SERVICE

MANUAL
CIVIC
CIVIC 4/5D
BODY REPAIR MANUAL 01

How to Use This Manual

How to Use This Manual

This manual covers the repairs of 2001 model series
CIVIC that have been involved in an accident and it
describes the work related to the replacement of
damage body parts.
Please read through instructions and familiarise
yourself with them before actually using this manual.
NOTE: Refer to the 2001 CIVIC Shop Manual (P/N.
60S5A00) for specifications, wire harness locations,
safety stand support points, etc.

1 General Info
2 Preparation of work
3 *Replacement
4 Body Dimensional Drawings
5 Rust Prevention
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,

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How to Use This Manual

figures and tables.

Fist Edition
8/2000

192
pages

All Rights Reserved

HONDA MOTOR CO., LTD.

Service Publication Office

Sections with * include SRS components; Special

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

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Index - Index

Index

4-door General Information

1-3

5-door General Information

1-15

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4-door General Information

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

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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.

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

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Index - General Information

General Information

1-5

Identification Number Locations

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

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Index - General Information

General Information

1-6

Lift and Support Points

NOTE: If you are going to remove heavy components such as

suspension or the fuel tank from the rear of the vehicle, first
support the front of the vehicle with a tall safety stands. When
substantial weight is removed from the rear of the vehicle, the
centre of gravity can change and cause the vehicle to tip
forward on the hoist.

Floor Jack
1.

1. Set the parking brake.

2. Block the wheels that are not being lifted.
3. When lifting the rear of the vehicle, put the gearshift
lever in reverse (or automatic transmission in Park
position).
4. Position the floor jack under the front jacking bracket
or rear jacking bracket, centre the jacking bracket in
the jack lift platform, and jack up the vehicle high
enough to fit the safety stands under it.

Frame Hoist
Position the hoist lift blocks, or safety stands, under the
vehicle's front support points and rear support points.

1.

1. FRONT SUPPORT POINT

2. HOIST LIFT BLOCKS
3. REAR SUPPORT POINT

2.

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

gently to be sure it is firmly supported.
2. Raise the hoist to full height, and inspect the lift
points for solid contact with the lift blocks.
Safety Stands
To support the vehicle on safety stands, use the same support
points as for a frame hoist. Always use safety stands when
working on a under vehicle that is supported only by a jack.

2.

3.

1.
2.
3.
4.

FRONT JACKING BRACKET

JACK LIFT PLATFORM
JACK LIFT PLATFORM
REAR JACKING BRACKET

5. Position the safety stands under the support points

and adjust them so the vehicle will level.
6. Lower the vehicle onto the stands.

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General Information

1-7

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)

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Index - General Information

General Information

1-8

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

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General Information

1-9

Construction

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

No.

Part Name

No.

Part Name

Hood (Hss, Zn)

22 Centre Pillar Stiffener (Sp)

Front Fender (Sp, Zn)

23 Side Sill Reinforcement (Hss, Zn)

Front Door (Hss, Zn)

24 Front Pillar Inner Lower (Hss)

Rear Door (Hss, Zn)

25 Front Pillar Inner Upper (Hss, Zn)

Trunk Lid (Sp, Zn)

26 Centre Inner Pillar (Hss, Zn)

Bulkhead Side (Sp, Zn)

27 Roof Side Rail (Hss)

Bulkhead Side Stray (Sp, Zn)

28 Roof Panel (Sp)

Bulkhead Upper Frame (Sp, Zn)

29 Rear Inner Panel (Sp, Zn)

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)

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Index - General Information

21 Front Pillar Upper Stiffener (Hss)

42 Rear Floor Cross-member (Sp, Zn)

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General Information

1-10

Door and Bumper Reinforcement Beams

Door and bumper reinforcement beams used on Honda vehicles are made from a metal equivalent to High Strength Steel.
If High Strength Steel is heated, the strength of the steel will b e reduced. If High Strength Steel is damaged, as in a vehicle
accident, where the door and bumper reinforcement beams are bent, the beams may crack if an attempt is made to straighten
them.
For this reason, the door and bumper reinforcement beams should NEVER be repaired; they should be replaced if they are
damaged.
NOTE: If a door beam is damaged, the whole door panel assembly should be replaced.
1. REAR BUMPER
REINFORCEMENT BEAM
2. REAR DOOR
REINFORCEMENT BEAM
3. FRONT DOOR
REINFORCEMENT BEAMS
4. FRONT BUMPER
REINFORCEMENT BEAM

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General Information

1-11

Zinc-plated Steel Plate Repair

The Zinc-plated steel plate used in some panels of the CIVIC 4-door requires different repair techniques than ordinary steel plate.
Refer to "Body Construction" (see page 1-9) for the location of the Zinc-plated panels.
1. ZINC-PLATED (5-6 microns)
2. Steel plate

1.

1. Before spot welding the zinc-plated steel plate, remove the paint from both sides of the flange to be welded. Apply sealer
to the flange after welding.

WARNING

To prevent eye injury, wear goggles or safety glassed whenever sanding, cutting or grinding.
NOTE: Seal the sanded surface thoroughly to prevent rust.
2.

2. The electric continuity properties of zinc-plated steel plate is different from the ordinary steel plate. When spot welding,
increase the current by 10-20%.
NOTE: The MIG welding procedures for Zinc-plated steel plate are the same an for ordinary steel plate.

WARNING

To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety
shoes.
3.

3. Before applying putty or body filler to the Zinc-plated steel plate, sand the zinc plating thoroughly to promote adhesion
and to prevent blistering.
NOTE: Use only epoxy-based putties and fillers on zinc-plated steel plate, following the manufacture's specifications.
4. When performing pain work, protect the ground wire and ground wire mounting hole threads with a bolt or a plug.
1.
2.
3.
4.

SPECIAL BOLT
GROUND WIRE
GROUND WIRE MOUNTING HOLE
PLUG

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General Information

1-12

Colour Chart Paint Specifications

P.: Pearl Paint / M.: Metallic Paint

KE
KG

NH-578
Taffeta
White

NH-623M B-92P
Night
Stain
Silver M. Hawk
Black P.

B-96P
Eternal
Blue P.

G-95P
Clover
Green P.

R-81
Mirano
Red

RP-32P
R504P
Ruby Red Vintage
Plum P.
P.

YR-525M
Titanium
M.

1.4S

1.6SE

1.4S

1.6LS

1.6ES

KB

1.4S

1.6ES

KQ

GLi

VTi

KY

LXi

EXi

VTi

KW

EXi

KT

LXi

EXi

EXi

VTi

VTi-S

LXi

EXi

KU

KV

VTi

DX

LX

EX

EXi

VTi

KF

EXi

LXi

KN

150I

170I

KX

LX

EX

KK

KH

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General Information

1-13

Colour Chart Paint Specifications (cont'd)

1. FRONT GRILLE
Body Colour
2. HOOD MOLDING
BASE
Chrome plated or body
colour
3. DOOR MIRROR BASE
Black (NH-70 Gloss 20)
4. DOOR MIRROR
Body colour or black
(NH-70 Gloss 20)
5. DOOR OUTER
HANDLE
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
Black (NH-70 Gloss 20)
9. DRIP MOULDING
Chrome plated or black
(NH-70 Gloss 20)
10. LICENSE TRIM
Chrome plated or body
colour
11. REAR BUMPER
Body Colour
12. DOOR MOULDING
Chrome plated or black
(NH-70 Gloss 20)
13. DOOR SASH TRIM
Black (NH-70 Gloss 20)
14. FRONT UNDER
SPOILER
Black (NH-68 Gloss 10)
15. GRILLE
BP. Dark grey (NH533)

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General Information

1-14

Type and Materials of Exterior Plastic Parts

NOTE: A standard symbol is stamped on the underside of each resin part to show the type of material of used.
Example:

1. FRONT GRILLE
Polypropylene (PP)
2. HOOD MOULDING
Acrylonitrile butadiene
styrene (ABS)
3. FRONT WINDSHIELD
MOULDING
Acrylonitrile ethylene
propylene dine rubber
styrene (A/EPDM/S)
4. DOOR OUTER
HANDLE
Polycarbonate (PC)
5. DOOR MIRROR
Painted: Acrylonitrile
butadiene styrene
(ABS)
Unpainted: Acrylonitrile
styrene acrylate (ASA)
6. FRONT BUMPER
Polypropylene (PP)
7. ROOF MOULDING
Polyvinyl chloride (PVC)
8. LICENSE TRIP
Acrylonitrile butadiene
styrene (ABS)
9. REAR BUMPER
Polypropylene (PP)
10. PROTECTOR
MOULDING
Polypropylene (PP)
11. DOOR SASH TRIM
Acrylontrile ethylene
propylene dinene
rubber styrene
(A/EPDM/S)
12. FRONT UNDER
SPOILER
Ethylene propylene
dinene rubber (EPDM)

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5-door General Information

5-door General Information

Supplemental Restraint System (SRS)

1-16

Identification Number Locations

1-17

Lift and Support Points

1-18

Body Specifications/Wheel Alignment

1-19

Exterior Parts Removal/Wheel Alignment

1-20

Construction

1-21

Door and Bumper Reinforcement Beams

1-22

Zinc-plated Steel Plate Repair

1-23

Colour Chart Paint Specifications

1-24

Types and Materials of Exterior Plastic Parts

1-26

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General Information

1-16

Supplemental Restraint System (SRS)

This model has an SRS which includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above
the glove box, seat belt tensioners in the front seat belt retractors and side airbags in the front seat backs. The SRS unit is
separated from the airbag assembly and has built-in sensors. The following precautions should be observed when performing sheet
metal work, paint work and repair work around the location of the SRS components.
1.

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

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General Information

1-17

Identification Number Locations

1. Built Data and Vehicle
Type
2. Vehicle Identification
Number (VIN)
3. Engine Number
4. Transmission Number
(Manual)
5. Transmission Number
(Automatic)

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General Information

1-18

Lift and Support Points

NOTE: If you are going to remove heavy components such as

suspension or the fuel tank from the rear of the vehicle, first
support the front of the vehicle with a tall safety stands. When
substantial weight is removed from the rear of the vehicle, the
centre of gravity can change and cause the vehicle to tip
forward on the hoist.

Floor Jack
1.

1. Set the parking brake.

2. Block the wheels that are not being lifted.
3. When lifting the rear of the vehicle, put the gearshift
lever in reverse (or automatic transmission in Park
position).
4. Position the floor jack under the front jacking bracket
or rear jacking bracket, centre the jacking bracket in
the jack lift platform, and jack up the vehicle high
enough to fit the safety stands under it.

Frame Hoist
Position the hoist lift blocks, or safety stands, under the
vehicle's front support points and rear support points.

1.

1. FRONT SUPPORT POINT

2. HOIST LIFT BLOCKS
3. REAR SUPPORT POINT

2.

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

gently to be sure it is firmly supported.
2. Raise the hoist to full height, and inspect the lift
points for solid contact with the lift blocks.
Safety Stands
To support the vehicle on safety stands, use the same support
points as for a frame hoist. Always use safety stands when
working on a under vehicle that is supported only by a jack.

2.

3.

1.
2.
3.
4.

FRONT JACKING BRACKET

JACK LIFT PLATFORM
JACK LIFT PLATFORM
REAR JACKING BRACKET

5. Position the safety stands under the support points

and adjust them so the vehicle will level.
6. Lower the vehicle onto the stands.

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General Information

1-19

Body Specifications/Wheel Alignment

Unit : mm(in.)
*1: With Roof Antenna
*2: European model (MPW condition)
*3: Except European model

Front Wheel Alignment:

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)

Rear Wheel Alignment:

Camber

-045'45'

Total toe

IN 2 3 (0.08 0.12)

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General Information

1-20

Exterior Parts Removal/Installation

NOTE: To adjust the alignment of the hood, the front door, rear door and trunk lid, refer to the CIVIC Shop Manual.
Mounting bolts/nuts torque:
6X1.0 mm: 9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
*6X1.0 mm: 1.8 Nm (1.8 kgf/m, 13 lbf/ft)
8X1.0 mm: 22 Nm (2.2 kgf/m, 16 lbf/ft)
*8X1.25 mm: 29 Nm (3.0 kgf/m, 22 lbf/ft)
1. HOOD
2. HOOD HINGE
3. REAR BUMPER SIDE
BRACKET
4. TAILGATE HINGE
5. TAILGATE
6. REAR BUMPER BEAM
7. FUEL DOOR
8. REAR BULKHEAD
GUSSET
9. REAR DOOR
10. REAR DOOR HINGE
11. FRONT DOOR
12. FRONT DOOR HINGE
13. FRONT FENDER
14. CORNER UPPER
BEAM
15. FRONT BUMPER
BEAM
16. FRONT BUMPER
LOWER STIFFENER
17. BATTERY SET BASE

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Index - General Information

General Information

1-21

Construction

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

No.

Part Name

No.

Part Name

Hood (Hss, Zn),/p>

22 Front Pillar Upper Stiffener (Hss)

Front Fender (Sp, Zn)

23 Centre Pillar Stiffener (Sp)

Front Door (Hss, Zn)

24 Side Sill Reinforcement (Hss, Zn)

Rear Door (Hss, Zn)

25 Front Pillar Inner Lower (Hss)

Trunk Lid (Sp, Zn)

26 Front Pillar Inner Upper (Hss, Zn)

Bulkhead Side (Sp, Zn)

27 Centre Inner Pillar (Hss, Zn)

Bulkhead Side Stray (Sp, Zn)

28 Roof Side Rail (Hss)

Bulkhead Upper Frame (Sp, Zn)

29 Roof Panel (Sp)

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)

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Index - General Information

General Information

1-22

Door and Bumper Reinforcement Beams

Door and bumper reinforcement beams used on Honda vehicles are made from a metal equivalent to High Strength Steel.
If High Strength Steel is heated, the strength of the steel will b e reduced. If High Strength Steel is damaged, as in a vehicle
accident, where the door and bumper reinforcement beams are bent, the beams may crack if an attempt is made to straighten
them.
For this reason, the door and bumper reinforcement beams should NEVER be repaired; they should be replaced if they are
damaged.
NOTE: If a door beam is damaged, the whole door panel assembly should be replaced.
1. REAR BUMPER
REINFORCEMENT BEAM
2. REAR DOOR
REINFORCEMENT BEAM
3. FRONT DOOR
REINFORCEMENT BEAMS
4. FRONT BUMPER
REINFORCEMENT BEAM

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Index - General Information

General Information

1-23

Zinc-plated Steel Plate Repair

The Zinc-plated steel plate used in some panels of the CIVIC 5-door requires different repair techniques than ordinary steel plate.
Refer to "Body Construction" (see page 1-21) for the location of the Zinc-plated panels.
1. ZINC-PLATED (5-6 microns)
2. Steel plate

1.

1. Before spot welding the zinc-plated steel plate, remove the paint from both sides of the flange to be welded. Apply sealer
to the flange after welding.

WARNING

To prevent eye injury, wear goggles or safety glassed whenever sanding, cutting or grinding.
NOTE: Seal the sanded surface thoroughly to prevent rust.
2.

2. The electric continuity properties of zinc-plated steel plate is different from the ordinary steel plate. When spot welding,
increase the current by 10-20% or increase the resistance welding time.Also increase the number of weld spots by 1020%.
NOTE: The MIG welding procedures for Zinc-plated steel plate are the same an for ordinary steel plate.

WARNING

To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety
shoes.
3.

3. Before applying putty or body filler to the Zinc-plated steel plate, sand the zinc plating thoroughly to promote adhesion
and to prevent blistering.
NOTE: Use only epoxy-based putties and fillers on zinc-plated steel plate, following the manufacture's specifications.
4. When performing pain work, protect the ground wire and ground wire mounting hole threads with a bolt or a plug.
1.
2.
3.
4.

SPECIAL BOLT
GROUND WIRE
GROUND WIRE MOUNTING HOLE
PLUG

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Index - General Information

General Information

1-24

Colour Chart Paint Specifications

P.: Pearl Paint / M.: Metallic Paint
NH-578 NH-623M B-92P
Night
Taffeta Stain
Silver M. Hawk
White
Black P.

KE

KQ
KT

PB-77M
G-502M
Lavender
Aqua
Green M. Mist M.

R504P
R-81
Mirano Ruby
Red P.
Red

B-96P
Eternal
Blue P.

G95P
Clover
Green P.

1.4S

1.6S

1.4SE

1.6LSE

Vi

VTi

EXi

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Index - General Information

General Information

1-25

Colour Chart Paint Specifications (cont'd)

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

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Index - General Information

General Information

1-26

Type and Materials of Exterior Plastic Parts

NOTE: A standard symbol is stamped on the underside of each resin part to show the type of material of used.
Example:

1. FRONT WINDSHIELD
MOULDING
Acrylonitrile ethylene
propylene dine rubber styrene
(A/EPDM/S)
2. DOOR OUTER HANDLE
Polycarbonate (PC)
3. DOOR MIRROR
Painted: Acrylonitrile
butadiene styrene (ABS)
Unpainted: Acrylonitrile
styrene acrylate (ASA)
4. ROOF MOULDING
Polyvinyl chloride (PVC)
5. LICENSE TRIP
Acrylonitrile butadiene styrene
(ABS)
6. REAR BUMPER
Polypropylene (PP)
7. DOOR SASH TRIM
Acrylontrile ethylene
propylene dinene rubber
styrene (A/EPDM/S)
8. FRONT BUMPER
Polypropylene (PP)

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Preparation of Work - Preparation of Work

Preparation of Work
Outline of Body Repair

2-2

General Safety Precaution

2-3

Accurate Inspection of Damaged Parts (Visual)

Description

2-4

Measurement

2-5

Reshaping
Correction of the Damaged Area

2-6

Replacement
Removal

2-7

Installation

2-8

Rust Prevention/Paint

2-10

Installation and Inspection

2-11

Repair Tools
Measurement Equipment

2-12

Protective Tools

2-12

Processing Tools

2-13

Cutting Tools

2-13

Shaping Tools

2-14

Fixing Tools

2-15

Welders

2-16

Sanding Tools

2-16

Welding Methods
Spot Welding

2-17

Carbon Dioxide Arc Welder (MIG Arc Weld)

2-19

Gas Welding

2-20

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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

Accurate inspection of Damaged Parts. (Visual)

Measurement

Reshape

Replacement

Rust Prevention

Paint
Installation and
Inspection

Wheelbase
Wheel Alignment
Body Dimensional
Drawings

1. Remove any related parts.

2. Attach the frame straightener to the body.
3. Pull out and straighten the damaged
areas.
4. Check the original position.

Adjust the hood, door, tailgate.

Measure the wheel alignment.
Clean the body.
Install related parts.

see section 4

see section 1

Body Dimensional
Drawings
Mass Production Body
Welding Diagram
Removal
Body Dimensional
Drawings
Installation

1. Apply the sealer.

2. Apply the undercoating.
3. Apply anti-rust agent to the inside of the
outer panel and frames.

1.
2.
3.
4.

see section 1

Shop Manual

1. Cut off and separate the damaged area.

2. Straighten any related parts.
3. Check the repair part installation and
alignment with the body.
4. Clean and degrease to the welded
surfaces.
5. Weld in the repair part.
6. Finish the welded areas.

Apply the paint

Reference
see section 1

see section 4
see section 3
see section 3
see section 4
see section 3

Cross Section of Body see section 5

and Sealants.
Soft Chipping Guard
Primer Coating
Diagram
PVC Coating Diagram
Area to be Covered by
Antirust Agents

see section 6
Shop Manual

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General Safety Precaution

General Safety Precaution

Disconnect the battery to reduce the possibility

of damage caused by electrical shorts.
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.

Remove the fuel tank and/or fuel lines if

welding equipment is to be used near the fuel
system.

1.

1.

2-3

1. FUEL TANK

The vehicle identification number is stamped on

the dashboard upper panel and is registered
with local authorities. If the dashboard upper
panel must be replaced because of damage,
check with local authorities first.

1. SAFETY CABLES

Cover the exterior parts and the interior parts

with a fireproof cover and protect the vehicle
when welding.
Do not damage the passenger compartment
parts when you heat the undercoat of the
welded flange with a torch.

2.

1. VEHICLE IDENTIFICATION NUMBER (VIN)

2. DASHBOARD UPPER

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

Accurate Inspection of Damaged Parts

(Visual)

2-4

Description

Most monocoque bodies are composed as a single until by welding together pressed parts made of steel plates, which come in a
variety of different shapes and sizes. Each part is responsible for displaying a certain strength and durability in order that it may
play its role in meeting the functions of the body.
Damage to the exterior of the body can be visually inspected, but where there has been external impact, it is necessary to inspect
the extent of the damage. In some cases, the deformation may have spread beyond the actual areas that were in the collision so
the deformation must be closely inspected.
Distortion to the vehicle, bends, inclines and gaps between parts should be thoroughly checked. Also, check for paint peeling at
welded areas, corners and the sealing coat.
: Carefully checked.

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

Accurate Inspection of Damaged Parts

(Visual)

2-5

Measurement

Whenever possible, make judgements and conclusions

based on measurements.
Measure the wheel alignment to prevent uneven
tyre wear or incorrect steering wheel alignment.
If there are any deviations, use a tram-tracking
gauge and measure the body parts.

To measure body dimensions, use a universal

tram gauge and convex tool.
Body Measuring Dimension/Opening Repair Chart:

Frame Repair Chart:

If there is any twisting to the body, measure

with a frame centring gauge.

Diagonal measurement:

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Reshape

Reshape

2-6

Correction of the Damaged Area

1.

1. Remove any related parts.

NOTE: See the Shop Manual.

2.

2. Connect the frame straightener to the vehicle

body.
The side sill is flangeless to allow reshaping
by pulling it out.
Use the horizontal pinch welds for anchoring
the vehicle.

3.

4.

1.

4. Check that the part of the body is more or less

restored to its original shapes. Check the
original positions using the body dimensional
drawings.

1. SUPPORT POINTS
(Jack-up stiffener)

3. Pull out and straighten damaged areas. Apply

load to the damaged section, and pull on it until
the section is almost restored to its original
shape. Do not pull out more than necessary.

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Preparation of Work - Replacement

Replacement

2-7

Removal
1.

1. Decide whether to replace all the affected parts

or whether to cut the weld joint parts and
replace them.
NOTE: When cutting the parts off, take special care
that you do not damage adjacent parts on the vehicle.

1.

2. Peel off the undercoat.

CAUTION

Be careful not to burn the fittings inside the

passenger compartment when heating.

Setting Condition for Replacement Parts Joint

Sections:
Make sure that you can perform
straightening work after welding.
Make sure that the locations will not be
susceptible to distortion caused by other
parts.
Make sure that there are few removable
parts and that the location allows for safe
welding.
Make sure that the joints are short, and that
paint repair can be performed easily.
Make sure that locations are such that the
joints can be finished in a way that will not
affect the outward appearance.
Make sure that the locations do not hinder
the removing and attaching of parts.
Parts which influence wheel alignment such as damper
housing and the side frames must be examined using the
frame repair charts.

2.

3. Remove the damaged parts.

WARNING

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.

2.

1. DAMPER HOUSING
2. OUTER PANEL
(New part)
3. FRONT SIDE FRAME
(New part)

3.

1. STIFFENER
2. OUTER PANEL

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Preparation of Work - Replacement

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Preparation of Work - Replacement

Replacement

2-8

Installation
1.

1. Straighten any damaged parts.

Where new panels cannot be spot welded,

make holes for plug welding.
Make holes to the size which corresponds to
the thickness of the welded plate (see page
2-19).
The position and the point by which holes
are made, refer to the old parts or Mass
Production Body Welding Diagram (see
section 3).

WARNING

To prevent eye injury and burns when

welding, wear an approved welding helmet,
gloves and safety shoes.
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.

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.

2.

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.

3.

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.

1. OVERLAP

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Preparation of Work - Replacement

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Preparation of Work - Replacement

Replacement

2-9

Installation
1.

4. Check the tack weld at positions of the new

parts.
Clamp the new part and check the position
of it using the body dimensional drawings
(see section 4).
Tack weld the clamped section.

Make 20% to 30% more spot welds than

there were holes drilled.
A new welding position should avoid an old
position as much as possible.
NOTE: If there is not room for spot welds, compensate
by using MIG welds
The electric continuity property of zincplated steel plate is different from ordinary
steel plate. When spot welding, increase the
current by 10-20%, or increase the
resistance welding line.

WARNING

To prevent eye injury and burns when

welding, wear an approved welding helmet,
gloves and safety shoes.

2.

5. Check the alignment of the exterior body parts.

Temporary install the exterior body parts,
windshield and rear 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.

3.

6. Main weld the repair parts.

Use proper welding methods (see pages 217, 2-18, 2-19, 2-20).

Fillet weld the repair outer side sill it will

overlap by 30 mm (1.2 in.) in the front and
back.
Butt weld the front pillar, centre pillar, rear
pillar and the wheel arch cut sections of the
repaired outer panel.
NOTE: Attach the patches at the cut sections of the
outer panel and plug weld them.

WARNING

To prevent eye injury and burns when

welding, wear an approved welding helmet,
gloves and safety shoes.
1.

1. BUTT WELD
2. PATCH
3. FILLET WELD

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Preparation of Work - Replacement

Rust Prevention/Paint
2-10

Replacement

Installation (cont'd)
1.

7. Finishing the welded areas.

Level the MIG welded areas with a disc
sander.

1.

WARNING

1. Applying the sealer. Seal the overlapped areas

of the outer panel, and the welded surfaces of
the new parts. Seal gaps completely.
2. Apply the paint.

WARNING

To prevent eye injury, wear goggles or safety

glasses whenever sanding, cutting or
grinding.

Ventilate when spraying paint. Most

paint contains substances that are
harmful if inhaled or swallowed. Read
the paint label before opening the
paint container.
Avoid contact with skin. Wear an
approved respirator, gloves, eye
protection and appropriate clothing
when painting.
Paint is flammable. Store it in a safe
place, and keep it away from sparks,
flames or cigarettes.

NOTE: Take care not to grind excessively.

Even out high areas with a hammer. Be
careful not to deform them.
Smooth out welded door and tailgate areas,
and window opening flanges with a hammer
and dolly.
Fill the deformed area and smooth out the
welded areas with body filler.
2.

3. Apply undercoat to the wheelhouse and underfloor.

4. Apply the anti-rust agent to the inside of the
outer panel and welded areas.

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Installation and Inspection

Installation and Inspection

1.

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.

2.

3.

4.

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.

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Preparation of Work - Repair Tools

Repair Tools

Protective Tools
2-12

Measurement Equipment
TRAM TRACKING GAUGE

FRAME CENTRING GAUGE

OPERATOR:
1 Protective goggles

Protective apron

2 Cap

Welding glove

3 Ear plugs

Foot protector

4 Shield for eyes

10

Safety shoes

5 Overalls with long

sleeves

11

Work glove

6 Dust-proof mask

12

Splatter guard

UNIVERSAL TRAM GAUGE

CONVEX TOOL

VEHICLE BODY:
Heat-resistant protective cover

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Preparation of Work - Repair Tools

Repair Tools

Cutting Tools
2-13

Processing Tools
SPOT CUTTER

AIRSAW

Install the spot cutter in the air drill, and drill a hole at the
spot weld nugget and the plug to make the hole.

Cut the outer panel.

AIR CHUCK GRINDER

AIR DRILL

Detaching the MIG welding part and the panel can be cut
by installing cut grinding wheel in air chuck grinder.

The rotation speed can be adjusted, and an adequate

hole opening can work.

AIR IMPACT CUTTER

Cut the outer panel roughly.

PRESSURE DRILL
The depth of the hole can be adjusted, and only
necessary plate thickness can puncture.

CHISEL SET
CENTRE PUNCH
When an accurate hole opening is necessary.

SPOT WELD CUTTER

Pry off the spot welded flange.

HAND NIBBLER

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Preparation of Work - Repair Tools

Repair Tools

Shaping Tools
2-14

Cutting Tools (cont'd)

HANDSAW

Skin Panel Shaping:

HAMMERS

DOLLIES
PLASMA CUTTER
Cut the thick plate.

SPOONS

GAS CUTTER
CHISEL

ACETYLENE BURNER

SNIPS/SHEARS

Peel off the undercoat.

FLANGE TOOLS
Edge preparation.

Body and Frame Shaping:

WASHER WELDER

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Preparation of Work - Repair Tools

Repair Tools

Fixing Tools
2-15

Shaping Tools (cont'd)

SLIDE HAMMER

VICE GRIPS

BODY JACK

SCREW CLAMP

FRAME CORRECTOR
SCREW VICES

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Preparation of Work - Repair Tools

Repair Tools

Sanding Tools
2-16

Welders

SPOT WELDER

DISC GRINDER
Grinding of welded flange.

DISC SANDER
Sand off the paint film and use to finish the welded
flanges
MIG WELDER

BELT SANDER
Finish off narrow welded flange.

DOUBLE ACTION SANDER

Featheredge and finish of putty.
GAS WELDER

LONG ORBITAL SANDER

Sanding putty within the wide range and finish.

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Preparation of Work - Welding Methods

Welding Methods

2-17

Spot Welding

Spot welding is also known as resistance spot welding, and it is the most suitable method of welding for vehicles. It has 3 main
features: the welding can be performed instantaneously, it has minimal effect on the source material, and it has a minimum affect
on distortion to the absolute minimum. However, please remember to remove all paint and other impurities from the surface of the
material you intend to weld for reliable results.
Welders:
1. Spot welder
2. Timer/Transformer

Welding Conditions:
When performing spot welding, make sure that you conform to the following conditions: use the correct current, conductivity time,
welding pressure, holding time, and shutdown time recommended for the spot welder.
Please bear in mind the following points when welding:
Plate thickness and minimum welding pitch
1. Intervals

NOTE: If the welding intervals are too short, branching may occur, making it impossible to maintain the desired soldering state.
Plate thickness and tip diameter.
1. Tip diameter

Unit: mm (in.)

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Preparation of Work - Welding Methods

Plate thickness

0.6 (0.02)

0.9 (0.04)

1.2 (0.05)

1.6 (0.06)

Minimum intervals

11 (0.43)

16 (0.63)

20 (0.79)

24 (0.94)
Unit: mm (in.)

Plate thickness

0.8 (0.03)

0.9 (0.04)

1.2 (0.05)

1.6 (0.06)

Tip diameter

45 (0.12)

5.0 (0.2)

5.5 (0.22)

6.0 (0.24)

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Preparation of Work - Welding Methods

Welding Methods

2-18

Spot Welding (cont'd)

Welding Strength Test
Even if you perform the welding according to the proper conditions, the strength of the welded sections may fluctuate due to drops
in the voltage and other factors. The quality of the welding cannot be evaluated unless the welded sections are destroyed.
Provide yourself with a steel plate of the same thickness and conduct a destruction test.
If holes appear in the steel plates, this means that the welding is of standard strength.

Drive a wedge between 2 panels near the nugget. If the welded parts do not come apart and the diameter of the nugget
is more than 3 mm (0.1 in.), the welding should be satisfactory.
1. WEDGE
2. Stop inserting the
wedge when the full
size of the nugget
appears.

NOTE:
It is difficult to perform spot welding in the following circumstances:
When it is not possible to remove any rust or paint attached to the welding surfaces.
When the tip of the spot welder cannot be inserted into the welding section.
When the welding surfaces can be seen from the outside and welding will impair the exterior appearance.
In all these cases, the gas welding method should be employed. Moreover, if it is not possible to perform spot welding because of
space restrictions, plug welding using on the arc welding method may be performed instead. For plug welding, the sections to be
welded must be close together.

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Preparation of Work - Welding Methods

2-19

Welding Methods

Carbon Dioxide Arc Welder (MIG Arc Weld)

This welding process uses inexpensive carbon dioxide instead of expensive inert gases as a shielding means. Consumable metal
electrodes are employed. It has a wide range of applications, including butt welding of a thin plate, fillet welding, plug welding and
MIG spot welding. In terms of the weld strength, it is also highly stable.
Welders:
1. Single-phase 110V
Three-phase 200-240V
2. Gas hose
3. Input cable
4. Gas regulator
5. Carbon dioxide or
Argon + Carbon dioxide
6. Welding power supply
(built-in wire feed
mechanism)
7. Welding torch
8. Workpiece
9. Work cable
10. Ground wire

CAUTION

Disconnect the negative battery cable before arc welding.

Welding Methods:
Butt welding

Fillet welding

Spot welding

Plug welding

Plug Welding Conditions:

Plate thickness and weld holes
Plate thickness
Weld hole diameter

Unit: mm (in.)
~1.0 (0.04) 1.0 (0.04) ~ 1.5 (0.06) 1.5 (0.06)~
5 (0.2)
6.5 (0.26)
8 (0.3)

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Preparation of Work - Welding Methods

Welding Methods

2-20

Gas Welding

Gas welding is indispensable for body repair because of the broad range of its applications to join the body panels, cut the
materials that construct the body, apply heat to reform panels, and also because it is easy to get hold of the tools.
However, this method requires experience.
Welders:
1.
2.
3.
4.
5.

Gas regulator
Gas regulator
Welder
Cutter
Oxygen/Acetylene tanks

Welding Methods:
Butt welding

Fillet welding or soldering

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Index - Index

Index
4-door Replacement

3-3

5-door Replacement

3-35

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Index - Front Bulkhead

Front Bulkhead

3-4

Mass Production Body Welding Diagram

A.

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

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Index - Front Bulkhead

Front Bulkhead

3-5 Installation

Removal

1.

1.

1.
2.
3.
4.
5.
6.
7.
8.

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:

BULKHEAD UPPER FRAME

BULKHEAD SIDE
FRONT DAMPER EXTENSION
WHEELHOUSE UPPER MEMBER
FRONT WHEELHOUSE
FRONT SIDE FRAME
BULKHEAD SIDE STAY
FRONT LOWER CROSS-MEMBER

2.

1.
2.
3.
4.
5.
6.
7.
8.

BULKHEAD UPPER FRAME

FRONT DAMPER EXTENSION
WHEELHOUSE UPPER MEMBER
BULKHEAD SIDE
FRONT SIDE FRAME
FRONT LOWER CROSS-MEMBER
FRONT WHEELHOUSE
BULKHEAD SIDE STAY

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Index - Front Bulkhead

9. FRONT SIDE FRAME

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Index - Front Wheelhouse/Damper Housing

Front Wheelhouse/Damper Housing

3-6

Mass Production Body Welding Diagram

a.

a. Front side frame

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

Passenger compartment side:

Wheelhouse upper member removed:
a.

a. Dashboard upper side

member
b. Damper housing extension
c. Front damper extension
d. Damper housing
e. Front wheelhouse

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Index - Front Wheelhouse/Damper Housing

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
2. FRONT DAMPER EXTENSION
3. WHEELHOUSE UPPER MEMBER
Reused.

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Index - Front Wheelhouse/Damper Housing

Front Wheelhouse/Damper Housing

3-8

Removal (cont'd)

Replace the front damper extension, damper housing and damper housing extension as an assembly.
Passenger compartment side:
1. FRONT DAMPER
EXTENSION
2. DASHBOARD UPPER
SIDE MEMBER
3. DAMPER HOUSING
4. FRONT DAMPER
EXTENSION
5. ENGINE MOUNT
BRACKET
6. FRONT SIDE FRAME
7. DAMPER HOUSING
EXTENSION
8. DAMPER HOUSING
EXTENSION

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Index - Front Wheelhouse/Damper Housing

3-9

Front Wheelhouse/Damper Housing

Installation
1.

1. Set the new damper housing assembly, front

wheelhouse and front bulkhead into position,
and measure the front compartment diagonally.

From the passenger compartment side, plug

the holes in the dashboard lower, damper
housing extension and front damper extension.

Check the body dimensions (see section 4).

2. Tack weld the clamped position.
3. Temporarily install the front sub-frame, and
check the front side frame position.
4. Temporarily install the hood, front fender,
headlight and front bumper, and check for
difference in level and clearance. Make sure the
body lines flow smoothly.
5. Perform the main welding:
Weld the damper housing and front side
frame.
Weld the front damper extension and
dashboard upper side member.

1.

1. FRONT DAMPER EXTENSION

2. DAMPER HOUSING EXTENSION

From wheelhouse side, plug weld the holes in

the dashboard upper and damper housing
extension.

2.

2.

1. DAMPER HOUSING EXTENSION

1. FRONT DAMPER EXTENSION

2. DASHBOARD UPPER SIDE MEMBER
3. FRONT SIDE FRAME

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Index - Front Wheelhouse/Damper Housing

4. DAMPER HOUSING

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Index - Front Wheelhouse/Damper Housing

Front Wheelhouse/Damper Housing

3-10

Installation (cont'd)

Weld the front wheelhouse, damper housing and front

side frame.

1.

1.
2.
3.
4.

DAMPER HOUSING
FRONT DAMPER EXTENSION
FRONT WHEELHOUSE
ENGINE MOUNT BRACKET

Weld the wheelhouse upper member.

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

2.

1. FRONT DAMPER EXTENSION

2. Butt Welding
3. WHEELHOUSE UPPER MEMBER

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Index - Front Side Frame/Outrigger

Front Side Frame/Outrigger

3-11

Mass Production Body Welding Diagram

a.

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.

a. Inside sill extension

VIEW (Z)

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Index - Front Side Frame/Outrigger

Passenger compartment side:

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Index - Front Side Frame/Outrigger

Front Side Frame/Outrigger

3-12

Removal

Passenger compartment side:

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

FRONT SIDE FRAME

DAMPER HOUSING
FRONT WHEELHOUSE
FRONT SIDE FRAME
SIDE FRAME
BULKHEAD REAR
ENGINE MOUNT
BRACKET
SIDE FRAME
BULKHEAD REAR
FRONT SIDE FRAME
FRONT SUB-FRAME
STAY
FRONT SIDE FRAME
SIDE FRAME
EXTENSION REAR
SIDE FRAME
BULKHEAD REAR
SIDE FRAME
EXTENSION REAR

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Index - Front Side Frame/Outrigger

Front Side Frame/Outrigger

3-13

Removal (cont'd)

Check the side frame bulkhead rear for position and damage. If necessary replace it.
1. SUB-FRAME REAR BRACKET
2. SIDE FRAME BULKHEAD REAR
3. SIDE FRAME EXTENSION REAR

If necessary, replace the side frame extension rear, outrigger and sub-frame rear bracket as an assembly.
NOTE: When removing the outrigger, leave the inside sill extension attached to the inside sill, if possible.
Passenger compartment side:
1. OUTRIGGER
2. SUB-FRAME REAR
BRACKET
3. SIDE FRAME
EXTENSION REAR
4. OUTRIGGER
5. INSIDE SILL
EXTENSION
6. FLOOR FRAME
7. SIDE FRAME
EXTENSION REAR
8. SUB-FRAME REAR
BRACKET

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Index - Front Side Frame/Outrigger

3-14

Front Side Frame/Outrigger

Installation
1.

1. Tack weld the new side frame bulkhead rear to

the side frame extension rear.

Plug weld the inside sill extension and floor

frame.
2.

3.

1. SIDE FRAME BULKHEAD REAR

2. Set the new front side frame, side frame

extension rear, outrigger and front bulkhead into
position and measure the front compartment
diagonally. Check the body dimensions (see
section 4).
3. Tack weld the clamped position.
4. Temporarily install the front sub-frame, and
check the front side frame position.
5. Temporarily install the hood, front render,
headlights and front bumper, and check for
differences in level and clearance.
Make sure the body lines flow smoothly.
6. Perform the main welding:
Plug weld the side frame extension rear,
side frame bulkhead rear and front side
frame.

1.

1. INSIDE SILL EXTENSION

2. FLOOR FRAME

From passenger compartment, plug weld the

dashboard lower and front floor.

4.

1. SIDE FRAME BULKHEAD REAR

2. FRONT SIDE FRAME
3. SIDE FRAME EXTENSION REAR

2.

1. OUTRIGGER
2. SUB-FRAME REAR BRACKET
3. SIDE FRAME EXTENSION REAR

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Index - Front Side Frame/Outrigger

Front Side Frame/Outrigger

3-15

Installation (cont'd)

Weld the damper housing, front wheelhouse

and front side frame.

1.

1. DAMPER HOUSING
2. FRONT WHEELHOUSE

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Index - Front Pillar Outer Panel

Front Pillar Outer Panel

3-16

Mass Production Body Welding Diagram

a.

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

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Index - Front Pillar Outer Panel

Front Pillar Outer Panel

3-17

Removal

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

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Index - Front Pillar Outer Panel

3-18

Front Pillar Outer Panel

Installation
1.

1. Glue the insulator to the inner lower at the front

pillar lower separator mounted position.
Insulator: P.N. 74416-SR1-000

1.

6. Clamp the repair part and recheck the

clearance and alignment of the front door, front
fender and windshield.
7. Perform the main welding:
Attach the patch at the cut section of the
front pillar outer panel and plug weld it.

Adhesive: Cemedine 366, or equivalent

2.

3.

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 difference
in level and clearance. Make sure the body
lines flow smoothly.
5. Remove the repair part, and weld the front
pillar lower stiffener, upper stiffener and side sill
reinforcement.
2.

3.

4.

1.
2.
3.
4.
5.

Butt welding
PATCH
OUTER PANEL
Fillet welding
Overlap
30 mm (1.2 in.)

8. Weld the wheelhouse upper member.

1. FRONT PILLAR UPPER STIFFENER

2. FRONT PILLAR LOWER STIFFENER
3. INSULATOR
4.

1. WHEELHOUSE UPPER MEMBER

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Index - Side Sill Outer Panel

Side Sill Outer Panel

3-19

Mass Production Body Welding Diagram

a.

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

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Index - Side Sill Outer Panel

Side Sill Outer Panel

3-20

Removal

Cut and pry off the side sill outer panel.

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

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Index - Side Sill Outer Panel

3-21

Side Sill Outer Panel

Installation
1.

1. Glue the insulator to the centre inner pillar at

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

1.

2.

3.

1. CENTRE INNER PILLAR

2. INSULATOR

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 into
position. Clamp the repair part, and check the
body dimensions (see section 4).
4. Temporarily install the front door, rear door and
front fender, and check for differences in level
and clearance. Make sure the body lines flow
smoothly.
5. Remove the repair part, and weld the centre
pillar lower stiffener and side sill reinforcement.

NOTE: Replace the driver side of the side sill

reinforcement with the assembly without cutting the side
sill reinforcement halfway, because there id the
reinforcement stiffener inside of the side sill
reinforcement. Therefore, cut the outer panel to under of
the front pillar.

2.

4.

1. Fillet welding
Overlap
20 mm (0.8 in.)
2. NEW CENTRE PILLAR STIFFENER

1. NEW SIDE SILL REINFORCEMENT

2. INSIDE SILL
3. CENTRE INNER PILLAR

1.
2.
3.
4.
5.

FRONT PILLAR OUTER PANEL

OUTER PANEL
SIDE SILL REINFORCEMENT
INSIDE SILL
REINFORCEMENT STIFFENER

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Index - Side Sill Outer Panel

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

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Index - Side Sill Outer Panel

Side Sill Outer Panel

3-22

Installation (cont'd)
1.

6. Clamp the repair part and recheck the clearance

and alignment of the front door, rear door and front
denser.
7. Perform the main welding:
Attach the patch at the cut section of the centre
pillar and wheel arch and plug weld them.

2.

1.
2.
3.
4.
5.
6.

Fillet welding
Butt welding
PATCH
PATCH
Butt welding
Overlap
30 mm (1.2 in.)

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Index - Roof Panel

Roof Panel

3-23

Mass Production Body Welding Diagram

Without roof panel:
a.

a.
b.
c.
d.
e.
f.
g.
h.

Front inner upper pillar

Front roof rail
Rear roof rail
Roof panel
Rear inner panel
Rear roof side rail
Outer panel
Front roof side rail

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Index - Roof Panel

Roof Panel

3-24

Removal

1.
2.
3.
4.
5.
6.
7.

ROOF PANEL
REAR INNER PANEL
ROOF ARCH GUSSET
REAR INNER PANEL
REAR ROOF RAIL
FRONT ROOF RAIL
FRONT INNER UPPER
PANEL
8. FRONT INNER UPPER
PILLAR

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Index - Roof Panel

3-25

Roof Panel

Installation
1.

1. Set the new roof panel into position and clamp

it. Check the body dimensions (see section 4),
and check the width of the roof moulding
installation.
2. Install the roof arch gusset, and tack weld the
roof panel.
3. Temporarily install the windshield, door and
rear window and check for difference in level
and clearance.
4. Perform the main welding.

2.

1.

5. From inside the vehicle, plug weld the front

pillar inner upper, rear inner panel and front and
rear roof rails.

1. OUTER PANEL
2. ROOF PANEL
3. ROOF SIDE RAIL

VIEW (Z)
2.

3.

1.
2.
3.
4.

FRONT INNER UPPER PILLAR

FRONT ROOF RAIL
REAR INNER PANEL
REAR ROOF RAIL

1. ROOF ARCH GUSSET

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Index - Rear Side Outer Panel

Rear Side Outer Panel

3-26

Mass Production Body Welding Diagram

a.

a. Rear damper
stiffener
b. Inner panel
extension
c. Inner panel
d. Rear panel side
stiffener
e. VIEW (Z)
f. Rear combination
adaptor
g. Wheel arch
extension

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Index - Rear Side Outer Panel

Rear Side Outer Panel

3-27

Removal

Cut and pry off rear side outer panel.

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

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Index - Rear Side Outer Panel

3-28

Rear Side Outer Panel

Installation
1.

1. Set the new repair part (outer panel and rear

combination adaptor and into position and clamp
them. Check the body dimensions (see section 4).
2. Tack weld the clamped position.
3. Temporarily install the door, rear window, trunk lid
and rear bumper and check for difference in level
and clearance.
Make sure the body lines flow smoothly.
4. Perform the main welding:
Attach the patch at the cut section of the rear
pillar and plug weld it.

Weld the rear combination adaptor and rear

panel.

1.

2.

1.
2.
3.
4.
5.
6.
7.

1. REAR COMBINATION ADAPTOR

OUTER PANEL
PARCEL SHELF
REAR GUTTER
Butt welding
NEW OUTER PANEL
Fillet welding
Overlap
30 mm (1.2 in.)

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Index - Rear Side Outer Panel

8. PATCH

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Index - Rear Panel

Rear Panel

3-29

Mass Production Body Welding Diagram

a.

a. Rear panel side

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

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4-door Replacement

4-door Replacement
*Front Bulkhead
Mass Production Body Welding Diagram

3-4

Removal

3-5

Installation

3-5

*Front Wheelhouse/Damper Housing

Mass Production Body Welding Diagram

3-6

Removal

3-7

Installation

3-9

*Front Side Frame Outrigger

Mass Production Body Welding Diagram

3-11

Removal

3-12

Installation

3-14

*Front Pillar Outer Panel

Mass Production Body Welding Diagram

3-16

Removal

3-17

Installation

3-18

*Side Sill Outer Panel

Mass Production Body Welding Diagram

3-19

Removal

3-20

Installation

3-21

Roof Panel
Mass Production Body Welding Diagram

3-24

Removal

3-24

Installation

3-25

Rear Side Outer Panel

Mass Production Body Diagram

3-26

Removal

3-27

Installation

3-28

Rear Panel
Mass Production Body Welding Diagram

3-29

Removal

3-30

Installation

3-31

Rear Floor
Mass Production Body Welding Diagram

3-32

Removal

3-33

Installation

3-34

Items marked with and asterisk (*) include SRS components; special caution is required when servicing.

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4-door Replacement

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Index - Rear Panel

Rear Panel

3-30

Removal

Cut and pry off the rear panel.

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

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Index - Rear Panel

3-31

Rear Panel

Installation
1.

1. Set the new rear panel and rear combination

adaptor into position and clamp them.
Check the body dimensions (see section 4).

2.

3.

1. NEW REAR COMBINATION ADAPTOR

2. NEW REAR PANEL

In the case of leave the rear panel side

stiffener and rear combination adopter and
replace rear panel.
Remove the new panel side stiffener from the
new rear panel.
Weld the rear panel side lower stiffener and
rear panel side stiffener.

1.

2. Tack weld the clamped position.

3. Temporarily install the trunk lid, tailgate, rear
bumper and check for difference in level and
clearance. Check for operation of the truck lid.
4. Perform the main welding:
Weld the rear combination adaptor, rear
gutter, outer panel and rear panel.

Weld the rear panel and rear floor.

2.

4.

1.
2.
3.
4.

1. REAR COMBINATION ADAPTOR

2. REAR PANEL SIDE STIFFENER
3. REAR PANEL SIDE LOWER STIFFENER
(New Part)

1. NEW REAR PANEL

OUTER PANEL
NEW REAR GUTTER
NEW REAR COMBINATION ADAPTOR
NEW REAR PANEL

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Index - Rear Floor

Rear Floor

3-32

Mass Production Body Welding Diagram

a.

a. Rear floor crossmember

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

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Index - Rear Floor

Rear Floor

3-33

Removal

Cut the rear floor 15 mm (0.6 in.) from the welded flange of the rear cross-member.
If necessary, replace the rear frame B.
Check the rear floor cross-member position for damage.
If necessary, replace the rear floor cross-member.
1. REAR FLOOR CROSSMEMBER
2. REAR FLOOR
3. Cut line
4. REAR FLOOR CROSSMEMBER
5. REAR FLOOR
6. REAR FLOOR CROSSMEMBER
7. REAR FRAME A
8. VIEW (Z)
9. REAR FRAME B
10. REAR FRAME A
11. REAR FRAME B

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Index - Rear Floor

3-34

Rear Floor

Installation
1.

1. Set the new rear cross-member and rear frame

B, into position.
2. Check the body dimensions (see section 4).
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.

8. Set the new rear floor, and plug weld the rear
floor cross-member, rear frame B and rear
frame A.

2.

2.

3.

1. NEW REAR FLOOR

2. Overlap
40 mm (1.6 in.)
3. NEW REAR FLOOR
4. REAR FLOOR CROSS-MEMBER
5. REAR FLOOR
(body side)

3.

1.
2.
3.
4.
5.

REAR
REAR
REAR
REAR
REAR

FRAME A
FLOOR CROSS-MEMBER
FRAME B
FRAME A
FLOOR CROSS-MEMBER

9. Perform the main welding to the rear floor.

5. Check the position of the rear inner panel and

rear panel.
6. Remove the new rear floor and plug weld the
rear floor cross-member.
7. Finish plug welding the area, and take not to
grind excessively.

4.

1. Filler welding

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Index - Rear Floor

4.

1. REAR FLOOR CROSS MEMBER

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5-door Replacement

5-door Replacement
*Front Bulkhead
Mass Production Body Welding Diagram

3-36

Removal

3-37

Installation

3-37

*Front Wheelhouse/Damper Housing

Mass production Body Welding Diagram

3-38

Removal

3-39

Installation

3-41

*Front Side Frame/Outrigger

Mass Production Body Welding Diagram

3-43

Removal

3-44

Installation

3-46

*Front Pillar Outer Panel

Mass Production Body Welding Diagram

3-48

Removal

3-49

Installation

3-50

*Side Sill Outer Panel

Mass Production Body Welding Diagram

3-51

Removal

3-52

Installation

3-53

Roof Panel
Mass Production Body Welding Diagram

3-55

Removal

3-56

Installation

3-57

Rear Side Outer Panel

Mass Production Body Welding Diagram

3-58

Removal

3-59

Installation

3-60

Rear Panel
Mass Production Body Welding Diagram

3-61

Removal

3-62

Installation

3-62

Rear Floor
Mass Production Body Welding Diagram

3-63

Removal

3-64

Installation

3-65

Items marked with an asterisk (*) include SRS components; special caution is required when servicing.

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5-door Replacement

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Index - Front Bulkhead

Front Bulkhead

3-36

Mass Production Body Welding Diagram

a.

a. Front wheelhouse
b. Wheelhouse
upper extension
c. Front side frame
d. Wheelhouse
upper member
e. Front lower
cross-member
f. Bulkhead side
g. Front side frame
h. 4-Plate welding
i. 4-Plate welding
j. Front lower
cross-member
k. Bulkhead side
stay
l. Bulkhead centre
stay
m. Bulkhead upper
frame

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Index - Front Bulkhead

Front Bulkhead

3-37

Installation

Removal

1.

1.

1.
2.
3.
4.
5.
6.
7.

1. Set the new front bulkhead into position and

measure the front compartment diagonally.
Check the body dimension (see section 4).
2. Tack weld the clamped position.
3. Temporarily install the hood, front fender,
headlight and front bumper and check for
differences in level and clearance.
4. Perform the main welding:

BULKHEAD UPPER FRAME

BULKHEAD SIDE
WHEELHOUSE UPPER EXTENSION
FRONT WHEELHOUSE
FRONT SIDE FRAME
BULKHEAD SIDE STAY
FRONT LOWER CROSS-MEMBER

2.

1.
2.
3.
4.
5.
6.
7.

BULKHEAD UPPER FRAME

WHEELHOUSE UPPER EXTENSION
WHEELHOUSE UPPER MEMBER
BULKHEAD SIDE
FRONT SIDE FRAME
FRONT LOWER CROSS-MEMBER
FRONT WHEELHOUSE

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Index - Front Bulkhead

8. BULKHEAD SIDE STAY
9. FRONT SIDE FRAME

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Front/Wheelhouse/Damper Housing

3-38

Front/Wheelhouse/Damper Housing

Mass Production Body Welding Diagram

a.

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.

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

Passenger compartment side:

a.

a. Wheelhouse upper member

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Front/Wheelhouse/Damper Housing

VIEW (X)

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Index - Front Wheelhouse/Damper Housing

Front Wheelhouse/Damper Housing

3-39

Removal

Cut and remove the wheelhouse upper member, and replace the front wheelhouse.
1. DAMPER HOUSING
2. WHEELHOUSE UPPER
EXTENSION
3. WHEELHOUSE UPPER
MEMBER Reused.
4. FRONT WHEELHOUSE
5. ENGINE MOUNT
BRACKET
6. FRONT SIDE FRAME

Check the wheelhouse upper extension and damper housing for position and damage. If Necessary, remove the
wheelhouse upper member and replace the damper housing and wheelhouse upper extension as an assembly. If
possible.
1. DAMPER HOUSING
2. WHEELHOUSE UPPER
EXTENSION
3. WHEELHOUSE UPPER MEMBER
EXTENSION
4. WHEELHOUSE UPPER MEMBER
Reused.

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Index - Front Wheelhouse/Damper Housing

Front Wheelhouse/Damper Housing

3-40

Removal (cont'd)

Replace the wheelhouse upper extension, damper housing extension as an assembly.

Passenger compartment side:
1. WHEELHOUSE UPPER
EXTENSION
2. DASHBOARD UPPER
SIDE MEMBER
3. DAMPER HOUSING
4. WHEELHOUSE UPPER
EXTENSION
5. ENGINE MOUNT
BRACKET
6. FRONT SIDE FRAME
7. DASHBOARD UPPER
8. MOUNTING BOLT
9. DAMPER HOUSING
EXTENSION

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Index - Front Wheelhouse/Damper Housing

Front Wheelhouse/Damper Housing

3-41

Installation
1.

1. Set the new damper housing assembly, front

wheelhouse and front bulkhead into position
and measure the front compartment diagonally.
Check the body dimensions (see section 4).
2. Tack weld the clamped position.
3. Temporarily install the front sub-frame and
check the front side frame position.
4. Temporarily install the hood, front fender,
headlight and front bumper, and check for
differences in level and clearance. Make sure
the lines flow smoothly.
5. Perform the main welding:
Weld the damper housing and front side
frame.
Weld the front damper extension and
dashboard upper side member.

From passenger compartment side, plug weld

the holes in the dashboard lower damper
housing extension and wheelhouse upper
extension.

1.

1. WHEELHOUSE UPPER EXTENSION

2. DAMPER HOUSING EXTENSION

Weld the dashboard upper and damper

housing.

2.

2.

1.
2.
3.
4.

1. DASHBOARD UPPER

WHEELHOUSE UPPER EXTENSION

DASHBOARD UPPER SIDE MEMBER
FRONT SIDE FRAME
DAMPER HOUSING

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Index - Front Wheelhouse/Damper Housing

Front Wheelhouse/Damper Housing

3-42

Installation (cont'd)

Weld the front wheelhouse, damper housing

and front side frame.

1.

1.
2.
3.
4.

DAMPER HOUSING
WHEELHOUSE UPPER EXTENSION
FRONT WHEELHOUSE
ENGINE MOUNT BRACKET

Weld the wheelhouse upper member.

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

2.

1.
2.
3.
4.

WHEELHOUSE UPPER EXTENSION

WHEELHOUSE UPPER MEMBER EXTENSION
Butt welding
WHEELHOUSE UPPER MEMBER

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Index - Front Side Frame/Outrigger

Front Side Frame/Outrigger

3-43

Mass Production Body Welding Diagram

a.

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.

a. Inside sill extension

VIEW (Y)
Passenger compartment side:

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Index - Front Side Frame/Outrigger

Front Side Frame/Outrigger

3-44

Removal

Passenger compartment side:

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

FRONT SIDE FRAME

DAMPER HOUSING
FRONT WHEELHOUSE
FRONT SIDE FRAME
ENGINE MOUNT
BRACKET
SIDE FRAME
BULKHEAD REAR
FRONT SIDE FRAME
FRONT SUB-FRAME
STAY
FRONT SIDE FRAME
SIDE FRAME
EXTENSION REAR
SIDE FRAME
BULKHEAD REAR
SIDE FRAME
BULKHEAD REAR
SIDE FRAME
EXTENSION REAR

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Index - Front Side Frame/Outrigger

Front Side Frame/Outrigger

3-45

Removal (cont'd)

Check the side frame bulkhead rear for position and damage. If Necessary replace it.
1. SUB-FRAME REAR BRACKET
2. SIDE FRAME BULKHEAD REAR
3. SIDE FRAME EXTENSION

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.
Passenger compartment side:
1. OUTRIGGER
2. SUB-FRAME REAR
BRACKET
3. SIDE FRAME
EXTENSION REAR
4. OUTRIGGER
5. INSIDE SILL
EXTENSION
6. FLOOR FRAME
7. SIDE FRAME
EXTENSION REAR
8. SUB-FRAME REAR
BRACKET

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Index - Front Side Frame/Outrigger

3-46

Front Side Frame/Outrigger

Installation
1.

1. Tack weld the new side frame bulkhead rear to

the side frame extension rear.

2.

3.

Plug weld the inside sill extension and floor

frame.

1. SIDE FRAME BULKHEAD REAR

2. Set the new front, side frame extension rear,

outrigger and front bulkhead into position and
measure the front compartment diagonally.
Check the body dimensions (see section 4).
3. Tack weld the clamped position.
4. Temporarily install the front sub-frame and
check the front side frame position.
5. Temporarily install the hood, front fender,
headlight and front bumper and check for
difference in level and clearance.
Make sure the body lines flow smoothly.
6. Perform the main welding:
Plug weld the side frame extension rear,
side frame bulkhead rear and front side
frame.
1.

1. INSIDE SILL EXTENSION

2. FLOOR FRAME

From passenger compartment, plug weld the

dashboard lower and front floor.

4.

1. SIDE FRAME BULKHEAD REAR

2. FRONT SIDE FRAME
3. SIDE FRAME EXTENSION REAR

2.

1. OUTRIGGER
2. SUB-FRAME REAR BRACKET

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Index - Front Side Frame/Outrigger

3. SIDE FRAME EXTENSION REAR

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Index - Front Side Frame/Outrigger

Front Side Frame/Outrigger

3-47

Installation (cont'd)

Weld the damper housing, front wheelhouse

and front side frame.

1.

1. DAMPER HOUSING
2. FRONT WHEELHOUSE

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Index - Front Pillar Outer Panel

Front Pillar Outer Panel

3-48

Mass Production Body Welding Diagram

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

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Index - Front Pillar Outer Panel

Front Pillar Outer Panel

3-49

Removal

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

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Index - Front Pillar Outer Panel

3-50

Front Pillar Outer Panel

Installation
1.

1. Glue the insulator to the inner lower at the front

pillar lower separator mounted position.
Insulator: P/N. 74416-SF1-000

1.

6. Clamp the repair part and recheck the

clearance and alignment of the front door, front
fender and windshield.
7. Perform the main welding:
Attach the patch at the cut the section of the
front pillar outer panel and plug weld it.

Adhesive: Cemedine 366 or equivalent

2.

3.

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.

2.

3.

4.

1. FRONT PILLAR UPPER STIFFENER

2. FRONT PILLAR LOWER STIFFENER
3. INSULATOR

1.
2.
3.
4.
5.

Butt welding
PATCH
OUTER PANEL
Fillet welding
Overlap
30 mm (1.2 in)

8. Weld the wheelhouse upper member.

4.

1. WHEELHOUSE UPPER MEMBER EXTENSION

2. WHEELHOUSE UPPER MEMBER

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Index - Side Sill Outer Panel

Side Sill Outer Panel

3-51

Mass Production Body Welding Diagram

a.

a. Center pillar
stiffener
reinforcement
b. Centre pillar
stiffener
c. 4-Plate welding
d. Centre pillar
separator
e. VIEW (Y)
f. Side sill
reinforcement
g. VIEW (Z)
h. Centre pillar
stiffener
i. VIEW (W)
j. VIEW (Y)
k. 4-Plate welding

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Index - Side Sill Outer Panel

Side Sill Outer Panel

3-52

Removal

Cut and pry off the side sill outer panel.

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

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Index - Side Sill Outer Panel

3-53

Side Sill Outer Panel

Installation
1.

1. Glue the insulator to the center inner pillar at the

centre pillar separator mounted position.
Insulator: PIN. 774416-SF1-000
Adhesive: Cemedine 366, or equivalent

1.

2.

3.

1. CENTRE INNER PILLAR

2. INSULATOR

2. Cut and set the new centre pillar stiffener and

side sill reinforcement into position and tack weld
the clamped position.
3. Cut the repair part (outer panel), set it into
position. Clamp the repair part and check the
body dimensions (see section 4).
4. Temporarily install the front door, rear door and
front fender and check for differences in level
and clearance.
Make sure the body lines flow smoothly.
5. Remove the repair part and weld the centre
pillar lower stiffener and side sill reinforcement.

NOTE: Replace the drive side of the side sill

reinforcement with the assembly without cutting the side
sill reinforcement halfway, because there is reinforcement
stiffener inside of the side sill reinforcement. Therefore,
cut the outer panel to under of the front pillar.

2.

4.

1. NEW SIDE SILL REINFORCEMENT

2. INSIDE SILL
3. CENTRE INNER PILLAR

1.
2.
3.
4.
5.

FRONT PILLAR OUTER PANEL

OUTER PANEL
SIDE SILL REINFORCEMENT
INSIDE SILL
REINFORCEMENT STIFFENER

1. NEW CENTRE PILLAR STIFFENER

Filler welding

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Index - Side Sill Outer Panel

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

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Index - Side Sill Outer Panel

Side Sill Outer Panel

3-54

Installation (cont'd)
1.

6. Clamp the repair part and recheck the clearance

alignment of the front door, rear door and front
fender.
7. Perform the main welding:
Attach the patches at the cut section of the
center pillar and wheel arch and plug weld
them.

2.

1.
2.
3.
4.
5.

Butt welding
PATCH
PATCH
Butt welding
Overlap
30 mm (1.2 in.)
6. Fillet welding

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Index - Roof Panel

Roof Panel

3-55

Mass Production Body Welding Diagram

Without roof panel:
a.
b.
c.
d.
e.
f.
g.
h.
i.

Front inner upper pillar

Front roof rail
Rear roof rail
Roof panel
Rear Pillar upper gutter
Rear inner panel
Rear roof side rail
Outer panel
Front roof side rail

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Index - Roof Panel

Roof Panel

3-56

Removal

1. ROOF PANEL
2. REAR INNER PANEL
3. REAR PILLAR
GUTTER UPPER
4. ROOF ARCH GUSSET
5. REAR INNER PANEL
6. REAR ROOF RAIL
7. FRONT ROOF RAIL
8. FRONT INNER UPPER
PILLAR
9. FRONT INNER UPPER
PILLAR

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Index - Roof Panel

3-57

Roof Panel

Installation
1.

1. Set the new roof panel into position and clamp

it.
Check the body dimensions (see section 4),
and check the width of the roof moulding
installation.
2. Install the roof arch gusset, rear roof rail
mounting bolts and tack weld the roof panel.
3. Temporarily install the windshield, door and
tailgate, check for difference in level and
clearance.
4. Perform the main welding.

1.

VIEW (Z)
1.

5. From inside the vehicle, plug weld the front

pillar inner upper, rear inner panel and front and
rear roof rail.

2.

1. OUTER PANEL
2. ROOF PANEL
3. ROOF SIDE RAIL

3.

FRONT INNER UPPER PILLAR

FRONT ROOF RAIL
REAR INNER PANEL
REAR ROOF RAIL

6. Weld the roof panel and rear pillar gutter upper.

4.

2.

1.
2.
3.
4.

1. REAR PILLAR GUTTER UPPER

1. ROOF ARCH GUSSET

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Index - Rear Side Outer Panel

Rear Side Outer Panel

3-58

Mass Production Body Welding Diagram

a.

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

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Index - Rear Side Outer Panel

Rear Side Outer Panel

3-59

Removal

Cut and pry off the rear side sill outer panel.
Check the rear pillar gutter lower and gutter upper position and for damage and if necessary, replace the rear pillar gutter
lower.
1. WHEEL ARCH
EXTENSION
2. QUARTER PILLAR
INNER
3. REAR PILLAR INNER
4. REAR PILLAR
GUTTER UPPER
5. REAR PILLAR
GUTTER LOWER
6. REAR INNER PANEL
7. REAR PILLAR
GUTTER LOWER
8. REAR PANEL
9. REAR PILLAR
GUTTER UPPER
10. REAR PANEL GUSSET
11. VIEW (Z)
12. REAR GUTTER
LOWER STIFFENER
13. OUTER PANEL

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Rear Side outer Panel

3-60

Rear Side outer Panel

Installation
1.

1. Set the new repair part (outer panel) and rear

pillar gutter lower and into position and clamp
them.
Check the body dimensions (see section 4).
2. Tack weld the clamped position.
3. Temporarily install the door, tailgate, tailgate and
rear bumper and check for differences in the
level and clearance. Make sure the body lines
flow smoothly.
4. Perform the main welding:
Attach the patch at the cut section of the
quarter pillar, rear pillar and plug weld them.

Weld the rear pillar gutter lower, gutter upper

and rear panel.

1.

2.

1. REAR GUTTER LOWER STIFFENER

2. REAR PILLAR GUTTER LOWER

1.
2.
3.
4.
5.

Butt welding
Butt welding
PATCH
NEW OUTER PANEL
Overlap
30 mm (1.2 in.)
Fillet welding
6. PATCH

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Index - Rear Panel

Rear Panel

3-61

Mass Production Body Welding Diagram

a.

a. Rear pillar gutter

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

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Index - Rear Panel

Rear Panel

3-62

Installation

Removal

Cut and pry off the rear panel.

Check the rear pillar gutter lower position and
for damage and if necessary, replace it (see
page 3-59).

1.

1. Set the new rear panel and check the body

dimensions (see section 4).
2. Tack weld the clamped position.
3. Temporarily install the tailgate, tailgate, rear
bumper and check for differences in level and
clearance. Check operation of the tailgate.
4. Perform the main welding:

2.

1.

1.
2.
3.
4.
5.
6.

1. REAR PANEL
2. REAP PILLAR GUTTER LOWER

REAR PANEL
REAR GUTTER LOWER STIFFENER
REAR PANEL
REAR FLOOR
JACK-UP STIFFENER
REAR PILLAR GUTTER LOWER

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Index - Rear Floor

Rear Floor

3-63

Mass Production Body Welding Diagram

a.

a.
b.
c.
d.
e.
f.
g.
h.

Rear floor
Rear panel gusset
Rear frame B
Rear floor
Rear floor cross-member
Rear frame
Rear frame A
Rear floor cross-member

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Index - Rear Floor

Rear Floor

3-64

Removal

Cut the rear floor 15 mm (0.6 in.) from the welded flange of the rear floor cross-member.
Id necessary, replace the rear frame B.
Check the rear floor cross-member position and for damage.
If necessary, replace the rear floor cross-member.
1. REAR FLOOR CROSSMEMBER
2. REAR FLOOR
3. Cut line
4. REAR FLOOR CROSSMEMBER
5. REAR FLOOR
6. REAR FLOOR CROSSMEMBER
7. REAR FRAME A
8. VIEW (Z)
9. REAR FRAME B
10. REAR FRAME A
11. REAR FRAME B

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Index - Rear Floor

3-65

Rear Floor

Installation
1.

1. Set the new rear cross-member and rear frame

B, into position.
2. Check the body dimensions (see section 4).
3. Tack weld the rear cross-member and rear
frame B.
4. Set the new floor to align it with the body.
Cut the new rear floor so it overlaps the body
side floor by about 40 mm (1.6 in.).

2.

3.

1. NEW REAR FLOOR

2. Overlap
40 mm (1.6 in.)
3. NEW REAR FLOOR
4. REAR CROSS-MEMBER
5. REAR FLOOR
(body side)

1.

8. Set the new rear floor and plug weld the rear
floor cross-member, rear frame B and rear
frame A.

2.

3.

1.
2.
3.
4.
5.

REAR
REAR
REAR
REAR
REAR

FRAME A
FLOOR CROSS-MEMBER
FRAME B
FRAME A
FLOOR CROSS-MEMBER

9. Perform the main welding to the rear floor.

5. Check the position of the rear inner panel and

rear panel.
6. Removal the new rear floor and plug weld the
rear floor cross-member.
7. Finish plug welding the area and take care not
to grind excessively.

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Index - Rear Floor

4.

1. REAR FLOOR CROSS MEMBER

4.

1. Fillet welding

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Index - Index

Index
4-door Body Dimensional Drawings

4-3

5-door Body Dimensional Drawings

4-13

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4-door Body Dimensional Drawings

4-door Body Dimensional Drawings

Upper Body Measuring Dimensions
Engine Compartment

4-4

Engine/Transmission Mount Positions and

Passenger Compartment

4-5

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

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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
Front Fender Mount
Hole 7 (0.3) Forward
6. B, b
Headlight Mount Hole 7
(0.3)
7. A, a
Bulkhead Upper Frame
Point 15 (0.59)

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Index - Upper Body Measuring Dimensions

Passenger
4-5 Compartment

Upper Body Measuring Dimensions

Engine/Transmission Mount Positions

Unit: mm (in.)

1.

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.

1. K, k

file:///C|/...EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CivBHtml/4-5.htm[8/25/2012 6:39:07 PM]

Index - Upper Body Measuring Dimensions

Front Seat Rear Side Bracket Point 9 (0.35)
2. L, l
Rear Damper Mount Hole 11 (0.43)

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Index - Under Body Measuring Dimensions

Under Body Measuring Dimensions

4-6

Engine Compartment and Front Floor Under View

Unit: mm (in.)
1. A, a
Radiator Mount Hole 15
(0.59)
2. B, b
Front Sub-frame Mount
Hole 15 (0.59) Forward
3. C, c
Front Sub-frame Mount
Hole 15 (0.59)
Rearward
4. D, d
Front Floor Frame Point
20 (0.79)

file:///C|/...EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CivBHtml/4-6.htm[8/25/2012 6:39:07 PM]

Index - Under Body Measuring Dimensions

Under Body Measuring Dimensions

4-7

Middle and Rear Floor Under View

Unit: mm (in.)

1. D,d
Front Floor Frame Point
20 (0.79)
2. E, e
Front Floor Point 25
(0.98)
3. F, f
Rear Frame Extension
Point 20 (0.79)
4. G, g
Trailing arm Mount
Holed 14 (0.55)
5. H, h
Upper Arm Mount Hole
15 (0.59)
6. I, I
Lower Arm Mount Hole
12.8 (0.5)
7. J, j
Rear Frame A Point 20
(0.79)
8. K, k
Rear Frame B Pint 15
(0.59)

file:///C|/...EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CivBHtml/4-7.htm[8/25/2012 6:39:08 PM]

Index - Frame Repair Chart

4-8

Frame Repair Chart

Top View

Unit: mm (in.)

For sub-frame o15 (0.59)

For damper mount o 11.5 (0.45)

: Inner diameter

b1

For engine mount o13 (0.51)

Damper centre o 78 (3.07)

b2

For engine mount o 13 (0.51)

For damper mount o 11.5 (0.45)

b3

For engine mount o 13 (0.51)

For damper mount o 11.5 (0.45)

c1

For transmission mount o13 (0.51)

For sub-frame o 11.5 (0.45)

c2

For transmission mount o13 (0.51)

For sub-frame o 11.5 (0.45)

c3

For transmission mount o13 (0.51)

Locate hole o 25 (0.98)

d1

For transmission mount o13 (0.51)

Locate hole o 50 (1.97)

d2

For transmission mount o13 (0.51)

d3

For transmission mount o13 (0.51)

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Index - Frame Repair Chart

file:///C|/...EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CivBHtml/4-8.htm[8/25/2012 6:39:08 PM]

Index - Frame Repair Chart

4-9

Frame Repair Chart

Top View (cont'd)

m

Locate hole o 25 (0.98)

For upper arm bracket center o 15 (0.59)

For trailing arm o 13 (0.51)

v1, v2

Locate hole o 13 (0.51)

Locate hole o 25 (0.98)

For upper arm o 13 (0.51)

Locate hole o 20 (0.79)

For rear lower arm centre

Trailing arm centre

Locate hole o 50 (1.97)

Rear damper center 73 x 68 (slot)

Locate hole o 20 (0.79)

For upper arm o 13 (0.51)

For trailing arm o 13 (0.51)

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Index - Frame Repair Chart

4-10

Frame Repair Chart

Side View

Unit: mm (in.)
o: Inner diameter

For sub-frame o 15 (0.59)

For damper mount o 11.5 (0.45)

b1

For engine mount o 13 (0.51)

Damper centre o 78 (3.07)

b2

For engine mount o 13 (0.51)

For damper mount o 11.5 (0.45)

b3

For engine mount o 13 (0.51)

For damper mount o 11.5 (0.45)

c1

For transmission mount o 13 (0.51)

For sub-frame o 11.5 (0.45)

c2

For transmission mount o 13 (0.51)

For sub-frame o 11.5 (0.45)

c3

For transmission mount o 13 (0.51)

Locate hole o 25 (0.98)

d1

For transmission mount o 13 (0.51)

Locate hole o 50 (1.97)

d2

For transmission mount o 13 (0.51)

d3

For transmission mount o 13 (0.51)

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Index - Frame Repair Chart

file:///C|/...U3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CivBHtml/4-10.htm[8/25/2012 6:39:04 PM]

Index - Frame Repair Chart

4-11

Frame Repair Chart

Side View (cont'd)

m

Locate hole o 25 (0.98)

For upper arm bracket center o15 (0.59)

For trailing arm o 13 (0.51)

v1, v2

Locate hole o 13 (0.51)

Locate hole o 25 (0.98)

For upper arm o 13 (0.51)

Locate hole o 20 (0.79)

For rear lower arm centre

Trailing arm centre

Locate hole o 50 (1.97)

Rear damper center 73 x 68 (slot)

Locate hole o 20 (0.79)

For upper arm o 13 (0.51)

For trailing arm o 13 (0.51)

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Index - Opening Repair Chart

Opening Repair Chart

4-12

Door and Windshield Openings:

Unit: mm (in.)

1.

1. A
Windshield lower dashboard guide pin
2. B, C
Windshield opening flange notch (2 places)
3. D, E, F, G, H, I, J, K,
Door opening flange notch (16 places)

Rear Window and Trunk Lip Openings:

2.

1. L, M
Rear window opening flange notch (3 places)
2. N
Trunk gutter area convex bead
3. O
Outer panel range end (2 places)
4. P

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Index - Opening Repair Chart

Trunk seal flange water drain notch

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5-door Body Dimensional Drawings

5-door Body Dimensional Drawings

Upper Body Measuring Dimensions
Engine Compartment

4-14

Engine/Transmission Mount Positions and

Passenger Compartment

4-15

Under Body Measuring Dimensions

Engine Compartment and Front Floor Under
View

4-16

Middle and Rear Floor Under View

4-17

Frame Repair Chart

Top View

4-18

Side View

4-20

Opening Repair Chart

4-22

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Index - Upper Body Measuring Dimensions

Upper Body Measuring Dimensions

4-14

Engine Compartment
Unit: mm (in.)

1. E, e
Front Damper Mount
Hole 11.5 (0.45)
2. G, g
Hood Hinge Mount Hole
7 (0.3) Forward
3. F, f
Front Fender Mount
Hole 7 (0.3) middle
4. D, d
Front Bumper Beam
Mount Hole 9 (0.35)
5. C, c
Front Fender Mount
Hole 7 (0.3) Forward
6. B, b
Headlight Mount Hole 7
(0.3)
7. A, a
Bulkhead Upper Frame
Point 15 (0.59)

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Index - Upper Body Measuring Dimensions

Upper Body Measuring Dimensions

4-15

Passenger Compartment

Engine/Transmission Mount Positions

Unit: mm (in.)

1.

Unit: mm (in.)

1. E
Front Damper Mount Hole 11.5 (0.45)
2. H
AT/MT Transmission bracket Mount Hole 13 (0.51)
3. I
Engine Bracket Mount Hole 13 (0.51)

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Index - Upper Body Measuring Dimensions

1.

1. J, j
Front seat Rear Side Bracket Point 9 (0.35)
2. K, k
Rear Damper Mount hole 11 (0.43)

file:///C|/...U3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CivBHtml/4-15.htm[8/25/2012 6:39:05 PM]

Index - Upper Body Measuring Dimensions

Upper Body Measuring Dimensions

4-16

Engine Compartment and Front Under View

Unit: mm (in.)
1. A, a
Radiator Mount Hole 15
(0.59)
2. B, b
Front Sub-frame Mount
Hole 15 (0.59) Forward
3. C, c
Front Sub-frame Mount
Hole 15 (0.59)
Rearward
4. D, d
Front Floor Frame Point
20 (0.79)

file:///C|/...U3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CivBHtml/4-16.htm[8/25/2012 6:39:05 PM]

Index - Upper Body Measuring Dimensions

Upper Body Measuring Dimensions

4-17

Middle and Rear Floor Under View

1. D, d
Front Floor Frame Point
20 (0.79)
2. E, e
Front Floor Point 25
(0.98)
3. F, f
Rear Frame Extension
Point 20 (0.79)
4. G, g
Trailing arm Mount Hole
14 (0.55)
5. H, h
Upper Arm Mount Hole
15 (0.59)
6. I, I
Lower Arm Mount Hole
12.8 (0.5)
7. J, j
Rear Frame A Point 20
(0.79)
8. K, k
Rear Frame B Point 25
(1.0)

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Index - Frame Repair Chart

4-18

Frame Repair Chart

Top View

Unit: mm (in.)

For sub-frame o 15 (0.59)

Damper centre o 78 (3.07)

: Inner diameter

b1

For engine mount o 13 (0.51)

For damper mount o 11.5 (0.45)

b2

For engine mount o 13 (0.51)

For damper mount o 11.5 (0.45)

b3

For engine mount o 13 (0.51)

For sub-frame o 11.5 (0.45)

c1

For transmission mount o 13 (0.51)

For sub-frame o 11.5 (0.45)

c2

For transmission mount o 13 (0.51)

Locate hole o 25 (0.98)

c3

For transmission mount o 13 (0.51)

Locate hole o 50 (1.97)

For damper mount o 11.5 (0.45)

file:///C|/...U3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CivBHtml/4-18.htm[8/25/2012 6:39:06 PM]

Index - Frame Repair Chart

4-19

Frame Repair Chart

Top View (cont'd)

l

Locate hole o 25 (0.98)

For upper arm bracket center o 15 (0.59)

For trailing arm o 13 (0.51)

u1, u2

Locate hole o 13 (0.51)

Locate hole o 25 (0.98)

For upper arm o 13 (0.51)

Locate hole o 20 (0.79)

Locate hole o 25 (0.98)

Trailing arm centre

For rear lower arm centre

Rear damper center 73 x 68 (slot)

Locate hole o 50 (1.97)

For upper arm o 13 (0.51)

Locate hole o 20 (0.79)

For trailing arm o 13 (0.51)

file:///C|/...U3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CivBHtml/4-19.htm[8/25/2012 6:39:06 PM]

Index - Frame Repair Chart

4-20

Frame Repair Chart

Side View

Unit: mm (in.)

For sub-frame o 15 (0.59)

Damper centre o 78 (3.07)

: Inner diameter

b1

For engine mount o 13 (0.51)

For damper mount o 11.5 (0.45)

b2

For engine mount o 13 (0.51)

For damper mount o 11.5 (0.45)

b3

For engine mount o 13 (0.51)

For sub-frame o 11.5 (0.45)

c1

For transmission mount o 13 (0.51)

For sub-frame o 11.5 (0.45)

c2

For transmission mount o 13 (0.51)

Locate hole o 25 (0.98)

c3

For transmission mount o 13 (0.51)

Locate hole o 50 (1.97)

For damper mount o 11.5 (0.45)

file:///C|/...U3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CivBHtml/4-20.htm[8/25/2012 6:39:06 PM]

Index - Frame Repair Chart

4-21

Frame Repair Chart

Side View (cont'd)

l

Locate hole o 25 (0.98)

For upper arm bracket center o 15 (0.59)

For trailing arm o 13 (0.51)

u1, u2

Locate hole o 13 (0.51)

Locate hole o 25 (0.98)

For upper arm o 13 (0.51)

Locate hole o 20 (0.79)

Locate hole o 13 (0.51)

Trailing arm centre

For rear lower arm centre

Rear damper center 73 x 68 (slot)

Locate hole o 50 (1.97)

For upper arm o 13 (0.51)

Locate hole o 20 (0.79)

For trailing arm o 13 (0.51)

file:///C|/...U3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CivBHtml/4-21.htm[8/25/2012 6:39:06 PM]

Index - Opening Repair Chart

Opening Repair Chart

4-22

Door and Windshield Openings:

Unit: mm (in.)

1.

1. A
Windshield lower dashboard guide pin
2. B, C
Windshield opening flange notch (3 places)
3. D, E, F, G, H, I, J, K,
Door opening flange notch (16 places)

Tailgate Opening:

2.

1. L
Roof lower Rail Flange notch
2. M

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Index - Opening Repair Chart

Rear Gutter Lower Stiffener flange end (2 places)
3. N
Rear panel upper stiffener water drain notch

file:///C|/...U3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CivBHtml/4-22.htm[8/25/2012 6:39:07 PM]

Index - Index

Index
4-door Rust Prevention

5-3

5-door Rust Prevention

5-17

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4-door Rust Prevention

4-door Rust Prevention

Cross Section of Body and Sealants
General

5-4

Engine Compartment, Front Wheelhouse and

Damper Housing

5-5

Dashboard Upper, Dashboard Lower and Roof

Panel

5-6

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

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Index - Cross Section of Body and Sealants

5-4

Cross Section of Body and Sealants

General

NOTE: Following the sealer manufacturer's instructions.

1.

1. Clean the areas to be sealed with the white

gasoline.
2. Wipe off any excess spot sealer with thinner.
After the primer is sprayed, sealer will fill to the
area where spot sealer was wiped off.
3. Make sure you can see the sealant when the
sealed part is in its proper location. See page
5-5 to page 5-9 of this manual.

2.

4. Finish sealing the engine compartment, the

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

1.

5. Apply sealer on any area that the replacement

part will cover. Smooth the sealer with a brush
is necessary.

file:///C|/...EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CivBHtml/5-4.htm[8/25/2012 6:39:13 PM]

Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants

5-5

Engine Compartment, Front Wheelhouse and

Damper Housing
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.

Bulkhead Upper Frame

Fender Bracket
Damper Housing
Front Damper
Extension
Front Damper Base
Front Damper
Extension
Front Damper Base
Front Damper Base
Dashboard Upper
Steering Joint Cover
Dashboard Lower
Dash Board Lower
Extension
Dashboard Lower
Windshield Lower
Outer Panel
Front Pillar Inner Upper
Dashboard Upper
Inner Lower
Outer Panel
Front Pillar Lower
Stiffener
Outrigger
Side Sill Extension
Outer Panel
Dashboard Lower
Dashboard Extension
VIEW (Z)
Damper Housing
Front Damper
Extension
Front Damper Base
Front Damper Housing
Extension
Dashboard Lower
Front Side Frame
Front Side Back Plate
Damper Housing
Front Side Frame
Front Side Back Plate
Front Damper Housing

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Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants

5-6

Dashboard Upper, Dashboard Lower and Roof

Panel
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.

Dashboard Upper
Windshield Lower
Dashboard Lower
Front Pillar Inner Lower
Dashboard Lower
Extension
Side Sill Extension
Front Side Outrigger
Front Pillar Inner Upper
Side Sill Extension
Side Sill Extension
Dashboard Lower
From Floor
Floor Cap
VIEW (Z)
Dashboard Upper
Dashboard Lower
Outer Panel
Roof Panel
Front Pillar Inner Lower
Dashboard Upper
Dashboard Lower
Front Floor
Dashboard Lower
Extension
Floor Cap
Inner Lower Extension
Dashboard Upper
Windshield Lower

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Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants

5-7

Front Floor and Rear Floor

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.

Front Floor
Inside Sill
Outer Panel
Side Sill Extension
Inside Sill
Middle Floor Crossmember Stiffener
Side Sill Extension
Rear Frame
Rear Floor
Wheelhouse
Rear Panel
Rear Floor
Rear Floor
Rear Panel
Jack Up Stiffener
Rear Panel
Outer Panel
Rear Floor
Floor Cap
Front Floor
Floor Cap
Middle Floor Crossmember
Rear Floor
Middle Floor Crossmember
Middle Floor Crossmember
Front Floor
Middle Floor Crossmember Stiffener
Middle Floor Crossmember
Front Floor
Middle Floor Crossmember Stiffener
Floor Cap
Front Floor

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Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants

5-8

Rear Side Outer Panel and Rear Panel

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.

Rear Floor
Wheelhouse
Outer Panel
Rear Floor Outer Panel
Outer Panel
Parcel Shelf
VIEW (Z)
Outer Panel
Rear Gutter
Outer Panel
Rear Panel
Rear Gutter
Combination Adaptor
Combination Adaptor
Rear Panel
VIEW (X)
Combination Adaptor
Rear Panel
Outer Panel
Combination Adaptor
Outer Panel
Combination Adaptor
Side Sill Extension
Side Sill Extension End
Flange
Outer Panel
Wheel Arch Extension
Wheel Arch Extension
End Flange
Outer Panel
Fuel Door Adaptor
Outer Panel
Rear Inner
Outer Panel
Rear Inner

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Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants

5-9

Under Floor

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.

Wheelhouse Stiffener
Damper Base
Rear Inner Panel
Wheel Arch Extension
Inner Panel
Wheelhouse
Outer Panel
Wheelhouse Stiffener
Rear Wheelhouse
Upper Arm Bracket
Rear Frame
Damper Base
Rear Frame
Damper Base
Upper Arm Bracket
VIEW (X)
Lower Arm Bracket B
Lower Arm Bracket A
Rear Floor Crossmember
Rear Floor
VIEW (Z)
Lower Arm Bracket B
Lower Arm Bracket A
Rear Floor Crossmember
Rear Floor
Front Floor
Front Floor Centre
Cross-member

(A): No need seal areas.

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

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Index - Soft Chipping Guard Primer Coat

5-10

Soft Chipping Guard Primer Coat

General

The removal of paint and undercoating by stones chips

immediately exposes metal to the atmosphere, causing
it to oxidise. The thickness of this oxidation increases if
the process continues unchecked. The soft chipping
guard primer protects against damage due to the
impact of such objects.

1.

Sectional View of Paint Coats:

Top coat
Intermediate coat
+
Chipping guard primer

Use a 2-part urethane primer surface

and a spray gun.
Mix the primer surface with the
additive and solvent, and in the
correct ratio.
Follow the primer surface
manufacturer's instructions.

Electrodeposition of primer
Base metal
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.

WARNING

Wear goggles or safety glasses to

prevent eye injury.
Ventilate when spraying undercoat.
1.

1. Sanding the replacement part.

NOTE:
Do not oversand the edges or corners of
the part.
Do not expose base metal.
Use a double action sander and #400 disc
sandpaper.

2. Air blowing/degreasing
Use alcohol, wax and grease remover.
3. Making
Use masking tape and paper.
4. Spraying primer surface
Spray 4~5 coats to get 20 microns of
thickness.
One coat deposits 5~7 microns
Do not try to cover the surface with one heavy
coat.
Apply several thin coats.

2.

5. Drying
After spraying primer surface, allow 7~10 minutes
of drying time, then force dry it with infrared lamps
or an industrial dryer.
6. Polishing
Check the primer surface has dried thoroughly,
then sand the primer surface.
Use a double action sander and #400~#600
disc sandpaper.
7. Intermediate coating and top coating
Refer to pages 6-8 to 6-10 of this manual for the
painting procedure.

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Index - Soft Chipping Guard Primer Coat

Soft Chipping Guard Primer Coat

5-11

Coating Diagram

Indicates chipping guard primer coating area.

NOTE: Make sure to coat the flange on front wheel arch.
Unit: mm (in.)
1.
2.
3.
4.
5.
6.

HOOD SKIN
OUTER PANEL
INNER PANEL
OUTER PANEL
FRONT FENDER
FRONT FENDER

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Index - Rust-preventive Treatments

5-12

Rust-preventive Treatments

General

Undercoat:

Anti-rust Agents:

WARNING

WARNING

Wear goggles or safety glasses to

prevent eye injury.
Ventilate when spraying undercoat.

Anti-rust agents contain substances

that are harmful if you breathe or
swallow them, or get them on your
skin. Wear overalls, gloves, eye
protection and an aspproved
respirator while using such agents.
Ventilate when spraying an anti-rust
agent since it contains a small
amount of organic solvent. Keep
sparks, flames and cigarettes away.

NOTE:

1.

Mask the exhaust system, oxygen sensors and

suspension mount area to prevent overspread
from the undercoat.
Follow the undercoating manufacturer's
instructions.
1. Clean the body with wax and grease remover
before the undercoat is sprayed.
2. Apply the undercoat to the front wheelhouse,
rear wheelhouse and undersides of the front
floor and rear floor (see page 5-13).
3. Coat the bottom of the fuel tank.

NOTE:

1.

Do not spray an anti-rust agent on the brake

system, exhaust system and its related parts,
emission control devices in the engine
compartment, ball joint cover, fuel strainer and
exterior and interior parts.
Wipe the excess agent with a clean rag
dampened with light oil.
Follow the anti-rust agent manufacturer's
instructions.
1. Before applying an anti-rust agent, thoroughly
clean the area to be coated with a steam
cleaner, etc., and let it dry. Waxoyl may be
applied to wet surface.
2. Apply anti-rust agent from the installation hole
and the access hole of parts in the outer panel
and the frame (see page 5-14). Spray an antirust agent sufficiently unit the excess amount
oozes out when filling the side sill.

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Index - Soft Chipping Guard Primer Coat

5-13

Soft Chipping Guard Primer Coat

Undercoating Diagram

Indicated PVC coating area.

NOTE:
Coating thickness 0.4mm (0.16 in.) MIN.
Front wheelhouse, rear wheelhouse and dashboard lower on the imported control area, and coating thickness 0.5 mm
(0.2 in.).
1.
2.
3.
4.

SECTION AA

SECTION BB

SECTION CC

FRONT SIDE DAMPER

DAMPER HOUSING
OUTER PANEL
FRONT FLOOR
CENTRE CROSSMEMBER

SECTION DD

SECTION EE
1.
2.
3.
4.
5.

Dashboard Lower
Front Floor
Middle Floor Cross-member
Rear Floor
Rear Floor Cross-member

SECTION FF
1.
2.
3.
4.

<Front Wheelhouse>
<Rear Wheelhouse>
OUTER PANEL
FUEL DOOR
ADAPTOR SECTION
5. FUEL DOOR
ADAPTOR
6. No Coating Area.

VIEW (Z)

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Index - Rust-prevention Treatments

Rust-prevention Treatments

5-14

Area to be Covered by Anti-rust Agents

Indicates anti-rust agents.
1. HOOD FRAME (inside)
2. HOOD HINGE
3. MIDDLE FLOOR
CROSS-MEMBER
(inside)
4. REAR FRAME (inside)
5. TRUNK LID FRAME
(inside)
6. REAR FLOOR CROSSMEMBER (inside)
7. JACK-UP STIFFENER
(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)
20. FRONT SIDE FRAME
(inside)
21. DASHBOARD UPPER
22. FLOOR FRAME (inside)
23. FLOOR CENTRE
FRAME (inside)

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Index - Materials and Tools

5-15

Materials and Tools

SEALER

SPRAY GUNS

Use urethane sealer.

Use the correct gun toe the agent being

used.

3m #08892 (internal)
3m #08893 (external)
or equivalents.

Use of a pressure type spray gun is

recommended when work involves a
considerable number of vehicles.

TOOLS
Cartridge type

Tube type

For nox-rust 409-20S/solton

1000S

Sealing gun

For rustop
UNDERCOAT
To be applied to under-floor and wheelhouse.
Nox-rust 409-20S
Solton 1000S
or equivalent.

For deox #100

ANTI-RUST AGENT
To be applied to weld joints inside the body panel.

For waxoyl

Rustop
Deox #100
Waxoyl
or equivalent.

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5-door Rust Prevention

5-door Rust Prevention

Cross Section of Body and Sealants
General

5-18

Engine Compartment, Front Wheelhouse and

Damper Housing

5-19

Dashboard Upper, Dashboard Lower and Roof

Panel

5-20

Front Floor and Rear Floor

5-21

Rear Side Outer Panel and Rear Panel

5-22

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

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Index - Cross Section of Body and Sealants

5-18

Cross Section of Body and Sealants

General

NOTE: Following the sealer manufacturer's instructions.

1.

1. Clean the areas to be sealed with the white

gasoline.
2. Wipe off any excess spot sealer with thinner.
After the primer is sprayed, sealer will fill to the
area where spot sealer was wiped off.
3. Make sure you can see the sealant when the
sealed part is in its proper location. See page
5-19 to page 5-23 of this manual.

2.

4. Finish sealing the engine compartment, the

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

1.

5. Apply sealer on any area that the replacement

part will cover. Smooth the sealer with a brush
is necessary.

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Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants

5-19

Engine Compartment, Front Wheelhouse and

Damper Housing
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.

Bulkhead Upper Frame

Fender Bracket
Damper Housing
Wheelhouse Upper
Extension
Front Damper Base
Wheelhouse Upper
Extension
Front Damper Base
Steering Joint Cover
Dashboard Lower
Dashboard Lower
Dashboard Lower
Extension
Windshield Lower
Outer Panel
Inner Lower
Dashboard Upper
Dashboard Lower
Dashboard Lower
extension
Front Side Frame
Inner Lower
Dashboard Lower
Outer Panel
Inner Lower
VIEW (Z)
Dashboard Lower
Dashboard Extension
Damper Housing
Wheelhouse Upper
Extension
Front Damper Base
Front Damper Housing
Extension Lower
Dashboard Lower
Front Side Frame
Front Side Back Plate
Damper Housing
Front Side Back Plate
Front Side Frame
Front Damper Housing

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Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants

5-20

Dashboard Upper, Dashboard Lower and Roof

Panel
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.

Dashboard Upper
Windshield Lower
Windshield Lower
Dashboard Upper
Inner Lower
Dashboard Lower
Dashboard Lower
Extension
Side Sill Extension
Outrigger
Inner Lower
Side Sill Extension
Side Sill Extension
Dashboard Lower
VIEW (Z)
Dashboard Upper
Inner Lower
Dashboard Upper
Dashboard Lower
Outer Panel
Roof Panel
Front Floor
Floor Cap
Front Floor
Dashboard Lower
Dashboard Lower
Extension
Floor Cap
Side Frame Extension
Dashboard Lower
Extension
Inner Lower Extension
Dashboard Upper
Windshield Lower

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Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants

5-21

Front Floor and Rear Floor

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.

Front Floor
Inside Sill
Outer Panel
Side Sill Extension
Inside Sill
Middle Floor Crossmember Stiffener
Side Sill Extension
Rear Frame
Rear Floor
Wheelhouse
Outer Panel
Inner Panel
Rear Floor
Gutter lower
Rear Floor
Rear Panel
Rear Floor
Rear Panel
Rear Panel
Jack-up Stiffener
Rear Floor
Floor Cap
Rear Floor
Floor Cap
Middle Floor Crossmember Stiffener
Rear Floor
Middle Floor Crossmember
Middle Floor Crossmember
Front Floor
Middle Floor Crossmember Stiffener
Middle Floor Crossmember
Front Floor
Middle Floor Crossmember
Front Floor
Floor Cap

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Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants

5-22

Rear Side Outer Panel and Rear Panel

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.

Outer Panel
Wheel Arch Extension
Outer Panel
Inner Panel
Tailgate Hinge
Roof Panel
Gutter Upper
Gutter Upper
Outer Panel
Outer Panel
Gutter Upper
Gutter Upper
Gutter Lower
Outer Panel
Rear Floor
Gutter Lower
Rear Panel
VIEW (Z)
Rear Panel
Rear Panel Lower
Rear Floor
Gutter Lower
Gutter Lower
Outer Panel
Side Sill Extension
Side Sill Extension End
Flange
Outer Panel
Wheel Arch Extension
Wheel Arch Extension
End Flange
Outer Panel
Fuel Door Adaptor
Outer Panel
Gutter Lower
Outer Panel
Inner Panel

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Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants

5-23

Under Floor

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.

Wheelhouse Stiffener
Damper Base
Rear Inner Panel
Wheel Arch Extension
Inner Panel
Wheelhouse
Outer Panel
Wheelhouse Stiffener
Rear Wheelhouse
Rear Frame
Upper Arm Bracket
Damper Base
Rear Frame
Damper Base
VIEW (X)
Upper Arm Bracket
Lower Arm Bracket B
Lower Arm Bracket A
Rear Floor Crossmember
Rear Floor
VIEW (Z)
Lower Arm Bracket B
Lower Arm Bracket A
Rear Floor Crossmember
Rear Floor
Front Floor
Front Floor Centre
Cross-member

(A): No need seal areas.

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

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Index - Soft Chipping Guard Primer Coat

5-24

Soft Chipping Guard Primer Coat

General

The removal of paint and undercoating by stones chips

immediately exposes metal to the atmosphere, causing
it to oxidise. The thickness of this oxidation increases if
the process continues unchecked. The soft chipping
guard primer protects against damage due to the
impact of such objects.

1.

Sectional View of Paint Coats:

Top coat
Intermediate coat
+

One coat deposits 5~7 microns

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.
Mix the primer surface with the
additive and solvent, and in the
correct ratio.
Follow the primer surface
manufacturer's instructions.

Electrodeposition of primer
Base metal
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.

WARNING

Wear goggles or safety glasses to

prevent eye injury.
Ventilate when spraying undercoat.
1.

1. Sanding the replacement part.

NOTE:
Do not oversand the edges or cornres of
the part.
Do not expose base metal.
Use a double action sander and #400 disc
sandpaper.

2. Air blowing/degreasing
Use alcohol, wax and grease remover.
3. Making
Use masking tape and paper.
4. Spraying primer surface
Spray 4~5 coats to get 20 microns of thickness.

2.

5. Drying
After spraying primer surface, allow 7~10 minutes
of drying time, then force dry it with infrared lamps
or an industrial dryer.
6. Polishing
Check the primer surface has dried thoroughly,
then sand the primer surface.
Use a double action sander and #400~#600
disc sandpaper.
7. Intermediate coating and top coating
Refer to pages 6-8 to 6-10 of this manual for the
painting procedure.

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Index - Soft Chipping Guard Primer Coat

Soft Chipping Guard Primer Coat

5-25

Coating Diagram

Indicates chipping guard primer coating area.

NOTE: Make sure to coat the flange on front wheel arch.
Unit: mm (in.)
1.
2.
3.
4.
5.
6.

HOOD SKIN
OUTER PANEL
INNER PANEL
OUTER PANEL
FRONT FENDER
FRONT FENDER

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Index - Rust-preventive Treatments

5-26

Rust-preventive Treatments

General

Undercoat:

Anti-rust Agents:

WARNING

WARNING

Wear goggles or safety glasses to

prevent eye injury.
Ventilate when spraying undercoat.

Anti-rust agents contain substances

that are harmful if you breathe or
swallow them, or get them on your
skin. Wear overalls, gloves, eye
protection and an approved respirator
while using such agents.
Ventilate when spraying an anti-rust
agent since it contains a small
amount of organic solvent. Keep
sparks, flames and cigarettes away.

NOTE:

1.

Mask the exhaust system, oxygen sensors and

suspension mount area to prevent overspread
from the undercoat.
Follow the undercoating manufacturer's
instructions.
1. Clean the body with wax and grease remover
before the undercoat is sprayed.
2. Apply the undercoat to the front wheelhouse,
rear wheelhouse and undersides of the front
floor and rear floor (see page 5-27).
3. Coat the bottom of the fuel tank.

NOTE:

1.

Do not spray an anti-rust agent on the brake

system, exhaust system and its related parts,
emission control devices in the engine
compartment, ball joint cover, fuel strainer and
exterior and interior parts.
Wipe the excess agent with a clean rag
dampened with light oil.
Follow the anti-rust agent manufacturer's
instructions.
1. Before applying an anti-rust agent, thoroughly
clean the area to be coated with a steam
cleaner, etc., and let it dry. Waxoyl may be
applied to wet surface.
2. Apply anti-rust agent from the installation hole
and the access hole of parts in the outer panel
and the frame (see page 5-28). Spray an antirust agent sufficiently unit the excess amount
oozes out when filling the side sill.

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Index - Soft Chipping Guard Primer Coat

5-27

Soft Chipping Guard Primer Coat

Undercoating Diagram

Indicated PVC coating area.

NOTE:
Coating thickness 0.4mm (0.16 in.) MIN.
Front wheelhouse, rear wheelhouse and dashboard lower on the imported control area, and coating thickness 0.5 mm
(0.2 in.).
1.
2.
3.
4.

SECTION AA

SECTION BB

SECTION CC

FRONT SIDE DAMPER

DAMPER HOUSING
OUTER PANEL
FRONT FLOOR
CENTRE CROSSMEMBER

SECTION DD

SECTION EE
1.
2.
3.
4.

Dashboard Lower
Front Floor
Middle Floor Cross-member
Rear Floor Cross-member

SECTION FF
1.
2.
3.
4.

<Front Wheelhouse>
<Rear Wheelhouse>
OUTER PANEL
FUEL DOOR
ADAPTOR SECTION
5. FUEL DOOR
ADAPTOR
6. No Coating Area.

VIEW (Z)

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Index - Rust-prevention Treatments

Rust-prevention Treatments

5-28

Area to be Covered by Anti-rust Agents

Indicates anti-rust agents.
1. HOOD FRAME (inside)
2. HOOD HINGE
3. FLOOR CENTRE
FRAME (inside)
4. MIDDLE FLOOR
CROSS-MEMBER
(inside)
5. REAR FRAME (inside)
6. TAILGATE FRAME
(inside)
7. REAR FLOOR CROSSMEMBER (inside)
8. JACK-UP STIFFENER
(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)
20. FRONT SIDE FRAME
(inside)
21. DASHBOARD FRAME
(inside)
22. FLOOR FRAME (inside)

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Index - Materials and Tools

5-29

Materials and Tools

SEALER

SPRAY GUNS

Use urethane sealer.

Use the correct gun toe the agent being used.

3m #08892 (internal)
3m #08893 (external)
or equivalents.

Use of a pressure type spray gun is recommended when

work involves a considerable number of vehicles.
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.

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Paints - Paints

Paints
General Safety Precautions

6-2

Body Paint
General

6-3

Refinishing Processes

6-4

Pre-processing of Painting

6-5

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

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General Safety Precautions

6-2

General Safety Precautions

1.

2.

3.

Most paints contain substances that are harmful

if inhaled or swallowed.
The following precautions are important items in
order to maintain safe painting work.
1. Wear an approved respirator and eye protection
when painting.

1.

4. Read the paint label before opening the

container. Cover spilled paint with sand, or wipe
it up at once.

2.

5. If paint gets in your mouth or your skin, rinse or

wash thoroughly with water. If paint gets in
your eyes, flush with water and get prompt
medical attention.

3.

6. After the painting work is finished, wash face

and gargle with water.

4.

7. Paint is flammable. Store it in a safe place, and

keep it away from sparks, flames or cigarettes.

2. Wear approved gloves, appropriate clothing

when painting. Avoid contact with skin.

3. Spray paint only in a well ventilated area.

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Paints - Body Paint

6-3

Body Paint

General

The 3-coat/3-bake (3C/3B) paint finishes give the Odyssey a deep gloss and stunning finish. This manual provides information on
paint defect, repair and refinishing. Throughout, the objective is to explain in a simple yet comprehensive manner the basic items
you should know about paint repairs. Select the correct material for the defect and repaint or refinish in the correct manner as
described in this manual.

WARNING

Most paints contain substances that are harmful if inhaled or swallowed. Read the
paint label before opening the container. Spray paint only in a well ventilated area.
Cover spilled paint with sand, or wipe it up at once.
Wear an approved respirator, gloves, eye protection and appropriate clothing when
painting. Avoid contact with skin.
If paint gets in your mouth or on your skin, rinse or wash thoroughly with water. If
paint gets in your eyes, flush with water and get prompt medical attention.
Paint is flammable. Store it in a safe place, and keep it away from sparks, flames or
cigarettes.
Basic Rules for Repairing a Paint Finish
To repair paint damage, always use the 2-part acrylic urethane paints designated: polish and bake each of the three coats, as in
production, to maintain the original film thickness, and to assure the same quality as the original finish.
Outline of Factory Painting Process:

Features in Each Work Process

1.

1. Pre-treatment and Electrodeposition

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

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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.

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Paints - Body Paint

6-5

Body Paint

Pre-processing of Painting
1.

1. Featheredging
NOTE
The paint film damaged area should be
sanded flat and smooth.
If this is not done correctly the end results
will not be acceptable.

If double action sander is not available, use a

rubber pad and wet or dry sandpaper.
Use the flexible block and #280, #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.

1.

2. Preparation of metal surface

Remove all corrosion from the damaged area.

Use a product that removes corrosion.

2.
3. Air blowing/degreasing
Use alcohol, wax and grease remover.
2.

1.
2.
3.
4.

Top coat
Intermediate coat
Undercoat
Metal surface

Use the double action sander and #60~#80 disc paper.

Sand the area larger than the damaged

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

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Paints - Body Paint

6-6

Body Paint

Treatment of Metal Surface

1.

1. Filling/drying
Small cracks or pinholes in the sheet metal should be
repaired with a body filler and sanded flat and smooth.
Use the 2-part polyester resin putty.
Mix the putty with the hardener in the correct
ratio.
Follow the body filler manufacturer's
instructions.
Mix the body filler and hardener quickly.

After applying the body filler, allow 5~6 minutes

of normal drying time, then force dry it with
infrared lamps or other industrial dryer at 50C
(122F)~60C (140F).
NOTE: Follow the body filler manufacturer's instructions
for drying time.
1.

2. Polishing
When the body filler is dry a white mark appears when
the surface is scratched with your finger nail.
1. Thoroughly sand the body filler surface.

Use the double action sander and #80~#120 disc paper.

Apply the body filler in several thin coats,

without air bubbles.
Do not try to cover the surface with one
heavy coat.
Apply the body filler over the damaged area
with a putty knife using light pressure.

2.

2. Sand the surface evenly, particularly the

area that was filled.
Use the flexible block and #120~#180 sandpaper.

1. Body Filler

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Paints - Body Paint

6-7Undercoating

Body Paint

Treatment of Metal Surface (cont'd)

3. Featheredge the paint coat.

1.

Sand the body filler surface until the proper dimensions

are met.
Use the double action sander and #240~#320#~400 disc
papers.

1.

1. Masking
Mask the area surrounding the damage to prevent
over spray from the primer surfacer.

Use the masking tape and paper.

2.
2. Spraying primer surfacer
Spray the primer surfacer over a wider area
than the body filler and the exposed surface
of the paint film.
Spray 2~3 coats to get 30 microns of
thickness.
Use the 2-part urethane primer surfacer and a
spray gun.
Mix the primer surfacer with the additive and
solvent, and in the correct ratio.
Follow the primer surfacer manufacturer's
instructions.

1. Body Filler
2. Featheredging

2.
3. Air blowing/degreasing
Use the alcohol, wax and grease remover.
Also clean and degrease the surfaces where masking
tape will be attached.

3.

4.

1. Primer Surfacer

3. Drying
After spraying primer surfacer, allow for 5~10 minutes
of normal drying time, then force dry it with infrared
lamps or other industrial dryer.
NOTE: Follow the primer surfacer manufacturer's
instructions for drying time.

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Paints - Body Paint

6-8Intermediate Coating

Body Paint

Undercoating (cont'd)
1.

4. Polishing
Check that the primer surfacer has dried thoroughly,
then sand the primer surfacer.

Use the double action sander and #320~#400~#600 disc

papers.

1.

1. Masking
Mask the area surrounding the damage to prevent
over spray from the intermediate coat.

Use masking tape and paper.

2.
2. Spraying top coat enamel
Spray the top coat enamel over the surface until the
primer surfacer is fully covered.
NOTE: For the 3-coat pearl paint, spray the colour
base over the surface.
Use the 2-part polyester urethane top coat
enamel and a spray gun.
Mix the top coat enamel with the additive and
solvent, and in the correct ratio.
Follow the top coat manufacturer's instructions.

2.
5. Air blowing/degreasing
Use the alcohol, wax and grease remover.
Also clean and degrease the surfaces where the
masking tape will be attached.

3.

3. Drying
After spraying top coat enamel or colour base (3-coat
pearl paint), allow 5~10 minutes of normal drying time,
then force dry it with infrared lamps or other industrial
dryer.
NOTE: Follow the top coat manufacturer's instructions
for drying time.

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Paints - Body Paint

6-9Top Coating

Body Paint

Intermediate Coating (cont'd)

1.

4. Polishing
Check that the top coat enamel has dried thoroughly,
then sand the top coat enamel.

Use the double action sander and #600~#800 disc

papers.
NOTE: Be careful not to polish down to the primer
surfacer.

1.

1. Masking
Mask the area surrounding the damage to prevent
over spray from the top coat.

Use masking tape and paper.

2.
2. Spraying top coat enamel/clear coat
Spray 2~3 double coat until the intermediate coat is
fully covered.
NOTE: See pages 6-11, 6-12 for the painting repair
(gradation) of the 3-coat pearl paint.
Use the 2-part polyester urethane top coat
enamel and spray gun.
Mix the top coat enamel with the additive and
solvent, and in the correct ratio.
Follow the top coat manufacturer's instructions.

When the painting repair (gradation) is almost done,

polish the area that will be top coated.
Use the #2000 sandpaper and compound.
2.
5. Air blowing/degreasing
Use alcohol, wax and grease remover.
Also clean and degrease surfaces where the masking
tap will be attached.
NOTE: See pages 6-11, 6-12 for the painting repair
(gradation) of the 3-coat pearl paint.

Drying
After spraying the top coat enamel, allow it to air dry,
then force dry it with infrared lamps or other industrial
dryer.
NOTE: Follow the top coat manufacturer's instructions
for drying time.
Spraying clear coat
Spray the top clear coat evenly over the surface of the
top coat enamel. Do not try to cover the surface with
one heavy coat.

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Paints - Body Paint

Body Paint

6-10

Top Coating (cont'd)

Drying
After spraying the clear coat, allow it to dry for 10
minutes, then force dry it with infrared lamps or other
industrial dryer.

4. After buffing, remove the masking paper and

tape, and thoroughly wash the entire
vehicle.

NOTE: Follow the top coat manufacturer's instructions

for drying times.
1.

3. Polishing/buffing
Check that the clear coat has dried thoroughly.
The clear coat is cooled.
1. Any adhesion or roughness on the top coat
should be wet sanded and repaired.

Use the #1200~#2000 and crystal block.

2. Polish any roughness caused by sanding.

NOTE: Clean the top coat surface frequently so you do
not damage the clear coat with the polishing particles.
Use a buffing towel, buffing wool and
compound.
2.
2. Finishes up with buffing.
NOTE:
Do not use a power buffer.
Do not polish too much; use light hand pressure.
Use the buffing sponge, fine compound, very
fine compound, then ultra fine compound.

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Paints - Plastic Parts Paint

6-11

Plastic Parts Paint

Features of Plastic Material

Check each of the plastic parts for solvent resistance and heat resistance temperatures before you do any repair work.
Select the repair material according to materials of the plastic parts.
Standard
Symbol

AAS

ABS

AES

Name

Acrylonitrile acrylic
styrene
Acrylonitrile
butadiene styrene
Acrylonitrile ethylene
styrene

A/EPDM/S Acrylonitrile /
ethylene propylene
diene rubber /
styrene
ASA

CAB

Acrylonitrile styrene
acrylate
Cellulose acetate
butylate

Heat
Resistance
Temperature
C (F)
80
(176)
80
(176)
80
(176)
80
(176)

80
(176)
80
(176)

Solvent Resistance

Note

A small amount of alcohol is

acceptable for a short time.
(Degreasing)

An organic solvent such as gasoline is not

recommended.

A small amount of alcohol is

acceptable for a short time.
(Degreasing)

An organic solvent such as gasoline is not

recommended.

A small amount of alcohol is

acceptable for a short time.
(Degreasing)

An organic solvent such as gasoline is not

recommended.

A small amount of alcohol is

acceptable for a short time.
(Degreasing)

An organic solvent such as gasoline is not

recommended.

A small amount of alcohol is

acceptable for a short time.
(Degreasing)

An organic solvent such as gasoline is not

recommended.

A small amount of alcohol is

acceptable for a short time.
(Degreasing)

An organic solvent such as gasoline is not

recommended.

An aroma product is not recommended.

An aroma product is not recommended.

An aroma product is not recommended.

An aroma product is not recommended.

An aroma product is not recommended.

An aroma product is not recommended.

Ethylene-vinyl
acetate

80
(176)

A small amount of alcohol and

gasoline are acceptable for a
short time. (Degreasing)

Soaking with an organic solvent such as

gasoline and alcohol is not recommended.

PA

Polyamide

80
(176)

Alcohol and gasoline are

acceptable.

Battery acid (sulphuric acid) is not

recommended.

PBT

Polybutylene
terephtalate

160
(320)

Alcohol and gasoline are

acceptable.

Solvent is not recommended.

PC

Polycarbonate
plastics

120
(248)

A small amount of alcohol is

acceptable for a short time.

Brake fluid, and wax and grease remover not

recommended.

PE

Polyethylene

80
(176)

Alcohol and gasoline are

acceptable.

Solvent is not recommended.

PF

Phenol formaldehyde

80
(176)

A small amount of alcohol is

acceptable for a short time.
(Degreasing)

Soaking with an organic solvent such as

gasoline and alcohol, is not recommended.

Polymethyl
methacrylate

80
(176)

A small amount of alcohol is

acceptable for a short time.
(Degreasing)

Soaking with an organic solvent such as

gasoline and alcohol, is not recommended.
Wash remover off with water thoroughly.

Polyoxymethylene
polyacetal

100
(212)

Alcohol and gasoline are

acceptable.

Solvent is not recommended.

E/VAC

PMMA

POM

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Paints - Plastic Parts Paint

Plastic Parts Paint

6-12

Features of Plastic Material (cont'd)

Standard
Symbol

Name

Heat
Resistance
Temperature
C (F)

Solvent Resistance

Note

PP

Polypropylene

80
(176)

Alcohol and gasoline are

acceptable.

Solvent is not recommended.

PPO
(PPE)

Polyphenylene
oxide

100
(212)

A small amount of alcohol is

acceptable for a short time.

Soaking with an organic solvent such as

gasoline and alcohol is not recommended.

Polystyrene

60
(140)

A small amount of alcohol is

acceptable for a short time.

Soaking with an organic solvent such as

gasoline and alcohol is not recommended.

PUR

Polyurethane

80
(176)

A small amount of alcohol is

acceptable for a short time.
(Degreasing)

Soaking with an organic solvent such as

gasoline and alcohol is not recommended.

PVC

Polyvinylchloride

80
(176)

A small amount of alcohol and

gasoline are acceptable for a
short time. (Degreasing)

Soaking with an organic solvent such as

gasoline and alcohol is not recommended.

SAN

Styrene acrylonitrile

80
(176)

Wiping alcohol off in a short time Soaking with an organic solvent such as
can be allowed.
gasoline and alcohol is not recommended.

SMC

Sheet moulding
compound

180
(356)

Alcohol and gasoline are

acceptable.

Solvent is not recommended.

TPE

Thermoplastic
polyester elastomer

80
(176)

Alcohol is acceptable and

wiping gasoline for a short time
can be allowed. (Degreasing)

Soaking with an organic solvent such as

gasoline and alcohol is not recommended.
Wash remover off with water thoroughly.

TPS

Thermoplastic
styrene elastomer

80
(176)

A small amount of alcohol and

gasoline are acceptable for a
short time. (Degreasing)

Soaking with an organic solvent such as

gasoline and alcohol is not recommended.
Wash remover off with water thoroughly.

TPO

Thermoplastic
olefin / elastomer

80
(176)

Alcohol is acceptable and

wiping gasoline for a short time
can be allowed. (Degreasing)

Soaking with an organic solvent such as

gasoline and alcohol is not recommended.
Wash remover off with water thoroughly.

TPU

Thermoplastic /
urethane /
elastomer

80
(176)

A small amount of alcohol and

gasoline are acceptable for a
short time. (Degreasing)

Soaking with an organic solvent such as

gasoline and alcohol is not recommended.
Wash remover off with water thoroughly.

Polyester

110
(230)

Alcohol and gasoline are

acceptable.

Alkali is not recommended.

PS

UP

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Paints - Plastic Parts Paint

Plastic Parts Paint

6-13

Use of the Repair Material (reference)

NOTE: Follow the materials manufacturer's instructions.

Mixing Ratio:

The use of a special polyester putty for PP bumper is

described here:
1.

1. Filler
Mixing Ratio:

1.
4. Intermediate coat and top coat
Use the 2-part polyester urethane top coat.
Top coat is also used for an intermediate coat.
Mixing Ratio:
NOTE: Be sure to mix the correct amount of the
hardener and softener.

2.

2. Sanding filler
Spray bumper primer (see page 6-19) on the
area where the PP material was used.
3. Primer surfacer
The primer surfacer is used to protect the PP
resin surface and fill cavities or flaws before the
intermediate coat and top coat.
Use the 2-component type primer surfacer (grey).

NOTE: Use a spray gun to apply the paint. Do not use

a brush.
Drying time:
Air dry 20C (68F)
Almost hardened
Thoroughly hardened

6~10 minutes Touch dry

12~24 hours
96 hours

Force dry the intermediate coat and top coat.

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

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Paints - Plastic Parts Paint

Plastic Parts Paint

6-14

Refinishing Processes

The following shows refinishing methods to various types of paint damage or defects.
Be careful not to deform and damage the parts when force drying.

A:

Hole/Deep Gouge

B:

Deep Abrasion 3 mm (0.12 in.) approx.

C:

Shallow Scratch 1 mm (0.04 in.) approx.

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Paints - Plastic Parts Paint

Undercoating
6-15

Plastic Parts Paint

Pre-processing of Painting
1.

1. Sanding
Sand the damage area flat and smooth.
Shallow Scratch:

1.

1. Spraying primer
Primer is used to fill cavities in the putty and primer
surfacer.
Spray primer on the exposed area.
Spray the 2~3 coats of primer on 2~3 coats
over the area you applied putty.
Apply primer to the back of the bumper if
the damage is a tear or hole.
Bumper primer (Reference)
Warm the primer if the ambient temperature is
below 10C (50F).
Follow the bumper primer manufacturer's
instructions.
Use the spray gun and brush.

Use a flexible block and #240~#400~#600 sandpaper.

Hole/Deep Gouge:
Cut out and make any torn or burred area flat.
Use a knife, flexible block and #180~#240 sandpapers.

2.

2. Air blowing/degreasing
Clean the damaged area thoroughly.
Use alcohol, and wax and grease remover.
Drying
NOTE: Take care not to let the heat lamp deform the
bumper during the drying process.
Dry the bumper primer thoroughly with an infrared
dryer or other suitable method.
Drying Time:
Air dry 20C (68F)
20 minutes
Force dry 60C (140F) 10 minutes

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Paints - Plastic Parts Paint

6-16

Plastic Parts Paint

Undercoating (cont'd)
1.

2. Filing/Sanding
Apply putty to repair any holes or deep gouges.

1.

Apply the putty on the damaged are in 2~3

steps.
Glue aluminium tape on the outside of the
bumper, and apply putty from the other side
of the bumper.
Remove the aluminium tape after the putty
dries, apply putty from the outside, and fill
the hole.
Use a special polyester putty (Reference) and a putty
knife.

5. Spraying primer surfacer

NOTE: Spray the bumper primer (see page 6-17) on
the area where the PP material was exposed and
around the putty.
Spray the primer surface wider than the
putty and painted surfaces of bumper
primer.
Spray 2~3 coats to get 20~30 microns of
thickness.
Use the 2-component type primer surfacer
(grey) and a spray gun.
Follow the materials manufacturer's
instructions.

Drying
2.

3.

3. Sanding
Sand the surface evenly, particularly at the area where
the PP material and putty meet.

Use a flexible block and #240~#400~#600 sandpaper.

4.

NOTE: Take care not to let the heat lamp deform the
bumper during the drying process.

1. Aluminium Tape
2. Outside

1. Featheredging

5.
4. Air blowing/degreasing
Use alcohol, a tack cloth, and wax and grease remover.

2.

6. Sanding
After drying, wet sand the area of the intermediate
coat.

Use the #600 sandpaper.

NOTE: Do not use less than #600.

3.
7. Air blowing/degreasing
Use alcohol, a tack cloth, and wax and grease remover.
Also clean and degrease the surfaces where the
masking tape will be attached.

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Paints - Plastic Parts Paint

6-17

Plastic Parts Paint

Intermediate Coating

NOTE: You must do this procedure on the PP parts of

the bumper and side sill panel.
1.

1. Masking
Mask the area surrounding the damage to prevent
overspray from the intermediate coat.

Use masking tape and paper.

2.
2. Spraying top coat enamel
Spray the top coat enamel over the surface
until the primer surfacer is fully covered.
Spray 2~3 coats to get 15~25 microns of
thickness.
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.

1.

3. Polishing
Check the top coat enamel has dried thoroughly, then
sand the top coat enamel.

Use a flexible block and #600~#800~#1000 sandpapers.

NOTE: Be careful not to sand down to the primer
surfacer.

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.
After spraying the top coat enamel, allow for 5~10
minutes of normal drying, then force dry it with infrared
lamps or other industrial dryer.

2.

1.
2.
3.
4.
5.

Material
Putty
Intermediate Coat
Sanding
Paint Coat

3.
4. Air blowing/degreasing
Use alcohol, a tack cloth, and wax and grease remover.
Clean and degrease the surfaces where the masking
tape will be attached.

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Paints - Plastic Parts Paint

6-18

Plastic Parts Paint

Top Coating
1.

1. Masking
Mask the area surrounding the damage to prevent
overspray of the top coat

Use masking tape and paper.

2.
2. Spraying top coat enamel / clear coat
Spray 2~3 coats in double coat until the intermediate coat
is fully covered.

Using a buffer and compound, remove any

polishing marks made from the sandpaper.
Use a buffing sponge, and buffing wool and
compounds.
Finish up with buffing:
1.

1. Wet sands with #2000 sandpaper and soapy

water.

NOTE:
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 you spray the clear coat.

2.

2. Remove moisture using compressed air.

3. Finish using fine compound and very fine
compound. Do not polish with an electric
polisher.
NOTE: Polish lightly.

3.

4. Check the finished area at an angle, and

make sure there are no polishing marks.
5. Polish with ultra fine compound and a
buffing sponge.

4.

6. Wax the finished area.

Drying
NOTE: Take care not to let the heat lamp deform the
bumper during the drying process.
After spraying the clear coat, allow for 5~10 minutes
drying time before you force dry it with infrared lamps or
other industrial dryer.
3.

3. Polishing/buffing
Check that the clear coat has dried thoroughly.
Wet sand to remove any imperfections.
Use a flexible block soap and #2000 sandpaper.

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Paints - Glossary

6-19

Glossary
All paint

Painting of complete surface.

Compressed air

Use compressed air to blow away dust and debris.

Block paint

Painting a section only, such as a door

Clear paint (clear coat)

Clear paint without dye (pigment).

Double coat

Application of two paint coats.

Dry film

Pain which left the spray gun and fried partially before it reached the surface, thereby making
the painted surface rough. Dry coating is caused by too little paint being fed, too high an air
pressure, too much distance between the painted surface and the gun, or moving the gun too
fast.

Dust coat

Paint is applied thinner than the dry coat. Painted surface becomes rough.

ED painting

Electrostatic discharge painting.

Enamel

Finishing paint pigmented with dye.

Featheredging

Smoothing out the edges of painted surface.

Flash off

Evaporation of the pain solvent. (Flash off time is the period between pain coat applications.)

Ford cup

A type of viscosity meter.

Gun stroke

Movement of the paint gun.

Hardener

Harding agent of two-liquid type paint or fillers.

Polycyanated and oxides are used for hardeners.

Heat-hardening acrylic resin

paint

Composed of acrylic resin and meramine resin and hardener (forms a paint film) by banking.

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Paints - Glossary

6-20

Glossary

Cont'd
Lacquer

A type of pain that uses cellulose nitrate or other chemicals and dries by evaporation of its
solvent agent.

Meramine resin

Used as component for aminoalkyd resin paint and heat-hardening acrylic resin paint.

Metallic-base paint

Paint with aluminium power for metallic tone.

Mist coat

Painting for fade-in sections. A small amount of paint may be dissolved with slow-evaporating
thinner, or thinner alone may be applied with low pressure.
150-200kPa (1.5-2.0kgf/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.

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Paints - Glossary

6-21

Glossary

cont'd

Wet coat

Paint is applied with an excess of solvent, thereby producing a painted surface that's smooth,
glossy and has a wet look.

Wet film

Paint which has not dried completely.

Wet on wet

Application of the next coat of paint before the previous layer has dried completely.

Wool bonnet

Wood grinder for compound polishing.

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