Civic Shop 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, figures and tables.
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Fist Edition
8/2000
192 pages HONDA MOTOR CO., LTD.
All Rights Reserved
Service Publication Office
Sections with * include SRS components; Special Caution is required

when servicing.
Index - Index
Index
4-door General Information
1-3
1-15
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Supplemental Restraint System (SRS)
1-4
Identification Number Locations
1-5
Lift and Support Points
1-6
Body Specifications/Wheel Alignment
1-7
Exterior Parts Removal/Installation
1-8
Construction
1-9
Door and Bumper Reinforcement Beams
1-10
Zinc-plated Steel Plate Repair
1-11
Colour Chart Paint Specifications
1-12
Types and Materials of Exterior Plastic Parts
1-14
Index - General Information
General Information
1-4
This model has an SRS which includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above the glove box, seat belt tensions in the front seat
belt retractors and side airbags in the front seat backs. The SRS unit is separate from the airbag assembly and has built-in sensors. The following precautions should be observed
when performing sheet metal work, paint work and repair work around the locations of the SRS components.
1. The SRS unit (including the safing sensor and the impact is located under the dashboard and the side impact sensors are located in each side still. Avoid any strong Impact with
a hammer or other tools when repairing the front side frame, the lower part of the dashboard and the side sill. Do not apply heat to these areas with a torch, etc.
2. Take extra care when painting or doing body work in the area below the centre pillar. Avoid direct exposure of the seat belt retractor with tensioner to heat guns, welding or
spraying equipment.
3. SRS electrical wiring harness are identified with yellow colour coding. Care should be taken not to damage the harness when repairing this area.
4. Do not apply heat of more than 212F (100C) when drying painted surfaces anywhere around the locations of SRS components.
5. If strong impact or high temperature needs to be applied to the areas around the locations of SRS components, remove the Components before performing the repair work.
6. If any of the SRS related components are damaged or deformed, be sure to replace them.
NOTE: Refer to the Restraints section of the Shop Manual for after deployment, and removal and replacement of SRS related components.
1. DRIVER'S AIRBAG
ASSEMBLY
2. CABLE REEL
3. FRONT PASSENGER'S
AIRBAG ASSEMBLY
4. SIDE AIRBAG
5. SEAT BELT TENSIONERS
6. SIDE IMPACT SENSOR
8. SIDE AIRBAG
9. SRS UNIT
(with built-in sensor)
10. UNDER-DASH FUSE/
RELAY BOX
General Information
15
1. Built Data and Vehicle Type
Except KK, KX, KY models
2. Vehicle Identification
Number (VIN)
3. Engine Number
4. Transmission Number
(Manual)
(Automatic)
(Honda Multi Matic)
General Information
1-6
NOTE: If you are going to remove heavy components such as suspension or the fuel
tank from the rear of the vehicle, first support the front of the vehicle with a tall safety
stands. When substantial weight is removed from the rear of the vehicle, the centre of
gravity can change and cause the vehicle to tip forward on the hoist.
Frame Hoist
Position the hoist lift blocks, or safety stands, under the vehicle's front support points
and rear support points.
Floor Jack
1. Set the parking brake.
2. Block the wheels that are not being lifted.
3. When lifting the rear of the vehicle, put the gearshift lever in reverse (or automatic
transmission in Park position).
4. Position the floor jack under the front jacking bracket or rear jacking bracket, centre
the jacking bracket in the jack lift platform, and jack up the vehicle high enough to
fit the safety stands under it.
1. FRONT SUPPORT POINT

2. HOIST LIFT BLOCKS
3. REAR SUPPORT POINT
1. Raise the hoist a few inches, and rock the vehicle gently to be sure it is firmly
supported.
2. Raise the hoist to full height, and inspect the lift points for solid contact with the lift
blocks.
Safety Stands
To support the vehicle on safety stands, use the same support points as for a frame
hoist. Always use safety stands when working on a under vehicle that is supported
only by a jack.
1.
2.
3.
4.
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.
General Information
1-7

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)
General Information
1-8
NOTE: To adjust the alignment of the hood, the front door, rear door and trunk lid, refer to the CIVIC Shop Manual.
Mounting bolts/nuts torque:
6X1.0 mm: 9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
*6X1.0 mm: 1.8 Nm (1.8 kgf/m, 13 lbf/ft)
8X1.0 mm: 22 Nm (2.2 kgf/m, 16 lbf/ft)
*8X1.25 mm: 29 Nm (3.0 kgf/m, 22 lbf/ft)
1. HOOD
2. HOOD HINGE
3. REAR BUMPER SIDE
BRACKET
4. TRUNK LID HINGE
5. TRUNK LID
6. REAR BUMPER BEAM
7. FUEL DOOR
8. REAR BULKHEAD GUSSET
9. REAR DOOR
10. REAR DOOR HINGE
11. FRONT DOOR
12. FRONT DOOR HINGE
13. FRONT FENDER
14. CORNER UPPER BEAM
15. FRONT BUMPER BEAM
16. BATTERY SET BASE
1-9
General Information
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)
21
Front Pillar Upper Stiffener (Hss)
42
Rear Floor Cross-member (Sp, Zn)
General Information
110
Door and bumper reinforcement beams used on Honda vehicles are made from a metal equivalent to High Strength Steel.
If High Strength Steel is heated, the strength of the steel will b e reduced. If High Strength Steel is damaged, as in a vehicle accident, where the door and bumper reinforcement
beams are bent, the beams may crack if an attempt is made to straighten them.
For this reason, the door and bumper reinforcement beams should NEVER be repaired; they should be replaced if they are damaged.
NOTE: If a door beam is damaged, the whole door panel assembly should be replaced.
1. REAR BUMPER REINFORCEMENT
BEAM
2. REAR DOOR REINFORCEMENT
BEAM
3. FRONT DOOR REINFORCEMENT
BEAMS
4. FRONT BUMPER
REINFORCEMENT BEAM
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111
General Information
The Zinc-plated steel plate used in some panels of the CIVIC 4-door requires different repair techniques than ordinary steel plate. Refer to "Body Construction" (see page 1-9) for the
location of the Zinc-plated panels.
1. ZINC-PLATED (5-6 microns)
2. Steel plate
1. Before spot welding the zinc-plated steel plate, remove the paint from both sides of the flange to be welded. Apply sealer to the flange after welding.
WARNING
To prevent eye injury, wear goggles or safety glassed whenever sanding, cutting or grinding.
NOTE: Seal the sanded surface thoroughly to prevent rust.
2. The electric continuity properties of zinc-plated steel plate is different from the ordinary steel plate. When spot welding, increase the current by 10-20%.
NOTE: The MIG welding procedures for Zinc-plated steel plate are the same an for ordinary steel plate.
WARNING
To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.
3. Before applying putty or body filler to the Zinc-plated steel plate, sand the zinc plating thoroughly to promote adhesion and to prevent blistering.
NOTE: Use only epoxy-based putties and fillers on zinc-plated steel plate, following the manufacture's specifications.
4. When performing pain work, protect the ground wire and ground wire mounting hole threads with a bolt or a plug.
1.
2.
3.
4.
SPECIAL BOLT
GROUND WIRE
GROUND WIRE MOUNTING HOLE
PLUG
112
General Information
P.: Pearl Paint / M.: Metallic Paint

NH-578
Taffeta
White
KE
KG
KB
KQ
KY
NH623M
Stain
Silver M.
B-92P
Night
Hawk
Black P.
B-96P
Eternal
Blue P.
G-95P
Clover
Green P.
R-81
Mirano
Red
R504P
RP-32P
Ruby Red Vintage
P.
Plum P.
YR-525M
Titanium
M.
1.4S
1.6SE
1.4S
1.6LS
1.6ES
1.4S
1.6ES
GLi
VTi
LXi
EXi
VTi
KW
EXi
KT
LXi
EXi
EXi
VTi
VTi-S
LXi
EXi
VTi
DX
LX
EX
EXi
VTi
EXi
LXi
150I
170I
LX
EX
KU
KV
KK
KH
KF
KN
KX
General Information
Colour Chart Paint Specifications (cont'd)
113
1. FRONT GRILLE
Body Colour
2. HOOD MOLDING BASE
Chrome plated or body
colour
3. DOOR MIRROR BASE
Black (NH-70 Gloss 20)
4. DOOR MIRROR
Body colour or black (NH70 Gloss 20)
5. DOOR OUTER HANDLE
Body colour or black (NH72 Gloss 30)
6. PROTECTER
MOULDINGS
Body colour or BP, Dark
grey (NH-533)
7. FRONT BUMPER
Body colour
8. ROOF MOULDING
9. DRIP MOULDING
Chrome plated or black
(NH-70 Gloss 20)
10. LICENSE TRIM
Chrome plated or body
colour
11. REAR BUMPER
Body Colour
12. DOOR MOULDING
Chrome plated or black
(NH-70 Gloss 20)
13. DOOR SASH TRIM
14. FRONT UNDER SPOILER
15. GRILLE
BP. Dark grey (NH-533)
General Information
Type and Materials of Exterior Plastic Parts
114
NOTE: A standard symbol is stamped on the underside of each resin part to show the type of material of used.
Example:
1. FRONT GRILLE
Polypropylene (PP)
2. HOOD MOULDING
Acrylonitrile butadiene
styrene (ABS)
3. FRONT WINDSHIELD
MOULDING
Acrylonitrile ethylene
propylene dine rubber
styrene (A/EPDM/S)
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
styrene (ABS)
9. REAR BUMPER
Polypropylene (PP)
10. PROTECTOR MOULDING
Polypropylene (PP)
11. DOOR SASH TRIM
Acrylontrile ethylene
propylene dinene rubber
styrene (A/EPDM/S)
Ethylene propylene dinene
rubber (EPDM)

1-16
1-17
1-18
1-19
Exterior Parts Removal/Wheel Alignment
1-20
Construction
1-21
1-22
1-23
1-24
1-26
General Information
116
This model has an SRS which includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above the glove box, seat belt tensioners in the front seat
belt retractors and side airbags in the front seat backs. The SRS unit is separated from the airbag assembly and has built-in sensors. The following precautions should be observed
when performing sheet metal work, paint work and repair work around the location of the SRS components.
1. The SRS unit (including the safing sensor and the impact sensor) is located under the dashboard and the side impact sensors are located in each side sill. Avoid any strong
impact with a hammer or other tools when repairing the front side frame, the lower part of the dashboard and side sill. Do not apply heat to these areas with a torch, etc.
2. Take extra care when painting or doing body work in the area below the centre pillar. Avoid direct exposure of the seat belt retractor with tensioner to heat guns, welding, or
spraying equipment.
3. SRS electrical wiring harnesses are identified with yellow colour coding. Care should be taken not to damage the harness when repairing this area.
4. Do not apply heat of more than 212F (100C) when drying painted surfaces anywhere around the locations of SRS components.
5. If strong impact or high temperature needs to be applied to the areas around the locations of SRS components, remove the components before performing the repair work.
NOTE: Refer to the restraints section of the Shop Manual for after deployment and remove and replacement of SRS related components.
1. SIDE AIRBAG
AIRBAG ASSEMBLY
3. DRIVER'S AIRBAG
ASSEMBLY
4. CABLE REEL
5. UNDER-DASH FUSE/
RELAY BOX
6. SRS UNIT
8. SIDE AIRBAG
General Information
117
1. Built Data and Vehicle Type
2. Vehicle Identification
Number (VIN)
3. Engine Number
(Manual)
(Automatic)
General Information
NOTE: If you are going to remove heavy components such as suspension or the fuel
tank from the rear of the vehicle, first support the front of the vehicle with a tall safety
stands. When substantial weight is removed from the rear of the vehicle, the centre of
gravity can change and cause the vehicle to tip forward on the hoist.
Frame Hoist
Position the hoist lift blocks, or safety stands, under the vehicle's front support points
and rear support points.
118
Floor Jack
1. Set the parking brake.
2. Block the wheels that are not being lifted.
3. When lifting the rear of the vehicle, put the gearshift lever in reverse (or automatic
transmission in Park position).
4. Position the floor jack under the front jacking bracket or rear jacking bracket, centre
the jacking bracket in the jack lift platform, and jack up the vehicle high enough to fit
the safety stands under it.
1. FRONT SUPPORT POINT

2. HOIST LIFT BLOCKS
3. REAR SUPPORT POINT
1. Raise the hoist a few inches, and rock the vehicle gently to be sure it is firmly
supported.
2. Raise the hoist to full height, and inspect the lift points for solid contact with the lift
blocks.
Safety Stands
To support the vehicle on safety stands, use the same support points as for a frame
hoist. Always use safety stands when working on a under vehicle that is supported only
by a jack.
1.
2.
3.
4.
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.
General Information
119
Unit : mm(in.)
*1: With Roof Antenna

*2: European model (MPW condition)
*3: Except European model

Camber
000'45'
Caster
1'33'1
Total toe
03 (00.13)
Wheel turning angle
in
4000'2 (D15B engine)

3800'2 (D17A engine)
out
3100' (D15B engine: Reference)

3000' (D17A engine: Reference)

Camber
-045'45'
Total toe
IN 2 3 (0.08 0.12)
General Information
120
NOTE: To adjust the alignment of the hood, the front door, rear door and trunk lid, refer to the CIVIC Shop Manual.
Mounting bolts/nuts torque:
6X1.0 mm: 9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
*6X1.0 mm: 1.8 Nm (1.8 kgf/m, 13 lbf/ft)
8X1.0 mm: 22 Nm (2.2 kgf/m, 16 lbf/ft)
*8X1.25 mm: 29 Nm (3.0 kgf/m, 22 lbf/ft)
1. HOOD
2. HOOD HINGE
3. REAR BUMPER SIDE
BRACKET
4. TAILGATE HINGE
5. TAILGATE
6. REAR BUMPER BEAM
7. FUEL DOOR
8. REAR BULKHEAD GUSSET
9. REAR DOOR
10. REAR DOOR HINGE
11. FRONT DOOR
12. FRONT DOOR HINGE
13. FRONT FENDER
14. CORNER UPPER BEAM
15. FRONT BUMPER BEAM
16. FRONT BUMPER LOWER
STIFFENER
17. BATTERY SET BASE
121
General Information
Construction
Sp: Steel plateHss: High strength steel plateZn: Zinc-plated

No.
Part Name
No.
Part Name
Hood (Hss, Zn),/p>
22
23
Front Door (Hss, Zn)
24
Rear Door (Hss, Zn)
25
Trunk Lid (Sp, Zn)
26
27
Bulkhead Side Stray (Sp, Zn)
28
29
Roof Panel (Sp)
30
10
31
11
32
12
33
13
34
14
35
15
36
16
37
Rear Floor (Sp, Zn)
17
38
Rear Panel (Sp, Zn)
18
39
19
Rear Pillar Gutter Lower (Sp, Zn)
40
20
Rear Pillar Gutter Upper (SP, Zn)
41
21
General Information
122
Door and bumper reinforcement beams used on Honda vehicles are made from a metal equivalent to High Strength Steel.
If High Strength Steel is heated, the strength of the steel will b e reduced. If High Strength Steel is damaged, as in a vehicle accident, where the door and bumper reinforcement
beams are bent, the beams may crack if an attempt is made to straighten them.
For this reason, the door and bumper reinforcement beams should NEVER be repaired; they should be replaced if they are damaged.
NOTE: If a door beam is damaged, the whole door panel assembly should be replaced.
1. REAR BUMPER
REINFORCEMENT BEAM
2. REAR DOOR
REINFORCEMENT BEAM
3. FRONT DOOR
REINFORCEMENT BEAMS
4. FRONT BUMPER
REINFORCEMENT BEAM
123
General Information
The Zinc-plated steel plate used in some panels of the CIVIC 5-door requires different repair techniques than ordinary steel plate. Refer to "Body Construction" (see page 1-21) for
the location of the Zinc-plated panels.
1. ZINC-PLATED (5-6 microns)
2. Steel plate
1. Before spot welding the zinc-plated steel plate, remove the paint from both sides of the flange to be welded. Apply sealer to the flange after welding.
WARNING
To prevent eye injury, wear goggles or safety glassed whenever sanding, cutting or grinding.
NOTE: Seal the sanded surface thoroughly to prevent rust.
2. The electric continuity properties of zinc-plated steel plate is different from the ordinary steel plate. When spot welding, increase the current by 10-20% or increase the resistance
welding time.Also increase the number of weld spots by 10-20%.
NOTE: The MIG welding procedures for Zinc-plated steel plate are the same an for ordinary steel plate.
WARNING
To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.
3. Before applying putty or body filler to the Zinc-plated steel plate, sand the zinc plating thoroughly to promote adhesion and to prevent blistering.
NOTE: Use only epoxy-based putties and fillers on zinc-plated steel plate, following the manufacture's specifications.
4. When performing pain work, protect the ground wire and ground wire mounting hole threads with a bolt or a plug.
1.
2.
3.
4.
SPECIAL BOLT
GROUND WIRE
GROUND WIRE MOUNTING HOLE
PLUG
124
General Information

NH-578 NH-623M
Taffeta Stain
White
Silver M.
KE
KQ
KT
B-92P
Night
Hawk
Black P.
G-502M
Aqua
Green M.
PB-77M
Lavender
Mist M.
R-81
Mirano
Red
R504P
Ruby
Red P.
B-96P
Eternal
Blue P.
G95P
Clover
Green P.
1.4S
1.6S
1.4SE
1.6LSE
Vi
VTi
EXi
General Information
125
1. DOOR MIRROR BASE
2. DOOR MIRROR
Body colour or black (NH-70
Gloss 20)
3. CHANNEL TAPE
Gloss 30)
5. CORNER TRIM
Black (NH-70 GLOSS 20)
6. ROOF MOULDING
7. LICENSE TRIM
Gloss 30)
8. REAR BUMPER
Body Clour
9. DOOR MOULDING
10. DOOR SASH TRIM
11. FRONT BUMPER
Body Colour
12. GRILLE
General Information
126
Example:
1. FRONT WINDSHIELD MOULDING

Acrylonitrile ethylene propylene dine
rubber styrene (A/EPDM/S)
Polycarbonate (PC)
3. DOOR MIRROR
Painted: Acrylonitrile butadiene
styrene (ABS)
Unpainted: Acrylonitrile styrene
acrylate (ASA)
4. ROOF MOULDING
5. LICENSE TRIP
Acrylonitrile butadiene styrene (ABS)
6. REAR BUMPER
Polypropylene (PP)
7. DOOR SASH TRIM
Acrylontrile ethylene propylene
dinene rubber styrene (A/EPDM/S)
8. FRONT BUMPER
Polypropylene (PP)
Preparation of Work - Preparation of Work
Preparation of Work
General Safety Precaution
2-3
Accurate Inspection of Damaged Parts (Visual)

Description
2-4
Measurement
2-5
Reshaping
Correction of the Damaged Area
2-6
Replacement
Removal
2-7
Installation
2-8
Rust Prevention/Paint
2-10
Installation and Inspection
2-11
Repair Tools
Measurement Equipment
2-12
Protective Tools
2-12
Processing Tools
2-13
Cutting Tools
2-13
Shaping Tools
2-14
Fixing Tools
2-15
Welders
2-16
Sanding Tools
2-16
Welding Methods
Spot Welding
2-17
Carbon Dioxide Arc Welder (MIG Arc Weld)
2-19
Gas Welding
2-20
Outline of Body Repair
2-2
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
Accurate inspection of Damaged Parts. (Visual)

Measurement
Information
Reshape
1.
2.
3.
4.
Remove any related parts.

Attach the frame straightener to the body.
Pull out and straighten the damaged areas.
Check the original position.
Rust Prevention
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.
1. Apply the sealer.
2. Apply the undercoating.
3. Apply anti-rust agent to the inside of the outer panel
and frames.
Installation and
Inspection
see section 1
see section 4
see section 1
Paint
see section 1
Shop Manual
Replacement
Wheelbase
Wheel Alignment
Body Dimensional Drawings
Reference

Mass Production Body Welding
Diagram
Removal
Installation
see section 4
see section 3
see section 3
see section 4
see section 3
Cross Section of Body and Sealants. see section 5

Soft Chipping Guard Primer Coating
Diagram
PVC Coating Diagram
Area to be Covered by Antirust Agents
Apply the paint
see section 6
1.
2.
3.
4.
Shop Manual
Adjust the hood, door, tailgate.

Measure the wheel alignment.
Clean the body.
Install related parts.
2-3
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. FUEL TANK
1. SAFETY CABLES
Cover the exterior parts and the interior parts with a fireproof cover
and protect the vehicle when welding.
Do not damage the passenger compartment parts when you heat the
undercoat of the welded flange with a torch.
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. VEHICLE IDENTIFICATION NUMBER (VIN)

2. DASHBOARD UPPER
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.
Preparation of Work - Accurate Inspection of Damaged Parts (Visual)
2-5
Accurate Inspection of Damaged Parts

(Visual)
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:
Reshape
Reshape
2-6
Correction of the Damaged Area
1. Remove any related parts.

NOTE: See the Shop Manual.
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.
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.
Preparation of Work - Replacement
2-7
Replacement
Removal
1. Decide whether to replace all the affected parts or whether to cut the
weld joint parts and replace them.
NOTE: When cutting the parts off, take special care that you do not
damage adjacent parts on the vehicle.
Setting Condition for Replacement Parts Joint Sections:
Make sure that you can perform straightening work after welding.
Make sure that the locations will not be susceptible to distortion
caused by other parts.
Make sure that there are few removable parts and that the location
allows for safe welding.
Make sure that the joints are short, and that paint repair can be
performed easily.
Make sure that locations are such that the joints can be finished in
a way that will not affect the outward appearance.
Make sure that the locations do not hinder the removing and
attaching of parts.
Parts which influence wheel alignment such as damper housing and the
side frames must be examined using the frame repair charts.
2. Peel off the undercoat.
CAUTION
Be careful not to burn the fittings inside the

passenger compartment when heating.
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.
1. DAMPER HOUSING
2. OUTER PANEL
(New part)
3. FRONT SIDE FRAME
(New part)
1. STIFFENER
2. OUTER PANEL
2-8
Replacement
Installation
1. Straighten any damaged parts.
WARNING
To prevent eye injury and burns when welding,

wear an approved welding helmet, gloves and
safety shoes.
Where new panels cannot be spot welded, make holes for plug
welding.
Make holes to the size which corresponds to the thickness of the
welded plate (see page 2-19).
The position and the point by which holes are made, refer to the old
parts or Mass Production Body Welding Diagram (see section 3).
Fill any holes by MIG welding and even out with a hammer and
dolly.
WARNING

Level and finish the burns on the welding flanges with a disc sander
or belt sander.
1. NEW PART
2. OLD PART
3. Apply rust prevention processing on welded surface.
WARNING
To prevent eye injury, wear goggles of safety

glasses whenever sanding.
Remove the undercoat from both sides of the areas to be spot
welded with a sander to expose the steel plate.
Apply the spot sealer to the welding surface of the new parts and
body side.
NOTE: Spread the spot sealer coat on the welding surface so that
there is no bare areas.
2. Preparations of new parts.

Cut the new outer panel so it will overlap by 20-30mm (0.8-1.2 in.)
to the panel of the body side.
1. OVERLAP
2-9
Replacement
Installation
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.
WARNING

safety shoes.
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 zinc-plated steel plate is different

from ordinary steel plate. When spot welding, increase the current
by 10-20%, or increase the resistance welding line.
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.
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.
6. Main weld the repair parts.

Use proper welding methods (see pages 2-17, 2-18, 2-19, 2-20).
WARNING

safety shoes.
1. BUTT WELD
2. PATCH
3. FILLET WELD
210
Replacement
Installation (cont'd)
7. Finishing the welded areas.

Level the MIG welded areas with a disc sander.
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
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.
Rust Prevention/Paint
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.
3. Apply undercoat to the wheelhouse and under-floor.

4. Apply the anti-rust agent to the inside of the outer panel and welded
areas.
211
1. Check the clearance of the door, hood, tailgate and adjust if necessary.
Check the operation of the parts and make sure the doors lock
securely.
2. Apply the sealer to the hinges of the hood, door and tailgate.
1. HOOD HINGE
2. DOOR HINGE
3. TAILGATE HINGE
3. Adjust the wheel alignment.

4. Check the windows for water leaks.
5. Clean the passenger compartments.
Preparation of Work - Repair Tools
212
Repair Tools
Measurement Equipment
TRAM TRACKING GAUGE
Protective Tools
OPERATOR:
1
Protective goggles
Protective apron
Cap
Welding glove
Ear plugs
Foot protector
Shield for eyes
10
Safety shoes
Overalls with long sleeves
11
Work glove
Dust-proof mask
12
Splatter guard
FRAME CENTRING GAUGE
UNIVERSAL TRAM GAUGE
CONVEX TOOL
VEHICLE BODY:
Heat-resistant protective cover
Preparation of Work - Repair Tools
Repair Tools
Processing Tools
213
SPOT CUTTER
AIRSAW
Install the spot cutter in the air drill, and drill a hole at the spot weld
nugget and the plug to make the hole.
Cut the outer panel.
Cutting Tools
AIR CHUCK GRINDER

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

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

Pry off the spot welded flange.
HAND NIBBLER
Preparation of Work - Welding Methods
219
Welding Methods
Carbon Dioxide Arc Welder (MIG Arc Weld)
This welding process uses inexpensive carbon dioxide instead of expensive inert gases as a shielding means. Consumable metal electrodes are employed. It has a wide range of
applications, including butt welding of a thin plate, fillet welding, plug welding and MIG spot welding. In terms of the weld strength, it is also highly stable.
Welders:
1. Single-phase 110V
Three-phase 200-240V
2. Gas hose
3. Input cable
4. Gas regulator
5. Carbon dioxide or Argon +
Carbon dioxide
6. Welding power supply
(built-in wire feed
mechanism)
7. Welding torch
8. Workpiece
9. Work cable
10. Ground wire
CAUTION
Disconnect the negative battery cable before arc welding.

Welding Methods:
Butt welding
Fillet welding
Spot welding
Plug welding
Plug Welding Conditions:

Plate thickness and weld holes
Unit: mm (in.)
Plate thickness
~1.0 (0.04)
1.0 (0.04) ~ 1.5 (0.06)
1.5 (0.06)~
Weld hole diameter
5 (0.2)
6.5 (0.26)
8 (0.3)
Preparation of Work - Welding Methods
220
Welding Methods
Gas Welding
Gas welding is indispensable for body repair because of the broad range of its applications to join the body panels, cut the materials that construct the body, apply heat to reform
panels, and also because it is easy to get hold of the tools.
However, this method requires experience.
Welders:
1.
2.
3.
4.
5.
Gas regulator
Gas regulator
Welder
Cutter
Oxygen/Acetylene tanks
Welding Methods:
Butt welding
Fillet welding or soldering
Index - Index
Index
4-door Replacement
3-3
5-door Replacement
3-35
4-door Replacement
4-door Replacement
*Front Bulkhead
Mass Production Body Welding Diagram
3-4
Removal
3-5
Installation
3-5
*Front Wheelhouse/Damper Housing

3-6
Removal
3-7
Installation
3-9
*Front Side Frame Outrigger

3-11
Removal
3-12
Installation
3-14
*Front Pillar Outer Panel

3-16
Removal
3-17
Installation
3-18
*Side Sill Outer Panel

3-19
Removal
3-20
Installation
3-21
Roof Panel
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
3-29
Removal
3-30
Installation
3-31
Rear Floor
3-32
Removal
3-33
Installation
3-34
Items marked with and asterisk (*) include SRS components; special caution is required when servicing.
4-door Replacement
Index - Front Bulkhead
Front Bulkhead
34
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
Front damper extension

Bulkhead upper frame
Bulkhead side stay
Wheelhouse upper
member
Front wheelhouse
Front side frame
4-Plate welding
Front lower cross-member
Bulkhead side
Bulkhead bracket
Front Bulkhead
3-5
Installation
Removal
1. Set the new front bulkhead into position and measure the front
compartment diagonally. Check the body dimensions (see section 4).
2. Tack weld the clamped position.
3. Temporarily install the hood, front fender, headlight and front bumper
and check for differences in level and clearance.
4. Perform the main welding:
1.
2.
3.
4.
5.
6.
7.
8.
BULKHEAD UPPER FRAME

BULKHEAD SIDE
FRONT DAMPER EXTENSION
WHEELHOUSE UPPER MEMBER
FRONT WHEELHOUSE
FRONT SIDE FRAME
BULKHEAD SIDE STAY
FRONT LOWER CROSS-MEMBER
1.
2.
3.
4.
5.
6.
7.
8.
9.

BULKHEAD SIDE
FRONT SIDE FRAME
FRONT WHEELHOUSE
BULKHEAD SIDE STAY
FRONT SIDE FRAME
Index - Front Wheelhouse/Damper Housing
Front Wheelhouse/Damper Housing

36
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
Front side frame

Engine mount bracket
Dashboard upper
Damper housing extension
Wheelhouse upper
member
Include (A)
Front side frame
Front wheelhouse
Passenger compartment side:

Wheelhouse upper member removed:
a.
b.
c.
d.
e.
Dashboard upper side member

Damper housing
Front wheelhouse
3-7
Removal
Cut and remove the wheelhouse upper member, and replace the front wheelhouse.
1. DAMPER HOUSING
2. FRONT DAMPER
EXTENSION
3. WHEELHOUSE UPPER
MEMBER Reused.
4. FRONT WHEELHOUSE
5. ENGINE MOUNT BRACKET
6. FRONT SIDE FRAME
Check the front damper extension and damper housing for position and damage. If necessary, remove the wheelhouse upper member and replace the damper housing and
front damper extension as an assembly, if possible.
1. DAMPER HOUSING
2. FRONT DAMPER EXTENSION
3. WHEELHOUSE UPPER MEMBER Reused.
3-8
Removal (cont'd)
Replace the front damper extension, damper housing and damper housing extension as an assembly.
1. FRONT DAMPER
EXTENSION
2. DASHBOARD UPPER
SIDE MEMBER
3. DAMPER HOUSING
4. FRONT DAMPER
EXTENSION
6. FRONT SIDE FRAME
7. DAMPER HOUSING
EXTENSION
8. DAMPER HOUSING
EXTENSION
3-9

Installation
1. Set the new damper housing assembly, front wheelhouse and front
bulkhead into position, and measure the front compartment diagonally.
Check the body dimensions (see section 4).
From the passenger compartment side, plug the holes in the

dashboard lower, damper housing extension and front damper
extension.

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

2. DAMPER HOUSING EXTENSION
From wheelhouse side, plug weld the holes in the dashboard upper
and damper housing extension.
1.
2.
3.
4.

DASHBOARD UPPER SIDE MEMBER
FRONT SIDE FRAME
DAMPER HOUSING

Weld the front wheelhouse, damper housing and front side frame.
1.
2.
3.
4.
310
DAMPER HOUSING
FRONT WHEELHOUSE
ENGINE MOUNT BRACKET
Weld the wheelhouse upper member.

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

2. Butt Welding
3. WHEELHOUSE UPPER MEMBER
Index - Front Side Frame/Outrigger
Front Side Frame/Outrigger
311
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
Front side frame

Sub-frame rear bracket
4-Plated welding
Side frame extension rear
Inside sill extension
Outrigger
Side frame bulkhead rear
4-Plate welding
and front side frame
l. Front wheelhouse
VIEW (Y)
a. Inside sill extension
VIEW (Z)
file:///C|/Users/Navindra/Desktop/Civic_2001-2005_englis...%20Civic%202001-2005(english)/EngCivic/CivBHtml/3-11.htm (1 of 2)7/6/2011 9:06:05 PM

Removal
312

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
SIDE FRAME BULKHEAD
REAR
FRONT SIDE FRAME
FRONT SUB-FRAME STAY
FRONT SIDE FRAME
SIDE FRAME EXTENSION
REAR
SIDE FRAME BULKHEAD
REAR
REAR

Removal (cont'd)
313
Check the side frame bulkhead rear for position and damage. If necessary replace it.
1. SUB-FRAME REAR BRACKET
2. SIDE FRAME BULKHEAD REAR
3. SIDE FRAME EXTENSION REAR
If necessary, replace the side frame extension rear, outrigger and sub-frame rear bracket as an assembly.
NOTE: When removing the outrigger, leave the inside sill extension attached to the inside sill, if possible.

1. OUTRIGGER
2. SUB-FRAME REAR
BRACKET
3. SIDE FRAME EXTENSION
REAR
4. OUTRIGGER
5. INSIDE SILL EXTENSION
6. FLOOR FRAME
REAR
8. SUB-FRAME REAR
BRACKET
314

Installation
1. Tack weld the new side frame bulkhead rear to the side frame
extension rear.
Plug weld the inside sill extension and floor frame.
2. Set the new front side frame, side frame extension rear, outrigger and
front bulkhead into position and measure the front compartment
diagonally. Check the body dimensions (see section 4).
4. Temporarily install the front sub-frame, and check the front side frame
position.
5. Temporarily install the hood, front render, headlights and front bumper,
Make sure the body lines flow smoothly.
Plug weld the side frame extension rear, side frame bulkhead rear
and front side frame.

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

front floor.

2. FRONT SIDE FRAME
1. OUTRIGGER
Index - Roof Panel
Roof Panel
Removal
324
1.
2.
3.
4.
5.
6.
7.
ROOF PANEL
REAR INNER PANEL
ROOF ARCH GUSSET
REAR INNER PANEL
REAR ROOF RAIL
FRONT ROOF RAIL
FRONT INNER UPPER
PANEL
8. FRONT INNER UPPER
PILLAR
Index - Roof Panel
Roof Panel
Installation
1. Set the new roof panel into position and clamp it. Check the body
dimensions (see section 4), and check the width of the roof moulding
installation.
2. Install the roof arch gusset, and tack weld the roof panel.
3. Temporarily install the windshield, door and rear window and check for
difference in level and clearance.
4. Perform the main welding.
325
5. From inside the vehicle, plug weld the front pillar inner upper, rear
inner panel and front and rear roof rails.
1. OUTER PANEL
2. ROOF PANEL
3. ROOF SIDE RAIL
VIEW (Z)
1.
2.
3.
4.
FRONT INNER UPPER PILLAR

FRONT ROOF RAIL
REAR INNER PANEL
REAR ROOF RAIL
1. ROOF ARCH GUSSET
Index - Rear Side Outer Panel
326
a.
b.
c.
d.
e.
f.
g.
Rear damper stiffener

Inner panel extension
Inner panel
Rear panel side stiffener
VIEW (Z)
Rear combination adaptor
Wheel arch extension

Removal
327
Cut and pry off rear side outer panel.

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

Installation
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).
3. Temporarily install the door, rear window, trunk lid and rear bumper and check
for difference in level and clearance.
Attach the patch at the cut section of the rear pillar and plug weld it.
328
Weld the rear combination adaptor and rear panel.
1. REAR COMBINATION ADAPTOR
1.
2.
3.
4.
5.
6.
7.
OUTER PANEL
PARCEL SHELF
REAR GUTTER
Butt welding
NEW OUTER PANEL
Fillet welding
Overlap
30 mm (1.2 in.)
8. PATCH
Index - Rear Panel
Rear Panel
329
a.
b.
c.
d.
e.
f.
Rear panel side stiffener

Trunk compartment side:
Rear panel
Jack-up stiffener
4-Plate welding
Index - Rear Panel
Rear Panel
Removal
330
Cut and pry off the rear panel.

NOTE: When removing the rear panel side stiffener attached to the rear combination adaptor, if possible.
Check the rear combination adaptor position and for damage and if necessary, remove the rear panel side stiffener, and replace the rear combination adaptor and rear gutter as
an assembly.
1. REAR PANEL SIDE
STIFFENER
2. REAR COMBINATION
ADAPTOR
3. REAR PANEL
4. REAR PANEL GUSSET
6. REAR FLOOR
7. REAR PANEL
8. REAR PANEL SIDE
STIFFENER
9. REAR COMBINATION
ADAPTOR
Index - Rear Panel
331
Rear Panel
Installation
1. Set the new rear panel and rear combination adaptor into position and
clamp them.

2. REAR PANEL SIDE STIFFENER
3. REAR PANEL SIDE LOWER STIFFENER
(New Part)
1. NEW REAR COMBINATION ADAPTOR

2. NEW REAR PANEL

3. Temporarily install the trunk lid, tailgate, rear bumper and check for
difference in level and clearance. Check for operation of the truck lid.
Weld the rear combination adaptor, rear gutter, outer panel and
rear panel.
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.
Weld the rear panel and rear floor.
1. NEW REAR PANEL
1.
2.
3.
4.
OUTER PANEL
NEW REAR GUTTER
NEW REAR COMBINATION ADAPTOR
NEW REAR PANEL
Index - Rear Floor
Rear Floor
332
a.
b.
c.
d.
e.
f.
g.
Rear floor cross-member

Rear floor
Rear panel gusset
Rear frame A
Rear frame B
Rear floor
Include (A)
Index - Rear Floor
Rear Floor
Removal
333
Cut the rear floor 15 mm (0.6 in.) from the welded flange of the rear cross-member.
If necessary, replace the rear frame B.
Check the rear floor cross-member position for damage.
If necessary, replace the rear floor cross-member.
1. REAR FLOOR CROSSMEMBER
2. REAR FLOOR
3. Cut line
5. REAR FLOOR
7. REAR FRAME A
8. VIEW (Z)
9. REAR FRAME B
10. REAR FRAME A
11. REAR FRAME B
Index - Rear Floor
Rear Floor
Installation
1.
2.
3.
4.
Set the new rear cross-member and rear frame B, into position.
Tack weld the rear cross-member and rear frame B.
Set the new rear floor to align it with the body.
Cut the new rear floor so it overlaps the body side floor by about 40
mm (1.6 in.).
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)
334
8. Set the new rear floor, and plug weld the rear floor cross-member, rear
frame B and rear frame A.
1.
2.
3.
4.
5.
REAR FRAME A
REAR FLOOR CROSS-MEMBER
REAR FRAME B
REAR FRAME A
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.
1. REAR FLOOR CROSS MEMBER

1. Filler welding
5-door Replacement
5-door Replacement
*Front Bulkhead
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

3-43
Removal
3-44
Installation
3-46
*Front Pillar Outer Panel

3-48
Removal
3-49
Installation
3-50

3-51
Removal
3-52
Installation
3-53
Roof Panel
3-55
Removal
3-56
Installation
3-57

3-58
Removal
3-59
Installation
3-60
Rear Panel
3-61
Removal
3-62
Installation
3-62
Rear Floor
3-63
Removal
3-64
Installation
3-65
Items marked with an asterisk (*) include SRS components; special caution is required when servicing.
5-door Replacement
Front Bulkhead
336
a. Front wheelhouse
b. Wheelhouse upper
extension
c. Front side frame
d. Wheelhouse upper
member
e. Front lower cross-member
f. Bulkhead side
g. Front side frame
h. 4-Plate welding
i. 4-Plate welding
j. Front lower cross-member
k. Bulkhead side stay
l. Bulkhead centre stay
m. Bulkhead upper frame
Front Bulkhead
Removal
337
Installation
1. Set the new front bulkhead into position and measure the front
compartment diagonally. Check the body dimension (see section 4).
1.
2.
3.
4.
5.
6.
7.

BULKHEAD SIDE
WHEELHOUSE UPPER EXTENSION
FRONT WHEELHOUSE
FRONT SIDE FRAME
BULKHEAD SIDE STAY
1.
2.
3.
4.
5.
6.
7.
8.
9.

BULKHEAD SIDE
FRONT SIDE FRAME
FRONT WHEELHOUSE
BULKHEAD SIDE STAY
FRONT SIDE FRAME
Front/Wheelhouse/Damper Housing
338
a.
b.
c.
d.
e.
f.
g.
Front side frame

Engine mount bracket dashboard upper
Wheelhouse upper extension
Wheelhouse upper member
Dashboard upper side member
Front wheelhouse
Wheelhouse upper member removed:

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

a. Wheelhouse upper member
VIEW (X)

Removal
339
Cut and remove the wheelhouse upper member, and replace the front wheelhouse.
1. DAMPER HOUSING
2. WHEELHOUSE UPPER
EXTENSION
3. WHEELHOUSE UPPER
MEMBER Reused.
4. FRONT WHEELHOUSE
6. FRONT SIDE FRAME
Check the wheelhouse upper extension and damper housing for position and damage. If Necessary, remove the wheelhouse upper member and replace the damper housing and
wheelhouse upper extension as an assembly. If possible.
1.
2.
3.
4.
DAMPER HOUSING
WHEELHOUSE UPPER MEMBER EXTENSION
WHEELHOUSE UPPER MEMBER Reused.

Removal (cont'd)
340
Replace the wheelhouse upper extension, damper housing extension as an assembly.

1. WHEELHOUSE UPPER
EXTENSION
2. DASHBOARD UPPER
SIDE MEMBER
3. DAMPER HOUSING
4. WHEELHOUSE UPPER
EXTENSION
6. FRONT SIDE FRAME
7. DASHBOARD UPPER
8. MOUNTING BOLT
9. DAMPER HOUSING
EXTENSION
341

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

dashboard lower damper housing extension and wheelhouse upper
extension.
1. WHEELHOUSE UPPER EXTENSION

Weld the dashboard upper and damper housing.
1. DASHBOARD UPPER
1.
2.
3.
4.

DASHBOARD UPPER SIDE MEMBER
FRONT SIDE FRAME
DAMPER HOUSING

Weld the front wheelhouse, damper housing and front side frame.
1.
2.
3.
4.
342
DAMPER HOUSING
FRONT WHEELHOUSE
Weld the wheelhouse upper member.

When replacing the front wheelhouse only, butt weld the wheelhouse
upper member.
1.
2.
3.
4.

WHEELHOUSE UPPER MEMBER EXTENSION
Butt welding
343
a.
b.
c.
d.
e.
f.
g.
h.
Front side frame

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

Removal
344

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
FRONT SIDE FRAME
FRONT SUB-FRAME STAY
FRONT SIDE FRAME
REAR
SIDE FRAME BULKHEAD
REAR
SIDE FRAME BULKHEAD
REAR
REAR

Removal (cont'd)
345
Check the side frame bulkhead rear for position and damage. If Necessary replace it.
If necessary, replace the side frame extension rear, outrigger and sub-frame rear bracket as an assembly.
NOTE: When removing the outrigger, leave the inside sill extension attached to the inside sill, if possible.

1. OUTRIGGER
2. SUB-FRAME REAR
BRACKET
REAR
4. OUTRIGGER
6. FLOOR FRAME
REAR
8. SUB-FRAME REAR
BRACKET
346

Installation
1. Tack weld the new side frame bulkhead rear to the side frame
extension rear.
Plug weld the inside sill extension and floor frame.
2. Set the new front, side frame extension rear, outrigger and front
bulkhead into position and measure the front compartment diagonally.
4. Temporarily install the front sub-frame and check the front side frame
position.
and check for difference in level and clearance.
Plug weld the side frame extension rear, side frame bulkhead rear
and front side frame.

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

front floor.

2. FRONT SIDE FRAME
1. OUTRIGGER

347
Weld the damper housing, front wheelhouse and front side frame.
1. DAMPER HOUSING
2. FRONT WHEELHOUSE
Index - Front Pillar Outer Panel
Front Pillar Outer Panel
348
a. Wheelhouse upper
member (see page 338)
b. Front pillar lower
stiffener
c. Inner lower
d. Front pillar upper
stiffener
e. VIEW (Z)
f. Side sill reinforcement
g. Front pillar stiffener
h. 4-Plate welding
i. Front pillar separator

Removal
349
Cut the wheelhouse upper member as necessary pry off the front pillar outer panel.
Check the front pillar lower stiffener position and for damage and replace it if necessary.
When replacing the front pillar lower stiffener, remove the front pillar separator and glue the insulator at the separator mounted position.
1.
2.
3.
4.
5.
6.
7.
8.
FRONT PILLAR UPPER STIFFENER

FRONT PILLAR LOWER STIFFENER
OUTER PANEL
SIDE SILL REINFORCEMENT
FRONT PILLAR SEPARATOR
INNER LOWER
FRONT PILLAR UPPER STIFFENER

Installation
1. Glue the insulator to the inner lower at the front pillar lower separator
mounted position.
Insulator: P/N. 74416-SF1-000
Adhesive: Cemedine 366 or equivalent
350
6. Clamp the repair part and recheck the clearance and alignment of the
front door, front fender and windshield.
Attach the patch at the cut the section of the front pillar outer panel
and plug weld it.
1. INNER LOWER
2. INSULATOR
2. Set the new front pillar lower stiffener into position and tack weld the
clamped position.
3. Cut the repair part (outer panel), set it into position. Clamp the repair
part and check the body dimensions (see section 4).
4. Temporarily install the windshield, front door, hood and front fender
and check for differences in level and clearance. Make sure the body
lines flow smoothly.
5. Removal the repair part and weld the front pillar lower stiffener, upper
stiffener and side sill reinforcement.
1.
2.
3.
4.
5.
Butt welding
PATCH
OUTER PANEL
Fillet welding
Overlap
30 mm (1.2 in)
8. Weld the wheelhouse upper member.
1. FRONT PILLAR UPPER STIFFENER

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

2. WHEELHOUSE UPPER MEMBER
Index - Side Sill Outer Panel
Side Sill Outer Panel
351
a. Center pillar stiffener
reinforcement
b. Centre pillar stiffener
c. 4-Plate welding
d. Centre pillar separator
e. VIEW (Y)
f. Side sill reinforcement
g. VIEW (Z)
h. Centre pillar stiffener
i. VIEW (W)
j. VIEW (Y)
k. 4-Plate welding

Removal
352
Cut and pry off the side sill outer panel.

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

Installation
353
1. Glue the insulator to the center inner pillar at the centre pillar separator
mounted position.
Insulator: PIN. 774416-SF1-000
Adhesive: Cemedine 366, or equivalent
1. NEW SIDE SILL REINFORCEMENT

2. INSIDE SILL

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.
5. Remove the repair part and weld the centre pillar lower stiffener and side
sill reinforcement.
NOTE: Replace the drive side of the side sill reinforcement with the
assembly without cutting the side sill reinforcement halfway, because there
is reinforcement stiffener inside of the side sill reinforcement. Therefore, cut
the outer panel to under of the front pillar.
1.
2.
3.
4.
5.
FRONT PILLAR OUTER PANEL

OUTER PANEL
INSIDE SILL
REINFORCEMENT STIFFENER
1. NEW CENTRE PILLAR STIFFENER

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

354
6. Clamp the repair part and recheck the clearance alignment of the front door,
rear door and front fender.
Attach the patches at the cut section of the center pillar and wheel arch and
plug weld them.
1.
2.
3.
4.
5.
Butt welding
PATCH
PATCH
Butt welding
Overlap
30 mm (1.2 in.)
6. Fillet welding
Index - Roof Panel
Roof Panel
355
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
Index - Roof Panel
Roof Panel
Removal
356
1. ROOF PANEL
2. REAR INNER PANEL
3. REAR PILLAR GUTTER
UPPER
4. ROOF ARCH GUSSET
5. REAR INNER PANEL
6. REAR ROOF RAIL
7. FRONT ROOF RAIL
PILLAR
PILLAR
Index - Roof Panel
Roof Panel
Installation
1. Set the new roof panel into position and clamp it.
Check the body dimensions (see section 4), and check the width of the
roof moulding installation.
2. Install the roof arch gusset, rear roof rail mounting bolts and tack weld
the roof panel.
3. Temporarily install the windshield, door and tailgate, check for
difference in level and clearance.
4. Perform the main welding.
357
5. From inside the vehicle, plug weld the front pillar inner upper, rear
inner panel and front and rear roof rail.
VIEW (Z)
1. OUTER PANEL
2. ROOF PANEL
3. ROOF SIDE RAIL
1.
2.
3.
4.
FRONT INNER UPPER PILLAR

FRONT ROOF RAIL
REAR INNER PANEL
REAR ROOF RAIL
6. Weld the roof panel and rear pillar gutter upper.
1. REAR PILLAR GUTTER UPPER

1. ROOF ARCH GUSSET
358
a.
b.
c.
d.
e.
f.
g.
h.
i.
Quarter pillar inner

Rear pillar inner
Rear panel
Rear pillar gutter lower
Rear inner panel
Rear pillar gutter upper
Rear gutter lower stiffener
Rear pillar lower and Rear
panel
j. VIEW (Z)
k. Wheelarch extension

Removal
359
Cut and pry off the rear side sill outer panel.
Check the rear pillar gutter lower and gutter upper position and for damage and if necessary, replace the rear pillar gutter lower.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
WHEEL ARCH EXTENSION

QUARTER PILLAR INNER
REAR PILLAR INNER
REAR PILLAR GUTTER
UPPER
REAR PILLAR GUTTER
LOWER
REAR INNER PANEL
REAR PILLAR GUTTER
LOWER
REAR PANEL
REAR PILLAR GUTTER
UPPER
REAR PANEL GUSSET
VIEW (Z)
REAR GUTTER LOWER
STIFFENER
OUTER PANEL
Rear Side outer Panel
360
Rear Side outer Panel

Installation
1. Set the new repair part (outer panel) and rear pillar gutter lower and into
position and clamp them.
3. Temporarily install the door, tailgate, tailgate and rear bumper and check
for differences in the level and clearance. Make sure the body lines flow
smoothly.
Attach the patch at the cut section of the quarter pillar, rear pillar and
plug weld them.
Weld the rear pillar gutter lower, gutter upper and rear panel.
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
Index - Rear Panel
Rear Panel
361
a.
b.
c.
d.
e.
f.

Rear gutter lower stiffener
Rear panel
Rear panel
Jack-up stiffener
Index - Rear Panel
Rear Panel
Removal

Check the rear pillar gutter lower position and for damage and if
necessary, replace it (see page 3-59).
362
Installation
1. Set the new rear panel and check the body dimensions (see section 4).
3. Temporarily install the tailgate, tailgate, rear bumper and check for
differences in level and clearance. Check operation of the tailgate.
1. REAR PANEL
2. REAP PILLAR GUTTER LOWER
1.
2.
3.
4.
5.
6.
REAR PANEL
REAR GUTTER LOWER STIFFENER
REAR PANEL
REAR FLOOR
JACK-UP STIFFENER
REAR PILLAR GUTTER LOWER
Index - Rear Floor
Rear Floor
363
a.
b.
c.
d.
e.
f.
g.
h.
Rear floor
Rear panel gusset
Rear frame B
Rear floor
Rear frame
Rear frame A
Index - Rear Floor
Rear Floor
Removal
364
Cut the rear floor 15 mm (0.6 in.) from the welded flange of the rear floor cross-member.
Id necessary, replace the rear frame B.
Check the rear floor cross-member position and for damage.
If necessary, replace the rear floor cross-member.
2. REAR FLOOR
3. Cut line
5. REAR FLOOR
7. REAR FRAME A
8. VIEW (Z)
9. REAR FRAME B
10. REAR FRAME A
11. REAR FRAME B
Index - Rear Floor
Rear Floor
Installation
1.
2.
3.
4.
Set the new rear cross-member and rear frame B, into position.
Tack weld the rear cross-member and rear frame B.
Set the new floor to align it with the body.
Cut the new rear floor so it overlaps the body side floor by about 40
mm (1.6 in.).
1. NEW REAR FLOOR

2. Overlap
40 mm (1.6 in.)
3. NEW REAR FLOOR
4. REAR CROSS-MEMBER
5. REAR FLOOR
(body side)
5. Check the position of the rear inner panel and rear panel.
6. Removal the new rear floor and plug weld the rear floor cross-member.
7. Finish plug welding the area and take care not to grind excessively.
365
8. Set the new rear floor and plug weld the rear floor cross-member, rear
frame B and rear frame A.
1.
2.
3.
4.
5.
REAR FRAME A
REAR FRAME B
REAR FRAME A
9. Perform the main welding to the rear floor.
1. REAR FLOOR CROSS MEMBER
Index - Rear Floor
1. Fillet welding
Index - Index
Index
4-door Body Dimensional Drawings
4-3
4-13

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
Index - Upper Body Measuring Dimensions
4-4
Engine Compartment
Unit: mm (in.)
1. E, e
Front Damper Mount Hole
11.5 (0.45)
2. F, f
Front Fender Mount Hole 7
(0.3) Rearward
3. G, g
Hood Hinge Mount Hole 7
(0.3) Forward
4. D, d
Front Bumper Beam Mount
Hole 9 (0.35)
5. C, c
(0.3) Forward
6. B, b
Headlight Mount Hole 7 (0.3)
7. A, a
Bulkhead Upper Frame
Point 15 (0.59)
4-5
Engine/Transmission Mount Positions
Unit: mm (in.)
Unit: mm (in.)
1. E
Front Damper Mount Hole 11.5 (0.45)
2. H
AT/MT Transmission Bracket Mount Holed 13 (0.51)
3. I
Engine Bracket Mount Hole 13 (0.51)
4. J
Honda Multi Matic Transmission Bracket Mount Hole 13 (0.51)
AT/MT:
Honda Multi Matic:
1. K, k
Front Seat Rear Side Bracket Point 9 (0.35)
2. L, l
Rear Damper Mount Hole 11 (0.43)
Index - Under Body Measuring Dimensions
Engine Compartment and Front Floor Under View
46
Unit: mm (in.)
1. A, a
Radiator Mount Hole 15
(0.59)
2. B, b
Front Sub-frame Mount
Hole 15 (0.59) Forward
3. C, c
Hole 15 (0.59) Rearward
4. D, d
Front Floor Frame Point 20
(0.79)
Index - Under Body Measuring Dimensions
4-7
Unit: mm (in.)
1. D,d
(0.79)
2. E, e
Front Floor Point 25 (0.98)
3. F, f
Rear Frame Extension Point
20 (0.79)
4. G, g
Trailing arm Mount Holed 14
(0.55)
5. H, h
Upper Arm Mount Hole 15
(0.59)
6. I, I
Lower Arm Mount Hole 12.8
(0.5)
7. J, j
Rear Frame A Point 20
(0.79)
8. K, k
Rear Frame B Pint 15 (0.59)
Index - Frame Repair Chart
48
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)
b3
c1
For transmission mount o13 (0.51)
For sub-frame o 11.5 (0.45)
c2
c3
Locate hole o 25 (0.98)
d1
d2
d3
49
Frame Repair Chart

Top View (cont'd)
For upper arm bracket center o 15 (0.59)
For trailing arm o 13 (0.51)
v1, v2
For upper arm o 13 (0.51)
For rear lower arm centre
Trailing arm centre
Rear damper center 73 x 68 (slot)
410
Frame Repair Chart

Side View
Unit: mm (in.)
o: Inner diameter
For sub-frame o 15 (0.59)
b1
b2
b3
c1
For transmission mount o 13 (0.51)
c2
c3
d1
d2
d3
411
Frame Repair Chart

Side View (cont'd)
For upper arm bracket center o15 (0.59)
v1, v2
Trailing arm centre
Index - Opening Repair Chart
412
Door and Windshield Openings:

Unit: mm (in.)
1. A
Windshield lower dashboard guide pin
2. B, C
Windshield opening flange notch (2 places)
3. D, E, F, G, H, I, J, K,
Door opening flange notch (16 places)
Rear Window and Trunk Lip Openings:
1. L, M
Rear window opening flange notch (3 places)
2. N
Trunk gutter area convex bead
3. O
Outer panel range end (2 places)
4. P
Trunk seal flange water drain notch

Engine Compartment
4-14
Engine/Transmission Mount Positions and

4-15

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

Top View
4-18
Side View
4-20
4-22

Engine Compartment
414
Unit: mm (in.)
1. E, e
Front Damper Mount Hole
11.5 (0.45)
2. G, g
Hood Hinge Mount Hole 7
(0.3) Forward
3. F, f
(0.3) middle
4. D, d
Front Bumper Beam Mount
Hole 9 (0.35)
5. C, c
(0.3) Forward
6. B, b
Headlight Mount Hole 7 (0.3)
7. A, a
Point 15 (0.59)

Unit: mm (in.)
415
Unit: mm (in.)
1. E
Front Damper Mount Hole 11.5 (0.45)
2. H
AT/MT Transmission bracket Mount Hole 13 (0.51)
3. I
Engine Bracket Mount Hole 13 (0.51)
1. J, j
Front seat Rear Side Bracket Point 9 (0.35)
2. K, k
Rear Damper Mount hole 11 (0.43)
Engine Compartment and Front Under View
416
Unit: mm (in.)
1. A, a
Radiator Mount Hole 15
(0.59)
2. B, b
Hole 15 (0.59) Forward
3. C, c
Hole 15 (0.59) Rearward
4. D, d
(0.79)

417
1. D, d
(0.79)
2. E, e
Front Floor Point 25 (0.98)
3. F, f
Rear Frame Extension Point
20 (0.79)
4. G, g
Trailing arm Mount Hole 14
(0.55)
5. H, h
Upper Arm Mount Hole 15
(0.59)
6. I, I
Lower Arm Mount Hole 12.8
(0.5)
7. J, j
Rear Frame A Point 20
(0.79)
8. K, k
Rear Frame B Point 25 (1.0)
418
Frame Repair Chart

Top View
Unit: mm (in.)
: Inner diameter
b1
b2
b3
c1
c2
c3
419
Frame Repair Chart

Top View (cont'd)
u1, u2
Trailing arm centre
420
Frame Repair Chart

Side View
Unit: mm (in.)
: Inner diameter
b1
b2
b3
c1
c2
c3
421
Frame Repair Chart

Side View (cont'd)
u1, u2
Trailing arm centre
422

Unit: mm (in.)
1. A
2. B, C
3. D, E, F, G, H, I, J, K,
Tailgate Opening:
1. L
Roof lower Rail Flange notch
2. M
Rear Gutter Lower Stiffener flange end (2 places)
3. N
Rear panel upper stiffener water drain notch
Index - Index
Index
4-door Rust Prevention
5-3
5-17

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
Index - Cross Section of Body and Sealants
5-4
General
NOTE: Following the sealer manufacturer's instructions.

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.
5. Apply sealer on any area that the replacement part will cover. Smooth
the sealer with a brush is necessary.
4. Finish sealing the engine compartment, the door opening, the truck
gutter and the tailgate gutter. Wipe of the excess sealer.

Damper Housing
55
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.

Fender Bracket
Damper Housing
Front Damper Extension
Front Damper Base
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 Base
Front Damper Housing
Extension
Dashboard Lower
Front Side Frame
Front Side Back Plate
Damper Housing
Front Side Frame
Dashboard Upper, Dashboard Lower and Roof Panel
56
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
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
Floor Cap
Inner Lower Extension
Dashboard Upper
Windshield Lower

57
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Front Floor
Inside Sill
Outer Panel
Side Sill Extension
Inside Sill
Middle Floor Cross-member
Stiffener
Side Sill Extension
Rear Frame
Rear Floor
Wheelhouse
Rear Panel
Rear Floor
Rear Floor
Rear Panel
Jack Up Stiffener
Rear Panel
Outer Panel
Rear Floor
Floor Cap
Front Floor
Floor Cap
Rear Floor
Front Floor
Stiffener
Front Floor
Stiffener
Floor Cap
Front Floor

58
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
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
End Flange
Outer Panel
Fuel Door Adaptor
Outer Panel
Rear Inner
Outer Panel
Rear Inner

Under Floor
59
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
(A): No need seal areas.

(B): No need seal areas.
30 mm (1.2 in.)
Wheelhouse Stiffener
Damper Base
Rear Inner Panel
Inner Panel
Wheelhouse
Outer Panel
Rear Wheelhouse
Upper Arm Bracket
Rear Frame
Damper Base
Rear Frame
Damper Base
Upper Arm Bracket
VIEW (X)
Lower Arm Bracket B
Lower Arm Bracket A
Rear Floor Cross-member
Rear Floor
VIEW (Z)
Lower Arm Bracket B
Lower Arm Bracket A
Rear Floor
Front Floor
Front Floor Centre Crossmember
Index - Soft Chipping Guard Primer Coat
510

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.
2. Air blowing/degreasing
Sectional View of Paint Coats:
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.
Top coat
Intermediate coat
Chipping guard primer

Electrodeposition of primer
Base metal
Use alcohol, wax and grease remover.

3. Making
Use masking tape and paper.
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.
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. Sanding the replacement part.

NOTE:
Do not oversand the edges or corners of the part.

Do not expose base metal.
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.
Use a double action sander and #400 disc sandpaper.

Coating Diagram
511
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
Index - Rust-preventive Treatments
512
General
Anti-rust Agents:
Undercoat:
WARNING
WARNING
Wear goggles or safety glasses to prevent

eye injury.
NOTE:
Mask the exhaust system, oxygen sensors and suspension mount
area to prevent overspread from the undercoat.
Follow the undercoating manufacturer's instructions.
1. Clean the body with wax and grease remover before the undercoat is
sprayed.
2. Apply the undercoat to the front wheelhouse, rear wheelhouse and
undersides of the front floor and rear floor (see page 5-13).
3. Coat the bottom of the fuel tank.
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:
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.
513

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
CROSS-MEMBER
SECTION DD
SECTION EE
1.
2.
3.
4.
5.
Dashboard Lower
Front Floor
Rear Floor
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)
Index - Rust-prevention Treatments
Rust-prevention Treatments
514
Indicates anti-rust agents.

1. HOOD FRAME (inside)
2. HOOD HINGE
3. MIDDLE FLOOR CROSSMEMBER (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 CROSSMEMBER (inside)
19. SUB-FRAME REAR
BRACKET (inside)
20. FRONT SIDE FRAME
(inside)
21. DASHBOARD UPPER
22. FLOOR FRAME (inside)
23. FLOOR CENTRE FRAME
(inside)
Index - Materials and Tools
515
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
For nox-rust 409-20S/solton 1000S
For rustop
For deox #100
For waxoyl
Tube type
Sealing gun
UNDERCOAT
To be applied to under-floor and wheelhouse.
Nox-rust 409-20S
Solton 1000S
or equivalent.
ANTI-RUST AGENT
To be applied to weld joints inside the body panel.
Rustop
Deox #100
Waxoyl
or equivalent.

General
5-18

Damper Housing
5-19
Dashboard Upper, Dashboard Lower and Roof

Panel
5-20
5-21
5-22
Under Floor
5-23

General
5-24
Coating Diagram
5-25
General
5-26
5-27
5-28
Materials and Tools
5-29

General

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.
518
5. Apply sealer on any area that the replacement part will cover. Smooth
the sealer with a brush is necessary.
4. Finish sealing the engine compartment, the door opening, the truck
gutter and the tailgate gutter. Wipe of the excess sealer.

Damper Housing
519
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.

Fender Bracket
Damper Housing
Wheelhouse Upper
Extension
Front Damper Base
Wheelhouse Upper
Extension
Front Damper Base
Steering Joint Cover
Dashboard Lower
Dashboard Lower
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
Extension Lower
Dashboard Lower
Front Side Frame
Damper Housing
Front Side Frame
Dashboard Upper, Dashboard Lower and Roof Panel
520
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Dashboard Upper
Windshield Lower
Windshield Lower
Dashboard Upper
Inner Lower
Dashboard Lower
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
Floor Cap
Side Frame Extension
Inner Lower Extension
Dashboard Upper
Windshield Lower

521
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
Front Floor
Inside Sill
Outer Panel
Side Sill Extension
Inside Sill
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
Stiffener
Rear Floor
Front Floor
Stiffener
Front Floor
Front Floor
Floor Cap

522
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
Outer Panel
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
End Flange
Outer Panel
Fuel Door Adaptor
Outer Panel
Gutter Lower
Outer Panel
Inner Panel

Under Floor
523
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
(A): No need seal areas.

(B): No need seal areas.
30 mm (1.2 in.)
Damper Base
Rear Inner Panel
Inner Panel
Wheelhouse
Outer Panel
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
VIEW (Z)
Lower Arm Bracket B
Lower Arm Bracket A
Rear Floor
Front Floor
Front Floor Centre Crossmember
524

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.
4. Spraying primer surface

One coat deposits 5~7 microns
Top coat
Intermediate coat
Chipping guard primer

Electrodeposition of primer
Base metal
Use alcohol, wax and grease remover.

3. Making
Use a 2-part urethane primer surface and a spray gun.

Mix the primer surface with the additive and solvent, and
Follow the primer surface manufacturer's instructions.
The soft chipping guard primer coat is applied over the E.D.
(Electrostatically Despotised) primer. It is followed by guide
coating and top coating.
The soft chipping guard primer produces a smooth surface
when dry. It should be sprayed so the thickness of the
protective film is 20 microns.
Basic Rules for Repairing a Soft Chipping
Guard Primer Coat:
Soft chipping guard primer coat is then applied to the most

susceptible area (see page 5-25).
Spray the primer surface (2-part urethane primer surfacer) on
the soft chipping guard primer coating areas when you
replaced parts using soft chipping guard primer coat.
WARNING
Wear goggles or safety glasses to

prevent eye injury.
1. Sanding the replacement part.

NOTE:
Do not oversand the edges or cornres of the part.

Do not expose base metal.
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.
Use a double action sander and #400 disc sandpaper.

Coating Diagram
525
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
Index - Rust-preventive Treatments
526
General
Anti-rust Agents:
Undercoat:
WARNING
WARNING
Wear goggles or safety glasses to prevent

eye injury.
NOTE:
Mask the exhaust system, oxygen sensors and suspension mount
area to prevent overspread from the undercoat.
Follow the undercoating manufacturer's instructions.
1. Clean the body with wax and grease remover before the undercoat is
sprayed.
2. Apply the undercoat to the front wheelhouse, rear wheelhouse and
undersides of the front floor and rear floor (see page 5-27).
3. Coat the bottom of the fuel tank.
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:
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.
527

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
CROSS-MEMBER
SECTION DD
SECTION EE
1.
2.
3.
4.
Dashboard Lower
Front Floor
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)
Index - Rust-prevention Treatments
Rust-prevention Treatments
528
Indicates anti-rust agents.

1. HOOD FRAME (inside)
2. HOOD HINGE
3. FLOOR CENTRE FRAME
(inside)
4. MIDDLE FLOOR CROSSMEMBER (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 CROSSMEMBER (inside)
19. SUB-FRAME BRACKET
(inside)
20. FRONT SIDE FRAME
(inside)
21. DASHBOARD FRAME
(inside)
22. FLOOR FRAME (inside)
Index - Materials and Tools
529
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
For rustop
For deox #100
For waxoyl
TOOLS
Cartridge type
Tube type
Sealing gun
UNDERCOAT
To be applied to under-floor and wheelhouse.
Nox-rust 409-20S
Solton 1000S
or equivalent.
ANTI-RUST AGENT
To be applied to weld joints inside the body panel.
Rustop
Deox #100
Waxoyl
or equivalent.
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
6-14
6-15
Undercoating
6-15
6-17
Top Coating
6-18
Glossary
6-19

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.
6-2
4. Read the paint label before opening the container. Cover spilled paint
with sand, or wipe it up at once.
5. If paint gets in your mouth or your skin, rinse or wash thoroughly with
water. If paint gets in your eyes, flush with water and get prompt
medical attention.
2. Wear approved gloves, appropriate clothing when painting. Avoid
contact with skin.
6. After the painting work is finished, wash face and gargle with water.
3. Spray paint only in a well ventilated area.
7. Paint is flammable. Store it in a safe place, and keep it away from

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

To repair paint damage, always use the 2-part acrylic urethane paints designated: polish and bake each of the three coats, as in production, to maintain the original film thickness,
and to assure the same quality as the original finish.
Outline of Factory Painting Process:
Features in Each Work Process

1. Pre-treatment and Electrodeposition
In the pre-treatment process, the entire body is degreased, cleaned and coated with zinc phosphate by dipping.
After the body has been cleaned with pure water, it is placed in an electrolytic bath of soluble primer (Cationic Electrodeposition). This produces a thorough corrosion inhibiting
coating on the inner surface and corners of the body, pillars, sills and panel joints. Chipping primer is then applied to the most susceptible areas (see page 5-11, 5-25).
2. Intermediate coat
The intermediate coat is applied to the prepared surface for further protection against damage.
3. Top Coat
Enamel paint and either polyester or acrylic resin paint are used in the top coat for higher solidity, smoothness, brightness and weather resistance.
3-Coat Pearl (White Pearl) Paint
Paints - Body Paint
Body Paint
6-4
Paint damage can appear in any form. Before making a repair, check the damaged area carefully, and determine the best procedure for repairing the damage. The following shows
you refinishing methods for various types of paint damage or defects.
: Indicates the best method depending on the degree of damage.
Paints - Body Paint
6-5
Body Paint
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.
2. Preparation of metal surface

Remove all corrosion from the damaged area.
Use a product that removes
corrosion.
1.
2.
3.
4.
Top coat
Intermediate coat
Undercoat
Metal surface
Use alcohol, wax and grease
remover.

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

#180~#240 disc paper.
Paints - Body Paint
6-6
Body Paint
Treatment of Metal Surface
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
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.
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.
#80~#120 disc paper.
2. Sand the surface evenly, particularly the area that was filled.
Apply the body filler in several thin coats, without air bubbles.
Apply the body filler over the damaged area with a putty knife
using light pressure.
Use the flexible block and #120~#180 sandpaper.
1. Body Filler
Paints - Body Paint
6-7
Body Paint
Undercoating
Treatment of Metal Surface (cont'd)

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

surfacer and a spray gun.
Mix the primer surfacer with the
additive and solvent, and in the
correct ratio.
Follow the primer surfacer
1. Body Filler
2. Featheredging
Use the alcohol, wax and grease remover.
Also clean and degrease the surfaces where masking tape will be
attached.
1. Primer Surfacer
3. Drying
After spraying primer surfacer, allow for 5~10 minutes of normal drying
time, then force dry it with infrared lamps or other industrial dryer.
NOTE: Follow the primer surfacer manufacturer's instructions for
drying time.
Paints - Body Paint
6-8
Body Paint
Undercoating (cont'd)
4. Polishing
Check that the primer surfacer has dried thoroughly, then sand the
primer surfacer.
#320~#400~#600 disc papers.
1. Masking
intermediate coat.
2. Spraying top coat enamel
Spray the top coat enamel over the surface until the primer surfacer is
fully covered.
NOTE: For the 3-coat pearl paint, spray the colour base over the
surface.
Use the 2-part polyester

urethane top coat enamel and
a spray gun.
Mix the top coat enamel with
the additive and solvent, and in
the correct ratio.
Follow the top coat
Use the alcohol, wax and grease
remover.
Also clean and degrease the surfaces where the masking tape will be
attached.
3. Drying
After spraying top coat enamel or colour base (3-coat pearl paint),
allow 5~10 minutes of normal drying time, then force dry it with infrared
lamps or other industrial dryer.
NOTE: Follow the top coat manufacturer's instructions for drying time.
Paints - Body Paint
6-9
Body Paint
Top Coating
Intermediate Coating (cont'd)
4. Polishing
Check that the top coat enamel has dried thoroughly, then sand the
top coat enamel.
#600~#800 disc papers.
NOTE: Be careful not to polish down to the primer surfacer.
1. Masking
top coat.
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.

spray gun.
the correct ratio.
Follow the top coat
When the painting repair (gradation) is almost done, polish the area
that will be top coated.
Use the #2000 sandpaper and
compound.
Use alcohol, wax and grease
remover.
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.
Paints - Body Paint
Body Paint
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.
610
4. After buffing, remove the masking paper and tape, and thoroughly
wash the entire vehicle.
NOTE: Follow the top coat manufacturer's instructions for drying times.
3. Polishing/buffing
Check that the clear coat has dried thoroughly.
The clear coat is cooled.
1. Any adhesion or roughness on the top coat should be wet sanded
and repaired.
Use the #1200~#2000 and crystal block.
2. Polish any roughness caused by sanding.

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

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

compound, then ultra fine compound.
Paints - Plastic Parts Paint
611
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
Name
Heat Resistance
Temperature C (
F)
AAS
Acrylonitrile acrylic styrene
80
(176)
A small amount of alcohol is acceptable

for a short time. (Degreasing)
An organic solvent such as gasoline is not recommended.
styrene
80
(176)

styrene
80
(176)

Acrylonitrile / ethylene
propylene diene rubber /
styrene
80
(176)

Acrylonitrile styrene
acrylate
80
(176)

Cellulose acetate butylate
80
(176)

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)
Solvent is not recommended.
PC
Polycarbonate plastics
120
(248)

for a short time.
Brake fluid, and wax and grease remover not

recommended.
PE
Polyethylene
80
(176)
PF
Phenol formaldehyde
80
(176)


alcohol, is not recommended.
PMMA
Polymethyl methacrylate
80
(176)


alcohol, is not recommended. Wash remover off with
water thoroughly.
POM
Polyoxymethylene
polyacetal
100
(212)
ABS
AES
A/EPDM/S
ASA
CAB
E/VAC
Solvent Resistance
Note
An aroma product is not recommended.


612
Plastic Parts Paint
Features of Plastic Material (cont'd)
Standard
Symbol
PP
Name
Heat Resistance
Temperature C (
F)
Solvent Resistance
Note
Polypropylene
80
(176)
Polyphenylene oxide
100
(212)

for a short time.

PS
Polystyrene
60
(140)

for a short time.

PUR
Polyurethane
80
(176)


PVC
Polyvinylchloride
80
(176)

(Degreasing)

SAN
Styrene acrylonitrile
80
(176)
Wiping alcohol off in a short time can be

allowed.

SMC
Sheet moulding
compound
180
(356)
TPE
Thermoplastic polyester
elastomer
80
(176)
Alcohol is acceptable and wiping gasoline Soaking with an organic solvent such as gasoline and
for a short time can be allowed.
alcohol is not recommended. Wash remover off with
(Degreasing)
water thoroughly.
TPS
Thermoplastic styrene
elastomer
80
(176)

(Degreasing)
TPO
Thermoplastic olefin /
elastomer
80
(176)
Alcohol is acceptable and wiping gasoline Soaking with an organic solvent such as gasoline and
for a short time can be allowed.
(Degreasing)
water thoroughly.
TPU
Thermoplastic /
urethane / elastomer
80
(176)

(Degreasing)

water thoroughly.
UP
Polyester
110
(230)
Alkali is not recommended.
PPO
(PPE)

water thoroughly.
Plastic Parts Paint
Use of the Repair Material (reference)
NOTE: Follow the materials manufacturer's instructions.
613
Mixing Ratio:
The use of a special polyester putty for PP bumper is described here:

1. Filler
Mixing Ratio:
4. Intermediate coat and top coat

Use the 2-part polyester urethane top coat.
Top coat is also used for an intermediate coat.
Mixing Ratio:
NOTE: Be sure to mix the correct amount of the hardener and softener.
2. Sanding filler
Spray bumper primer (see page 6-19) on the area where the PP
material was used.
3. Primer surfacer
The primer surfacer is used to protect the PP resin surface and fill
cavities or flaws before the intermediate coat and top coat.
Use the 2-component type primer surfacer (grey).
NOTE: Use a spray gun to apply the paint. Do not use a brush.
Drying time:
Air dry 20C (68F)
6~10 minutes Touch dry
Almost hardened
12~24 hours
Thoroughly hardened
96 hours
Force dry the intermediate coat and top coat.

NOTE: Mix only an amount that can be used before it hardens.
Plastic Parts Paint
614
The following shows refinishing methods to various types of paint damage or defects.
Be careful not to deform and damage the parts when force drying.
A:
Hole/Deep Gouge
B:
Deep Abrasion 3 mm (0.12 in.) approx.
C:
Shallow Scratch 1 mm (0.04 in.) approx.
615
Plastic Parts Paint
1. Sanding
Sand the damage area flat and smooth.
Undercoating
1. Spraying primer
Primer is used to fill cavities in the putty and primer surfacer.
Shallow Scratch:
Use a flexible block and

#240~#400~#600 sandpaper.
Spray primer on the exposed area.

Spray the 2~3 coats of primer on 2~3 coats over the area you
applied putty.
Apply primer to the back of the bumper if the damage is a tear or
hole.
Bumper primer (Reference)

Warm the primer if the ambient
temperature is below 10C (50
F).
Follow the bumper primer
Use the spray gun and brush.
Hole/Deep Gouge:
Cut out and make any torn or burred area flat.
Use a knife, flexible block and
#180~#240 sandpapers.
Clean the damaged area thoroughly.
Use alcohol, and wax and grease
remover.
Drying
NOTE: Take care not to let the heat lamp deform the bumper during
the drying process.
Dry the bumper primer thoroughly with an infrared dryer or other
suitable method.
Drying Time:
Air dry 20C (68 20 minutes
F)
Force dry 60C
(140F)
10 minutes
616
Plastic Parts Paint
Undercoating (cont'd)
2. Filing/Sanding
Apply putty to repair any holes or deep gouges.
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
Drying
1. Aluminium Tape
2. Outside
3. Sanding
Sand the surface evenly, particularly at the area where the PP material
and putty meet.
#240~#400~#600 sandpaper.
the drying process.
6. Sanding
After drying, wet sand the area of the intermediate coat.
Use the #600 sandpaper.
NOTE: Do not use less than #600.
1. Featheredging
Use alcohol, a tack cloth, and wax
and grease remover.

and grease remover.
Also clean and degrease the surfaces where the masking tape will be
attached.
Plastic Parts Paint

NOTE: You must do this procedure on the PP parts of the bumper and
side sill panel.
1. Masking
Mask the area surrounding the damage to prevent overspray from the
intermediate coat.
2. Spraying top coat enamel
Spray the top coat enamel over the surface until the primer surfacer
is fully covered.
Spray 2~3 coats to get 15~25 microns of thickness.
617
3. Polishing
Check the top coat enamel has dried thoroughly, then sand the top
coat enamel.
#600~#800~#1000 sandpapers.
NOTE: Be careful not to sand down to the primer surfacer.

a spray gun.
the correct ratio.
Follow the top coat
When the painting repair is almost complete, polish the top coat.
Use #1500 sandpaper and
compound.
Drying
the drying process.
After spraying the top coat enamel, allow for 5~10 minutes of normal
drying, then force dry it with infrared lamps or other industrial dryer.
1.
2.
3.
4.
5.
Material
Putty
Intermediate Coat
Sanding
Paint Coat
and grease remover.
Clean and degrease the surfaces where the masking tape will be
attached.
Plastic Parts Paint

Top Coating
1. Masking
Mask the area surrounding the damage to prevent overspray of the top coat
2. Spraying top coat enamel / clear coat
Spray 2~3 coats in double coat until the intermediate coat is fully covered.
NOTE:
618
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. Wet sands with #2000 sandpaper and soapy water.
Do not cover the surface with one heavy coat.

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. Remove moisture using compressed air.

3. Finish using fine compound and very fine compound. Do not
polish with an electric polisher.
NOTE: Polish lightly.
Drying
4. Check the finished area at an angle, and make sure there are
no polishing marks.
5. Polish with ultra fine compound and a buffing sponge.
NOTE: Take care not to let the heat lamp deform the bumper during the drying
process.
After spraying the clear coat, allow for 5~10 minutes drying time before you
force dry it with infrared lamps or other industrial dryer.
3. Polishing/buffing
Check that the clear coat has dried thoroughly.
Wet sand to remove any imperfections.
Use a flexible block soap and #2000 sandpaper.
6. Wax the finished area.
Paints - Glossary
619
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.
Paints - Glossary
620
Glossary
Cont'd
Lacquer
A type of pain that uses cellulose nitrate or other chemicals and dries by evaporation of its solvent agent.
Meramine resin
Used as component for aminoalkyd resin paint and heat-hardening acrylic resin paint.
Metallic-base paint
Paint with aluminium power for metallic tone.
Mist coat
Painting for fade-in sections. A small amount of paint may be dissolved with slow-evaporating thinner, or thinner alone may
be applied with low pressure.
150-200kPa (1.5-2.0kgf/cm, 21.3-28.4 psi)
Mixing scale
Colour mixing device.
Overlap
Blending of spray patterns.
Overspray
Spraying other than the area that needs painting.
Paddle
A tool to mix paint.
Paint dust
Dust of paint formed by spraying.
Paper dispenser
A paper posting device (masker) that combines tape and paper.
Scrapes
Traces of scratches.
Scuffing
Particles on the painted surface are lightly polished with fine emery paper (#600 or over).
Set (setting)
Evaporation time of solvent in the paint, before drying the layer forcefully or by banking. (May be considered the same as
flash-off time).
Single coat
Application of paint in single layer.
Spot paint
Painting of small section, such as for touch-up.
Undercoat
Undercoat paint (such as primer and surface).

May be applied to lower section of car for moist prevention and rust proofing.
Paints - Glossary
621
Glossary
cont'd
Wet coat
Paint is applied with an excess of solvent, thereby producing a painted surface that's smooth, glossy and has a wet look.
Wet film
Paint which has not dried completely.
Wet on wet
Application of the next coat of paint before the previous layer has dried completely.
Wool bonnet
Wood grinder for compound polishing.
Introduction
Introduction
This manual covers the repairs of 2001 model series CIVIC 3-door that
have been involved in an accident and it describes the work related to the
replacement of damage body parts.
Please read through these instructions and familiarise yourself with them
before actually using this manual.
NOTE: Refer to the 2001 CIVIC 4-door/CIVIC 5-door Body Repair Manual
(P/N. 62S5A30), CIVIC Shop Manual (P/N. 62S5A00) and CIVIC Shop
Manual supplement (P/N. 62S5A20) on this CD for specifications, wire
harness locations, safety stand support points, etc.
1 General Info
3 *Replacement
5 Rust Prevention
Sections with an * include SRS
components; special caution is
required when servicing.
Special Information
WARNING
Indicates a strong possibility of severe

personal injury or death if instructions are
not followed.
CAUTION

followed.
CAUTION
Detailed descriptions of standard workshop

operations are not included. Please note
that this manual does contain warnings and
cautions against some specific service
methods which could cause PERSONAL
INJURY, damage a vehicle, or make it
unsafe. Please understand that these
warnings cannot cover all conceivable ways
in which service, whether or not
recommended by Honda, might be done or of
the possible hazardous consequences of
each conceivable way, nor could Honda
investigate all such ways. Anyone using
service procedures or tools, whether or not
recommended by Honda, must satisfy
themselves thoroughly that neither personal
safety or vehicle safety will be jeopardised.
All information contained in this manual is based on the latest product information
available at the time of printing. We reserve the right to make changes at any time
without notice. No part of this publication may be reproduced, stored in retrieval
system, or transmitted, in any form by an means, electronic, mechanical,
photocopying, recording or otherwise, without the prior written permission of the
publisher. This includes text, figures and tables.
HONDA MOTOR CO., LTD.
Fist Edition 3/2001 40 pages
All Rights Reserved
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1-1
General Information
1-2
1-3
Body Construction
1-4
1-5
1-7
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1-2
General Information
1-2
This model has an SRS which includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above the glove box, seat belt tensions in the front seat
1. The SRS unit is located under the dashboard and the side impact sensors are located in each side sill. The front sensors are located behind the right and left end of the front
bumper. Avoid any strong Impact with a hammer or other tools when repairing the front side frame, the lower part of the dashboard and the side sill. Do not apply heat to these
areas with a torch, etc.
2. Take extra care when painting or doing body work in the area below the centre pillar. Avoid direct exposure of the seat belt retractor and tensioner to heat guns, welding or
spraying equipment.
3. SRS electrical wiring harnesses and connectors are identified with yellow colour coding. Care should be taken not to damage the harness when repairing this area.
4. Do not apply heat of more than 100C (212F) when drying painted surfaces anywhere around the locations of SRS components.
NOTE: Refer to the Restraints section of the Shop Manual for after deployment procedures, and removal and replacement of SRS related components.
1. FRONT SENSOR
2. DRIVER'S AIRBAG
ASSEMBLY
3. FRONT SENSOR
4. CABLE REEL
AIRBAG
6. SIDE AIRBAG
10. SIDE AIRBAG
11. SRS UNIT
12. UNDER-DASH FUSE/RELAY
BOX
1-3
1-3
General Information

Unit: mm (in.)

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

Camber
-045' 45'
Total toe
IN 2 3 (0.08 0.12)
1-4
1-4
General Information
Body Construction
Sp: Steel plate
Hss: High strength steel plate
No.
Zn: Zinc-plated
Part Name
No.
Part Name
Hood (Hss, Zn)
23
Centre Pillar Stiffener Lower (Sp)
24
Door (Hss, Zn)
25
Front Pillar Inner Lower (Hss, Zn)
Tailgate (Sp, Zn)
26
Front Pillar Inner Upper (Hss)
27
Bulkhead Side Stay (Sp, Zn)
28
29
Roof Panel (Sp)
30
Rear Inner Pillar (Sp)
31
10
32
11
Wheelhouse Upper Extension (Hss, Zn)
33
12
34
13
35
14
36
15
37
Middle Floor Gusset (Sp)
16
38
17
39
Rear Floor (Sp, Zn)
18
Rear Pillar Gutter Lower (Sp, Zn)
40
Rear Panel (Sp, Zn)
19
Rear Pillar Gutter Upper (Sp, Zn)
41
Rear Gutter Lower Stiffener (Sp)
20
Front Pillar Lower Stiffener (Hss)
42
21
43
22
Centre Pillar Stiffener upper (Sp)
44
1-5
1-5
General Information

Paint Code Colour Name NH-623M Satin

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

1. DOOR MIRROR BASE
2. DOOR MIRROR
Gloss 20)
Gloss 30)
4. CORNER TRIM
5. ROOF MOULDING
6. TAILGATE SPOILER
Body colour
7. LICENSE TRIM
Gloss 20)
8. REAR BUMPER
Body Colour
9. DOOR MOULDING
10. REAR DOOR SASH TRIM
11. FRONT BUMPER
Body Colour
12. GRILL
1-7
General Information
1-7
Example:
1. FRONT WINDSHIELD
MOULDING
propylene diene rubber
styrene (A/EPDM/S)
Polycarbonate (PC)
3. DOOR MIRROR
Unpainted: Acrylonitrile
styrene acrylate (ASA)
4. TAILGATE SPOILER
Acrylonitrile butadiene styrene
(ABS)
5. LICENSE TRIM
Unpainted: Acrylontirile
ethylene styrene (AES)
6. REAR BUMPER
Polypropylene (PP)
7. DOOR SASH TRIM
Acrylontrile styrene acrylate
(ASA)
8. ROOF MOULDING
9. FRONT BUMPER
Polypropylene (PP)
3-2
3-2
3-3
3-3
Removal

Check the centre pillar stiffener lower and side sill reinforcement position and check for damage. If necessary, replace the side sill reinforcement.
Replace the driver's side sill reinforcement as an assembly because of the way the stiffener is attached inside the side sill reinforcement.
1. OUTER PANEL
2. SIDE SILL REINFORCEMENT
3. REINFORCEMENT
STIFFENER (Driver side)
4. INSIDE SILL
8. VIEW (Z)
9. CENTRE PILLAR STIFFENER
LOWER
10. WHEEL ARCH EXTENSION
12. OUTER PANEL
13. FRONT PILLAR LOWER
STIFFENER
3-4
3-4
Installation
1. Cut and set the new side sill reinforcement into position and tack weld the clamped
position.
2. Cut the repair part (outer panel) and set it into position. Clamp the repair part and
check the body dimensions (see section 4).
3. Temporarily install the door and front fender and check for differences in level and
clearance. Make sure the body lines flow smoothly.
4. Remove the repair part and weld the center pillar stiffener, lower side sill
reinforcement and front pillar lower stiffener (driver's side).
Driver's side
Passenger's side
When replacing the side sill reinforcement, cut the new side sill reinforcement so it
overlaps the body side reinforcement by 20 mm (1.8 in.) and fillet weld it.
1. Fillet welding Overlap

20 mm (1.8 in.)
VIEW (Z)
5. Clamp the repair part and recheck the clearance and alignment of the door and
front fender.
Attach a patch at the cut section of the front pillar (driver's side), side sill
(passenger's side) and wheel arch and plug weld them.
Driver's side
1.
2.
3.
4.
5.
PATCH
Butt welding
Butt welding
PATCH
OUTER PANEL
Passenger's side:
1. PATCH
2. Butt welding
3. OUTER PANEL
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3-5
Roof Panel
3-5
Without roof panel:
3-6
3-6
3-7
3-7
Removal
Cut and pry off the rear side outer panel.

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

Insulator: P/N. 774416-SF1-000
Adhesive: Cemedine 366, or equivalent.
3. Set the new repair part (outer panel) and rear pillar gutter lower into position and
clamp them.
Remove the repair part (outer panel) and weld the centre pillar stiffener lower.

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

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

2. MIDDLE FLOOR GUSSET
3-9
3-9
6. Do the main welding:

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

1.
2.
3.
4.
5.
6.
7.
8.
Butt welding
PATCH
Butt welding
PATCH
Butt welding
NEW OUTER PANEL
PATCH
NEW REAR GUTTER LOWER
3-10
Rear Panel
310
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3-11
Rear Panel
Removal

Check the rear pillar gutter lower position and check it for damage.
If necessary, replace the rear pillar gutter lower (see page 3-7)
311
Installation
1. Set the new rear panel and check the body dimensions (see section 4).
3. Temporarily install the tailgate, taillight, rear bumper and check for differences in
level and clearance. Check for operation of the tailgate.
4. Do the main welding.
1. NEW REAR PANEL
1.
2.
3.
4.
5.
6.
REAR PANEL
REAR GUTTER LOWER STIFFENER
REAR PANEL
REAR FLOOR
JACK-UP STIFFENER
REAR PILLAR GUTTER LOWER
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4-1

Engine/Transmission Mount Positions and Passenger Compartment
4-2

4-3
Frame Repair Chart

Top View
4-4
Side View
4-6
4-8
4-2
4-2
Unit: mm (in.)
Unit: mm (in.)
AT/MT:
Honda Multi Matic:
4-3
4-3
4-4
Frame Repair Chart
4-4
Top View
Unit: mm (in.)
: Inner diameter
For sub-frame 15 (0.59)
Damper centre 78 (3.07)
b1
For engine mount 13 (0.51)
For damper mount 11.5 (0.45)
b2
b3
c1
For transmission mount 15 (0.59)
c2
Locate hole 25 (0.98)
c3
4-5
4-5
Frame Repair Chart

Top View (cont'd)
For upper arm bracket center 15 (0.59)
For trailing arm 13 (0.51)
u1, u2
For upper arm 13 (0.51)
Trailing arm centre
Rear damper center 73 x 68 (Slot)
4-6
4-6
Frame Repair Chart

Side View
Unit: mm (in.)
: Inner diameter
Damper centre 78 (3.07)
b1
b2
b3
c1
c2
c3
4-7
4-7
Frame Repair Chart

Side View (cont'd)
For upper arm bracket center 15 (0.59)
u1, u2
Trailing arm centre
Rear damper center 73 x 68 (Slot)
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This manual covers the repairs of 2001 model series CIVIC 2-door that
have been involved in an accident, and it describes the work related to
the replacement of damage body parts.
1 General Info
Please read through these instructions and familiarise yourself with

them before actually using this manual.
5 Rust Prevention
NOTE: Refer to the 2001 CIVIC 4-door/CIVIC 5-door Body Repair

Manual (P/N. 62S5A30), CIVIC Shop Manual (P/N. 62S5A00) and
CIVIC Shop Manual supplement (P/N. 62S5A20) for specifications,
wire harness locations, safety stand support points, etc.
3 *Replacement
Sections with * include SRS
components; special caution is
required when servicing.
Special Information
WARNING
Indicates a strong possibility of severe

personal Injury or death if instructions are not
followed.
CAUTION

followed.
CAUTION
Detailed descriptions of standard workshop

operations are not included. Please note that
this manual does contain warnings and
cautions against some specific service
methods which could cause PERSONAL
INJURY, damage a vehicle, or make it unsafe.
Please understand that these warnings cannot
cover all conceivable ways in which service,
whether or not recommended by Honda, might
be done or of the possible hazardous
consequences of each conceivable way, nor
could Honda investigate all such ways.
Anyone using service procedures or tools,
whether or not recommended by Honda, must
satisfy himself thoroughly that neither
personal safety or vehicle safety will be
jeopardised.
All information contained in this manual is based on the latest product
information available at the time of printing. We reserve the right to make
changes at any time without notice. No part of this publication may be
reproduced, stored in retrieval system, or transmitted, in any form by an
means, electronic, mechanical, photocopying, recording, or otherwise,
without the prior written permission of the publisher. This included text,
figures and tables.
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HONDA MOTOR CO., LTD.

First Edition 10/2000
32 pages
All Rights Reserved
General Information - General Information
General Information
1-2
1-3
Construction
1-4
1-5
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General Information
1-2
This model has an SRS which includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above the glove box, seat belt tensioners in the front seat
1. The SRS unit (including the safing sensor and the impact sensor) is located under the dashboard and the side impact sensors are located in each side sill. The front impact
sensors are located behind the right and left end of the front bumper. Avoid any strong impact with a hammer or other tools when repairing the front side frame, the lower part of
the dashboard and the side sill. Do not apply heat to these areas with a torch, etc.
2. Take extra care when painting or doing body work in the area below the centre pillar. Avoid direct exposure of the seat belt retractor and tensioner to heat guns, welding or
spraying equipment.
3. SRS electrical wiring harnesses and connectors are identified with yellow colour coding. Care should be taken not to damage the harness when repairing this area.
4. Do not apply heat of more than 100C (212F) when drying painted surfaces anywhere around the locations of SRS components.
NOTE: Refer to the Restraints section of the Shop Manual for after deployment procedures, and removal and replacement of SRS related components.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
FRONT IMPACT SENSOR

DRIVER'S AIRBAG ASSEMBLY
FRONT IMPACT SENSOR
CABLE REEL
FRONT PASSENGER'S AIRBAG ASSEMBLY
SIDE AIRBAG
SEAT BELT TENSIONERS
SIDE IMPACT SENSOR
SIDE IMPACT SENSOR
SIDE AIRBAG
SRS UNIT
12. UNDER-DASH FUSE/RELAY BOX
General Information
1-3

Unit : mm(in.)

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

Camber
-045' 45'
Total toe
2 +2 -1 (1/16 +1/16 -1/32)
1-4
General Information
Construction
Sp: Steel plate / Hss: High strength steel plate / Zn: Zinc-plating
No.
Part Name
No.
Part Name
(1)
Hood (Hss, Zn)
(22)
(2)
(23)
(3)
Door (Hss, Zn)
(24)
(4)
Trunk Lid (Sp, Zn)
(25)
(5)
(26)
Roof Panel (Sp)
(6)
Bulkhead Side Stay (Sp, Zn)
(27)
(7)
(28)
(8)
(29)
(9)
(30)
(10)
(31)
(11)
(32)
(12)
(33)
Middle Floor Gusset (Hss)
(13)
(34)
Rear parcel Shelf (Sp)
(14)
(35)
(15)
(36)
Rear Floor (Sp, Zn)
(16)
(37)
Rear Panel (Sp, Zn)
(17)
(38)
Rear Panel Side Stiffener (Sp)
(18)
Rear Combination Adapter (Sp, Zn)
(39)
(19)
(40)
(20)
(41)
(21)
1-5
General Information

Paint Code Colour
Name
KE
NH-578
NH-623M Stain
Taffeta White
Silver M.
B-92P Night
Hawk Black P.
B-96P Eternal
Blue P.
G-95P Clover
Green P.
R-513 Rallye
Red
Y-61P Inca P.
YR-525M
Titanium M.
SE
SE EXEC
LS
LSG
ES
ESG
KK
EX
KY
VTi
KX
EX
KB
LS
ES
KG
NOTE: In case of vehicles painted with NH-578, NH-623M, Y-61P and YR-525M and apply black (NH-70 Gloss 20) to the lower surface of the side sill (A) section.
1. FRONT BUMPER
Body colour
2. FRONT GRILLE
Body colour
3. HOOD MOULDING
Body colour
4. DOOR MIRROR
Body colour or black (NH-72 Gloss 30)
6. SIDE SILL
7. ROOF MOULDING
8. LICENSE PLATE TRIM
9. REAR BUMPER
Body colour
10. DOOR MOULDING
11. DOOR SASH TRIM
Replacement - Replacement
Replacement
3-2
Removal
3-3
Installation
3-4
Roof Panel
3-5

3-6
Removal
3-7
Installation
3-8
Rear Panel
3-9
Items marked with and asterisk (*) include SRS components; special caution is required when servicing.
Replacement - Side Sill Outer Panel
32
a.
b.
c.
d.
e.
VIEW (Y)
Centre pillar stiffener
Outer panel stiffener
Side sill reinforcement
VIEW (Z)
3-3
Removal

Check the centre pillar stiffener and side sill reinforcement position and check for damage. If necessary replace the side sill reinforcement.
Replace the driver's side sill reinforcement as an assembly because of the way the stiffener is attached inside the side sill reinforcement.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
OUTER PANEL
REINFORCEMENT STIFFENER (Driver side)
INSIDE SILL
REAR INNER PANEL
VIEW (Z)
CENTRE PILLAR STIFFENER
OUTER PANEL STIFFENER
WHEEL ARCH EXTENSION
OUTER PANEL
3-4
Installation
1. Cut and set the new side sill reinforcement into position, and tack weld the
clamped position.
2. Cut the repaired part (outer panel) and set it into position. Clamp the repair part
and check the body dimensions (see section 4).
3. Temporarily install the door and front fender and check for differences in level and
clearance. Make sure the body lines flow smoothly.
4. Remove the repaired part and weld the centre pillar stiffener, side sill reinforcement
and front pillar lower stiffener (driver's side).
Driver's side
Passenger's side
When replacing the side sill reinforcement, cut the new side sill reinforcement so it
overlaps the body side reinforcement by 20 mm (1.8 in.), and fillet weld it.
1. Fillet welding
Overlap
20 mm (1.8 in.)
VIEW (Z)
5. Clamp the repair part and recheck the clearance and alignment of the door and
front fender.
Attach a patch at the cut section of the front pillar (driver's side) center pillar and
wheel arch and plug weld them.
Driver's side

1.
2.
3.
4.
5.
PATCH
Butt welding
Butt welding
PATCH
OUTER PANEL
Passenger's side:
1. Fillet welding
Overlap
30 mm (1.2 in.)
2. OUTER PANEL
Roof Panel
Roof Panel
3-5
Without roof panel:

a.
b.
c.
d.
Outer panel
Roof panel
Front roof rail
Rear roof rail
Replacement - Rear Side Outer Panel
36
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
Rear parcel shelf

Rear damper stiffener
Rear gutter
Inner panel
Rear panel
Rear Combination adaptor
Rear gutter
Outer panel stiffener
VIEW (Z)
Wheel arch extension
Side sill reinforcement
Centre pillar stiffener
3-7
Removal
Cut and pry off the rear side outer panel.

Check the rear combination adaptor position, and check it for damage. If necessary, replace the rear combination adopter and rear gutter as an assembly.
Check the centre pillar stiffener position and check it for damage. If necessary, cut and replace it.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
CENTRE PILLAR STIFFENER

INNER PANEL
REAR DAMPER STIFFENER
PARCEL SHELF
REAR COMBINATION ADAPTOR
REAR GUTTER
REAR PANEL
REAR COMBINATION ADAPTOR
OUTER PANEL
REAR FLOOR
3-8
Installation
1. Cut and set the new centre pillar stiffener into position, and install the middle floor
gusset.
8. Temporarily install the door, rear window, trunk lid and rear bumper, and check for
differences in level and clearance.
9. Do the main welding:
Attach a patch at the cut section of the rear pillar and plug weld it.
1. MIDDLE FLOOR GUSSET

2. Set the new repaired part (outer panel) and rear combination adaptor into position
and clamp them.
Remove the repaired part (outer panel) and weld the centre pillar stiffener.
1.
2.
3.
4.
5.
6.
7.
8.
OUTER PANEL
PARCEL SHELF
REAR GUTTER
Butt welding
PATCH
Butt welding
NEW OUTER PANEL
Fillet welding
Overlap
30 mm (1.2 in.)
9. PATCH
Weld the rear combination adaptor and rear panel.
1. Fillet welding
Overlap
20 mm (0.8 in.)
7. Tack weld the outer panel and rear combination adaptor.
Rear Panel
Rear Panel
39
a.
b.
c.
d.
e.

Passenger's compartment
Rear panel
Jack-up stiffener
4-plate welding
Body Dimensional Drawings - Body Dimensional Drawings

4-2
4-3
4-2
Unit: mm (in.)
1. K, k
Front Seat Rear Side Bracket Point 7 (0.3)
2. L, l
Rear Damper Mount Hole 11 (0.43)
4-3
Unit: mm (in.)
1. A
2. B, C
3. D, E, F, G
Rear Window and Trunk Lid Openings:

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

2. Wipe off any excess spot sealer with thinner. After the primer is sprayed, sealer will
fill in the area where spot sealer was wiped off.
3. Make sure you can see the sealant when the sealed part is in its proper location.
Refer to page 5-3 of this manual, refer to the 2001 CIVIC 4-door/CIVIC 5-door
Body Repair Manual (P/N. 62S5A30) on this CD for the items not shown in this
manual.
5. Apply sealer on any area that the replacement part will cover. Smooth the sealer
with a brush is necessary.
4. Finish sealing the engine compartment, the door opening, the truck gutter and the
tailgate gutter. Wipe of the excess sealer.
Rust Prevention - Cross Section of Body and Sealants

53
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Rear gutter
Outer Panel
Outer Panel
Parcel Shelf
Outer Panel
Rear gutter
Rear panel
Outer Panel
Rear gutter extension
Rear gutter
Gutter extension
Rear gutter
Quarter lower extension
Outer panel

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How to Use This Manual

How to Use This Manual

Indicates a strong possibility of server

Indicates a possibility of personal injury or

Detailed description of standard workshop

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How to Use This Manual

192 pages HONDA MOTOR CO., LTD.

All Rights Reserved

Service Publication Office

Sections with * include SRS components; Special Caution is required

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5-door General Information

4-door General Information

4-door General Information

Identification Number Locations

Lift and Support Points

Body Specifications/Wheel Alignment

Exterior Parts Removal/Installation

Door and Bumper Reinforcement Beams

Zinc-plated Steel Plate Repair

Colour Chart Paint Specifications

Types and Materials of Exterior Plastic Parts

Index - General Information

Supplemental Restraint System (SRS)

Index - General Information

Identification Number Locations

Index - General Information

Lift and Support Points

1. FRONT SUPPORT POINT

FRONT JACKING BRACKET

Index - General Information

Body Specifications/Wheel Alignment

*1: Eurpoean model

Front Wheel Alignment:

Wheel turning angle

4000'2 (D15B engine)

3100' (D15B engine: Reference)

Rear Wheel Alignment:

Index - General Information

Exterior Parts Removal/Installation

Index - General Information

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

Hood (Hss, Zn)

Centre Pillar Stiffener (Sp)

Front Fender (Sp, Zn)

Side Sill Reinforcement (Hss, Zn)

Front Door (Hss, Zn)

Front Pillar Inner Lower (Hss)

Rear Door (Hss, Zn)

Front Pillar Inner Upper (Hss, Zn)

Trunk Lid (Sp, Zn)

Centre Inner Pillar (Hss, Zn)

Bulkhead Side (Sp, Zn)

Roof Side Rail (Hss)

Bulkhead Side Stray (Sp, Zn)

Roof Panel (Sp)

Bulkhead Upper Frame (Sp, Zn)

Rear Inner Panel (Sp, Zn)

Front Lower Cross-member (Hss, Zn)

Wheel Arch Extension (Sp, Zn)

Wheelhouse Upper Member (Sp)

Rear Wheelhouse (Sp, Zn)

Front Wheelhouse (Sp, Zn)