few inches, and rock the vehicle gently to be sure it is firmly
1. FRONT JACKING BRACKET
supported.
2. JACK LIFT PLATFORM
2. Raise the hoist to full height, and inspect the lift points for solid contact with the lift 3. JACK LIFT PLATFORM
blocks. 4. REAR JACKING BRACKET
Safety Stands
To support the vehicle on safety stands, use the same support points as for a frame 5. Position the safety stands under the support points and adjust them so the vehicle
hoist. Always use safety stands when working on a under vehicle that is supported only will level.
by a jack. 6. Lower the vehicle onto the stands.
19
Unit : mm(in.)
*1: With Roof Antenna
*2: European model (MPW condition)
*3: Except European model

Camber 000'45'
Caster 1'33'1
Total toe 03 (00.13)
Wheel turning angle in 4000'2 (D15B engine)
3800'2 (D17A engine)
out 3100' (D15B engine: Reference)

3000' (D17A engine: Reference)

Camber -045'45'
Total toe IN 2 3 (0.08 0.12)
Exterior Parts Removal/Installation
20
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
Construction
21
Sp: Steel plateHss: High strength steel plateZn: Zinc-plated

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)
Door and Bumper Reinforcement Beams
22
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
Zinc-plated Steel Plate Repair
23
The Zinc-plated steel plate used in some panels of the CIVIC 5-door requires different repair techniques than ordinary steel plate. Refer to "Body Construction" (see page 1-21) for
the location of the Zinc-plated panels.
1. ZINC-PLATED (5-6 microns)
2. Steel plate
1. Before spot welding the zinc-plated steel plate, remove the paint from both sides of the flange to be welded. Apply sealer to the flange after welding.
WARNING
To prevent eye injury, wear goggles or safety glassed whenever sanding, cutting or grinding.
NOTE: Seal the sanded surface thoroughly to prevent rust.
2. The electric continuity properties of zinc-plated steel plate is different from the ordinary steel plate. When spot welding, increase the current by 10-20% or increase the resistance
welding time.Also increase the number of weld spots by 10-20%.
NOTE: The MIG welding procedures for Zinc-plated steel plate are the same an for ordinary steel plate.
WARNING
To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.
3. Before applying putty or body filler to the Zinc-plated steel plate, sand the zinc plating thoroughly to promote adhesion and to prevent blistering.
NOTE: Use only epoxy-based putties and fillers on zinc-plated steel plate, following the manufacture's specifications.
4. When performing pain work, protect the ground wire and ground wire mounting hole threads with a bolt or a plug.
1. SPECIAL BOLT
2. GROUND WIRE
3. GROUND WIRE MOUNTING HOLE
4. PLUG
24
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
25
1. DOOR MIRROR BASE
2. DOOR MIRROR
Body colour or black (NH-70
Gloss 20)
3. CHANNEL TAPE
Gloss 30)
5. CORNER TRIM
Black (NH-70 GLOSS 20)
6. ROOF MOULDING
7. LICENSE TRIM
Gloss 30)
8. REAR BUMPER
Body Clour
9. DOOR MOULDING
10. DOOR SASH TRIM
11. FRONT BUMPER
Body Colour
12. GRILLE
26
Example:
1. FRONT WINDSHIELD MOULDING

Acrylonitrile ethylene propylene dine
rubber styrene (A/EPDM/S)
Polycarbonate (PC)
3. DOOR MIRROR
Painted: Acrylonitrile butadiene
styrene (ABS)
Unpainted: Acrylonitrile styrene
acrylate (ASA)
4. ROOF MOULDING
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
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
Outline of Body Repair 2-2

The contents described in this section are the basic processes of repair procedures needed to cut and replace welded parts. Reshape the light damage, outer panel with filler after
repair by the washer welder, the hammer and dolly.
The table below shows information to this model.
Processes Repair Procedures Information Reference
Accurate inspection of Damaged Parts. (Visual) Wheelbase see section 1
Measurement Wheel Alignment see section 1
Body Dimensional Drawings see section 4
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.
4. Check the original position.
see section 4
Body Dimensional Drawings
Replacement 1. Cut off and separate the damaged area. Mass Production Body Welding see section 3
2. Straighten any related parts. Diagram see section 3
3. Check the repair part installation and alignment with Removal see section 4
the body. Body Dimensional Drawings see section 3
4. Clean and degrease to the welded surfaces. Installation
5. Weld in the repair part.
6. Finish the welded areas.
Rust Prevention 1. Apply the sealer. Cross Section of Body and Sealants. see section 5
2. Apply the undercoating. Soft Chipping Guard Primer Coating
3. Apply anti-rust agent to the inside of the outer panel Diagram
and frames. 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
General Safety Precaution 2-3

Disconnect the battery to reduce the possibility of damage caused by Remove the fuel tank and/or fuel lines if welding equipment is to be
electrical shorts. used near the fuel system.
Check for fuel leaks and repair as necessary.
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. FUEL TANK
The vehicle identification number is stamped on the dashboard upper

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

2. DASHBOARD UPPER
Preparation of Work - Accurate Inspection of Damaged Parts (Visual)
Accurate Inspection of Damaged Parts 2-4

(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)
Accurate Inspection of Damaged Parts 2-5

(Visual)
Measurement
Whenever possible, make judgements and conclusions based on To measure body dimensions, use a universal tram gauge and convex
measurements. tool.
Measure the wheel alignment to prevent uneven tyre wear or incorrect Body Measuring Dimension/Opening Repair Chart:
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
Reshape 2-6
Correction of the Damaged Area
1. Remove any related parts. 4. Check that the part of the body is more or less restored to its original
NOTE: See the Shop Manual. shapes. Check the original positions using the body dimensional
2. Connect the frame straightener to the vehicle body. drawings.
The side sill is flangeless to allow reshaping by pulling it out.
Use the horizontal pinch welds for anchoring the vehicle.
1. SUPPORT POINTS
(Jack-up stiffener)
3. Pull out and straighten damaged areas. Apply load to the damaged
section, and pull on it until the section is almost restored to its original
shape. Do not pull out more than necessary.
Preparation of Work - Replacement
Replacement 2-7
Removal
1. Decide whether to replace all the affected parts or whether to cut the 2. Peel off the undercoat.
weld joint parts and replace them.
NOTE: When cutting the parts off, take special care that you do not CAUTION
damage adjacent parts on the vehicle. Be careful not to burn the fittings inside the
Setting Condition for Replacement Parts Joint Sections: passenger compartment when heating.
Make sure that you can perform straightening work after welding.
Make sure that the locations will not be susceptible to distortion
caused by other parts.
Make sure that there are few removable parts and that the location
allows for safe welding.

Make sure that the joints are short, and that paint repair can be
performed easily.
Make sure that locations are such that the joints can be finished in
a way that will not affect the outward appearance.

Make sure that the locations do not hinder the removing and 3. Remove the damaged parts.
attaching of parts.
Parts which influence wheel alignment such as damper housing and the WARNING
side frames must be examined using the frame repair charts. To prevent eye injury, wear goggles or safety
glasses whenever sanding, cutting or grinding.
Centre punch around the spot weld imprints on the welded flange
and drill holes using the spot cutter.
NOTE: Make a drill hole so that the installation of the repair parts may
become easy.
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.
1. DAMPER HOUSING
2. OUTER PANEL
(New part)
3. FRONT SIDE FRAME
(New part)
1. STIFFENER
2. OUTER PANEL
Replacement 2-8
Installation
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 the thickness of the
To prevent eye injury and burns when welding, welded plate (see page 2-19).
wear an approved welding helmet, gloves and The position and the point by which holes are made, refer to the old
safety shoes. parts or Mass Production Body Welding Diagram (see section 3).
Fill any holes by MIG welding and even out with a hammer and
dolly.
WARNING
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. 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.
NOTE: Spread the spot sealer coat on the welding surface so that
there is no bare areas.
2. Preparations of new parts.
Cut the new outer panel so it will overlap by 20-30mm (0.8-1.2 in.)
to the panel of the body side.
1. OVERLAP
Replacement 2-9
Installation
4. Check the tack weld at positions of the new parts. Make 20% to 30% more spot welds than there were holes drilled.
Clamp the new part and check the position of it using the body A new welding position should avoid an old position as much as
dimensional drawings (see section 4). possible.
Tack weld the clamped section. NOTE: If there is not room for spot welds, compensate by using MIG
welds
WARNING The electric continuity property of zinc-plated steel plate is different
To prevent eye injury and burns when welding, from ordinary steel plate. When spot welding, increase the current
wear an approved welding helmet, gloves and by 10-20%, or increase the resistance welding line.
safety shoes.
Fillet weld the repair outer side sill it will overlap by 30 mm (1.2 in.)
in the front and back.
Butt weld the front pillar, centre pillar, rear pillar and the wheel arch
cut sections of the repaired outer panel.

5. Check the alignment of the exterior body parts. NOTE: Attach the patches at the cut sections of the outer panel and
Temporary install the exterior body parts, windshield and rear
plug weld them.
window glass, and check for differences in level and clearances.
NOTE: Check the fit of the front fender, door and the rear fender, and
make sure the body lines flow smoothly.
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. BUTT WELD
2. PATCH
3. FILLET WELD
Replacement 2- Rust Prevention/Paint
Installation (cont'd)
10
7. Finishing the welded areas. 1. Applying the sealer. Seal the overlapped areas of the outer panel, and
Level the MIG welded areas with a disc sander. the welded surfaces of 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 grinding. Ventilate when spraying paint. Most paint
contains substances that are harmful if
NOTE: Take care not to grind excessively. inhaled or swallowed. Read the paint label
Even out high areas with a hammer. Be careful not to deform them. before opening the paint container.
Smooth out welded door and tailgate areas, and window opening Avoid contact with skin. Wear an approved
flanges with a hammer and dolly. respirator, gloves, eye protection and
Fill the deformed area and smooth out the welded areas with body appropriate clothing when painting.
filler. Paint is flammable. Store it in a safe place,
and keep it away from sparks, flames or
cigarettes.
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
Installation and Inspection 2-

11
1. Check the clearance of the door, hood, tailgate and adjust if necessary.
Check the operation of the parts and make sure the doors lock
securely.
2. Apply the sealer to the hinges of the hood, door and tailgate.
1. HOOD HINGE
2. DOOR HINGE
3. TAILGATE HINGE
3. Adjust the wheel alignment.

4. Check the windows for water leaks.
5. Clean the passenger compartments.
Preparation of Work - Repair Tools
Repair Tools 2- Protective Tools
Measurement Equipment
12
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 sleeves 11 Work glove
6 Dust-proof mask 12 Splatter guard
FRAME CENTRING GAUGE
UNIVERSAL TRAM GAUGE
CONVEX TOOL
VEHICLE BODY:
Heat-resistant protective cover
Preparation of Work - Repair Tools
Repair Tools 2- Cutting Tools
Processing Tools
13
SPOT CUTTER AIRSAW
Install the spot cutter in the air drill, and drill a hole at the spot weld Cut the outer panel.
nugget and the plug to make the hole.
AIR CHUCK GRINDER

Detaching the MIG welding part and the panel can be cut by installing cut
AIR DRILL 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
Preparation of Work - Welding Methods
Welding Methods 2-
Carbon Dioxide Arc Welder (MIG Arc Weld)
19
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)
Preparation of Work - Welding Methods
Welding Methods 2-
Gas Welding
20
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
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
Rear Side Outer Panel

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 - Front Bulkhead
Front Bulkhead 3-
Mass Production Body Welding Diagram
4
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
Front Bulkhead 3-5 Installation
Removal
1. Set the new front bulkhead into position and measure the front
compartment diagonally. Check the body dimensions (see section 4).
2. Tack weld the clamped position.
3. Temporarily install the hood, front fender, headlight and front bumper
and check for differences in level and clearance.
4. Perform the main welding:
1. 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
Front Wheelhouse/Damper Housing 3-

6
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. Dashboard upper side member
b. Damper housing extension
c. Front damper extension
d. Damper housing
e. Front wheelhouse
Front Wheelhouse/Damper Housing 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
3. WHEELHOUSE UPPER MEMBER Reused.

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
6. FRONT SIDE FRAME
7. DAMPER HOUSING
EXTENSION
8. DAMPER HOUSING
EXTENSION

Installation
1. Set the new damper housing assembly, front wheelhouse and front From the passenger compartment side, plug the holes in the
bulkhead into position, and measure the front compartment diagonally. dashboard lower, damper housing extension and front damper
Check the body dimensions (see section 4). extension.
3. Temporarily install the front sub-frame, and check the front side frame
position.
4. Temporarily install the hood, front fender, headlight and front bumper,
and check for 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.

2. DAMPER HOUSING EXTENSION
From wheelhouse side, plug weld the holes in the dashboard upper
and damper housing extension.

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

10
Weld the front wheelhouse, damper housing and front side frame.
1. DAMPER HOUSING
3. FRONT WHEELHOUSE
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
Front Side Frame/Outrigger 3-

11
a. Front side frame
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. Inside sill extension
VIEW (Z)
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Removal
12
1. FRONT SIDE FRAME
2. DAMPER HOUSING
3. FRONT WHEELHOUSE
4. FRONT SIDE FRAME
5. SIDE FRAME BULKHEAD
REAR
REAR
8. FRONT SIDE FRAME
9. FRONT SUB-FRAME STAY
10. FRONT SIDE FRAME
11. SIDE FRAME EXTENSION
REAR
REAR
REAR

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

Installation
14
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. 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 check the front side frame
position.
5. Temporarily install the hood, front render, headlights and front bumper,
Make sure the body lines flow smoothly.
Plug weld the side frame extension rear, side frame bulkhead rear
and front side frame.

2. FLOOR FRAME
From passenger compartment, plug weld the dashboard lower and

front floor.

2. FRONT SIDE FRAME
1. OUTRIGGER
Index - Roof Panel
Roof Panel 3-
Removal
24
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
Roof Panel 3-
Installation
25
1. Set the new roof panel into position and clamp it. Check the body 5. From inside the vehicle, plug weld the front pillar inner upper, rear
dimensions (see section 4), and check the width of the roof moulding inner panel and front and 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.
1. OUTER PANEL
2. ROOF PANEL
3. ROOF SIDE RAIL
VIEW (Z)
1. FRONT INNER UPPER PILLAR

2. FRONT ROOF RAIL
3. REAR INNER PANEL
4. REAR ROOF RAIL
1. ROOF ARCH GUSSET
Index - Rear Side Outer Panel
Rear Side Outer Panel 3-

26
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

Removal
27
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

Installation
28
1. Set the new repair part (outer panel and rear combination adaptor and into Weld the rear combination adaptor and rear panel.
position and clamp 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. REAR COMBINATION ADAPTOR
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
Rear Panel 3-
29
a. Rear panel side stiffener
b. Rear combination adaptor
c. Trunk compartment side:
d. Rear panel
e. Jack-up stiffener
f. 4-Plate welding
Index - Rear Panel
Rear Panel 3-
Removal
30
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
Rear Panel 3-
Installation
31
1. Set the new rear panel and rear combination adaptor into position and In the case of leave the rear panel side stiffener and rear combination
clamp them. adopter and replace rear panel.
Check the body dimensions (see section 4). Remove the new panel side stiffener from the new rear panel.
Weld the rear panel side lower stiffener and rear panel side stiffener.

2. REAR PANEL SIDE STIFFENER
3. REAR PANEL SIDE LOWER STIFFENER
1. NEW REAR COMBINATION ADAPTOR (New Part)
2. NEW REAR PANEL
Weld the rear panel and rear floor.

3. Temporarily install the trunk lid, tailgate, rear bumper and check for
difference in level and clearance. Check for operation of the truck lid.
Weld the rear combination adaptor, rear gutter, outer panel and
rear panel.
1. NEW REAR PANEL
1. OUTER PANEL
2. NEW REAR GUTTER
3. NEW REAR COMBINATION ADAPTOR
4. NEW REAR PANEL
Index - Rear Floor
Rear Floor 3-
32
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
Rear Floor 3-
Removal
33
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
Rear Floor 3-
Installation
34
1. Set the new rear cross-member and rear frame B, into position. 8. Set the new rear floor, and plug weld the rear floor cross-member, rear
2. Check the body dimensions (see section 4). frame B and rear 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.).
1. REAR FRAME A
2. REAR FLOOR CROSS-MEMBER
3. REAR FRAME B
4. REAR FRAME A
1. NEW REAR FLOOR
2. Overlap
40 mm (1.6 in.) 9. Perform the main welding to the rear floor.
3. NEW REAR FLOOR
5. REAR FLOOR
(body side)
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.
1. REAR FLOOR CROSS MEMBER
1. Filler welding
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

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

Front Bulkhead 3-
36
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
Front Bulkhead 3- Installation
Removal
37
1. Set the new front bulkhead into position and measure the front
compartment diagonally. 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
Front/Wheelhouse/Damper Housing 3-
38
a. Front side frame
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. Front wheelhouse
b. Dashboard upper side
member
c. Wheelhouse upper
extension
d. Damper housing extension
e. Damper housing
f. Front side frame

a. Wheelhouse upper member

Front/Wheelhouse/Damper Housing
VIEW (X)


Removal
39
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
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
3. WHEELHOUSE UPPER MEMBER EXTENSION
4. WHEELHOUSE UPPER MEMBER Reused.

Removal (cont'd)
40
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
6. FRONT SIDE FRAME
7. DASHBOARD UPPER
8. MOUNTING BOLT
9. DAMPER HOUSING
EXTENSION

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

Weld the dashboard upper and damper housing.
1. DASHBOARD UPPER

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

42
Weld the front wheelhouse, damper housing and front side frame.
1. DAMPER HOUSING
3. FRONT WHEELHOUSE
Weld the wheelhouse upper member.

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

3. Butt welding

43
a. Front side frame
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. Inside sill extension
VIEW (Y)

Removal
44
1. FRONT SIDE FRAME
2. DAMPER HOUSING
3. FRONT WHEELHOUSE
4. FRONT SIDE FRAME
REAR
7. FRONT SIDE FRAME
8. FRONT SUB-FRAME STAY
9. FRONT SIDE FRAME
REAR
REAR
REAR
REAR

Removal (cont'd)
45
Check the side frame bulkhead rear for position and damage. If Necessary replace it.
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
REAR
4. OUTRIGGER
6. FLOOR FRAME
REAR
8. SUB-FRAME REAR
BRACKET

Installation
46
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. Set the new front, side frame extension rear, outrigger and front
bulkhead into position and measure the front compartment diagonally.
Check the body dimensions (see section 4).
4. Temporarily install the front sub-frame and check the front side frame
position.
and check for difference in level and clearance.
Plug weld the side frame extension rear, side frame bulkhead rear
and front side frame.

2. FLOOR FRAME
From passenger compartment, plug weld the dashboard lower and

front floor.

2. FRONT SIDE FRAME
1. OUTRIGGER



47
Weld the damper housing, front wheelhouse and front side frame.
1. DAMPER HOUSING
2. FRONT WHEELHOUSE
Index - Front Pillar Outer Panel
Front Pillar Outer Panel 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

Removal
49
Cut the wheelhouse upper member as necessary pry off the front pillar outer panel.
Check the front pillar lower stiffener position and for damage and replace it if necessary.
When replacing the front pillar lower stiffener, remove the front pillar separator and glue the insulator at the separator mounted position.
1. FRONT PILLAR UPPER STIFFENER
2. FRONT PILLAR LOWER STIFFENER
3. OUTER PANEL
4. SIDE SILL REINFORCEMENT
5. FRONT PILLAR SEPARATOR
6. INNER LOWER

Installation
50
1. Glue the insulator to the inner lower at the front pillar lower separator 6. Clamp the repair part and recheck the clearance and alignment of the
mounted position. front door, front fender and windshield.
Insulator: P/N. 74416-SF1-000 7. Perform the main welding:
Attach the patch at the cut the section of the front pillar outer panel
Adhesive: Cemedine 366 or equivalent
and plug weld it.
1. INNER LOWER
2. INSULATOR
2. Set the new front pillar lower stiffener into position and tack weld the
clamped position.
3. Cut the repair part (outer panel), set it into position. Clamp the repair
part and check the body dimensions (see section 4).
4. Temporarily install the windshield, front door, hood and front fender
and check for differences in level and clearance. Make sure the body
lines flow smoothly.
5. Removal the repair part and weld the front pillar lower stiffener, upper
stiffener and side sill reinforcement.
1. Butt welding
2. PATCH
3. OUTER PANEL
4. Fillet welding
5. Overlap
30 mm (1.2 in)
8. Weld the wheelhouse upper member.

3. INSULATOR
Index - Side Sill Outer Panel
Side Sill Outer Panel 3-

51
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

Removal
52
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

Installation
53
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. NEW SIDE SILL REINFORCEMENT

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

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

Filler welding
Overlap
2. 20 mm (0.8 in.)
4. Fillet welding
Overlap
20 mm (0.8 in.)



54
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.
1. Butt welding
2. PATCH
3. PATCH
4. Butt welding
5. Overlap
30 mm (1.2 in.)
6. Fillet welding
Index - Roof Panel
Roof Panel 3-
55
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
Roof Panel 3-
Removal
56
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
Roof Panel 3-
Installation
57
1. Set the new roof panel into position and clamp it. 5. From inside the vehicle, plug weld the front pillar inner upper, rear
Check the body dimensions (see section 4), and check the width of the inner panel and front and rear roof rail.
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)
1. OUTER PANEL
2. ROOF PANEL 1. FRONT INNER UPPER PILLAR
3. ROOF SIDE RAIL 2. FRONT ROOF RAIL
3. REAR INNER PANEL
4. REAR ROOF RAIL
6. Weld the roof panel and rear pillar gutter upper.
1. REAR PILLAR GUTTER UPPER
1. ROOF ARCH GUSSET

58
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

Removal
59
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
UPPER
LOWER
6. REAR INNER PANEL
LOWER
8. REAR PANEL
UPPER
11. VIEW (Z)
12. REAR GUTTER LOWER
STIFFENER
13. OUTER PANEL
Rear Side outer Panel
Rear Side outer Panel 3-

Installation
60
1. Set the new repair part (outer panel) and rear pillar gutter lower and into Weld the rear pillar gutter lower, gutter upper and rear panel.
position and clamp 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. REAR GUTTER LOWER STIFFENER

2. REAR PILLAR GUTTER LOWER
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
Rear Panel 3-
61
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
Rear Panel 3- Installation
Removal
62
Cut and pry off the rear panel. 1. Set the new rear panel and check the body dimensions (see section 4).
Check the rear pillar gutter lower position and for damage and if 2. Tack weld the clamped position.
necessary, replace it (see page 3-59). 3. Temporarily install the tailgate, tailgate, rear bumper and check for
differences in level and clearance. Check operation of the tailgate.
1. REAR PANEL
2. REAP PILLAR GUTTER LOWER
1. REAR PANEL
3. REAR PANEL
4. REAR FLOOR
5. JACK-UP STIFFENER
Index - Rear Floor
Rear Floor 3-
63
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
Rear Floor 3-
Removal
64
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
Rear Floor 3-
Installation
65
1. Set the new rear cross-member and rear frame B, into position. 8. Set the new rear floor and plug weld the rear floor cross-member, rear
2. Check the body dimensions (see section 4). frame B and rear 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.).
1. NEW REAR FLOOR

2. Overlap
40 mm (1.6 in.) 1. REAR FRAME A
3. NEW REAR FLOOR 2. REAR FLOOR CROSS-MEMBER
4. REAR CROSS-MEMBER 3. REAR FRAME B
5. REAR FLOOR 4. REAR FRAME A
(body side) 5. REAR FLOOR CROSS-MEMBER
5. Check the position of the rear inner panel and rear panel. 9. Perform the main welding to the rear floor.
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.
1. REAR FLOOR CROSS MEMBER

Index - Rear Floor
1. Fillet welding

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 View 4-6
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
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
(0.3) Forward
6. B, b
Headlight Mount Hole 7 (0.3)
7. A, a
Bulkhead Upper Frame
Point 15 (0.59)
Upper Body Measuring Dimensions 4-5 Passenger Compartment
Engine/Transmission Mount Positions
Unit: mm (in.) Unit: mm (in.)
1. E
Front Damper Mount Hole 11.5 (0.45)
2. H
AT/MT Transmission Bracket Mount Holed 13 (0.51)
3. I
Engine Bracket Mount Hole 13 (0.51)
4. J
Honda Multi Matic Transmission Bracket Mount Hole 13 (0.51)
AT/MT:
Honda Multi Matic:
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
Under Body Measuring Dimensions 4-

Engine Compartment and Front Floor Under View
6
Unit: mm (in.)
1. A, a
Radiator Mount Hole 15
(0.59)
2. B, b
Front Sub-frame Mount
Hole 15 (0.59) Forward
3. C, c
Hole 15 (0.59) Rearward
4. D, d
Front Floor Frame Point 20
(0.79)
Index - Under Body Measuring Dimensions
Under Body Measuring Dimensions 4-7

Middle and Rear Floor Under View
Unit: mm (in.)
1. D,d
(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
Frame Repair Chart 4-

Top View
8
Unit: mm (in.) a For sub-frame o15 (0.59) e For damper mount o 11.5 (0.45)
: 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)



Top View (cont'd)
9
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)

Side View
10
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)



Side View (cont'd)
11
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
Opening Repair Chart 4-

12
Door and Windshield Openings:
Unit: mm (in.)
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:
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

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

Top View 4-18
Side View 4-20
Upper Body Measuring Dimensions 4-

Engine Compartment
14
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
(0.3) middle
4. D, d
Front Bumper Beam Mount
Hole 9 (0.35)
5. C, c
(0.3) Forward
6. B, b
Headlight Mount Hole 7 (0.3)
7. A, a
Bulkhead Upper Frame
Point 15 (0.59)
Upper Body Measuring Dimensions 4- Passenger Compartment

15
1. E
Front Damper Mount Hole 11.5 (0.45)
2. H
AT/MT Transmission bracket Mount Hole 13 (0.51)
3. I
Engine Bracket Mount Hole 13 (0.51)
1. J, j
Front seat Rear Side Bracket Point 9 (0.35)
2. K, k

Rear Damper Mount hole 11 (0.43)


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

17
1. D, d
(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)

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

Top View (cont'd)
19
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)

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

Side View (cont'd)
21
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)
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)
Opening Repair Chart 4-

22
Unit: mm (in.)
1. A
2. B, C
3. D, E, F, G, H, I, J, K,
Tailgate Opening:
1. L
Roof lower Rail Flange notch
2. M
Rear Gutter Lower Stiffener flange end (2 places)

3. N
Rear panel upper stiffener water drain notch

Index - Index
Index
4-door Rust Prevention 5-3

5-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
Cross Section of Body and Sealants 5-4

General
NOTE: Following the sealer manufacturer's instructions. 5. Apply sealer on any area that the replacement part will cover. Smooth
1. Clean the areas to be sealed with the white gasoline. the sealer with a brush is necessary.
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.
4. Finish sealing the engine compartment, the door opening, the truck
gutter and the tailgate gutter. Wipe of the excess sealer.
Cross Section of Body and Sealants 5-

Engine Compartment, Front Wheelhouse and
Damper Housing
5
1. Bulkhead Upper Frame
2. Fender Bracket
3. Damper Housing
4. Front Damper Extension
5. Front Damper Base
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
30. Front Damper Housing
Extension
31. Dashboard Lower
32. Front Side Frame
33. Front Side Back Plate
34. Damper Housing

Dashboard Upper, Dashboard Lower and Roof Panel
6
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
24. Floor Cap
25. Inner Lower Extension
26. Dashboard Upper

Front Floor and Rear Floor
7
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
23. Rear Floor
26. Front Floor
Stiffener
29. Front Floor
Stiffener
31. Floor Cap
32. Front Floor

Rear Side Outer Panel and Rear Panel
8
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

Under Floor
9
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)
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
Soft Chipping Guard Primer Coat 5-

General
10
The removal of paint and undercoating by stones chips 2. Air blowing/degreasing
immediately exposes metal to the atmosphere, causing it to Use alcohol, wax and grease remover.
oxidise. The thickness of this oxidation increases if the process
continues unchecked. The soft chipping guard primer protects 3. Making
against damage due to the impact of such objects. Use masking tape and paper.
Sectional View of Paint Coats: 4. Spraying primer surface
Spray 4~5 coats to get 20 microns of thickness.
Top coat One coat deposits 5~7 microns
Intermediate coat Do not try to cover the surface with one heavy coat.
+ Apply several thin coats.

Chipping guard primer Use a 2-part urethane primer surface and a spray gun.
Electrodeposition of primer Mix the primer surface with the additive and solvent, and
in the correct ratio.
Base metal Follow the primer surface manufacturer's instructions.
The soft chipping guard primer coat is applied over the E.D.
(Electrostatically Despotised) primer. It is followed by guide
coating and top coating.
The soft chipping guard primer produces a smooth surface
when dry. It should be sprayed so the thickness of the

protective film is 20 microns.
Basic Rules for Repairing a Soft Chipping
Guard Primer Coat:
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 using soft chipping guard primer coat. 5. Drying
After spraying primer surface, allow 7~10 minutes of drying time, then force
WARNING dry it with infrared lamps or an industrial dryer.
Wear goggles or safety glasses to 6. Polishing
prevent eye injury. Check the primer surface has dried thoroughly, then sand the primer surface.
Ventilate when spraying undercoat. Use a double action sander and #400~#600 disc
1. Sanding the replacement part. sandpaper.
NOTE: 7. Intermediate coating and top coating
Do not oversand the edges or corners of the part. Refer to pages 6-8 to 6-10 of this manual for the painting procedure.
Do not expose base metal.
Use a double action sander and #400 disc sandpaper.

Coating Diagram
11
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
Rust-preventive Treatments 5-
General
12
Undercoat: Anti-rust Agents:
WARNING WARNING
Wear goggles or safety glasses to prevent Anti-rust agents contain substances that are
eye injury. harmful if you breathe or swallow them, or
Ventilate when spraying undercoat. get them on your skin. Wear overalls, gloves,
NOTE: eye protection and an aspproved respirator
while using such agents.
Mask the exhaust system, oxygen sensors and suspension mount Ventilate when spraying an anti-rust agent
area to prevent overspread from the undercoat. since it contains a small amount of organic
Follow the undercoating manufacturer's instructions.
solvent. Keep sparks, flames and cigarettes
1. Clean the body with wax and grease remover before the undercoat is away.
sprayed.
2. Apply the undercoat to the front wheelhouse, rear wheelhouse and NOTE:
undersides of the front floor and rear floor (see page 5-13). Do not spray an anti-rust agent on the brake system, exhaust system
3. Coat the bottom of the fuel tank. and its related parts, emission control devices in the engine
compartment, ball joint cover, fuel strainer and exterior and interior
parts.
Wipe the excess agent with a clean rag dampened with light oil.
Follow the anti-rust agent manufacturer's instructions.
1. Before applying an anti-rust agent, thoroughly clean the area to be

coated with a steam cleaner, etc., and let it dry. Waxoyl may be
applied to wet surface.
2. Apply anti-rust agent from the installation hole and the access hole of
parts in the outer panel and the frame (see page 5-14). Spray an anti-
rust agent sufficiently unit the excess amount oozes out when filling
the side sill.

Undercoating Diagram
13
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
4. Rear Floor
SECTION FF
1. <Front Wheelhouse>
2. <Rear Wheelhouse>
3. OUTER PANEL
4. FUEL DOOR ADAPTOR
SECTION
6. No Coating Area.
VIEW (Z)
Index - Rust-prevention Treatments
Rust-prevention Treatments 5-
Area to be Covered by Anti-rust Agents
14
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
Materials and Tools 5-

15
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
3m #08893 (external) when work involves a considerable number of
or equivalents. vehicles.
TOOLS For nox-rust 409-20S/solton 1000S
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.

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
Under Floor 5-23
Soft Chipping Guard Primer Coat

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

General
18
NOTE: Following the sealer manufacturer's instructions. 5. Apply sealer on any area that the replacement part will cover. Smooth
1. Clean the areas to be sealed with the white gasoline. the sealer with a brush is necessary.
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.
4. Finish sealing the engine compartment, the door opening, the truck
gutter and the tailgate gutter. Wipe of the excess sealer.

Engine Compartment, Front Wheelhouse and
Damper Housing
19
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
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

Dashboard Upper, Dashboard Lower and Roof Panel
20
1. Dashboard Upper
2. Windshield Lower
3. Windshield Lower
4. Dashboard Upper
5. Inner Lower
6. Dashboard Lower
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
26. Floor Cap
27. Side Frame Extension
29. Inner Lower Extension
30. Dashboard Upper

Front Floor and Rear Floor
21
1. Front Floor
2. Inside Sill
3. Outer Panel
5. Inside Sill
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
Stiffener
26. Rear Floor
29. Front Floor
Stiffener
32. Front Floor
34. Front Floor
35. Floor Cap

22
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

Under Floor
23
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)
20. Rear Floor
21. VIEW (Z)
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.)

General
24
The removal of paint and undercoating by stones chips 2. Air blowing/degreasing
immediately exposes metal to the atmosphere, causing it to Use alcohol, wax and grease remover.
oxidise. The thickness of this oxidation increases if the process
continues unchecked. The soft chipping guard primer protects 3. Making
against damage due to the impact of such objects. Use masking tape and paper.
Sectional View of Paint Coats: 4. Spraying primer surface
Top coat One coat deposits 5~7 microns
Intermediate coat Do not try to cover the surface with one heavy coat.
+ Apply several thin coats.

Chipping guard primer Use a 2-part urethane primer surface and a spray gun.
Electrodeposition of primer Mix the primer surface with the additive and solvent, and
in the correct ratio.
Base metal Follow the primer surface manufacturer's instructions.
The soft chipping guard primer coat is applied over the E.D.
(Electrostatically Despotised) primer. It is followed by guide
coating and top coating.
The soft chipping guard primer produces a smooth surface
when dry. It should be sprayed so the thickness of the

protective film is 20 microns.
Basic Rules for Repairing a Soft Chipping
Guard Primer Coat:
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 parts using soft chipping guard primer coat. 5. Drying
After spraying primer surface, allow 7~10 minutes of drying time, then force
WARNING dry it with infrared lamps or an industrial dryer.
Wear goggles or safety glasses to 6. Polishing
prevent eye injury. Check the primer surface has dried thoroughly, then sand the primer surface.
Ventilate when spraying undercoat. Use a double action sander and #400~#600 disc
1. Sanding the replacement part. sandpaper.
NOTE: 7. Intermediate coating and top coating
Do not oversand the edges or cornres of the part. Refer to pages 6-8 to 6-10 of this manual for the painting procedure.
Do not expose base metal.
Use a double action sander and #400 disc sandpaper.

Coating Diagram
25
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
Rust-preventive Treatments 5-
General
26
Undercoat: Anti-rust Agents:
WARNING WARNING
Wear goggles or safety glasses to prevent Anti-rust agents contain substances that are
eye injury. harmful if you breathe or swallow them, or
Ventilate when spraying undercoat. get them on your skin. Wear overalls, gloves,
NOTE: eye protection and an approved respirator
while using such agents.
Mask the exhaust system, oxygen sensors and suspension mount Ventilate when spraying an anti-rust agent
area to prevent overspread from the undercoat. since it contains a small amount of organic
Follow the undercoating manufacturer's instructions.
solvent. Keep sparks, flames and cigarettes
1. Clean the body with wax and grease remover before the undercoat is away.
sprayed.
2. Apply the undercoat to the front wheelhouse, rear wheelhouse and NOTE:
undersides of the front floor and rear floor (see page 5-27). Do not spray an anti-rust agent on the brake system, exhaust system
3. Coat the bottom of the fuel tank. and its related parts, emission control devices in the engine
compartment, ball joint cover, fuel strainer and exterior and interior
parts.
Wipe the excess agent with a clean rag dampened with light oil.
Follow the anti-rust agent manufacturer's instructions.
1. Before applying an anti-rust agent, thoroughly clean the area to be

coated with a steam cleaner, etc., and let it dry. Waxoyl may be
applied to wet surface.
2. Apply anti-rust agent from the installation hole and the access hole of
parts in the outer panel and the frame (see page 5-28). Spray an anti-
rust agent sufficiently unit the excess amount oozes out when filling
the side sill.

Undercoating Diagram
27
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
SECTION FF
1. <Front Wheelhouse>
2. <Rear Wheelhouse>
3. OUTER PANEL
SECTION
6. No Coating Area.
VIEW (Z)
Index - Rust-prevention Treatments
Rust-prevention Treatments 5-
Area to be Covered by Anti-rust Agents
28
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
Materials and Tools 5-

29
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 work involves a
3m #08893 (external) 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
General Safety Precautions 6-2

Most paints contain substances that are harmful if inhaled or 4. Read the paint label before opening the container. Cover spilled paint
swallowed. with sand, or wipe it up at once.
The following precautions are important items in order to maintain safe
painting work.
1. Wear an approved respirator and eye protection when painting.
5. If paint gets in your mouth or your skin, rinse or wash thoroughly with
water. If paint gets in your eyes, flush with water and get prompt
medical attention.
2. Wear approved gloves, appropriate clothing when painting. Avoid

contact with skin.
6. After the painting work is finished, wash face and gargle with water.
3. Spray paint only in a well ventilated area.
7. Paint is flammable. Store it in a safe place, and keep it away from

sparks, flames or cigarettes.
Paints - Body Paint
Body Paint 6-3

General
The 3-coat/3-bake (3C/3B) paint finishes give the Odyssey a deep gloss and stunning finish. This manual provides information on paint defect, repair and refinishing. Throughout,
the objective is to explain in a simple yet comprehensive manner the basic items you should know about paint repairs. Select the correct material for the defect and repaint or
refinish in the correct manner as described in this manual.
WARNING
Most paints contain substances that are harmful if inhaled or swallowed. Read the paint label
before opening the container. Spray paint only in a well ventilated area.
Cover spilled paint with sand, or wipe it up at once.
Wear an approved respirator, gloves, eye protection and appropriate clothing when painting.
Avoid contact with skin.
If paint gets in your mouth or on your skin, rinse or wash thoroughly with water. If paint gets in
your eyes, flush with water and get prompt medical attention.
Paint is flammable. Store it in a safe place, and keep it away from sparks, flames or cigarettes.
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. 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
Body Paint 6-4

Refinishing Processes
Paint damage can appear in any form. Before making a repair, check the damaged area carefully, and determine the best procedure for repairing the damage. The following shows
you refinishing methods for various types of paint damage or defects.
: Indicates the best method depending on the degree of damage.
Paints - Body Paint
Body Paint 6-5

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

Sand the damaged area flat and smooth.
Use the disc sander and #60~#80

disc paper. 2. Preparation of metal surface
Remove all corrosion from the damaged area.
Use a product that removes
corrosion.
1. Top coat 3. Air blowing/degreasing

2. Intermediate coat Use alcohol, wax and grease
3. Undercoat
4. Metal surface remover.

#60~#80 disc paper.
Sand the area larger than the damaged area.

#180~#240 disc paper.
Paints - Body Paint
Body Paint 6-6

Treatment of Metal Surface
1. Filling/drying After applying the body filler, allow 5~6 minutes of normal drying time,
Small cracks or pinholes in the sheet metal should be repaired with a then force dry it with infrared lamps or other industrial dryer at 50C
body filler and sanded flat and smooth. (122F)~60C (140F).
NOTE: Follow the body filler manufacturer's instructions for drying time.
Use the 2-part polyester resin
putty. 2. Polishing
Mix the putty with the hardener When the body filler is dry a white mark appears when the surface is
in the correct ratio. scratched with your finger nail.
Follow the body filler 1. Thoroughly sand the body filler surface.
manufacturer's instructions.
#80~#120 disc paper.
Mix the body filler and hardener quickly.
2. Sand the surface evenly, particularly the area that was filled.
Apply the body filler in several thin coats, without air bubbles. Use the flexible block and #120~#180 sandpaper.
Do not try to cover the surface with one heavy coat.
Apply the body filler over the damaged area with a putty knife
using light pressure.
1. Body Filler
Paints - Body Paint
Body Paint 6-7 Undercoating
Treatment of Metal Surface (cont'd)
3. Featheredge the paint coat. 1. Masking

Sand the body filler surface until the proper dimensions are met. Mask the area surrounding the damage to prevent over spray from the
primer surfacer.
#240~#320#~400 disc papers. Use the masking tape and paper.
2. Spraying primer surfacer
Spray the primer surfacer over a wider area than the body filler and
the exposed surface of the paint film.

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
1. Body Filler
2. Featheredging
3. Air blowing/degreasing
Use the alcohol, wax and grease remover.
Also clean and degrease the surfaces where masking tape will be
attached.
1. Primer Surfacer
3. Drying
After spraying primer surfacer, allow for 5~10 minutes of normal drying
time, then force dry it with infrared lamps or other industrial dryer.
NOTE: Follow the primer surfacer manufacturer's instructions for
drying time.
Paints - Body Paint
Body Paint 6-8 Intermediate Coating
Undercoating (cont'd)
4. Polishing 1. Masking
Check that the primer surfacer has dried thoroughly, then sand the Mask the area surrounding the damage to prevent over spray from the
primer surfacer. intermediate coat.
Use the double action sander and Use masking tape and paper.
#320~#400~#600 disc papers. 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 solvent, and in
the correct ratio.
Follow the top coat
Use the alcohol, wax and grease
remover.
Also clean and degrease the surfaces where the masking tape will be
attached.
3. Drying
After spraying top coat enamel or colour base (3-coat pearl paint),
allow 5~10 minutes of normal drying time, then force dry it with infrared
lamps or other industrial dryer.
NOTE: Follow the top coat manufacturer's instructions for drying time.
Paints - Body Paint
Body Paint 6-9 Top Coating
Intermediate Coating (cont'd)
4. Polishing 1. Masking
Check that the top coat enamel has dried thoroughly, then sand the Mask the area surrounding the damage to prevent over spray from the
top coat enamel. top coat.
Use the double action sander and Use masking tape and paper.
#600~#800 disc papers. 2. Spraying top coat enamel/clear coat
Spray 2~3 double coat until the intermediate coat is fully covered.
NOTE: Be careful not to polish down to the primer surfacer.
NOTE: See pages 6-11, 6-12 for the painting repair (gradation) of the
3-coat pearl paint.
spray gun.
the correct ratio.
Follow the top coat
When the painting repair (gradation) is almost done, polish the area
that will be top coated.
Use the #2000 sandpaper and
compound.
Use alcohol, wax and grease
remover. Drying
After spraying the top coat enamel, allow it to air dry, then force dry it
Also clean and degrease surfaces where the masking tap will be with infrared lamps or other industrial dryer.
attached. NOTE: Follow the top coat manufacturer's instructions for drying time.
NOTE: See pages 6-11, 6-12 for the painting repair (gradation) of the Spraying clear coat
3-coat pearl paint. 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
Body Paint 6-
Top Coating (cont'd)
10
Drying 4. After buffing, remove the masking paper and tape, and thoroughly
After spraying the clear coat, allow it to dry for 10 minutes, then force wash the entire vehicle.
dry it with infrared lamps or other industrial dryer.
NOTE: Follow the top coat manufacturer's instructions for drying times.
3. Polishing/buffing
Check that the clear coat has dried thoroughly.
The clear coat is cooled.
1. Any adhesion or roughness on the top coat should be wet sanded
and repaired.
Use the #1200~#2000 and crystal block.
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. 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
Plastic Parts Paint 6-

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

(176)
PF Phenol formaldehyde 80 A small amount of alcohol is acceptable Soaking with an organic solvent such as gasoline and
(176) for a short time. (Degreasing) alcohol, is not recommended.
PMMA Polymethyl methacrylate 80 A small amount of alcohol is acceptable Soaking with an organic solvent such as gasoline and
(176) for a short time. (Degreasing) alcohol, is not recommended. Wash remover off with
water thoroughly.
POM Polyoxymethylene 100 Alcohol and gasoline are acceptable. Solvent is not recommended.
polyacetal (212)

Features of Plastic Material (cont'd)
12
Standard Name Heat Resistance Solvent Resistance Note
Symbol Temperature C (
F)
PP Polypropylene 80 Alcohol and gasoline are acceptable. Solvent is not recommended.
(176)
PPO Polyphenylene oxide 100 A small amount of alcohol is acceptable Soaking with an organic solvent such as gasoline and
(PPE) (212) for a short time. alcohol is not recommended.
PS Polystyrene 60 A small amount of alcohol is acceptable Soaking with an organic solvent such as gasoline and
(140) for a short time. alcohol is not recommended.
PUR Polyurethane 80 A small amount of alcohol is acceptable Soaking with an organic solvent such as gasoline and
(176) for a short time. (Degreasing) alcohol is not recommended.
PVC Polyvinylchloride 80 A small amount of alcohol and gasoline Soaking with an organic solvent such as gasoline and
(176) are acceptable for a short time. alcohol is not recommended.
(Degreasing)
SAN Styrene acrylonitrile 80 Wiping alcohol off in a short time can be Soaking with an organic solvent such as gasoline and
(176) allowed. alcohol is not recommended.
SMC Sheet moulding 180 Alcohol and gasoline are acceptable. Solvent is not recommended.
compound (356)
TPE Thermoplastic polyester 80 Alcohol is acceptable and wiping gasoline Soaking with an organic solvent such as gasoline and
elastomer (176) for a short time can be allowed. alcohol is not recommended. Wash remover off with
(Degreasing) water thoroughly.
TPS Thermoplastic styrene 80 A small amount of alcohol and gasoline Soaking with an organic solvent such as gasoline and
elastomer (176) are acceptable for a short time. alcohol is not recommended. Wash remover off with
TPO Thermoplastic olefin / 80 Alcohol is acceptable and wiping gasoline Soaking with an organic solvent such as gasoline and
elastomer (176) for a short time can be allowed. alcohol is not recommended. Wash remover off with
TPU Thermoplastic / 80 A small amount of alcohol and gasoline Soaking with an organic solvent such as gasoline and
urethane / elastomer (176) are acceptable for a short time. alcohol is not recommended. Wash remover off with
UP Polyester 110 Alcohol and gasoline are acceptable. Alkali is not recommended.
(230)

Use of the Repair Material (reference)
13
NOTE: Follow the materials manufacturer's instructions. Mixing Ratio:
The use of a special polyester putty for PP bumper is described here:
1. Filler
Mixing Ratio:
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. Sanding filler
Spray bumper primer (see page 6-19) on the area where the PP
material was used.
3. Primer surfacer
The primer surfacer is used to protect the PP resin surface and fill
cavities or flaws before the intermediate coat and top coat.
Use the 2-component type primer surfacer (grey). NOTE: Use a spray gun to apply the paint. Do not use a brush.
Drying time:
Air dry 20C (68F) 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.

Refinishing Processes
14
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.
Plastic Parts Paint 6- Undercoating
Pre-processing of Painting
15
1. Sanding 1. Spraying primer
Sand the damage area flat and smooth. Primer is used to fill cavities in the putty and primer surfacer.
Shallow Scratch: Spray primer on the exposed area.
Spray the 2~3 coats of primer on 2~3 coats over the area you
Use a flexible block and

applied putty.
#240~#400~#600 sandpaper.
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 10C (50
F).
Follow the bumper primer
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.
Drying
Use alcohol, and wax and grease NOTE: Take care not to let the heat lamp deform the bumper during
remover. the drying process.
Dry the bumper primer thoroughly with an infrared dryer or other
suitable method.
Drying Time:
Air dry 20C (68 20 minutes
F)
Force dry 60C 10 minutes
(140F)

Undercoating (cont'd)
16
2. Filing/Sanding 5. Spraying primer surfacer
Apply putty to repair any holes or deep gouges. NOTE: Spray the bumper primer (see page 6-17) on the area where
Apply the putty on the damaged are in 2~3 steps. the PP material was exposed and around the putty.
Glue aluminium tape on the outside of the bumper, and apply putty Spray the primer surface wider than the putty and painted surfaces
from the other side of the bumper. of bumper primer.
Remove the aluminium tape after the putty dries, apply putty from Spray 2~3 coats to get 20~30 microns of thickness.
the outside, and fill the hole.
Use the 2-component type
Use a special polyester putty primer surfacer (grey) and a
(Reference) and a putty knife. spray gun.
Follow the materials
Drying
1. Aluminium Tape NOTE: Take care not to let the heat lamp deform the bumper during
2. Outside the drying process.
6. Sanding
3. Sanding After drying, wet sand the area of the intermediate coat.
Sand the surface evenly, particularly at the area where the PP material
and putty meet. Use the #600 sandpaper.
NOTE: Do not use less than #600.
Use a flexible block and
#240~#400~#600 sandpaper.
Use alcohol, a tack cloth, and wax
and grease remover.
1. Featheredging
Also clean and degrease the surfaces where the masking tape will be
4. Air blowing/degreasing attached.
and grease remover.

Intermediate Coating
17
NOTE: You must do this procedure on the PP parts of the bumper and 3. Polishing
side sill panel. Check the top coat enamel has dried thoroughly, then sand the top
1. Masking coat enamel.
Mask the area surrounding the damage to prevent overspray from the Use a flexible block and
intermediate coat. #600~#800~#1000 sandpapers.
Use masking tape and paper.
NOTE: Be careful not to sand down to the primer surfacer.
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.

a spray gun.
the correct ratio.
Follow the top coat
When the painting repair is almost complete, polish the top coat.
Use #1500 sandpaper and
compound.
Drying
NOTE: Take care not to let the heat lamp deform the bumper during
the drying process.
1. Material
After spraying the top coat enamel, allow for 5~10 minutes of normal 2. Putty
drying, then force dry it with infrared lamps or other industrial dryer. 3. Intermediate Coat
4. Sanding
5. Paint Coat
and grease remover.
Clean and degrease the surfaces where the masking tape will be
attached.

Top Coating
18
1. Masking Using a buffer and compound, remove any polishing marks
Mask the area surrounding the damage to prevent overspray of the top coat made from the sandpaper.
Use masking tape and paper. Use a buffing sponge, and buffing
wool and compounds.
2. Spraying top coat enamel / clear coat
Spray 2~3 coats in double coat until the intermediate coat is fully covered. Finish up with buffing:
NOTE: 1. Wet sands with #2000 sandpaper and soapy water.
Do not cover the surface with one heavy coat.
Apply several thin coats.
Use the 2-part polyester urethane top coat enamel and a spray gun.
Mix the top coat enamel with the additive and solvent, and in the correct
ratio.
Follow the top coat manufacturer's instructions.
After spraying the top coat enamel, allow for 5~10 minutes drying time before 2. Remove moisture using compressed air.
you spray the clear coat. 3. Finish using fine compound and very fine compound. Do not
polish with an electric polisher.
NOTE: Polish lightly.
Drying 4. Check the finished area at an angle, and make sure there are
no polishing marks.
NOTE: Take care not to let the heat lamp deform the bumper during the drying
5. Polish with ultra fine compound and a buffing sponge.
process.
After spraying the clear coat, allow for 5~10 minutes drying time before you
force dry it with infrared lamps or other industrial dryer.
3. Polishing/buffing
Check that the clear coat has dried thoroughly.
Wet sand to remove any imperfections.
Use a flexible block soap and #2000 sandpaper.
6. Wax the finished area.
Paints - Glossary
Glossary 6-
19
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 paint Composed of acrylic resin and meramine resin and hardener (forms a paint film) by banking.
Paints - Glossary
Glossary 6-
Cont'd
20
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/cm, 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
Glossary 6-
cont'd
21
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.
Introduction
Introduction
This manual covers the repairs of 2001 model series CIVIC 3-door that 1 General Info
have been involved in an accident and it describes the work related to the 3 *Replacement
replacement of damage body parts.
4 Body Dimensional Drawings
Please read through these instructions and familiarise yourself with them
before actually using this manual. 5 Rust Prevention
NOTE: Refer to the 2001 CIVIC 4-door/CIVIC 5-door Body Repair Manual Sections with an * include SRS
(P/N. 62S5A30), CIVIC Shop Manual (P/N. 62S5A00) and CIVIC Shop
components; special caution is
Manual supplement (P/N. 62S5A20) on this CD for specifications, wire
harness locations, safety stand support points, etc. required when servicing.
Special Information
WARNING
Indicates a strong possibility of severe
personal injury or death if instructions are
not followed.
CAUTION
followed.
CAUTION
Detailed descriptions of standard workshop
operations are not included. Please note
that this manual does contain warnings and
cautions against some specific service
methods which could cause PERSONAL
INJURY, damage a vehicle, or make it
unsafe. Please understand that these
warnings 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
themselves 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 includes text, figures and tables.
HONDA MOTOR CO., LTD.
Service Publication Office
Fist Edition 3/2001 40 pages
All Rights Reserved
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1-1
General Information

Body Construction 1-4
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1-2

This model has an SRS which includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above the glove box, seat belt tensions in the front seat
1. The SRS unit is located under the dashboard and the side impact sensors are located in each side sill. The front sensors are located behind the right and left end of the front
bumper. Avoid any strong Impact with a hammer or other tools when repairing the front side frame, the lower part of the dashboard and the side sill. Do not apply heat to these
areas with a torch, etc.
2. Take extra care when painting or doing body work in the area below the centre pillar. Avoid direct exposure of the seat belt retractor and tensioner to heat guns, welding or
spraying equipment.
3. SRS electrical wiring harnesses and connectors are identified with yellow colour coding. Care should be taken not to damage the harness when repairing this area.
4. Do not apply heat of more than 100C (212F) when drying painted surfaces anywhere around the locations of SRS components.
NOTE: Refer to the Restraints section of the Shop Manual for after deployment procedures, and removal and replacement of SRS related components.
1. FRONT SENSOR
2. DRIVER'S AIRBAG
ASSEMBLY
3. FRONT SENSOR
4. CABLE REEL
AIRBAG
6. SIDE AIRBAG
10. SIDE AIRBAG
11. SRS UNIT
12. UNDER-DASH FUSE/RELAY
BOX
1-3

Unit: mm (in.)

Camber 000' 45'
Caster 133' 1
Total toe 0 3 (0 0.12)
Wheel turning angle in 4000' 2
out 3100' (Reference)

Camber -045' 45'
Total toe IN 2 3 (0.08 0.12)
1-4

Body Construction
Sp: Steel plate Hss: High strength steel plate Zn: Zinc-plated
1 Hood (Hss, Zn) 23 Centre Pillar Stiffener Lower (Sp)
2 Front Fender (Sp, Zn) 24 Side Sill Reinforcement (Hss, Zn)
3 Door (Hss, Zn) 25 Front Pillar Inner Lower (Hss, Zn)
4 Tailgate (Sp, Zn) 26 Front Pillar Inner Upper (Hss)
5 Bulkhead Side (Sp, Zn) 27 Centre Inner Pillar (Hss, Zn)
6 Bulkhead Side Stay (Sp, Zn) 28 Roof Side Rail (Hss)
7 Bulkhead Upper Frame (Sp, Zn) 29 Roof Panel (Sp)
8 Front Lower Cross-member (Hss, Zn) 30 Rear Inner Pillar (Sp)
9 Wheelhouse Upper Member (Sp) 31 Rear Inner Panel (Sp, Zn)
10 Front Wheelhouse (Sp, Zn) 32 Wheel Arch Extension (Sp, Zn)
11 Wheelhouse Upper Extension (Hss, Zn) 33 Rear Wheelhouse (Sp, Zn)
12 Damper Housing (Hss, Zn) 34 Inside Sill (Hss, Zn)
13 Front Side Frame (Hss, Zn) 35 Front Floor (Sp, Zn)
14 Side Frame Extension Rear/Front Side Outrigger (Hss, Zn) 36 Middle Floor Cross-member (Hss, Zn)
15 Dashboard Lower (Sp, Zn) 37 Middle Floor Gusset (Sp)
16 Dashboard Upper (Sp, Zn) 38 Rear Floor Upper Cross-member (Sp)
17 Outer Panel (Sp, Zn) 39 Rear Floor (Sp, Zn)
18 Rear Pillar Gutter Lower (Sp, Zn) 40 Rear Panel (Sp, Zn)
19 Rear Pillar Gutter Upper (Sp, Zn) 41 Rear Gutter Lower Stiffener (Sp)
20 Front Pillar Lower Stiffener (Hss) 42 Rear Frame A (Sp, Zn)
21 Front Pillar Upper Stiffener (Hss) 43 Rear Frame B (Hss, Zn)
22 Centre Pillar Stiffener upper (Sp) 44 Rear Floor Cross-member (Sp, Zn)
1-5


Paint Code Colour Name NH-623M Satin B-92P Night B-94 Midnight B-96P Eternal R-81 Mirano R-504P Ruby G-503P YR-62 Corona
Silver M. Hawk Black P. Blue Blue P. Red Red P. Amazon Gold P.
Green P.
KE 1.4 B O O O O O O O O
1.4 S
1.4 SE
1.6 S
1.6 SE
1.6 SEE
KG 1.4 S O O O O O O O O
1.4 LS
1.6 S
1.6 LS
1.6 ES
KR 1.4 S O O O O O O O O
1.4 LS
1.6 S
1.6 LS
1.6 ES
KS 1.4 S O O O O O O O O
1.4 LS
1.6 LS
1-6

1. DOOR MIRROR BASE

2. DOOR MIRROR
Gloss 20)
Gloss 30)
4. CORNER TRIM
5. ROOF MOULDING
6. TAILGATE SPOILER
Body colour
7. LICENSE TRIM
Gloss 20)
8. REAR BUMPER
Body Colour
9. DOOR MOULDING
10. REAR DOOR SASH TRIM
11. FRONT BUMPER
Body Colour
12. GRILL
1-7

Example:
1. FRONT WINDSHIELD
MOULDING
Acrylonitrile ethylene
propylene diene rubber
styrene (A/EPDM/S)
Polycarbonate (PC)
3. DOOR MIRROR
Unpainted: Acrylonitrile
styrene acrylate (ASA)
4. TAILGATE SPOILER
Acrylonitrile butadiene styrene
(ABS)
5. LICENSE TRIM
Unpainted: Acrylontirile
ethylene styrene (AES)
6. REAR BUMPER
Polypropylene (PP)
7. DOOR SASH TRIM
Acrylontrile styrene acrylate
(ASA)
8. ROOF MOULDING
9. FRONT BUMPER
Polypropylene (PP)
3-2
Side Sill Outer Panel 3-2

3-3

Removal

Check the centre pillar stiffener lower and side sill reinforcement position and check for damage. If necessary, replace the side sill reinforcement.
Replace the driver's side sill reinforcement as an assembly because of the way the stiffener is attached inside the side sill reinforcement.
1. OUTER PANEL
3. REINFORCEMENT
STIFFENER (Driver side)
4. INSIDE SILL
8. VIEW (Z)
9. CENTRE PILLAR STIFFENER
LOWER
12. OUTER PANEL
13. FRONT PILLAR LOWER
STIFFENER
3-4

Installation
1. Cut and set the new side sill reinforcement into position and tack weld the clamped Passenger's side
position. When replacing the side sill reinforcement, cut the new side sill reinforcement so it
2. Cut the repair part (outer panel) and set it into position. Clamp the repair part and overlaps the body side reinforcement by 20 mm (1.8 in.) and fillet weld it.
check the body dimensions (see section 4).
3. Temporarily install the door and front fender and check for differences in level and
clearance. Make sure the body lines flow smoothly.
4. Remove the repair part and weld the center pillar stiffener, lower side sill
reinforcement and front pillar lower stiffener (driver's side).
Driver's side
1. Fillet welding Overlap

20 mm (1.8 in.)
5. Clamp the repair part and recheck the clearance and alignment of the door and
front fender.
Attach a patch at the cut section of the front pillar (driver's side), side sill
VIEW (Z) (passenger's side) and wheel arch and plug weld them.
Driver's side
1. PATCH
1. NEW SIDE SILL REINFORCEMENT 2. Butt welding
3. Butt welding
4. PATCH
5. OUTER PANEL
Passenger's side:
1. PATCH
2. Butt welding
3. OUTER PANEL
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3-5
Roof Panel 3-5

Without roof panel:
3-6
Rear Side Outer Panel 3-6

3-7

Removal
Cut and pry off the rear side outer panel.

Check the rear pillar gutter lower and gutter upper position and check if for damage and if necessary, replace the rear pillar gutter lower.
Check the centre pillar stiffener and check for damage. If necessary, replace the centre pillar stiffener lower.
When replacing the centre pillar stiffener lower, remove the centre pillar separator and glue the insulator at the separator mounted position.
1. OUTER PANEL
LOWER
3. CENTRE PILLAR SEPARATOR
UPPER
5. REAR INNER PILLAR
UPPER
7. REAR PANEL
LOWER
9. REAR INNER PANEL
UPPER
LOWER
15. REAR PANEL
16. REAR GUTTER LOWERS
STIFFENER
17. VIEW (Z)
3-8

Installation
1. Glue the insulator to the centre inner pillar as shown. 3. Set the new repair part (outer panel) and rear pillar gutter lower into position and
Insulator: P/N. 774416-SF1-000 clamp them.
Adhesive: Cemedine 366, or equivalent. Check the body dimensions (see section 4).
Remove the repair part (outer panel) and weld the centre pillar stiffener lower.

2. INSULATOR
2. Set the new centre pillar stiffener lower into position and install the middle floor
gusset.
1. NEW CENTRE PILLAR STIFFENER LOWER

2. CENTRE PILLAR STIFFENER UPPER
4. Tack weld the outer panel and rear pillar gutter lower.
5. Temporarily install the door, tailgate and rear bumper and check for differences in
level and clearance.
1. NEW CENTRE PILLAR STIFFENER LOWER

2. MIDDLE FLOOR GUSSET
3-9

6. Do the main welding: VIEW (Z)

Attach a patch at the cut section of the side sill, centre pillar, rear pillar and plug
weld them.
1. NEW REAR GUTTER LOWER STIFFENER

1. Butt welding
2. PATCH
3. Butt welding
4. PATCH
5. Butt welding
6. NEW OUTER PANEL
7. PATCH
8. NEW REAR GUTTER LOWER
3-10
Rear Panel 3-
10
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3-11
Rear Panel 3- Installation
Removal
11
Cut and pry off the rear panel. 1. Set the new rear panel and check the body dimensions (see section 4).
Check the rear pillar gutter lower position and check it for damage. 2. Tack weld the clamped position.
If necessary, replace the rear pillar gutter lower (see page 3-7) 3. Temporarily install the tailgate, taillight, rear bumper and check for differences in
level and clearance. Check for operation of the tailgate.
4. Do the main welding.
1. NEW REAR PANEL
1. REAR PANEL
3. REAR PANEL
4. REAR FLOOR
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4-1

Engine/Transmission Mount Positions and Passenger Compartment 4-2

Frame Repair Chart

Top View 4-4
Side View 4-6
4-2
Upper Body Measuring Dimensions 4-2 Passenger Compartment
AT/MT:
Honda Multi Matic:
4-3
Under Body Measuring Dimensions 4-3

4-4
Frame Repair Chart 4-4

Top View
Unit: mm (in.) a For sub-frame 15 (0.59) e Damper centre 78 (3.07)

: Inner diameter b1 For engine mount 13 (0.51) f For damper mount 11.5 (0.45)
b2 For engine mount 13 (0.51) g For damper mount 11.5 (0.45)
b3 For engine mount 13 (0.51) h For sub-frame 11 (0.43)
c1 For transmission mount 15 (0.59) I For sub-frame 15 (0.59)
c2 For transmission mount 15 (0.59) j Locate hole 25 (0.98)
c3 For transmission mount 13 (0.51) k Locate hole 50 (1.97)
d For damper mount 11.5 (0.45)
4-5

Top View (cont'd)
l Locate hole 25 (0.98) t For upper arm bracket center 15 (0.59)

m For trailing arm 13 (0.51) u1, u2 Locate hole 13 (0.51)
n Locate hole 25 (0.98) v For upper arm 13 (0.51)
o Locate hole 20 (0.79) w Locate hole 25 (0.98)
q Rear damper center 73 x 68 (Slot) y Locate hole 50 (1.97)
r For upper arm 13 (0.51) z Locate hole 20 (0.79)
s For trailing arm 13 (0.51)
4-6

Side View
Unit: mm (in.) a For sub-frame 15 (0.59) e Damper centre 78 (3.07)

: Inner diameter b1 For engine mount 13 (0.51) f For damper mount 11.5 (0.45)
b2 For engine mount 13 (0.51) g For damper mount 11.5 (0.45)
b3 For engine mount 13 (0.51) h For sub-frame 11 (0.43)
c1 For transmission mount 15 (0.59) I For sub-frame 15 (0.59)
c2 For transmission mount 15 (0.59) j Locate hole 25 (0.98)
c3 For transmission mount 13 (0.51) k Locate hole 50 (1.97)
d For damper mount 11.5 (0.45)
4-7

Side View (cont'd)
l Locate hole 25 (0.98) t For upper arm bracket center 15 (0.59)

m For trailing arm 13 (0.51) u1, u2 Locate hole 13 (0.51)
n Locate hole 25 (0.98) v For upper arm 13 (0.51)
o Locate hole 20 (0.79) w Locate hole 25 (0.98)
q Rear damper center 73 x 68 (Slot) y Locate hole 50 (1.97)
r For upper arm 13 (0.51) z Locate hole 20 (0.79)
s For trailing arm 13 (0.51)
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This manual covers the repairs of 2001 model series CIVIC 2-door that 1 General Info
have been involved in an accident, and it describes the work related to 3 *Replacement
the replacement of damage body parts. 4 Body Dimensional Drawings
Please read through these instructions and familiarise yourself with 5 Rust Prevention
them before actually using this manual.
Sections with * include SRS
NOTE: Refer to the 2001 CIVIC 4-door/CIVIC 5-door Body Repair
Manual (P/N. 62S5A30), CIVIC Shop Manual (P/N. 62S5A00) and components; special caution is
CIVIC Shop Manual supplement (P/N. 62S5A20) for specifications, required when servicing.
wire harness locations, safety stand support points, etc.
Special Information
WARNING
Indicates a strong possibility of severe
personal Injury or death if instructions are not
followed.
CAUTION
followed.
CAUTION
Detailed descriptions of standard workshop
operations are not included. Please note that
this manual does contain warnings and
cautions against some specific service
methods which could cause PERSONAL
INJURY, damage a vehicle, or make it unsafe.
Please understand that these warnings 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,
figures and tables.
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HONDA MOTOR CO., LTD.

Service Publication Office
First Edition 10/2000 32 pages
All Rights Reserved

General Information - General Information
General Information
Construction 1-4
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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
1. The SRS unit (including the safing sensor and the impact sensor) is located under the dashboard and the side impact sensors are located in each side sill. The front impact
sensors are located behind the right and left end of the front bumper. Avoid any strong impact with a hammer or other tools when repairing the front side frame, the lower part of
the dashboard and the side sill. Do not apply heat to these areas with a torch, etc.
2. Take extra care when painting or doing body work in the area below the centre pillar. Avoid direct exposure of the seat belt retractor and tensioner to heat guns, welding or
spraying equipment.
3. SRS electrical wiring harnesses and connectors are identified with yellow colour coding. Care should be taken not to damage the harness when repairing this area.
4. Do not apply heat of more than 100C (212F) when drying painted surfaces anywhere around the locations of SRS components.
NOTE: Refer to the Restraints section of the Shop Manual for after deployment procedures, and removal and replacement of SRS related components.
1. FRONT IMPACT SENSOR
2. DRIVER'S AIRBAG ASSEMBLY
3. FRONT IMPACT SENSOR
4. CABLE REEL
5. FRONT PASSENGER'S AIRBAG ASSEMBLY
6. SIDE AIRBAG
10. SIDE AIRBAG
11. SRS UNIT
12. UNDER-DASH FUSE/RELAY BOX

Unit : mm(in.)

Camber 000' 45'
Caster 133' 1
Total toe 0 2 (0 1/16)
Wheel turning angle in 4000' 2
out 3100' (Reference)

Camber -045' 45'
Total toe 2 +2 -1 (1/16 +1/16 -1/32)

Construction
Sp: Steel plate / Hss: High strength steel plate / Zn: Zinc-plating
(1) Hood (Hss, Zn) (22) Side Sill Reinforcement (Hss, Zn)
(2) Front Fender (Sp, Zn) (23) Front Pillar Inner Lower (Hss)
(3) Door (Hss, Zn) (24) Front Pillar Inner Upper (Hss, Zn)
(4) Trunk Lid (Sp, Zn) (25) Roof Side Rail (Hss)
(5) Bulkhead Side (Sp, Zn) (26) Roof Panel (Sp)
(6) Bulkhead Side Stay (Sp, Zn) (27) Rear Inner Panel (Sp, Zn)
(7) Bulkhead Upper Frame (Sp, Zn) (28) Wheel Arch Extension (Sp, Zn)
(8) Front Lower Cross-member (Hss, Zn) (29) Rear Wheelhouse (Sp, Zn)
(9) Wheelhouse Upper Member (Sp) (30) Inside Sill (Hss, Zn)
(10) Front Wheelhouse (Sp, Zn) (31) Front Floor (Sp, Zn)
(11) Front Damper Extension (Hss, Zn) (32) Middle Floor Cross-member (Hss, Zn)
(12) Damper Housing (Hss, Zn) (33) Middle Floor Gusset (Hss)
(13) Front Side Frame (Hss, Zn) (34) Rear parcel Shelf (Sp)
(14) Side Frame Extension Rear/Front Side Outrigger (Hss, Zn) (35) Rear Floor Upper Cross-member (Sp)
(15) Dashboard Lower (Sp, Zn) (36) Rear Floor (Sp, Zn)
(16) Dashboard Upper (Sp, Zn) (37) Rear Panel (Sp, Zn)
(17) Outer Panel (Sp, Zn) (38) Rear Panel Side Stiffener (Sp)
(18) Rear Combination Adapter (Sp, Zn) (39) Rear Frame A (Sp, Zn)
(19) Front Pillar Lower Stiffener (Sp, Zn) (40) Rear Frame B (Hss, Zn)
(20) Front Pillar Upper Stiffener (Hss) (41) Rear Floor Cross-member (Sp, Zn)
(21) Centre Pillar Stiffener (Sp)


Paint Code Colour NH-578 NH-623M Stain B-92P Night B-96P Eternal G-95P Clover R-513 Rallye Y-61P Inca P. YR-525M
Name Taffeta White Silver M. Hawk Black P. Blue P. Green P. Red Titanium M.
KE SE O O O O O O O O
SE EXEC O O O O O O O O
KG LS O O O O O O O O
LSG O O O O O O O O
ES O O O O O O O O
ESG O O O O O O O O
KK EX O O O O
KY VTi O O O O O O
KX EX O O O O O
KB LS O O O O O O O O
ES O O O O O O O O
NOTE: In case of vehicles painted with NH-578, NH-623M, Y-61P and YR-525M and apply black (NH-70 Gloss 20) to the lower surface of the side sill (A) section.
1. FRONT BUMPER
Body colour
2. FRONT GRILLE
Body colour
3. HOOD MOULDING
Body colour
4. DOOR MIRROR
Body colour or black (NH-72 Gloss 30)
6. SIDE SILL
7. ROOF MOULDING
8. LICENSE PLATE TRIM
9. REAR BUMPER
Body colour
10. DOOR MOULDING
11. DOOR SASH TRIM
Replacement - Replacement
Replacement

Removal 3-3
Installation 3-4
Roof Panel

Removal 3-7
Installation 3-8
Rear Panel
Items marked with and asterisk (*) include SRS components; special caution is required when servicing.
Replacement - Side Sill Outer Panel

2
a. VIEW (Y)
b. Centre pillar stiffener
c. Outer panel stiffener
d. Side sill reinforcement
e. VIEW (Z)

Removal

Check the centre pillar stiffener and side sill reinforcement position and check for damage. If necessary replace the side sill reinforcement.
Replace the driver's side sill reinforcement as an assembly because of the way the stiffener is attached inside the side sill reinforcement.
1. OUTER PANEL
3. REINFORCEMENT STIFFENER (Driver side)
4. INSIDE SILL
5. REAR INNER PANEL
7. VIEW (Z)
9. OUTER PANEL STIFFENER
12. OUTER PANEL

Installation
1. Cut and set the new side sill reinforcement into position, and tack weld the Passenger's side
clamped position. When replacing the side sill reinforcement, cut the new side sill reinforcement so it
2. Cut the repaired part (outer panel) and set it into position. Clamp the repair part overlaps the body side reinforcement by 20 mm (1.8 in.), and fillet weld it.
and check the body dimensions (see section 4).
3. Temporarily install the door and front fender and check for differences in level and
clearance. Make sure the body lines flow smoothly.
4. Remove the repaired part and weld the centre pillar stiffener, side sill reinforcement
and front pillar lower stiffener (driver's side).
Driver's side
1. Fillet welding
Overlap
20 mm (1.8 in.)
5. Clamp the repair part and recheck the clearance and alignment of the door and
front fender.
1. NEW SIDE SILL REINFORCEMENT Attach a patch at the cut section of the front pillar (driver's side) center pillar and
VIEW (Z) wheel arch and plug weld them.

Driver's side
1. PATCH
2. Butt welding
3. Butt welding
4. PATCH
5. OUTER PANEL
Passenger's side:

1. Fillet welding
Overlap
30 mm (1.2 in.)
2. OUTER PANEL

Roof Panel
Roof Panel 3-5

Without roof panel:

a. Outer panel
b. Roof panel
c. Front roof rail
d. Rear roof rail
Replacement - Rear Side Outer Panel

6
a. Rear parcel shelf
b. Rear damper stiffener
c. Rear gutter
d. Inner panel
e. Rear panel
f. Rear Combination adaptor
g. Rear gutter
h. Outer panel stiffener
i. VIEW (Z)
j. Wheel arch extension
k. Side sill reinforcement
l. Centre pillar stiffener

Removal
Cut and pry off the rear side outer panel.

Check the rear combination adaptor position, and check it for damage. If necessary, replace the rear combination adopter and rear gutter as an assembly.
Check the centre pillar stiffener position and check it for damage. If necessary, cut and replace it.
2. INNER PANEL
3. REAR DAMPER STIFFENER
4. PARCEL SHELF
6. REAR GUTTER
7. REAR PANEL
9. OUTER PANEL
10. REAR FLOOR

Installation
1. Cut and set the new centre pillar stiffener into position, and install the middle floor 8. Temporarily install the door, rear window, trunk lid and rear bumper, and check for
gusset. differences in level and clearance.
9. Do the main welding:
Attach a patch at the cut section of the rear pillar and plug weld it.
1. MIDDLE FLOOR GUSSET

2. Set the new repaired part (outer panel) and rear combination adaptor into position
and clamp them.
Remove the repaired part (outer panel) and weld the centre pillar stiffener.
1. OUTER PANEL
2. PARCEL SHELF
3. REAR GUTTER
4. Butt welding
5. PATCH
6. Butt welding
7. NEW OUTER PANEL
8. Fillet welding
Overlap
30 mm (1.2 in.)
9. PATCH
Weld the rear combination adaptor and rear panel.

1. Fillet welding
Overlap
20 mm (0.8 in.)
7. Tack weld the outer panel and rear combination adaptor.


Rear Panel
Rear Panel 3-
9
a. Rear combination adaptor
b. Passenger's compartment
c. Rear panel
d. Jack-up stiffener
e. 4-plate welding
Body Dimensional Drawings - Body Dimensional Drawings

Passenger Compartment 4-2
Upper Body Measuring Dimensions 4-2

Unit: mm (in.)
1. K, k
Front Seat Rear Side Bracket Point 7 (0.3)
2. L, l
Rear Damper Mount Hole 11 (0.43)

Opening Repair Chart

Unit: mm (in.)
1. A
2. B, C
3. D, E, F, G
Rear Window and Trunk Lid Openings:

1. H, I
Rear window opening flange notch (3 places)
2. J
Parcel shelf convex bead
3. K
Trunk gutter area convex bead
4. L
Rear gutter area outer panel flange end (2 places)
5. M
Trunk seal flange water drain notch
Rust Prevention - Rust Prevention
Rust Prevention

General 5-2
Rust Prevention - Cross Section of Body and Sealants
Cross Section of Body and Sealants 5-2

General
NOTE: Following the sealer manufacturer's instructions. 5. Apply sealer on any area that the replacement part will cover. Smooth the sealer
1. Clean the areas to be sealed with the white gasoline. with a brush is necessary.
2. Wipe off any excess spot sealer with thinner. After the primer is sprayed, sealer will
fill in 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.
Refer to page 5-3 of this manual, refer to the 2001 CIVIC 4-door/CIVIC 5-door
Body Repair Manual (P/N. 62S5A30) on this CD for the items not shown in this
manual.
4. Finish sealing the engine compartment, the door opening, the truck gutter and the
tailgate gutter. Wipe of the excess sealer.
Rust Prevention - Cross Section of Body and Sealants

3
1. Rear gutter
2. Outer Panel
3. Outer Panel
4. Parcel Shelf
5. Rear combination adaptor
6. Outer Panel
7. Rear gutter
10. Rear panel
12. Outer Panel
14. Rear gutter extension
16. Rear gutter
17. Gutter extension
18. Rear gutter
19. Quarter lower extension
20. Outer panel

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NOTE: Gives helpful information.

All information contained in this manual is based on the latest product

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Fist Edition 192 pages HONDA MOTOR CO., LTD.

Sections with * include SRS components; Special Caution is required

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4-door General Information 1-3

4-door General Information

Supplemental Restraint System (SRS) 1-4

General Information 1-4

General Information 1-6

1. FRONT SUPPORT POINT

General Information 1-7

Front Wheel Alignment:

out 3100' (D15B engine: Reference)

Rear Wheel Alignment:

General Information 1-8

General Information 1-9

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

5-door General Information

Supplemental Restraint System (SRS) 1-16

1. FRONT SUPPORT POINT

Front Wheel Alignment:

out 3100' (D15B engine: Reference)

Rear Wheel Alignment:

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

1. FRONT WINDSHIELD MOULDING

General Safety Precaution 2-3

Accurate Inspection of Damaged Parts (Visual)

Outline of Body Repair 2-2

Outline of Body Repair 2-2

Reshape 1. Remove any related parts. Shop Manual

General Safety Precaution 2-3

The vehicle identification number is stamped on the dashboard upper

1. VEHICLE IDENTIFICATION NUMBER (VIN)

Accurate Inspection of Damaged Parts 2-4

Accurate Inspection of Damaged Parts 2-5

Frame Repair Chart:

If there is any twisting to the body, measure with a frame centring

Use the horizontal pinch welds for anchoring the vehicle.

allows for safe welding.

a way that will not affect the outward appearance.

Cut off the outer panel with an airsaw.

NOTE: Be careful not to cut the inner section.

to the panel of the body side.

cut sections of the repaired outer panel.

6. Main weld the repair parts.

Replacement 2- Rust Prevention/Paint

Installation and Inspection 2-

3. Adjust the wheel alignment.

Repair Tools 2- Protective Tools

UNIVERSAL TRAM GAUGE

Repair Tools 2- Cutting Tools

AIR CHUCK GRINDER

AIR IMPACT CUTTER

SPOT WELD CUTTER

Plug Welding Conditions:

4-door Replacement 3-3

*Front Wheelhouse/Damper Housing

*Front Side Frame Outrigger