Honda 2013 Odyssey, 2015 Odyssey Body Repair Manual

2011–2015 Odyssey Body Repair Manual
INTRODUCTION
How to Use This Manual
This manual covers the repairs of the 2011––-2015 model-series Odyssey that has been involved
in a collision, and it describes the work related to the replacement of damaged body parts.
Please read through these instructions and familiarize yourself with them before actually
using this manual.
1
General
Information
2
Paint
Information
3
*Replacement
4
Body Dimensional
Drawings
5
Rust
Prevention
NOTE: Refer to the appropriate Odyssey Service Manual for specifications, wire harness
locations, safety stand support points, etc.
Special Information
WARNING
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
CAUTION
You CAN be HURT if you don’t follow instructions.
NOTE: Gives helpful information.
CAUTION
Detailed descriptions of standard workshop procedures, safety principles and service 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 jeopardized.
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 any 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.
Customer Service Technology
Development Division
General Safety
Precautions
Reference
Sections with an * include SRS
components; special caution is
required when servicing.
First Edition 09/2010
All Rights Reserved
A Few Words About Safety
Service Information
The repair information contained in this manual is
intended for use by qualified, professional technicians.
Attempting repairs without the proper training, tools,
and equipment could cause injury to you or others. It
could also damage the vehicle or create an unsafe
condition.
This manual describes the proper methods and
procedures for doing repairs. Some procedures require
the use of specially designed tools and dedicated
equipment. Any person who intends to use a
replacement part, a repair procedure, or a tool that is not
recommended by Honda, must determine the risks to
their personal safety and the safe operation of the
vehicle.
If you need to replace a part, use Honda parts with the
correct part number, or an equivalent part. We strongly
recommend that you do not use replacement parts of
inferior quality.
FOR YOUR CUSTOMER'S SAFETY
Proper repair is essential to the customer's safety and
the reliability of the vehicle. Any error or oversight while
repairing a vehicle can result in faulty operation,
damage to the vehicle, or injury to others.
Improper repairs can create an unsafe condition that
can cause your customer or others to be seriously
hurt or killed.
Follow the procedures and precautions in this manual
and other service materials carefully.
FOR YOUR SAFETY
Because this manual is intended for the professional
service technician, we do not provide warnings about
many basic shop safety practices (for example, hot
part - wear gloves). If you have not received shop safety
training or do not feel confident about your knowledge
of safe repairing practices, we recommend that you do
not attempt to do the procedures described in this
manual.
Failure to properly follow instructions and
precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this manual
carefully.
Some of the most important general service safety
precautions are given below. However, we cannot warn
you of every conceivable hazard that can arise in doing
repair procedures. Only you can decide whether or not
you should do a given task.
IMPORTANT SAFETY PRECAUTIONS
●
Make sure you have a clear understanding of all basic
shop safety practices and that you are wearing
appropriate clothing and using safety equipment.
When doing any repair task, follow these precautions:
– Read all of the instructions before you begin, and
make sure you have the tools, the replacement or
repair parts, and the skills required to do the tasks
safely and completely.
– Protect your eyes by using proper safety glasses,
goggles, or face shields any time you hammer, drill,
grind, or work around pressurized air or liquids and
springs or other stored-energy components. If there
is any doubt, put on eye protection.
– Use other protective wear when necessary, for
example, gloves or safety shoes. Handling hot or
sharp parts can cause severe burns or cuts. Before
you grab something that looks like it can hurt you,
stop and put on gloves.
– Protect yourself and others whenever you have the
vehicle up in the air. Any time you raise the vehicle,
either with a lift or a jack, make sure that it is always
securely supported. Use jack stands.
– Protect yourself by wearing an approved welding
helmet, gloves, and safety shoes any time you are
welding. Protect yourself from burns from hot parts;
allow the parts to cool before working in that area.
– Protect yourself from paints and harmful chemicals
by wearing an approved respirator, eye protection,
and gloves whenever you are painting. Spray paint
only in an approved paint booth that is well
ventilated.
Introduction
Special Information
How to Use This Manual
This m anual covers the repairs of a 2011-15 m odel-series Odyssey that has been involved in a collision, and it
describes the work related to the replacem ent of dam aged body parts.
Please read through these instructions and familiarize yourself with them before actually using this manual.
NOTE: Refer to the appropriate Odyssey Service Manual for specifications, wire harness locations, safety stand
support points, etc.
Special Information
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
NOTE: Gives helpful information.
Detailed descriptions of standard workshop procedures, safety principles, and service 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 jeopardized.
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 a
retrieval system, or transmitted, in any form, by any means, electronic, mechanical, photocopying, recording, or
otherwise, without the prior written permission of the publisher. This includes text, images, and tables.
Honda Motor Co., Ltd.
Service Publication Office
First Edition 09/2010
All Rights Reserved
Reference
Symbols
Replacement
Body Dimensional Drawings
The welding symbols in the removal/installation have
these meanings.
Body measuring dimensions show the distance
between the forward or upper edge of positioning
bosses and/or holes shown in the detail illustration.
: 2-Plate spot welding
Black dots: Measuring point
: 3-Plate spot welding
Black Dot
: 4-Plate spot welding
: MAG plug welding
: MAG welding (butt or fillet)
Front
Front
Front
L=Welding length unit: mm (in)
( ) and ( )*: The number of welds
Fillet welding
2-Plate spot
welding
(1)
L=190
(7.48)
(6)
L=10 (0.39)
(9)
Detail
Illustration
C
F
(20)
(2)
However, the measuring points in the frame repair chart
are always the centers of the holes.
(ᰟ)*
Rust Prevention
(9)
Butt
welding
3-Plate spot
welding
(12)
The following type of illustration shows the areas where
sealant is to be applied.
SEALANT
4-Plate spot
welding
DAMPER
HOUSING
(8)
(ᰣ)*
MAG plug
welding
(6)
L=330
(12.99)
WHEELHOUSE
UPPER
EXTENSION
General Information
General Information
Supplemental Restraint System (SRS) • • • • • • • • • • • • • • • • • 1–2
SRS Component Replacement/Inspection After
Deployment • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 1–4
Battery Terminal Disconnection and Reconnection • • 1–5
Identification Number Locations • • • • • • • • • • • • • • • • • • • • • • • • 1–6
Parts Marking • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 1–7
Lift and Support Points • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 1–8
Body Specifications/Wheel Alignment • • • • • • • • • • • • • • • • • 1–9
Exterior Parts Removal/Installation • • • • • • • • • • • • • • • • • • • • • 1–10
Front Body Construction • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 1–12
Roof and Side Panel Construction • • • • • • • • • • • • • • • • • • • • • • 1–14
Floor and Rear Body Construction • • • • • • • • • • • • • • • • • • • • • • 1–16
Door and Bumper Reinforcement Beams, and
High-Strength Steel (1500 MPa) Parts • • • • • • • • • • • • • • • 1–18
Zinc-Plated Steel Plate Repair • • • • • • • • • • • • • • • • • • • • • • • • • • • 1–19
High-Strength Steel Sheet Framed Areas • • • • • • • • • • • • • •1–20
Precautions for High-Strength Steel Parts Area
Repair • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 1–21
Parts Replacement Description • • • • • • • • • • • • • • • • • • • • • • • • • 1–21
MAG Welding Specifications for High-Strength Steel
Parts 590 MPa or Higher (except 1500 MPa) • • • • • • • • 1–22
High-Strength Steel (1500 MPa) Parts Welding
Specifications • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 1–23
General Information
Supplemental Restraint System (SRS)
This model has an SRS which includes a driver's airbag in the steering wheel hub, a front passenger's airbag in the
dashboard above the glove box, front seat belt tensioners in the front seat belt retractors, driver's seat belt outer lap
tensioner in the front seat belt lower anchor, side airbags in the front seat-backs, and side curtain airbags in the sides of
the roof. The SRS unit is separate from the airbag assembly and has built-in sensors. The following precautions should
be observed when doing sheetmetal work, paint work, and repair work around the locations of the SRS components.
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 and rear wheel arch. The front impact sensors are located behind the right and left
ends 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, the side sill, and the rear wheel arch. Do not apply heat to these areas with a torch,
etc.
● Take extra care when painting or doing body work in the area below the B-pillar. Do not expose the seat belt retractor
and tensioner to heat guns, welding, or spraying equipment.
● SRS electrical connectors are identified by yellow color coding. Take care when repairing this area. Prevent damage to
the harness.
● Do not apply heat of more than 212 °F (100 °C) when drying painted surfaces anywhere around the SRS components
locations.
● If strong impact or high temperature need to be applied to the areas around the locations of SRS components, remove
the components before doing the repair work.
● If any of the SRS-related components are damaged or deformed, be sure to replace them.
●
NOTE: For after-deployment procedures, and removal and replacement of SRS-related components, refer to the
Odyssey Service Manual.
DRIVER'S AIRBAG
FRONT PASSENGER'S AIRBAG
CABLE REEL
DATA LINK
CONNECTOR (DLC)
PASSENGER'S
UNDER-DASH
FUSE/RELAY
BOX
OPDS SENSOR/
SEAT-BACK COVER/PAD
FRONT PASSENGER'S
SIDE AIRBAG
ODS UNIT
RIGHT SIDE IMPACT
SENSOR (FIRST)
DRIVER'S
UNDER-DASH
FUSE/RELAY BOX
FRONT PASSENGER'S
SEAT BELT TENSIONER
SRS UNIT
FRONT PASSENGER'S
WEIGHT SENSORS
DRIVER'S SIDE AIRBAG
DRIVER'S SEAT
POSITION SENSOR
LEFT SIDE IMPACT SENSOR (FIRST)
1-2
DRIVER'S SEAT BELT OUTER
LAP TENSIONER
DRIVER'S SEAT BELT TENSIONER
LEFT SIDE CURTAIN AIRBAG
RIGHT SIDE CURTAIN AIRBAG
LEFT FRONT
IMPACT SENSOR
RIGHT SIDE IMPACT
SENSOR (THIRD)
RIGHT FRONT
IMPACT SENSOR
LEFT SIDE IMPACT SENSOR
(SECOND)
LEFT SIDE IMPACT SENSOR
(THIRD)
SIDE AIRBAG CUTOFF
INDICATOR (AMBER)
USA
models
Canada
models
REAR SAFING SENSOR
RIGHT SIDE IMPACT SENSOR
(SECOND)
SRS INDICATOR (RED)
SEAT BELT REMINDER
INDICATOR (RED)
USA
models
Canada
models
FRONT PASSENGER'S AIRBAG
CUTOFF INDICATOR (AMBER)
1-3
General Information
SRS Component Replacement/Inspection After Deployment
NOTE:
● Before doing any SRS repairs, check for DTCs with the
HDS; refer to the appropriate Odyssey Service
Manual, for the less obvious deployed components
(front seat belt tensioners, driver's seat belt outer lap
tensioner, front impact sensors, side impact sensors,
rear safing sensor, etc).
● Do not repair damaged SRS'wiring. Replace the
affected wiring harness(es).
● Do not replace the ODS unit unless it is physically
damaged or a specific fault was found during DTC
troubleshooting. Because it could complicate
troubleshooting other DTCs.
● After a vehicle collision, do the ODS unit operation
check; refer to the appropriate Odyssey Service
Manual.
● After a vehicle collision, inspect the front seat active
head restraints; refer to the appropriate Odyssey
Service Manual.
After a collision where the front seat belt tensioners
deployed, replace these items:
● SRS unit
● Front seat belt(s)
● Driver's seat belt outer lap tensioner
● Front impact sensor(s)
After a collision where the driver's seat belt outer lap
tensioner deployed, replace there items:
● SRS unit
● Front seat belt(s)
● Driver's seat belt outer lap tensioner
● Front impact sensor(s)
After a collision where the front airbag(s) deployed,
replace these items:
● SRS unit
● Deployed front airbag(s)
● Front seat belt(s)
● Driver's seat belt outer lap tensioner
● Front impact sensor(s)
● Dashboard
After a collision where the side airbag has deployed,
replace the items for the side(s) that deployed:
● SRS unit
● Deployed side airbag(s)
● Side impact sensor(s) (first)
● Side impact sensor(s) (second)
● Side impact sensor(s) (third)
● Rear safing sensor
● B-pillar lower trim
● Seat frame and related parts
● Front seat belt(s)
● Driver's seat belt outer lap tensioner
After a collision where a side curtain airbag has
deployed, replace the items for the side(s) that deployed:
● SRS unit
● Front seat belt(s)
● Driver's seat belt outer lap tensioner
● Deployed side curtain airbag(s)
● Side impact sensor(s) (first)
● Side impact sensor(s) (second)
● Side impact sensor(s) (third)
● Rear safing sensor
● A-pillar upper trim
● B-pillar upper trim
● C-pillar trim
● D-pillar trim
● Front grab handle
● Rear grab handle
● All related trim clips
● Sunvisor
● Headliner
After a moderate to severe side or rear collision, inspect
for any damage on the side curtain airbag or other
related components. Replace the components as
needed.
During the repair process, inspect these areas:
● Inspect all the SRS wire harnesses. Replace, do not
repair, any damaged harnesses.
● Inspect the cable reel for heat damage. If there is any
damage, replace the cable reel; refer to the
appropriate Odyssey Service Manual.
After the vehicle is completely repaired, turn the ignition
switch to ON (II). If the SRS indicator comes on for about
6 seconds and then goes off, the SRS is OK. If the
indicator does not function properly, use the HDS to
check for the DTCs; refer to the appropriate Odyssey
Service Manual. If you cannot retrieve a code, do the
SRS Symptom Troubleshooting.
1-4
Battery Terminal Disconnection and Reconnection
Disconnection
Reconnection
NOTE: Some systems store data in memory (including
seat position, mirror position, etc) that is lost when the
battery is disconnected. Do the following procedures
before disconnecting the battery.
NOTE: Some systems store data in memory (including
seat position, mirror position, etc) that is lost when the
battery is disconnected. Do the following procedures to
restore the systems back to normal operation.
1. Make sure you have the anti-theft code(s) for the
audio system.
1. Clean the battery terminals.
2. Make sure the ignition switch is in LOCK (0).
2. Test the battery; refer to the appropriate Odyssey
Service Manual.
3. Disconnect and isolate the negative cable from the
battery.
3. Reconnect the positive cable (A) to the battery (B) first,
then reconnect the negative cable (C) to the battery.
NOTE: Always disconnect the negative cable from the
battery first.
NOTE: Always connect the positive cable to the
battery first.
4. Disconnect the positive cable from the battery.
A
2.9－5.9 N·m
(0.30－0.60 kgf·m, 2.1－4.4 lbf·ft)
B
C
4. Apply multipurpose grease to the terminals to
prevent corrosion.
5. Enter the anti-theft code(s) for the audio system.
6. Enter the audio presets.
7. Set the clock (for vehicles without navigation).
1-5
General Information
Identification Number Locations
Vehicle Identification
Number (VIN)
Vehicle Identification
Number (VIN)
Vehicle Identification Number,
Federal Motor Vehicle Safety
Standard Certification, and
Paint Code Label.
Vehicle Identification Number,
Canadian Motor Vehicle Safety
Standard Certification, and
Paint Code Label.
Engine Number
Transmission Number
(5-speed A/T model)
PAINT CODE
Transmission Number
(6-speed A/T model)
1-6
INTERIOR
COLOR CODE
Parts Marking
To deter vehicle theft, certain major components are
marked with the vehicle identification number (VIN).
Original parts have self-adhesive labels. Replacement
body parts have generic self-adhesive labels. These
labels should not be removed. The original engine or
transmission VIN plates are not transferable to the
replacement engine or transmission.
NOTE: Be careful not to damage the parts marking labels
during body repair. Mask the labels before repairing the
part.
1-7
General Information
Lift and Support Points
NOTE: If you are going to remove heavy components
such as suspension or the fuel tank from the rear of the
vehicle, first support the front of the vehicle with tall
safety stands. When substantial weight is removed from
the rear of the vehicle, the center of gravity can change,
causing the vehicle to tip forward on the lift.
Floor Jack
1. When lifting the front of the vehicle, set the parking
brake. When lifting the rear of the vehicle, put the shift
lever in P.
2. Block the wheels that are not being lifted.
Vehicle Lift
1. Position the lift pads (A) under the vehicle's front
support points (B) and rear support points (C).
Be sure the lift pads are properly placed to avoid
damaging the vehicle.
3. Position the floor jack under the front jacking bracket
(A) or the rear jacking bracket (B). Center the jacking
bracket on the jack lift platform (C), and jack up the
vehicle high enough to fit the safety stands under it.
Be sure the lift floor jack is properly placed to avoid
damaging the vehicle.
A
B
A
C
2. Raise the lift a few inches, and rock the vehicle gently
to be sure it is firmly supported.
3. Raise the lift to its full height, and inspect the vehicle
support points for solid contact with the lift pads.
Safety Stands
To support the vehicle on safety stands, use the same
support points as for a vehicle lift. Always use safety
stands when working on or under any vehicle that is
supported only by a jack.
1-8
B
C
4. Position the safety stands under the support points,
and adjust them so the vehicle is level side-to-side.
5. Lower the vehicle onto the stands.
Body Specifications/Wheel Alignment
1,737 mm (68.4 in)
Body Specifications
1,730 mm (68.1 in)
1,997 mm (78.6 in)
3,000 mm (118.1 in)
1,732 mm (68.2 in)
5,153 mm (202.9 in)
Front Wheel Alignment
Camber
Caster
Total toe-in
Wheel turning angle
0 ° 00 ’ ᤣ45 ’
2 ° 36 ’ ᤣ36 ’
0ᤣ2 mm (0ᤣ0.08 in)
Inward
42 ° 06 ’ ᤣ2 °
Outward
34 ° 40 ’ (Reference)
Rear Wheel Alignment
Camber
Total toe-in
－0 ° 30 ’ ᤣ45 ’
2ᤣ2 mm (0.08ᤣ0.08 in)
1-9
General Information
Exterior Parts Removal/Installation
NOTE:
● When removing the front fender, do not deform its upper portion (A).
● When reinstalling the front fender, apply the sealer all the way around the front pillar end block and the front fender
without gaps.
● When adjusting the front door in or out, replace the mounting bolts (B); refer to the appropriate Parts Catalog for the
necessary adjusting bolts.
● Apply spot sealer to the mating surfaces, then install the front fenders, the hood, the front doors, the tailgate, and the
hinges.
● Check the hood, the doors, and the tailgate positions; refer to the external parts fitting positions (see page 4-15).
● Apply sealant around the tailgate hinges (see page 5-6).
TAILGATE HINGE
HOOD
6 x 1.0 mm
18 N·m
(1.8 kgf·m, 13 lbf·ft)
8 x 1.25 mm
22 N·m
(2.2 kgf·m, 16 lbf·ft)
8 x 1.25 mm
22 N·m
(2.2 kgf·m,
16 lbf·ft)
TAILGATE
6 x 1.0 mm
9.3 N·m
(0.95 kgf·m, 6.9 lbf·ft)
Right side only
HOOD HINGE
6 x 1.0 mm
18 N·m
(1.8 kgf·m, 13 lbf·ft)
6 x 1.0 mm
18 N·m
(1.8 kgf·m,
13 lbf·ft)
FUEL FILL DOOR
FRONT PILLAR
END BLOCK
SEALER
6 x 1.0 mm
9.3 N·m
(0.95 kgf·m, 6.9 lbf·ft)
UPPER FRONT
DOOR HINGE
SLIDE DOOR
(A)
FRONT DOOR
FRONT FENDER
LOWER FRONT
DOOR HINGE
6 x 1.0 mm
9.3 N·m
(0.95 kgf·m, 6.9 lbf·ft)
FRONT FENDER
1-10
(B)
8 x 1.25 mm
22 N·m
(2.2 kgf·m, 16 lbf·ft)
6 x 1.0 mm
9.3 N·m
(0.95 kgf·m, 6.9 lbf·ft)
8 x 1.25 mm
29 N·m
(3.0 kgf·m, 21 lbf·ft)
6 x 1.0 mm
9.3 N·m
(0.95 kgf·m, 6.9 lbf·ft)
10 x 1.25 mm
38 N·m
(3.9 kgf·m, 28 lbf·ft)
8 x 1.25 mm
22 N·m
(2.2 kgf·m, 16 lbf·ft)
8 x 1.25 mm
22 N·m
(2.2 kgf·m,
16 lbf·ft)
REAR ENTERTAINMENT
SYSTEM BRACKET
(For some models)
BATTERY
SET BASE
REAR BUMPER BEAM
BATTERY SET
LOWER STAY
FRONT BUMPER
BEAM
8 x 1.25 mm
22 N·m
(2.2 kgf·m, 16 lbf·ft)
1-11
General Information
Front Body Construction
NOTE: To confirm which parts are sold as repair parts, refer to the appropriate Parts Catalog.
᫔
ᫎ
a
-2
b
-1
c
᫓
f
b
e
᫕
Rear
Upper
c
Front
Lower
d
-4
Rear
-2
Front
᫖
b
-1
-3
d
-3
᫑
a
a
᫒
a
c
-4
b
-1
-1
c
B
-2
-2
d
e
i
A
f
h
-3
᫐
1-12
g
᫏
NOTE:
● The parts marked with numbers are sold as repair parts.
● The parts marked with letters are not sold separately and are shown only for reference.
● [ ]: Thickness unit: mm (in)
● High-strength steel sheet: Tensile strength 340 to 590 MPa.
No.
ᫎ
Hood
᫏
᫐
-1
-2
-3
᫑
-1
-2
-3
-4
᫒
᫓
-1
-2
-3
-4
᫔
-1
-2
᫕
᫖
Part Name
Skin [0.7 (0.028)]
Frame [0.6 (0.024)]
Front Fender [0.75 (0.0295)]
Front Bulkhead Complete
Front Bulkhead Upper Frame Set
a:
Front Bulkhead Upper Center Frame A [0.8 (0.031)]
b:
Front Bulkhead Upper Center Frame B [0.8 (0.031)]
Front Bulkhead Side Stay Set
c:
Front Bulkhead Upper Frame [0.8 (0.031)]
d:
Front Bulkhead Upper Support [0.8 (0.031)]
e:
Front Bulkhead Side Plate [0.8 (0.031)]
f:
Front Bulkhead Side Stay [0.8 (0.031)]
Front Bulkhead Lower Crossmember Set
g:
Front Bulkhead Lower Crossmember [1.0 (0.039)]
h:
Lower Crossmember Extension Plate [1.0 (0.039)]
i:
Front Bulkhead Lower Crossmember Upper [1.0 (0.039)]
Front Damper Housing Complete
a:
Front Damper Housing [1.2 (0.047)]
b:
Front Damper Base [3.2 (0.126)]
c:
Front Damper Housing Extension [1.0 (0.039)]
d:
Front Damper Stiffener [1.0 (0.039)]
Front Bulkhead Side Member [1.0 (0.039)]
Front Fender Side Bracket [1.2 (0.047)]
Wheelhouse Gusset A [1.0 (0.039)]
Engine Side Mount Bracket [1.2 (0.047)]
Front Wheelhouse Upper Member [1.0 (0.039)]
Front Side Frame Complete
a:
Front Beam Support Bracket [2.0 (0.079)]
b:
Front Side Outrigger [1.6 (0.063)]
c:
Front Side Frame Gusset [1.8 (0.071)]
d:
Rear Support Bracket [1.8 (0.071)]
e:
Front Side Frame Gusset A [1.0 (0.039)]
f:
Front Side Frame Gusset B [1.6 (0.063)]
Front Side Frame, Front [1.6 (0.063)]/Rear [2.0 (0.079)]
Front Side Extension, Front [1.6 (0.063)]/Rear [2.0 (0.079)]
Front Bumper Beam Bracket [1.8 (0.071)]
Front Side Frame End Outrigger [1.2 (0.047)]
Dashboard Upper Complete
a:
Windshield Lower [1.0 (0.039)]
b:
Dashboard Upper [1.0 (0.039)]
c:
Dashboard Upper Side Member [1.6 (0.063)]
Front Fender Rear Bracket [1.0 (0.039)]
Front Fender Bracket [1.2 (0.047)]
Dashboard Lower
Upper [0.9 (0.035)]
Lower [1.4 (0.055)]
Floor Front Crossmember A [1.8 (0.071)]
Tensile
Strength
(MPa)
340
270
270
Zinc-Plating
440
440
○
○
440
440
440
440
○
○
○
○
590
270
270
○
○
○
270
270
440
270
A: 270/B: 440
270
440
270
270
○
○
○
○
○
○
○
○
○
270
590
440
440
590
590
440
440
270
590
○
○
○
○
○
○
○
○
○
○
270
270
440
270
270
270
590
440
○
○
○
○
○
○
○
○
○
○
○
1-13
General Information
Roof and Side Panel Construction
NOTE: To confirm which parts are sold as repair parts, refer to the appropriate Parts Catalog.
ᫎ
᫞
d
a
e
᫑
᫐
b
᫏
a
᫜
c
b
a
-2
-1
᫝
᫛
᫕
Upper
᫚
d
c
᫔
Lower
᫖
b
a
a
b
b
᫓
᫙
᫗
a
᫘
᫠
᫒
Front
1-14
Rear
᫟
NOTE:
● The parts marked with numbers are sold as repair parts.
● The parts marked with letters are not sold separately and are shown only for reference.
● [ ]: Thickness unit: mm (in)
● High-strength steel sheet: Tensile strength 340 to 1500 MPa.
No.
ᫎ
᫏
᫐
᫑
᫒
᫓
᫔
᫕
᫖
᫗
᫘
᫙
᫚
᫛
᫜
᫝
᫞
-1
-2
᫟
᫠
Part Name
Roof Panel Complete
a:
Roof Panel [0.7 (0.028)]
Roof Front Rail [1.6 (0.063)]
Roof Arch D [1.2 (0.047)]
Rear Roof Rail [1.0 (0.039)]
Side Sill Outer Panel [0.7 (0.028)]
Front Side Outer Panel Set [0.7 (0.028)]
Rear Side Outer Panel Set [0.7 (0.028)]
Rear Pillar Gutter [0.7 (0.028)]
Rear Combination Adapter [0.7 (0.028)]
Front Pillar Stiffener Complete
a:
Front Pillar Lower Stiffener [1.2 (0.047)]
b:
Front Pillar Upper Stiffener [1.8 (0.071)]
Side Sill Reinforcement [1.2 (0.047)]
Center Pillar Stiffener [1.6 (0.063)]
Roof Side Outer Complete
a:
Outer Upper [2.0 (0.079)/1.0 (0.039)]
b:
Outer Lower [1.0 (0.039)]
Front Inner Pillar Complete
a:
Front Inner Lower Pillar [1.0 (0.039)]
b:
Jack-Up Base [2.6 (0.102)]
c:
Front Inner Middle Pillar [1.4 (0.055)]
d:
Front Inner Upper Pillar [1.8 (0.071)]
Roof Side Rail Complete
a:
Roof Side Front Rail [1.4 (0.055)]
b:
Roof Side Rear Rail [1.2 (0.047)]
Center Inner Pillar
Upper [1.8 (0.071)]
Lower [1.6 (0.063)]
Rear Inner Panel Complete
Rear Wheel Arch Extension [0.75 (0.0295)]
a:
Quarter Inner Upper Pillar [1.0 (0.039)]
b:
Quarter Inner Lower Pillar [0.8 (0.031)]
c:
Rear Inner Panel [0.65 (0.0256)]
d:
Rear Inner Upper Rail [0.7 (0.028)]
e:
Rear Inner Pillar, Upper [1.6 (0.063)]/Lower [1.0 (0.039)]
Rear Wheelhouse [0.8 (0.031)]
Front Door
Skin [0.8 (0.031)]
Panel, Front [1.4 (0.055)]/Rear [0.7 (0.028)]
Sliding Door
Skin [0.9 (0.035)]
Panel [0.7 (0.028)]
Tensile
Strength
(MPa)
Zinc-Plating
340
270
USIBOR 1500P
590
270
270
270
270
270
○
590
590
590
980
○
○
○
○
○
○
○
590
270
○
○
590
440
590
590
○
○
○
USIBOR 1500P
590
980
590
○
270
590
440
270
440
440
270
340
270
340
270
○
○
○
○
○
○
○
○
1-15
General Information
Floor and Rear Body Construction
NOTE: To confirm which parts are sold as repair parts, refer to the appropriate Parts Catalog.
᫝
᫜
᫐
a
᫏
b
b
᫒
-1
a
a
a
d
-1
b
c
c
b
c
ᫎ
᫓
a
b
᫑
᫘
᫗
᫖
-4
b
-3
-2
᫕
᫔
a
c
a
-1
᫛
b
d
a
c
᫙
a
b
1-16
᫚
NOTE:
● The parts marked with numbers are sold as repair parts.
● The parts marked with letters are not sold separately and are shown only for reference.
● [ ]: Thickness unit: mm (in)
● High-strength steel sheet: Tensile strength 340 to 980 MPa.
No.
ᫎ
᫏
᫐
᫑
᫒
-1
᫓
᫔
᫕
᫖
᫗
᫘
᫙
᫚
᫛
-1
-2
-3
-4
᫜
-1
᫝
Part Name
Floor Panel Set
a:
Floor Panel [0.65 (0.0256)]
b:
Second-Seat Plate B [2.0 (0.079)]
c:
Floor Panel Patch [0.8 (0.031)] Right side only
Under Floor Pan Crossmember Complete
a:
Under Floor Pan Upper Crossmember A [1.6 (0.063)]
b:
Under Floor Pan Lower Crossmember A [1.6 (0.063)]
c:
Front Seat Inner Bracket [1.8 (0.071)]
d:
Front Seat Rear Outer Bracket [2.0 (0.079)]
Under Floor Pan Complete
a:
Spare Tire Pan [0.65 (0.0256)]
b:
Under Floor Pan Crossmember B [0.7 (0.028)]
Floor Rear Extension A [2.0 (0.079)]
Third Floor Pan Set
Third-Seat Pan Stiffener [0.7 (0.028)]
a:
Third-Seat Pan [0.7 (0.028)]
b:
Third Row Seat Mount Panel [1.8 (0.071)]
Floor Rear Extension B [0.6 (0.024)]
Floor Front Crossmember B [1.6 (0.063)]
Floor Middle Crossmember A [2.3 (0.091)]
Middle Floor Crossmember B Complete
a:
Floor Middle Crossmember B [1.6 (0.063)]
b:
Middle Floor Crossmember B Stiffener [1.6 (0.063)]
Middle Crossmember C [1.2 (0.047)]
Middle Floor Crossmember D [1.4 (0.055)]
Front Floor Frame Complete
a:
Floor Front Frame [1.6 (0.063)]
b:
Front Floor Frame Stiffener [1.6 (0.063)] Left side only
c:
Floor Front Extension [2.0 (0.079)] Left side only
Front Inside Sill Complete
a:
Front Inside Sill A [1.4 (0.055)]
b:
Inside Sill Stiffener [1.2 (0.047)] Left side only
c:
Front Inside Sill B [1.6 (0.063)]
d:
Quarter Pillar Stiffener Extension [1.0 (0.039)]
Rear Frame Complete
a:
Rear Frame Stiffener [1.2 (0.047)]
Rear Frame [2.0 (0.079)]
Rear Floor Outrigger [1.4 (0.055)]
Rear Frame Outrigger B [1.2 (0.047)]
Rear Bumper Beam Bracket [2.3 (0.091)]
Floor Rear Crossmember Complete
a:
Rear Floor Outer Crossmember [1.4 (0.055)/0.8 (0.031)]
b:
Rear Floor Inner Crossmember [1.2 (0.047)/0.8 (0.031)]
c:
Rear Floor Crossmember Extension [0.6 (0.024)]
Rear Bumper Face Stiffener [0.9 (0.035)]
Tailgate
Upper Skin [0.7 (0.028)]
Lower Skin [0.7 (0.028)]
Frame [0.6 (0.024)]
Tensile
Strength
(MPa)
Zinc-Plating
270
440
270
○
○
○
590
590
590
590
○
270
270
270
○
○
○
270
270
590
270
440
590
○
○
○
○
○
○
980
590
590
590
○
○
○
○
Left side: 780/
Right side: 590
780
590
○
590
780
440
270
○
○
○
○
590
440
270
270
590
○
○
○
○
○
270
270
270
270
340
270
270
○
○
○
○
○
○
○
○
○
1-17
General Information
Door and Bumper Reinforcement Beams, and High-Strength Steel (1500
MPa) Parts
The door and bumper reinforcement beams are made from high-strength steel.
The roof side front rail and roof arch D are made from the high-strength steel (1500 MPa) parts.
If high-strength steel is heated, the strength of the steel is reduced. If high-strength steel is damaged, for example, in a
collision, and the door and bumper reinforcement beams or the boron steel parts are bent, the beams or the boron steel
parts may crack when attempting to straighten them. If a door beam is damaged, the whole door panel assembly must
be replaced.
For this reason, the door, bumper reinforcement beams, and the boron steel parts should NEVER be repaired, and
NEVER be welded by MAG welding; they must be replaced by only spot welding if they are damaged.
ROOF ARCH D
Do not repair.
ROOF SIDE FRONT RAIL
Do not repair.
FRONT BUMPER
REINFORCEMENT BEAM
Do not repair.
REAR BUMPER
REINFORCEMENT BEAM
Do not repair.
SLIDING DOOR
REINFORCEMENT BEAM
Do not repair.
FRONT DOOR
REINFORCEMENT BEAM
Do not repair.
1-18
Zinc-Plated Steel Plate Repair
The zinc-plated steel plate used in some panels of the Odyssey require different repair techniques than ordinary steel
plate. Refer to Front Body Construction (see page 1-12), Roof and Side Panel Construction (see page 1-14), and Floor and
Rear Body Construction (see page 1-16) for the locations of the zinc-plated panels.
ZINC PLATING (5－6 microns)
STEEL PLATE
1. Before spot welding the zinc-plated steel plate, remove the paint from both sides of the flange to be welded. Apply
spot sealer to the flange before welding.
NOTE: Seal the sanded surfaces thoroughly to prevent rust.
2. Before applying putty or body filler to the zinc-plated steel plates, sand the zinc plating thoroughly to promote
adhesion and prevent blistering.
NOTE: Use only epoxy-based putties and fillers on zinc-plated steel plates, and follow the manufacturer's
specifications.
3. When doing paint work, protect the ground wire and the ground wire mounting hole threads with a bolt or a plug.
GROUND
WIRE
SPECIAL BOLT
GROUND WIRE
MOUNTING HOLE
PLUG
1-19
General Information
High-Strength Steel Sheet Framed Areas
The new high-strength steel sheet has greater tensile strength than conventional high-strength steel sheet. Although it's
a thinner sheet, it is as strong as the previous thicker ones. Because the manufacturing press process has improved, its
usage has expanded. For this vehicle, the new high-strength steel sheet is used for the main frame and the passenger
compartment to make this model lightweight and to improve the high-crush absorption frame.
: New high-strength (590－1500 MPa) steel sheet
ROOF SIDE REAR RAIL
ROOF SIDE
FRONT RAIL
(1500 MPa)
UNDER FLOOR PAN
CROSSMEMBER
FLOOR FRONT FRAME
FRONT INNER
UPPER PILLAR
ROOF SIDE
OUTER UPPER
QUARTER INNER
UPPER PILLAR
ROOF ARCH D
(1500 MPa)
REAR ROOF RAIL
THIRD ROW SEAT
MOUNT PANEL
ROOF
ARCH B
CENTER
INNER
PILLAR
REAR FRAME
STIFFENER
REAR BUMPER
BEAM BRACKET
FRONT INNER
MIDDLE PILLAR
FRONT INNER
LOWER PILLAR
FRONT
INSIDE SILL A
FRONT
SIDE FRAME
GUSSET B
MIDDLE FLOOR
CROSSMEMBER D
FRONT
SIDE FRAME
GUSSET A
MIDDLE
CROSSMEMBER C
MIDDLE FLOOR
CROSSMEMBER B
FLOOR FRONT EXTENSION
CENTER PILLAR STIFFENER
FLOOR MIDDLE CROSSMEMBER A
FRONT PILLAR UPPER STIFFENER
FRONT BULKHEAD
LOWER CROSSMEMBER
SIDE SILL REINFORCEMENT
FRONT SIDE
OUTRIGGER
FRONT FLOOR FRAME STIFFENER
DASHBOARD LOWER B
FRONT PILLAR LOWER STIFFENER
FRONT SIDE FRAME END OUTRIGGER
1-20
Precautions for High-Strength Steel
Parts Area Repair
Parts Replacement Description
The new high-strength steel parts of the frame are all
spot welded together. To disassemble, drill a hole in
the sections that are spot welded together with a very
sharp spot weld bit.
● The new high-strength steel sheet is more rigid than
previous steel sheets, making it difficult to straighten.
When an automobile's frame is partially constructed
with the new high-strength steel sheet, it must be
straightened using an accurate frame straightening
system. Inspect the body and frame for stress-related
damage to the sections that are not made from the
new high-strength steel after the repair is complete.
● High-strength steel has more memory than normal
steel, and it is necessary to monitor the body
dimensions closely during the straightening process.
● Spot welding is acceptable for replacement parts as
long as the proper number of welds is used in the
repair. For replacement part welding locations, refer
to the appropriate replacement procedures in this
manual.
Because of changes in body structure to improve
collision safety and body rigidity, the materials and
thickness of steel sheets and internal reinforcements
(patch, stiffener) of components have become very
specific. High-strength steel is extensively used. To
ensure the same level of body performance as when it is
produced, avoid cut and joining replacement
(sectioning); repair by assembly replacement.
●
NOTE:
● Cut and joint replacement should basically be avoided
except for outer panels and floor panels.
● Confirm in what state the component to be replaced is
delivered, and replace the component as an assembly
as much as possible.
AIR DRILL
SPOT CUTTER
SPOT CUTTER GRINDING
MACHINE
1-21
General Information
MAG Welding Specifications for High-Strength Steel Parts 590 MPa or
Higher (except 1500 MPa)
NOTE:
● If 590 MPa parts are plug or butt welded to 590 MPa or
higher parts (except 1500 MPa), use the following
welding wire or equivalent.
● MAG welding: Metal active gas welding where the
shielding gas being used contains a mixture of 80%
Argon (Ar) and 20% Carbon Dioxide (CO2). It is
considered active because the CO2 undergoes a
limited reaction with the molten weld pool.
● To ensure proper weld strength when doing MAG
plug welding, Start welding 1 mm from the outer
circumference of the edge of the plug hole and use a
spiral torch pattern to fill in the hole.
Confirmation of welded state
Do a preliminary welding test using a test piece of the
same material, and confirm that the bead protrudes
from the back surface. Do the main welding in the same
manner.
MAG plug welding
1 mm
(0.039 in)
The chart below shows the approved welding
procedures for each steel tensile strength. Failure to
observe these approved methods can result in an unsafe
repair.
Tensile strength and welding methods for steel sheet
Tensile strength
of steel sheet
(MPa)
270
340
440
590
780
980
Spot
welding
○
○
○
○
○
○
Welding method
MAG welding
Plug
Butt
○
○
○
○
○
○
○
○
○
○
○
ᤲ
MAG butt welding
Welding Specifications
A
Welding
wire
Welding wire applicable to the
high-strength steel sheet with a tensile
strength of 590 MPa or higher (except
1500 MPa)
A
BEAD
NOTE: This wire is available from the
Honda Tool & Equipment Program
http://honda.snapon.com or
1-866-346-8858
Approx. 4 mm (0.16 in)
[SECTION: AA]
Example: Bosch Automotive Service
Solutions solid wire (SSJ-DS980J)
Shielding
gas
Gas mixture: Ar 80%, CO2 20%
NOTE: For details concerning the welding wire, confirm
the product specifications issued by the welding wire
manufacturer.
1-22
Bead protrusion
at the rear side
Approx. 2 mm (0.08 in)
High-Strength Steel (1500 MPa) Parts Welding Specifications
High-Strength Steel (1500 MPa) Parts Welding
Specifications
Spot welding specifications
Current: 9000 A
Pressure: 3432 N (350 kgf, 772 lbf)
● Welding cycle: 26
●
The high-strength steel (1500 MPa) material is used for
the front pillar area, the roof side area, the center pillar
area, and the side sill area of the vehicles.
Parts replacement for the reinforcement and/or the
stiffener may be required depending on the damage to
the side panel. Take notice that spot welding conditions
for welding the replacement parts differ from the normal
welding conditions. MIG brazing must be used where
spot welding cannot be done. NEVER perform MAG
welding.
●
NOTE: When spot welding is performed, make sure that
the following conditions are maintained: the specified
current, conductivity time, welding pressure, holding
time, and shutdown time recommended for spot welder.
Follow the spot welder manufacturer's instructions.
MIG brazing specifications
MIG brazing machine with pulse controller
Wire: CuSi3
● Shielding gas: Argon gas (100%)
●
●
MIG brazing welding method
To ensure adequate joint strength, use a pulsed MIG
welder with specified wire and the following brazing
technique. This will create a capillary action in order to
liquefy the solder so that it can penetrate into the upper
and lower plates:
● Begin brazing about 5 mm (0.20 in) before the hole(s).
● Move the torch across the hole in a zigzag pattern as
you close the hole(s).
● Continue the brazing operation about 10 mm (0.39 in)
past the hole(s).
NOTE:
● For details about correct brazing current and voltage,
refer to the equipment manufacturer's
recommendations.
● MIG welding/brazing: Metal inert gas welding or
brazing where 100% Argon (Ar) shielding gas is used.
Argon is inert and does not react with the molten weld
pool or brazing operation.
Brazing hole size
For joining, or brazing of stiffener (340 and 980 MPa) and
the high-strength steel (1500 MPa) parts: Drill two holes
φ8 mm (0.31 in) in about 10 mm (0.39 in) pitch.
φ: Inner diameter
φ8 mm
(0.31 in)
φ8 mm
(0.31 in)
5 mm
(0.20 in)
About
10 mm
(0.39 in)
For joining, or brazing of outer panel (270 MPa) and the
high-strength steel (1500 MPa) parts: Drill one hole φ8
mm (0.31 in) at the outer panel.
φ: Inner diameter
φ8 mm
(0.31 in)
5 mm
(0.20 in)
1-23
Paint Information
Paint Information
Paint Safety Precautions • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 2–2
General • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 2–3
Color Chart Paint Specifications • • • • • • • • • • • • • • • • • • • • • • • • 2–4
Features of Plastic Materials • • • • • • • • • • • • • • • • • • • • • • • • • • • • 2–5
Types and Materials of Exterior Plastic Parts • • • • • • • • • • 2–7
Soft Chipping Guard Primer Coat
General Safety Precautions • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 2–8
Coating Areas • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 2–9
Paint Information
Paint Safety Precautions
Most paints contain substances that are harmful if
inhaled or swallowed. Read the paint label before
opening the container.
Observe the following precautions to maintain a safe
painting work area.
Wear an approved respirator and eye protection when
painting.
● Wear approved gloves and appropriate clothing when
painting. Avoid contact with skin.
● Spray paint only in a well ventilated area.
● Cover spilled paint with sand, or wipe it up at once.
● If paint gets in your mouth or on your skin, rinse and
wash thoroughly with water. If paint gets in your eyes,
flush with water and get prompt medical attention.
● After the painting work is finished, wash your face and
gargle with water.
● Paint is flammable. Store it in a safe place, and keep it
away from sparks, flames, or cigarettes.
●
2-2
General
The 3-coat·3-bake (3C·3B) paint finish gives the Odyssey a deep gloss and a stunning finish. This manual provides
information on paint defects, 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.
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
Pretreatment
Electrodeposition
of primer
(Chipping Primer)
Intermediate coat
Top coat
Features In Each Work Process
Pretreatment and electrodeposition
In the pretreatment 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, the pillars, the sills,
and the panel joints.
Chipping primer is then applied to the most susceptible areas (see page 2-9).
Intermediate coat
The intermediate coat is applied to the prepared surface to further protect against damage.
Top coat
Enamel paint and either polyester or acrylic resin paint are used in the top coat for higher solidity, smoothness,
brightness, and weather resistance.
Sectional view of paint coats
3-COAT PEARL PAINT
(White pearl)
CLEAR COAT
ENAMEL COAT
CLEAR COAT
INTERMEDIATE COAT
About
120 microns
(0.12 mm)
PEARL BASE COAT
COLOR BASE COAT
CHIPPING PRIMER
UNDERCOAT
(Electrodeposition)
BASE METAL
2-3
Paint Information
Color Chart Paint Specifications
NOTE:
● For model year paint code information, refer to the appropriate service manual.
● Apply black paint to the visible surface of the front wheelhouse and the rear wheelhouse after repairing and painting
(except vehicles painted with black color).
WINDSHIELD SIDE TRIM
Black (NH-70 Gloss 20)
DOOR OUTER MOLDINGS
Stainless steel
COWL COVER
Black (NH-696 Gloss 5)
FRONT GRILLE
· BASE:
Black (NH-70 Gloss 20)
· SURROUND MOLDING:
EX warm gray (NH-661)
· MOLDING, UPPER and
CENTER:
Chrome plated
QUARTER BEZEL,
UPPER and LOWER
Stainless steel
CENTER RAIL COVER
Body color
DOOR GLASS OUTER
WEATHERSTRIPS
Stainless steel
SIDE SILL PANEL
Body color or
Bumper dark gray (NH-533)
FRONT BUMPER FACE
Body color
FRONT BUMPER
LOWER MESH
Black (NH-70 Gloss 20)
DOOR MIRROR HOUSING,
BASE COVER, LOWER COVER
Formal black (NH-707) or
Black (NH-70 Gloss 20)
FRONT CORNER BEZEL
Stainless steel
FRONT FOG LIGHT COVER
Black (NH-70 Gloss 20)
DOOR SASH OUTER TRIM
Formal black (NH-707) or
Black (NH-70 Gloss 20)
ROOF
MOLDING
Black
TAILGATE HINGE COVER
Black (NH-70 Gloss 20)
TAILGATE SIDE TRIM
Formal black (NH-707) or
Black (NH-70 Gloss 20)
TAILGATE SPOILER TRIM
Formal black (NH-707) or
Black (NH-70 Gloss 20)
FRONT SPLASH GUARD
(Canada models)
Bumper dark gray
(NH-533)
REAR LICENSE TRIM
Lens or
Chrome plated
DOOR OUTER HANDLE
· HANDLE and BASE:
Body color or Black (NH-70 Gloss 20)
· HANDLE STRIP and BASE STRIP:
Chrome plated or Black (NH-70 Gloss 20)
REAR BUMPER STEP
Bumper dark gray (NH-533)
REAR BUMPER FACE
Body color
2-4
Features of Plastic Materials
Check each of the plastic parts for solvent resistance and heat resistance before you do any repair work.
Select the repair material according to materials of the plastic parts.
● Alcohol can be used for degreasing in small amounts, and for short periods of time. Do not soak.
● Contact your paint and material supplier for other recommended cleaners for the type of plastic you are working on.
●
●
Standard
Symbol
Name
Heat
Resistance
Temperature
°F (°C)
Note
AAS
Acrylonitrile acrylic styrene
176
(80)
ABS
Acrylonitrile butadiene styrene
176
(80)
AES
Acrylonitrile ethylene styrene
176
(80)
A/EPDM/S
Acrylonitrile/ethylene propylene
diene monomer
(rubber)/styrene
176
(80)
ASA
Acrylonitrile styrene acrylate
176
(80)
CAB
Cellulose acetate butylate
176
(80)
E/VAC
Ethylene-vinyl acetate
176
(80)
PA
Polyamide
176
(80)
Battery acid (sulfuric acid) can damage
the material.
PBT
Polybutylene terephtalate
320
(160)
Solvent can damage the material.
PC
Polycarbonate plastics
248
(120)
Brake fluid, and wax and grease remover
can damage the material.
PE
Polyethylene
176
(80)
Solvent can damage the material.
PF
Phenol formaldehyde
176
(80)
PMMA
Polymethyl methacrylate
176
(80)
Wash remover off with water thoroughly.
POM
Polyoxymethylene polyacetal
212
(100)
Solvent can damage the material.
PP
Polypropylene
176
(80)
Solvent can damage the material.
Polyphenylene oxide
212
(100)
PPO (PPE)
(cont'd)
2-5
Paint Information
Features of Plastic Materials (cont'd)
Standard
Symbol
2-6
Name
Heat
Resistance
Temperature
°F (°C)
Note
PS
Polystyrene
140
(60)
PUR
Polyurethane
176
(80)
PVC
Polyvinyl chloride
176
(80)
SAN
Styrene acrylonitrile
176
(80)
SMC
Sheet molding compound
356
(180)
Solvent can damage the material.
TPE
Thermoplastic polyester
elastomer
176
(80)
Wash remover off with water thoroughly.
TPS
Thermoplastic styrene
elastomer
176
(80)
Wash remover off with water thoroughly.
TPO
Thermoplastic olefin/elastomer
176
(80)
Wash remover off with water thoroughly.
TPU
Thermoplastic
polyurethane/elastomer
176
(80)
Wash remover off with water thoroughly.
UP
Unsaturated polyester
230
(110)
Alkali can damage the material.
Types and Materials of Exterior Plastic Parts
NOTE:
● For the full plastic name, refer to the features of plastic materials (see page 2-5).
● A standard symbol is stamped on the underside of each plastic part to show the type of material used.
WINDSHIELD SIDE TRIM
(AES)
Example:
COWL COVER
(PP)
FRONT GRILLE
· BASE:
(ASA+PC)
· SURROUND MOLDING:
(ASA+PC)
· MOLDING, UPPER and
CENTER:
(ABS)
CENTER RAIL COVER
(ABS)
SIDE SILL PANEL
(PP)
FRONT BUMPER FACE
(PP)
FRONT BUMPER
LOWER MESH
(PP)
DOOR MIRROR HOUSING,
BASE COVER, LOWER COVER
Painted (ABS)/
Unpainted (AES)
FRONT FOG
LIGHT COVER
(PP)
TAILGATE
HINGE COVER
(AES)
DOOR SASH OUTER TRIM
Painted (ABS)/
Unpainted (AES)
TAILGATE SIDE TRIM
· OUTER:
Painted (ABS)/Unpainted (AES)
· INNER, SIDE:
(ABS)
TAILGATE SPOILER TRIM
Painted (ABS)/
Unpainted (AES)
FRONT SPLASH GUARD
(Canada models)
(PP)
REAR LICENSE TRIM
· Lens:
LENS (PMMA)/
HOUSING (ASA)
· Chrome plated:
(ABS)
DOOR OUTER HANDLE
· HANDLE and BASE:
(PC)
· HANDLE STRIP and BASE STRIP:
Painted (PC/ABS)/
Unpainted (PC/PET)
REAR BUMPER FACE
(PP)
REAR BUMPER STEP
(TPO)
2-7
Soft Chipping Guard Primer Coat
General Safety Precautions
The removal of paint and undercoating by stone chips
immediately exposes metal to the atmosphere, causing
it to oxidize. 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.
Use alcohol, and wax and grease remover.
3. Protect from overspray.
Use masking tape and paper to protect the related
areas from overspray.
The soft chipping guard primer coat is applied over
the E. D. (electrostatically deposited) primer. It is
followed by the guide coating and the 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.
●
Sectional view of paint coats:
Top coat
Intermediate coat
＋
Chipping guard primer
Electrodeposition
Base metal
A soft chipping guard primer coat is then applied to
the most susceptible areas (see page 2-9).
● Spray the primer surface (2-part urethane primer
surfacer) on the soft chipping guard primer coating
areas when you replace parts using soft chipping
guard primer coat.
4. Spraying primer surfacer.
●
Coating Procedures
Wear goggles or safety glasses to prevent eye
injury.
● Ventilate when spraying undercoat.
●
1. Sanding the replacement part.
Use a double action sander and 400 grit sandpaper.
NOTE:
● Do not oversand the edges or corners of the part.
● Do not expose base metal.
Spray about four to five coats to get 20 microns of
thickness. One coat deposits about 5 to 7 microns.
● Do not try to cover the surface with one heavy coat.
Applying several thin coats is recommended.
● Use a 2-part urethane primer surfacer and a spray
gun.
● Mix the primer surfacer with the correct ratio of
additive and solvent.
● Follow the primer surfacer manufacturer's
instructions.
●
5. Drying.
After spraying primer surfacer, allow 7 to 10 minutes
of drying time, then force dry it with infrared lamps or
an industrial dryer.
6. Polishing.
Check that the primer surfacer has dried
thoroughly, then sand the primer surfacer.
● Use a double action sander and 400－600 grit
sandpaper.
●
7. Intermediate coating and top coating.
2-8
Coating Areas
: Indicates chipping guard primer coating area.
NOTE: Make sure to coat the flanges on the front and rear wheel arches.
Unit: mm (in)
HOOD SKIN
300 (11.81)
OUTER PANEL
100 (3.94)
FRONT PILLAR
HOOD
OUTER PANEL
SLIDING DOOR
200 (7.87)
FRONT FENDER
FRONT DOOR
DOOR SKIN
100 (3.94)
FRONT FENDER
190 (7.48)
2-9
Replacement
Front Bulkhead
Removal • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–2
Installation • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–4
Front Wheelhouse/Damper Housing
Removal • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–6
Installation • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–10
Front Side Frame/Side Frame Gusset
Removal • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–13
Installation • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–16
Front Pillar Outer Panel
Removal • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–19
Installation • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–21
Side Sill Outer Panel
Removal • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–23
Installation • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–25
Center Pillar Outer Panel
Removal • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–28
Installation • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–30
Inside Sill, Rear
Removal • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–33
Installation • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–36
Roof Panel
Removal • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–41
Installation • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–43
Rear Side Outer Panel
Removal • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–45
Installation • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–47
Floor Rear Crossmember
Removal • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–51
Installation • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–53
Third-Seat Pan/Rear Frame
Removal • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–56
Installation • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–61
Floor Insulators
Insulator Locations • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–65
Insulator Sizes • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3–66
Front Bulkhead
Removal
Mass production body welding positions and numbers
NOTE:
● Welding symbols
: 2-Plate spot welding; : 3-Plate spot welding;
L=Welding length unit: mm (in)
● ( ): The number of welds
: 4-Plate spot welding;
BULKHEAD UPPER
FRAME
BULKHEAD UPPER
(4)
CENTER FRAME
: MAG plug welding;
[VIEW: X]
BULKHEAD UPPER
FRAME
BULKHEAD
LOWER
CROSSMEMBER
: MAG welding
BULKHEAD
SIDE STAY
(1)
(4)
FRONT SIDE
FRAME
[VIEW: Z]
SIDE STAY
PLATE
(2)
FRONT SIDE FRAME
BULKHEAD UPPER
CENTER FRAME
(5)
[Z]
(3)
BULKHEAD UPPER
FRAME
(2)
BULKHEAD LOWER
CROSSMEMBER
BULKHEAD SIDE
MEMBER
(5)
(3)
((3)
3)
(4)
BULKHEAD
SIDE STAY
(4)
(5)
[X]
BULKHEAD SIDE
MEMBER
(4)
BULKHEAD LOWER CROSSMEMBER
3-2
FRONT SIDE
FRAME
SIDE FRAME
END OUTRIGGER
Construction
NOTE:
● This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer
to the appropriate Service Manual.
● The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to
the area and the degree of damage on the body.
●
●
Replace the bulkhead upper center frame, the bulkhead side stay, and the bulkhead lower crossmember.
Replace the bulkhead side stay, the side stay plate, and the bulkhead upper frame as an assembly.
BULKHEAD UPPER
CENTER FRAME
BULKHEAD UPPER FRAME
BULKHEAD SIDE STAY
SIDE STAY PLATE
BULKHEAD
SIDE MEMBER
FRONT SIDE FRAME
BULKHEAD LOWER
CROSSMEMBER
3-3
Front Bulkhead
Installation
NOTE:
● Welding symbols
: 2-Plate spot welding
: 3-Plate spot welding
: 4-Plate spot welding
: MAG plug welding
: MAG welding
L=Welding length unit: mm (in)
● ( ): The number of welds
[VIEW: Z]
(2)
A
(4)
1. Set the new parts bulkhead, and measure the front
compartment diagonally.
(1)
C
2. Check the body dimensions.
(3)
Front bulkhead position (see page 4-3)
Engine compartment (see page 4-4)
● Bulkhead side member position (see page 4-6)
● Engine compartment and front floor, under view
(see page 4-17)
● Repair chart, top view (see page 4-20)
● Repair chart, side view (see page 4-22)
●
●
B
6. Weld the bulkhead upper center frame (A) to the
bulkhead upper frame (B) and the bulkhead side stay
(C).
3. Tack weld the new parts into position.
B
A
4. Temporarily install the front fender, the hood, and the
door, then check for differences in level and
clearance.
Check the external parts fitting positions (see page
4-15). If necessary, check the headlight and the front
bumper positions. Make sure the body lines flow
smoothly.
5. Do the main welding.
Weld the bulkhead side stay (A), the bulkhead lower
crossmember (B), and the front side frame (C).
[Z]
(3)
(5)
C
(4)
C
B
A
(2)
(6)
(4)
A
C
(2)
B
3-4
(4)
7. Weld the bulkhead upper frame (A) to the bulkhead
side member (B).
B
A
(4)
(5)
A
B
3-5
Front Wheelhouse/Damper Housing
Removal
Mass production body welding positions and numbers (Wheelhouse upper member and
bulkhead side member)
NOTE:
● Welding symbols
: 2-Plate spot welding; : 3-Plate spot welding;
L=Welding length unit: mm (in)
● ( ): The number of welds
With front bulkhead removed
: 4-Plate spot welding;
: MAG plug welding;
: MAG welding
DASHBOARD UPPER SIDE MEMBER
DAMPER HOUSING EXTENSION
WHEELHOUSE
UPPER MEMBER
BULKHEAD SIDE MEMBER
(7)
(4)
(3)
(2) L=10 (0.39)
WHEELHOUSE
UPPER MEMBER
(4) L=5 (0.20)
FRONT INNER
LOWER PILLAR
(1)
(9)
(4)
(2)
DAMPER HOUSING EXTENSION
(3)
BULKHEAD
SIDE MEMBER
DAMPER HOUSING
EXTENSION
BULKHEAD
SIDE MEMBER
(5)
(10)
(10)
SIDE FRAME END
OUTRIGGER
3-6
Mass production body welding positions and numbers (Damper housing)
NOTE:
● Welding symbols
: 2-Plate spot welding; : 3-Plate spot welding;
L=Welding length unit: mm (in)
● ( ): The number of welds
DASHBOARD UPPER
: 4-Plate spot welding;
: MAG plug welding;
: MAG welding
(3)
DAMPER HOUSING
DASHBOARD UPPER
SIDE MEMBER
(7)
DASHBOARD UPPER
SIDE MEMBER EXTENSION
(2)
DAMPER HOUSING
EXTENSION
(5)
(2)
DAMPER
HOUSING
(5)
(4)
(5)
(1)
FRONT SIDE
FRAME
(3)
(8)
(7)
(5)
(6)
INNER LOWER PILLAR
Right side: 2-Plate welding
DAMPER
HOUSING
Right side
Front
DAMPER
HOUSING
DASHBOARD
LOWER
ENGINE SIDE
MOUNT
BRACKET
(7)
(5)
(cont'd)
3-7
Front Wheelhouse/Damper Housing
Removal (cont'd)
Construction (Wheelhouse upper member and bulkhead side member)
NOTE:
● This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer
to the appropriate Service Manual.
● The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to
the area and the degree of damage on the body.
●
●
Remove the wheelhouse upper member.
Replace the bulkhead side member, check the side frame end outrigger position for damage. If necessary, replace it.
DASHBOARD UPPER SIDE MEMBER
DAMPER HOUSING
EXTENSION
WHEELHOUSE
UPPER MEMBER
BULKHEAD SIDE
MEMBER
DAMPER HOUSING
EXTENSION
BULKHEAD SIDE
MEMBER
FRONT SIDE FRAME
3-8
SIDE FRAME END
OUTRIGGER
Construction (Damper housing and damper housing extension)
NOTE:
● This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer
to the appropriate Service Manual.
● The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to
the area and the degree of damage on the body.
Check the damper housing position for damage.
If necessary, replace the damper housing, wheelhouse gusset A, and the damper housing extension as an assembly.
● When replacing the damper housing, peel back the front inner lower pillar.
● When sliding the damper housing out, drill the four spot welded points [A] at the joint for side frame gusset B, and pry
up its weld flange.
●
●
SIDE FRAME GUSSET B
DASHBOARD UPPER
SIDE MEMBER
[A]
FRONT SIDE FRAME
FRONT INNER
LOWER PILLAR
Peel back.
DAMPER HOUSING
WHEELHOUSE GUSSET A
DAMPER HOUSING EXTENSION
Right side
DAMPER HOUSING
ENGINE SIDE
MOUNT BRACKET
MOUNTING BOLT
6 x 1.0 mm
SIDE FRAME GUSSET A
3-9
Front Wheelhouse/Damper Housing
Installation
NOTE:
● Welding symbols
: 2-Plate spot welding
: 3-Plate spot welding
: 4-Plate spot welding
: MAG plug welding
: MAG welding
L=Welding length unit: mm (in)
● ( ): The number of welds
6. Do the main welding.
Weld the damper housing (A) and wheelhouse lower
gusset B to the front side frame (C).
A
B
(6)
1. Clamp the new damper housing, the bulkhead side
member, the side frame end outrigger, and the front
bulkhead, and measure the front compartment
diagonally.
(6)
2. Check the body dimensions.
Front bulkhead position (see page 4-3)
Engine compartment (see page 4-4)
● Engine side mount position (see page 4-5)
● Bulkhead side member position (see page 4-6)
● Engine compartment and front floor, under view
(see page 4-17)
● Repair chart, top view (see page 4-20)
● Repair chart, side view (see page 4-22)
C
●
●
7. Weld the damper housing (C) and wheelhouse gusset
A (D) to side frame gusset A and gusset B.
Right side: Weld the engine side mount bracket (E).
C
(2)
(4)
D
3. Tack weld the new parts and the front bulkhead into
position.
4. Temporarily install the front subframe, and check the
front side frame position.
5. Temporarily install the front fender, the hood, and the
door, then check for differences in level and
clearance.
Check the external parts fitting positions (see page
4-15). If necessary, check the headlight and the front
bumper positions. Make sure the body lines flow
smoothly.
(8)
B
Right side
(2)
A
6 x 1.0 mm
9.3 N·m
(0.95 kgf·m, 6.9 lbf·ft)
D
(7)
A
E
(4)
(1)
3-10
8. From the passenger's compartment, plug weld the
damper stiffener (A), the damper housing extension
(C), wheelhouse lower gusset B, and the damper
housing (D) to the dashboard lower (E).
10. Weld the damper housing extension (A) and the front
inner lower pillar (B).
(3)
A
(5)
D
C
A
(2)
(5)
(2)
E
(7)
(2)
B
(2)
11. Weld the damper housing extension (A), the bulkhead
side member (B), and the bulkhead upper frame (C).
B
A
C
9. Weld the damper base (A), the damper housing
extension (B), and the damper housing bracket (C) to
the dashboard upper (D) and the dashboard upper
side member (E).
(4)
A
E
(3)
B
D
(2)
(1)
B
A
(7)
C
(2)
(2)
C
(3)
B
(3)
(cont'd)
3-11
Front Wheelhouse/Damper Housing
Installation (cont'd)
12. Weld the side frame end outrigger (A) and the
bulkhead side member (B).
Weld the bulkhead side stay (C) and the bulkhead
lower crossmember (D) (see step 5 on page 3-4).
13. Weld the wheelhouse upper member (A). When
reusing the wheelhouse upper member, weld it with
MIG plug welding.
(2)
L=10 (0.39)
C
(5)
(7)
(9)
(10)
(15)
(4)
L=5 (0.20)
[Z]
D
A
(4)
A
B
[VIEW: Z]
(5)
A
(2)
3-12
(1)
Front Side Frame/Side Frame Gusset
Removal
Mass production body welding positions and numbers (Front side frame)
NOTE:
● Welding symbols
: 2-Plate spot welding; : 3-Plate spot welding;
L=Welding length unit: mm (in)
● ( ): The number of welds
: 4-Plate spot welding;
: MAG welding
SIDE FRAME GUSSET
SIDE FRAME
GUSSET B
With front bulkhead removed
FRONT SIDE FRAME
: MAG plug welding;
SIDE FRAME
GUSSET A
(17)
BULKHEAD
SIDE MEMBER
SIDE FRAME GUSSET B
SIDE FRAME GUSSET A
(14)
(10)
SIDE FRAME
END OUTRIGGER
(13)
DAMPER HOUSING
(1)
FRONT SIDE FRAME
Inside (12)
Outside (10)
Right
ight side
R
Front
ENGINE SIDE
MOUNT
BRACKET
SIDE FRAME
GUSSET
(8)
SIDE FRAME
GUSSET A
(cont'd)
3-13
Front Side Frame/Side Frame Gusset
Removal (cont'd)
Mass production body welding positions and numbers (Outrigger and side frame gusset)
NOTE:
● Welding symbols
: 2-Plate spot welding; : 3-Plate spot welding;
L=Welding length unit: mm (in)
● ( ): The number of welds
[A]
REAR SUPPORT BRACKET
: 4-Plate spot welding;
: MAG welding
FLOOR FRONT CROSSMEMBER A
[X]
[A]: Bottom of the
floor panel
: MAG plug welding;
FRONT FLOOR FRAME
REAR SUPPORT BRACKET
[VIEW: X]
(5)
(19)
(19)
Front
(2)
(5)
FLOOR FRONT
CROSSMEMBER A
OUTRIGGER
SIDE FRAME GUSSET
INSIDE SILL
(3)
(2)
OUTRIGGER GUSSET
SIDE FRAME GUSSET
OUTRIGGER GUSSET
(6)
INSIDE SILL
(3)
(5)
(4)
(2)
(3)
(2)
(4)
OUTRIGGER
[VIEW: Z]
(11)
(21)
(18)
(5)
[Z]
3-14
(4)
SIDE FRAME
GUSSET
Front
FLOOR FRONT
CROSSMEMBER A
Construction
NOTE:
● This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer
to the appropriate Service Manual.
● The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to
the area and the degree of damage on the body.
Remove side frame gusset B, and replace the front side frame.
Check the side frame gusset and the rear support bracket positions for damage.
● If necessary, remove the outrigger and the outrigger gusset, then replace the side frame gusset and the rear support
bracket as an assembly.
● [A]: Carefully cut the front welded flange of floor front crossmember A.
● [B]: Cut the rear welded flange of the outrigger.
●
●
SIDE FRAME GUSSET B
BULKHEAD SIDE
MEMBER
SIDE FRAME GUSSET
SIDE FRAME
GUSSET A
FRONT SIDE
FRAME
REAR SUPPORT BRACKET
SIDE FRAME GUSSET
INSIDE SILL
FRONT FLOOR
FRAME
OUTRIGGER
GUSSET
REAR SUPPORT
BRACKET
Front
ront
F
[B]
[A]
Front
FLOOR FRONT CROSSMEMBER A
OUTRIGGER
3-15
Front Side Frame/Side Frame Gusset
Installation
4. Tack weld the new parts and the front bulkhead into
position.
NOTE:
● Welding symbols
: 2-Plate spot welding
: 3-Plate spot welding
: 4-Plate spot welding
: MAG plug welding
: MAG welding
L=Welding length unit: mm (in)
● ( ): The number of welds
5. Temporarily install the front subframe, and check the
front side frame and the side frame gusset positions.
1. Remove the outrigger gusset (A) and the outrigger (B)
from new side frame gusset (C).
Weld the rear support bracket (D) and the support
stiffener (E), shown in [DETAIL Z].
A
B
6. Temporarily install the front fender, the hood, and the
door, then check for differences in level and
clearance.
Check the external parts fitting positions (see page
4-15). If necessary, check the headlight and the front
bumper positions. Make sure the body lines flow
smoothly.
7. Do the main welding.
Weld the side frame gusset (B) and the front floor
frame (C).
● Weld the rear support bracket (D) and floor front
crossmember A.
●
B
C
C
(11)
(11)
D
[DETAIL Z]
E
[X]
Front
Front
[Z]
A
(1)
D
[VIEW: X]
D
(2)
E
2. Set the side frame gusset and the front side frame.
Clamp the front bulkhead, and measure the front
compartment diagonally.
L=73 (2.87)
3. Check the body dimensions.
Front bulkhead position (see page 4-3)
Engine compartment (see page 4-4)
● Engine side mount position (see page 4-5)
● Bulkhead side member position (see page 4-6)
● Engine compartment and front floor, under view
(see page 4-17)
● Repair chart, top view (see page 4-20)
● Repair chart, side view (see page 4-22)
●
Front
A
●
3-16
(4)
9. Weld the outrigger (A) to the side frame gusset (B)
and the inside sill (C).
[VIEW: Z]
(2)
B
A
(4)
(4)
B
(14)
(2)
(3)
(14)
C
Front
(4)
(18)
Front
8. Weld the outrigger gusset (A) to the side frame gusset
(B) and the inside sill (C).
A
C
(4)
(1)
C
B
B
L=95 (3.74)
A
10. From the passenger's compartment, plug weld the
holes in the dashboard lower (A) and the floor panel
(B).
A
(16)
(5)
Front
(5)
(5)
A
B
(4)
(3)
(cont'd)
3-17
Front Side Frame/Side Frame Gusset
Installation (cont'd)
11. When only replacing the front side frame (A), main
weld the side frame gusset (B) and the front side
frame.
13. Weld side frame gusset B.
[X] area: Drill the three holes for welding the new front
side frame (A), and plug weld the side frame gusset
(C).
B
A
(1)
(2)
(4)
(9)
(10)
(5)
(13)
A
(4)
A
B
Front
[X]
B
Front
C
B
A
12. Weld the front side frame (A) and the damper housing
(B).
Right side: Weld the engine side mount bracket (C).
A
14. Weld the side frame end outrigger (A) to the bulkhead
side member (B).
Weld the bulkhead side stay (C) and the bulkhead
lower crossmember (D) (see step 5 on page 3-4).
(8)
C
B
(5)
(6)
Right side
B
(10)
(4)
C
(4)
3-18
D
A
A
Front Pillar Outer Panel
Removal
Mass production body welding positions and numbers (Outer panel and front pillar lower
stiffener)
NOTE:
● Welding symbols
: 2-Plate spot welding; : 3-Plate spot welding;
L=Welding length unit: mm (in)
● ( ): The number of welds
: 4-Plate spot welding;
: MAG plug welding;
: MAG welding
(24)
(1) L=10 (0.39)
With outer panel removed
4-Plate welding
FRONT PILLAR
UPPER STIFFENER
(13)
(14)
(7)
(4)
(2)
(9)
(19)
FRONT PILLAR
LOWER
STIFFENER
(1)
FRONT PILLAR
OUTER SEPARATOR
(Adhesive type)
(2)
(18)
(14)
(4)
(6)
FRONT PILLAR
(1) INNER SEPARATOR
(7)
(cont'd)
3-19
Front Pillar Outer Panel
Removal (cont'd)
Construction
NOTE:
● This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer
to the appropriate Service Manual.
● The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to
the area and the degree of damage on the body.
●
●
Remove the wheelhouse upper member (see page 3-6).
Cut and pry off the outer panel at the front pillar and side sill portions.
NOTE: Select the cutting positions in consideration of the front side outer panel repair part (see page 1-14).
●
●
Check the front pillar lower stiffener position for damage. If necessary, replace it.
Replace the front pillar inner separator.
OUTER PANEL
FRONT PILLAR
UPPER STIFFENER
FRONT PILLAR
UPPER STIFFENER
FRONT PILLAR
LOWER
STIFFENER
OUTER PANEL
OUTER PANEL
FRONT PILLAR
INNER SEPARATOR
SIDE SILL
REINFORCEMENT
SIDE SILL
REINFORCEMENT
3-20
FRONT PILLAR
OUTER
SEPARATOR
(Adhesive type)
Installation
NOTE:
● Welding symbols
: 2-Plate spot welding
: 3-Plate spot welding
: 4-Plate spot welding
: MAG plug welding
: MAG welding
L=Welding length unit: mm (in)
● ( ): The number of welds
6. Remove the outer panel repair part, and weld the
front pillar lower stiffener (A) to the upper stiffener (B)
and the side sill reinforcement (C).
NOTE: When welding position [X], do not burn the
sealer (D) behind the front pillar lower stiffener.
B
1. Install the new front pillar inner separator (A) on the
front inner lower pillar (B).
(4)
NOTE: Apply the sealer (C) all the way around the
separator and inside the front pillar lower stiffener (D)
without gaps.
B
(2)
A
A
D
[X]
C
(1)
2. Set the new front pillar lower stiffener, and tack weld
it into position.
3. Rough-cut the front side outer panel repair part,
clamp it to the body, and check the body dimensions.
Bulkhead side member position (see page 4-6)
Door hinge positions (see page 4-7)
● Windshield and door openings (see page 4-13)
●
●
7. Weld the patches (A) at the cut sections of the body
side outer panel (B).
Front pillar section
Side sill section
30 mm
(1.18 in)
(6)
40 mm
(1.57 in)
4. Temporarily install the windshield, the door, the
hood, and the front fender, then check for differences
in level and clearance.
Check the external parts fitting positions (see page
4-15). Make sure the body lines flow smoothly.
5. Trim the cut and joint areas of the outer panel repair
part as needed, and prepare the butt-welding areas.
C
(1)
D
B
A
A
(7)
B
(cont'd)
3-21
Front Pillar Outer Panel
Installation (cont'd)
8. Apply the sealer (A) on the front pillar lower stiffener
(B) at the outer separator location.
(6)
Sealer thickness: 10 mm (0.39 in)
C
B
(16)
(5)
L=195
(7.68)
(1)
(1)
(8)
A
9. Clamp the outer panel repair part, and recheck the
clearance and alignment of the door, the front fender,
and the windshield.
(9)
10. Do the main welding.
Weld the outer panel repair part (A), the front pillar
lower stiffener (B), and the patches (C).
(22)
[X]
(15)
(5)
A
[X] Portion: Excessive heat from welding can burn or
melt the sealer (D) behind the front pillar lower
stiffener. Carefully weld one small area at a time,
allowing time to cool before welding the next area. If
the sealer becomes damaged, insert the nozzle
through the hole of the inner lower pillar (E), and fill
the gaps with commercially available expanding
urethane foam (F).
B
L=245
(9.65)
(15)
(3)
A
Windshield opening
B
A
(6)
(8)
C
Flange
Notch
(7)
D
(18)
F
E
(1)
L=10 (0.39)
(1)
11. Weld the wheelhouse upper member (see step 13 on
page 3-12).
3-22
Side Sill Outer Panel
Removal
Mass production body welding positions and numbers (Outer panel and side sill reinforcement)
NOTE:
● Welding symbols
: 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding;
L=Welding length unit: mm (in)
● ( ): The number of welds
● The figure shows the size of side sill outer panel repair part.
: MAG plug welding;
: MAG welding
Top end positions of the side
sill outer panel repair part
Rear edge position of the side
sill outer panel repair part
(1)
FRONT PILLAR OUTER
SEPARATOR (Adhesive type)
(10)
(12)
(4)
(13)
(11)
((11)
11)
(38)
(8)
CENTER PILLAR OUTER SEPARATOR A
CENTER PILLAR OUTER SEPARATOR B
(Adhesive type)
With outer panel removed
FRONT PILLAR LOWER STIFFENER
(3)
(1)
(1)
(6)
(4)
SIDE SILL
REINFORCEMENT
CENTER PILLAR STIFFENER
(cont'd)
3-23
Side Sill Outer Panel
Removal (cont'd)
Construction
NOTE:
● This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer
to the appropriate Service Manual.
● The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to
the area and the degree of damage on the body.
●
Cut and pry off the side sill outer panel, and replace it.
NOTE: Select the cutting positions in consideration of the side sill outer panel repair part (see page 1-14).
●
●
Replace center pillar outer separator A.
Check the side sill reinforcement for damage. If necessary, replace it.
FRONT PILLAR
LOWER STIFFENER
OUTER PANEL
OUTER PANEL
CENTER PILLAR
STIFFENER
FRONT PILLAR
LOWER STIFFENER
INSIDE SILL A
FRONT PILLAR
OUTER SEPARATOR
(Adhesive type)
CENTER PILLAR
STIFFENER
CENTER PILLAR OUTER SEPARATOR B
(Adhesive type)
CENTER PILLAR
OUTER SEPARATOR A
SIDE SILL
REINFORCEMENT
OUTER PANEL
REAR DOOR
RAIL SUPPORT
INSIDE SILL B
REAR DOOR RAIL
SUPPORT BULKHEAD
3-24
OUTER PANEL
Installation
NOTE:
● Welding symbols
: 2-Plate spot welding
: 3-Plate spot welding
: 4-Plate spot welding
: MAG plug welding
: MAG welding
L=Welding length unit: mm (in)
● ( ): The number of welds
NOTE: When welding position [X], do not burn or melt
the inner separator (C) behind the front pillar lower
stiffener.
(2)
B
1. Clamp the side sill reinforcement, and check the body
dimensions.
B
Passenger's compartment (see page 4-9)
● Engine compartment and front floor, under view
(see page 4-17)
● Front floor and rear floor, under view (see page
4-18)
● Inside sill positions (see page 4-19)
● Repair chart, top view (see page 4-20)
● Repair chart, side view (see page 4-22)
●
2. Tack weld the side sill reinforcement.
C
[X]
A
(1)
A
Front
(1)
8. Weld the side sill reinforcement (A) and the center
pillar stiffener (B).
3. Rough-cut the side sill outer panel repair part, and
clamp it to the body.
4. Check the body dimensions.
Bulkhead side member position (see page 4-6)
Door hinge positions (see page 4-7)
● Sliding door female guide and striker positions (see
page 4-8)
● Sliding door rail lower support positions (see page
4-10)
● Windshield and door openings (see page 4-13)
●
●
[X] Portion: Excessive heat from welding can burn or
melt the inner separator (C) behind the center pillar
stiffener. Carefully weld one small area at a time,
allowing time to cool before welding the next area. If
the separator becomes damaged, insert the nozzle
through the hole of the center inner pillar (D), and fill
the gaps with sealer (E).
A
C
5. Temporarily install the front fender, the front door,
and the sliding door, then check for differences in
level and clearance.
Check the external parts fitting positions (see page
4-15). Make sure the body lines flow smoothly.
6. Trim the cut and joint areas of the outer panel repair
part as needed, and prepare the butt-welding
connections.
(1)
[X]
(6)
B
D
7. Remove the side sill outer panel repair part, and weld
the side sill reinforcement (A) and the front pillar
lower stiffener (B).
E
(cont'd)
3-25
Side Sill Outer Panel
Installation (cont'd)
9. Weld the patches (A) at the cut sections of the body
side outer panel (B).
10. Install new center pillar outer separator A on the
center pillar stiffener (C).
NOTE: Apply the sealer (D) all the way around the
separator and inside the outer panel repair part (E)
without gaps.
Front pillar section
(2)
40 mm
(1.57 in)
Apply the sealer on the center pillar stiffener at outer
separator B location.
Sealer thickness: 10mm (0.39in)
C
A
A
B
B
Center pillar section
B
(9)
40 mm
(1.57 in)
D
A
E
11. Apply the sealer (A) on the front pillar lower stiffener
(B) at the outer separator location.
Sealer thickness: 10mm (0.39in)
Side sill section
30 mm
(1.18 in)
B
A
A
(4)
B
12. Clamp the outer panel repair part, and recheck the
clearance and alignment of the sliding door, the front
door, and the front fender.
3-26
13. Do the main welding.
Weld the outer panel repair part (A) and the patches
(B).
Lower center pillar and side sill rear areas
[VIEW: Z]
L=360 (14.17)
B
[X] Portion: Excessive heat from welding can burn or
melt the inner separator (C) behind the front pillar
lower stiffener (D). Carefully weld one small area at a
time, allowing time to cool before welding the next
area. If the separator becomes damaged, insert the
nozzle through the hole of the inner lower pillar (E),
and fill the gaps with commercially available
expanding urethane foam (F).
(9)
(10)
A
Lower front pillar and side sill front areas
(2)
B
L=165 (6.50)
A
C
(5)
A
[X]
(11)
[Z]
(12)
D
(8)
C
F
E
(10)
L=155
(6.10)
B
A
A
(15)
(12)
(12)
(14)
(4)
(19)
3-27
Center Pillar Outer Panel
Removal
Mass production body welding positions and numbers (Outer panel and side sill reinforcement)
NOTE:
● Welding symbols
: 2-Plate spot welding; : 3-Plate spot welding;
L=Welding length unit: mm (in)
● ( ): The number of welds
: 4-Plate spot welding;
: MAG plug welding;
: MAG welding
Front side outer panel
repair part rear upper edge
(9)
(7)
(16)
(34)
(37)
FRONT PILLAR
UPPER STIFFENER
With outer panel removed
CENTER PILLAR
INNER SEPARATOR
ROOF SIDE RAIL
EXTENSION
CENTER PILLAR
STIFFENER
(1)
(2)
CENTER PILLAR OUTER
SEPARATOR B (Adhesive type)
((6)
6)
(3)
(2)
SIDE SILL
REINFORCEMENT
(13)
(11)
(37)
CENTER PILLAR OUTER
SEPARATOR A
3-28
(8)
Front side outer panel
repair part rear lower edge
Construction
NOTE:
● This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer
to the appropriate Service Manual.
● The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to
the area and the degree of damage on the body.
●
If there is any damage to the center pillar, cut the [A] position, pry off the outer panel, and replace it.
NOTE: Select the cutting positions in consideration of the front side outer panel repair part (see page 1-14).
Replace center pillar outer separator A.
Check the center pillar stiffener position for damage. If necessary, replace it.
● When replacing the center pillar stiffener, cut the [B] position at the roof side portion of the outer panel.
● Replace the center pillar inner separator.
● If necessary, replace the side sill reinforcement (see page 3-23).
●
●
OUTER PANEL
[VIEW: X]
OUTER
PANEL
58 mm
(2.28 in)
[B]
ROOF
SIDE RAIL
EXTENSION
[VIEW: Z]
ROOF SIDE
FRONT RAIL
200 mm
(7.87 in)
[A]
[Z]
35 mm
(1.38 in) CENTER
PILLAR
STIFFENER
ROOF SIDE
FRONT RAIL
[B]
CENTER INNER
PILLAR
[A]
CENTER
PILLAR
STIFFENER
CENTER
PILLAR
STIFFENER
CENTER PILLAR
STIFFENER
[X]
SIDE SILL
REINFORCEMENT
OUTER
PANEL
FRONT PILLAR
OUTER
SEPARATOR
(Adhesive type)
CENTER PILLAR
INNER SEPARATOR
REAR DOOR RAIL SUPPORT
OUTER PANEL
CENTER PILLAR OUTER
SEPARATOR B
(Adhesive type)
CENTER PILLAR
OUTER SEPARATOR A
REAR DOOR RAIL
SUPPORT BULKHEAD
OUTER PANEL
3-29
Center Pillar Outer Panel
Installation
5. Check the body dimensions.
NOTE:
● Welding symbols
: 2-Plate spot welding
: 3-Plate spot welding
: 4-Plate spot welding
: MAG plug welding
: MAG welding
L=Welding length unit: mm (in)
● ( ) and ( )*: The number of welds
Bulkhead side member position (see page 4-6)
Door hinge positions (see page 4-7)
● Sliding door female guide and striker positions (see
page 4-8)
● Sliding door rail lower support positions (see page
4-10)
● Windshield and door openings (see page 4-13)
●
●
1. Check the body dimensions.
Passenger's compartment (see page 4-9)
Engine compartment and front floor, under view
(see page 4-17)
● Front floor and rear floor, under view (see page
4-18)
● Inside sill positions (see page 4-19)
● Repair chart, top view (see page 4-20)
● Repair chart, side view (see page 4-22)
●
●
2. Install the new center pillar inner separator (A) on the
center inner pillar (B).
NOTE: Apply the sealer (C) all the way around the
separator and inside the center pillar stiffener (D)
without gaps.
B
6. Temporarily install the front fender, the front door,
and the sliding door, then check for differences in
level and clearance.
Check the external parts fitting positions (see page
4-15). Make sure the body lines flow smoothly.
7. Trim the cut and joint areas of the outer panel repair
part as needed, and prepare the butt-welding
connections.
8. Weld the side sill reinforcement (A) and the center
pillar stiffener (B).
[X] Portion: Excessive heat from welding can burn or
melt the sealer (C) behind the center pillar stiffener.
Carefully weld one small area at a time, allowing time
to cool before welding the next area. If the sealer
becomes damaged, insert the nozzle through the hole
of the center inner pillar (D), and fill the gaps with
sealer (E).
A
(1)
A
C
[X]
C
D
(6)
D
3. Clamp the new center pillar stiffener, and tack weld it
into position.
4. Rough-cut the front side outer panel repair part, and
clamp it to the body.
E
3-30
B
9. Weld the top of the center pillar stiffener (A) to the
front pillar upper stiffener (B), the roof side rail
extension (C), and the roof side front rail (D).
(ᤝ)*: Welding position with the roof side front rail, the
high-strength steel (1500 MPa). Confirm a spot
welding condition (see page 1-23).
10. Weld the patches (A) at the cut sections of the body
side outer panel (B).
Front pillar and side sill section (see step 9 on page
3-26)
Roof side section
40 mm
(1.57 in)
A
(7)
C
A
B
(6)
B
Center pillar section
C
D
(1)
In case of outer panel replacement only.
B
A
A
D
D
(ᰞ)*
B
A
30 mm
(1.18 in)
(5)
11. Install new center pillar outer separator A on the
center pillar stiffener, and apply the sealer to the
separator and inside the outer panel repair part.
Apply the sealer on the center pillar stiffener at the
outer separator B location (see step 10 on page 3-26).
12. Apply the sealer on the front pillar lower stiffener (see
step 11 on page 3-26).
(cont'd)
3-31
Center Pillar Outer Panel
Installation (cont'd)
13. Do the main welding.
Weld the outer panel repair part (A) and the patches
(B).
In case of outer panel replacement only.
L=180 (7.09)
B
Lower front pillar and side sill areas (see step 13 on
page 3-27)
(ᤝ)*: Welding position with the roof side front rail (C),
the high-strength steel (1500 MPa). Confirm a spot
welding condition (see page 1-23).
(5)
A
L=140 (5.51)
B
L=240 (9.45)
(6)
A
(33)
(1)
(2)
A
(4)
(1)
(36)
(2)
(ᰠ)*
A
C
3-32
Inside Sill, Rear
Removal
Mass production body welding positions and numbers
NOTE:
● Welding symbols
: 2-Plate spot welding; : 3-Plate spot welding;
L=Welding length unit: mm (in)
● ( ): The number of welds
: 4-Plate spot welding;
With outer panel removed
(1) L=10 (0.39)/(3) L=5 (0.20)
[VIEW: W]
: MAG plug welding;
: MAG welding
QUARTER PILLAR
STIFFENER EXTENSION
[VIEW: X]
(1)
(1)
L=5 (0.20)
(6)
L=5 (0.20)
(1)
ELR
STIFFENER
(3)
UNDER FLOOR PAN
UPPER CROSSMEMBER [B]
[Y]
MOUNTING
BOLTS
8 x 1.25 mm
(1)
L=5 (0.20)
REAR DOOR
RAIL SUPPORT
INSIDE SILL B
[Z]
[X]
[W]
[A]
(15)
(15)
(14)
[A]: Bottom of the floor panel
[B]: Bottom of the under floor pan upper
crossmember and the floor panel
(left side only)
QUARTER PILLAR
STIFFENER EXTENSION
INSIDE SILL A
INSIDE SILL SEPARATORS
(Adhesive type)
[VIEW: Y]
(4)
(7)
REAR WHEEL
ARCH EXTENSION
FLOOR PANEL
TRAILING ARM
OUTRIGGER B
[VIEW: Z]
TRAILING ARM
OUTRIGGER A
WHEEL ARCH
OUTER SEPARATOR
(3)
(9)
MIDDLE
FLOOR
OUTRIGGER
STIFFENER
Left side
only
(8)
(1)
FLOOR
FRAME
OUTRIGGER
(1)
(5)
(1)
Front
INSIDE SILL B
INSIDE SILL B
(4)
MIDDLE TIE DOWN
GUSSET
Front
(4)
(cont'd)
3-33
Inside Sill, Rear
Removal (cont'd)
Construction
NOTE:
● This section explains the procedures after removal of all related parts. For the related parts’ removal procedure, refer
to the appropriate Service Manual.
● The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to
the area and the degree of damage on the body.
●
Cut and pry off the outer panel, and replace it.
NOTE: Select the cutting positions in consideration of the front side outer panel repair parts (see page 1-14).
Remove the rear wheel arch extension and the quarter pillar stiffener extension.
Replace the wheel arch outer separator.
● Remove the middle floor outrigger, and replace inside sill B as shown.
●
●
NOTE: When removing the front portion [A] of left inside sill B, refer to the front portion removal procedures.
CENTER PILLAR
STIFFENER
SIDE SILL
REINFORCEMENT
MIDDLE FLOOR
OUTRIGGER
[A]
INSIDE SILL
SEPARATORS
(Adhesive type)
GUARTER PILLAR
STIFFENER EXTENSION
INSIDE SILL B
REAR WHEELHOUSE
QUARTER INNER
PILLAR
REAR WHEEL ARCH
EXTENSION
WHEEL ARCH OUTER
SEPARATOR
OUTER PANEL
REAR WHEEL ARCH
EXTENSION
3-34
OUTER PANEL
Front portion removal procedure
1. Carefully drill the seven spot welded points at the joint
for the under floor pan upper crossmember (A) and
the floor panel (B), and cut the side edge of the under
floor pan upper crossmember as shown. Remove the
mounting bolts (C).
4. Drill the eight spot welded points on inside sill B, the
under floor pan upper crossmember (C), and the floor
panel (D).
NOTE: Drill through the two welding nuggets (1, 2).
Carefully slit the [X] and [Y] positions of the floor
panel.
NOTE: Drill through the three welding nuggets (1, 2,
3).
Front
A
C
Cut line
[Y]
C
Front
(6)
1
1
2
D
3
A
Reuse.
[X]
2
4
3
B
6
2. Drill the one spot welded point at the joint for the front
seat rear bracket (A) and the under floor pan upper
crossmember (B) with a 10mm (0.39 in) spot cutter
(C).
7
8
5
B
5. Peel back the side edge of the floor panel (C), drill the
four spot welded points on inside sill B, then move it
backward while turning it inward, and remove it from
inside sill A and the inside sill stiffener (D).
B
A
B
C
A
3. Grind away the floor panel (A) with a belt sander (C),
then drill the one spot welded point at the joint for
inside sill B and the inside sill stiffener (D).
C
C
4
C
3
A
1
2
D
A
D
B
B
A
3-35
Inside Sill, Rear
Installation
3. While inserting inside sill B into inside sill A, push the
tip of inside sill B to the side sill reinforcement side
(C), and align inside sill B in inside sill A.
NOTE:
● Welding symbols
: 2-Plate spot welding
: 3-Plate spot welding
: 4-Plate spot welding
: MAG plug welding
: MAG welding
L=Welding length unit: mm (in)
● ( ): The number of welds
1. Separate new inside sill B and inside sill A. Remove
the middle floor outrigger (C), the floor frame
outrigger (D), the trailing arm outrigger (E), and the
quarter pillar stiffener extension (F) from new inside
sill B.
B
C
D
C
A
E
4. Install the front seat rear bracket mounting bolts (A),
and clamp inside sill B.
A
A
8 x 1.25 mm
22 N·m (2.2 kgf·m, 16 lbf·ft)
B
F
2. Insert inside sill B into the inside sill stiffener (A) under
the floor panel (C) halfway, and apply the sealer (D) on
the center pillar lower extension (E) at the inside sill
separator locations.
Sealer thickness: 10mm (0.39in)
B
A
5. Clamp the new quarter pillar stiffener extension and
the rear wheel arch extension.
C
B
6. Check the body dimensions.
D
Sliding door rail lower support positions (see page
4-10)
● Front floor and rear floor, under view (see page
4-18)
● Inside sill positions (see page 4-19)
● Repair chart, top view (see page 4-20)
● Repair chart, side view (see page 4-22)
●
B
E
3-36
D
7. Tack weld the new parts, and check the rear
suspension position.
8. Rough-cut the side sill outer panel repair part and the
rear side outer panel repair part, and clamp them to
the body.
12. Weld side sill B, side sill A, and the side sill stiffener
(C).
C
(Left side only)
(2)
9. Check the body dimensions.
Door hinge positions (see page 4-7)
Sliding door female guide and striker positions (see
page 4-8)
● Passenger's compartment (see page 4-9)
● Windshield and door openings (see page 4-13)
●
●
(8)
10. Temporarily install the front door and the sliding
door, then check for differences in level and
clearance.
Check the external parts fitting positions (see page
4-15). Make sure the body lines flow smoothly.
NOTE: Check that the sliding door opens and closes
smoothly.
B
Front
(2)
A
13. Weld the middle floor outrigger (A) to inside sill B and
the floor frame (C).
11. From under the floor, weld inside sill B to the floor
frame outrigger (A), the trailing arm outrigger (C), and
the rear wheel arch extension (D).
C
D
L=42 (1.65)
C
A
A
[Z]
(3)
(3)
(8)
(3)
Front
B
(4)
(1)
L=35
(1.38)
Front
A
[VIEW: Z]
B
L=42 (1.65)
B
C
Front
(1)
L=80 (3.14)
(cont'd)
3-37
Inside Sill, Rear
Installation (cont'd)
14. From the passenger’s compartment side, weld the
ELR stiffener (A) and the center inner pillar (B).
B
A
16. Plug weld inside sill B to inside sill A, the floor panel
(C), the under floor pan upper crossmember (D), and
the front seat rear bracket (E).
Plug weld the front weld flange of the under floor pan
upper crossmember and the middle floor outrigger
(F).
E
D
C
B
(1) L=10 (0.39)
(3) L=5 (0.20)
(3)
(1) L=5 (0.20)
15. Plug weld inside sill B to inside sill A and the side sill
stiffener (C).
(1)
F
E
(2)
D
C
B
L=45 (1.77)
L=45 (1.77)
A
C
(2)
B
(2)
(1)
(2)
(4)
17. Weld the side edge of the under floor pan upper
crossmember (A).
B
C
L=70 (2.76)
L=60 (2.36)
A
(6)
A
3-38
18. Plug weld inside sill B to the floor panel (A) and the
second seat plate (C).
(5)
(1) L=5 (0.20)
A
A
B
(1)
B
(8)
22. Weld the patch (A) at the cut sections of the body side
outer panel (B).
B
Front pillar and center pillar cut section (see step 9 on
page 3-26)
C
30 mm (1.18 in)
(7)
B
(8)
A
19. Recheck the clearance and alignment of the front door
and the sliding door.
20. Trim the cut and joint areas of the outer panel repair
part as needed, and prepare the butt-welding
connections. Remove the outer panel repair parts.
21. Weld the quarter pillar stiffener extension (A) and the
rear wheel arch extension (B).
B
A
(1)
23. Install the new wheel arch outer separator (A) on the
rear wheel arch extension (B).
NOTE: Apply the sealer (C) all the way around the
separator and inside the outer panel (D) without gaps.
Front pillar outer separator (see step 11 on page
3-26)
● Center pillar outer separators (see step 10 on page
3-26)
●
(1)
A
(6)
L=5 (0.20)
B
(1)
C
D
(cont'd)
3-39
Inside Sill, Rear
Installation (cont'd)
24. Weld the rear side outer panel repair part (A) and the
patches (B).
Side sill outer panel repair part (see step 13 on page
3-27)
B
L=280 (11.02)
(8)
A
(6)
(6)
L=155 (6.10)
(7)
(3)
(11)
B
3-40
(4)
A
Roof Panel
Removal
Mass production body welding positions and numbers
NOTE:
● Welding symbols
: 2-Plate spot welding; : 3-Plate spot welding;
L=Welding length unit: mm (in)
● ( ): The number of welds
ROOF PANEL
: 4-Plate spot welding;
: MAG plug welding;
: MAG welding
Roof rails and outer panel welding positions with roof panel removed
(28)
INNER UPPER EXTENSION
ROOF FRONT RAIL
(11)
(3)
(4)
ROOF SIDE RAIL
M
MOUNTING
OUNTING BOLTS
6 x 1.0 mm
OUTER PANEL
(3)
ROOF ARCH D
(9)
(9)
QUARTER INNER
PILLAR
OUTER PANEL
REAR ROOF
RAIL
(7)
(6)
(9)
[VIEW: Z]
REAR PILLAR
STIFFENER
(4)
(18)
4-Pate welding
[Z]
ROOF PANEL
(cont'd)
3-41
Roof Panel
Removal (cont'd)
Construction
NOTE: This section explains the procedures after removal of all related parts. For the related parts' removal procedure,
refer to the appropriate Service Manual.
●
●
Remove the mounting bolts, drill the welded flange of the roof panel, and remove it.
Check the roof front rail, roof arch D, and the rear roof rail positions for damage. If necessary, replace them.
ROOF PANEL
REAR ROOF RAIL
ROOF ARCH D
ROOF FRONT RAIL
REAR PILLAR
STIFFENER
QUARTER INNER
PILLAR
ROOF SIDE RAIL
INNER UPPER
EXTENSION
3-42
MOUNTING BOLTS
6 x 1.0 mm
Installation
NOTE:
● Welding symbols
: 2-Plate spot welding
: 3-Plate spot welding
: 4-Plate spot welding
: MAG plug welding
: MAG welding
L=Welding length unit: mm (in)
● ( ) and ( )*: The number of welds
5. Remove the roof panel, and weld the roof front rail
(A), roof arch D, and the rear roof rail (B).
(ᤝ)*: Welding position with roof arch D (USIBOR
1500). Confirm a spot welding condition (see page
1-23).
(4)
1. Set the new the roof front rail (A), roof arch D, and the
rear roof rail (B). Clamp the new roof panel (C), and
tighten the mounting bolts (E).
A
B
D
C
A
(ᰠ)*
D
Front
B
(1)
E
6 x 1.0 mm
9.3 N·m
(0.95 kgf·m, 6.9 lbf·ft)
(1)
2. Check the body dimensions.
Roof rail positions (see page 4-11)
Windshield and door openings (see page 4-13)
● Tailgate opening (see page 4-14)
● Passenger's compartment (see page 4-9)
● Door hinge positions (see page 4-7)
●
●
(1)
(2)
Front
3. Tack weld the new roof front rail, roof arch D, and the
rear roof rail.
4. Temporarily install the roof moldings, the windshield,
the tailgate, the front doors, and the sliding doors,
then check for differences in level and clearance.
Check the external parts fitting positions (see page
4-15). Make sure the body lines flow smoothly.
(cont'd)
3-43
Roof Panel
Installation (cont'd)
6. Apply a soft type sealer (A) to the mating surfaces of
the roof panel and the roof front rail (B), roof arch D,
and the rear roof rail (C).
9. Do the main welding.
Weld the front, rear, and side flanges of the roof panel
(A) and both sides edge of the rear roof rail (B).
B
(28)
A
A
D
A
(9)
A
A
C
(3)
A
(8)
7. Clamp the roof panel, recheck the clearance and
alignment of the windshield, the tailgate, and the
outer panel.
8. Tighten the mounting bolts (A).
A
Front
(1)
(1)
B
(7)
A
6 x 1.0 mm
9.3 N·m
(0.95 kgf·m, 6.9 lbf·ft)
3-44
(1)
(15)
Rear Side Outer Panel
Removal
Mass production body welding positions and numbers (Outer panel and rear gutter)
NOTE:
● Welding symbols
: 2-Plate spot welding; : 3-Plate spot welding;
L=Welding length unit: mm (in)
● ( ): The number of welds
: 4-Plate spot welding;
: MAG plug welding;
: MAG welding
(4)
(16)
(14)
Front upper edge positions
of the rear side outer panel
repair part
(11)
[Z]
(17)
(7)
MOUNTING
M
OUNTING BOLTS
8 x 1.25 mm
(9)
OUTER PANEL
REAR WHEEL ARCH
OUTER SEPARATOR
(21)
(11)
(8)
(11)
(5)
(8)
[VIEW: Z]
(10)
REAR PILLAR
GUTTER
(10)
Front lower edge positions
of the rear side outer panel
repair part
(12)
(3)
REAR
COMBINATION
SIDE ADAPTER
(2)
(13)
REAR FLOOR
CROSSMEMBER
MOUNTING BOLTS
6 x 1.0 mm
(cont'd)
3-45
Rear Side Outer Panel
Removal (cont'd)
Construction
NOTE:
● This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer
to the appropriate Service Manual.
● The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to
the area and the degree of damage on the body.
●
Cut and pry off the rear side outer panel, and replace it.
NOTE: Select the cutting positions in consideration of the rear side outer panel repair part (see page 1-14).
●
●
Check the rear combination adapter for damage. If necessary, replace it.
Replace the wheel arch outer separator.
QUARTER INNER
PILLAR
REAR PILLAR
STIFFENER
OUTER PANEL
REAR PILLAR
GUTTER
QUARTER
INNER PILLAR
REAR WHEEL
ARCH EXTENSION
[Z]
OUTER PANEL
REAR PILLAR GUTTER
REAR PILLAR
STIFFENER
REAR COMBINATION
ADAPTER
REAR INNER
PANEL
REAR WHEEL ARCH
OUTER SEPARATOR
[VIEW: Z]
FLOOR REAR
CROSSMEMBER
MOUNTING BOLTS
6 x 1.0 mm
OUTER PANEL
OUTER PANEL
MOUNTING BOLTS
8 x 1.25 mm
3-46
QUARTER INNER
PILLAR
Installation
NOTE:
● Welding symbols
: 2-Plate spot welding
: 3-Plate spot welding
: 4-Plate spot welding
: MAG plug welding
: MAG welding
L=Welding length unit: mm (in)
● ( ): The number of welds
6. Weld the patches (A) at the cut sections of the body
side outer panel (B).
Quarter pillar section
B
(4)
40 mm
(1.57 in)
A
1. Clamp the new rear combination adapter, and tighten
the mounting bolts.
2. Rough-cut the rear side outer panel repair part, and
clamp it to the body.
3. Check the body dimensions.
Rear pillar section
Door hinge positions (see page 4-7)
Sliding door female guide and striker positions (see
page 4-8)
● Passenger's compartment (see page 4-9)
● Sliding door rail lower support positions (see page
4-10)
● Rear pillar gutter and floor rear crossmemer
positions (see page 4-12)
● Windshield and door openings (see page 4-13)
● Tailgate opening (see page 4-14)
●
40 mm
(1.57 in)
●
A
B
4. Temporarily install the sliding door, the tailgate, and
the quarter glass, then check for differences in level
and clearance.
Check the external parts fitting positions (see page
4-15). Make sure the body lines flow smoothly.
5. Trim the cut and joint areas of the outer panel repair
part as needed, and prepare the butt-welding
connections. Remove the outer panel repair part.
(9)
Side sill section
B
30 mm
(1.18 in)
(4)
A
7. Clamp the outer panel repair part, and recheck the
clearance and alignment of the sliding door, the
quarter glass, and the tailgate. Tighten the mounting
bolts.
(cont'd)
3-47
Rear Side Outer Panel
Installation (cont'd)
8. Install the new wheel arch outer separator (A) on the
wheel arch extension (B).
Door opening and side sill area
B
L=150
(5.91)
NOTE: Apply the sealer (C) all the way around the
separator and inside the outer panel repair part (D)
without gaps.
(4)
(8)
B
[Z]
A
(8)
A
C
D
[VIEW: Z]
9. Do the main welding.
Weld the outer panel repair part (A) and the patches
(B).
8 x 1.25 mm
22 N·m
(2.2 kgf·m, 16 lbf·ft)
Quarter glass opening and rear pillar area
L=305 (12.01)
(9)
B
A
A
(5)
(12)
(7)
(16)
(7)
(3)
A
(4)
B
L=155 (6.10)
3-48
(11)
Wheel arch area
10. Weld the rear combination adapter (A) and the rear
pillar gutter (B).
(2)
A
(4)
(13)
A
(16)
(1)
(6)
(4)
6 x 1.0 mm
18 N·m
(1.8 kgf·m,
13 lbf·ft)
Rear end area
(6)
B
(9)
(13)
A
(9)
(cont'd)
3-49
Rear Side Outer Panel
Installation (cont'd)
11. With BSI radar unit: Check the BSI radar unit
mounting holes position. Install 6 mm bolts (A),
45－60 mm long, in the BSI radar unit mounting holes
(B, C, D). Tape the plumb line (E) against the outer
panel (F) directly above each mounting hole, and
thread each bolt in or out until the head of the bolt just
touches the plumb line. At each bolt, measure the
distance from the head to the end of the threaded
insert in the outer panel. If any of the distances are out
of specification, adjust the hole positions of the outer
panel in order of B, C, D.
Hole B: 22.6 mm (0.890 in)
Hole C: 47.5 mm (1.870 in)
Hole D: 44.3 mm (1.744 in)
E
A
C
B
D
A
F
3-50
Floor Rear Crossmember
Removal
Mass production body welding positions and numbers
NOTE:
● Welding symbols
: 2-Plate spot welding; : 3-Plate spot welding;
L=Welding length unit: mm (in)
● ( ): The number of welds
REAR COMBINATION
ADAPTER
: 4-Plate spot welding;
: MAG plug welding;
: MAG welding
MOUTING BOLTS
6 x 1.0 mm
[Y]
CROSSMEMBER SEPARATOR
CROSSMEMBER
EXTENSION
FLOOR REAR CROSSMEMBER
[Z]
(5)
(25)
REAR BUMPER BEAM BRACKET
THIRD-SEAT PAN
[VIEW: Z]
(5)
L=10 (0.39)
[VIEW: Y]
OUTER PANEL
INNER CROSSMEMBER
REAR INNER PILLAR
(2)
(8)
THIRD-SEAT PAN
(6)
[A]
CROSSMEMBER
EXTENSION
[A]: Bottom of the third-seat pan
[B]: Bottom of floor rear extension B
(7)
[B]
FLOOR REAR EXTENSION B
(cont'd)
3-51
Floor Rear Crossmember
Removal (cont'd)
Construction
NOTE:
● This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer
to the appropriate Service Manual.
● The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to
the area and the degree of damage on the body.
Remove floor rear extension B from one side.
Cut the rear edge [A] of the third-seat pan where it wraps over the inner crossmember, and peel it back.
● Cut the position [B] of the inner crossmember, and drill the six spot welded points [C] on the inner crossmember.
● Drill the three spot welded points [D] on the outer crossmember from outside of it, and separate the side and the
center with the inner crossmember.
● Leave the left side of the inner crossmember on the body side, while lowering the left side of the outer crossmember,
move the other side diagonally, and remove the floor rear crossmemer as shown.
● Replace the crossmember separator of one side.
●
●
[VIEW: Z]
[VIEW: X]
INNER CROSSMEMBER
INNER CROSSMEMBER
[A]
Cut and peel back.
[C]
[B]
Cut line
THIRD-SEAT PAN
100 mm (3.94 in)
RIGHT FLOOR REAR
EXTENSION B
REAR COMBINATION
ADAPTER
[X]
[Z]
INNER CROSSMEMBER
MOUNTING BOLTS
6 x 1.0 mm
CROSSMEMBER
SEPAREATOR
Reuse.
CROSSMEMBER
SEPARATOR
Replace.
CROSSMEMBER EXTENSION
Leave on the body side.
FLOOR REAR CROSSMEMBER
MOUNTING BOLTS
6 x 1.0 mm
OUTER CROSSMEMBER
INNER CROSSMEMBER
OUTER CROSSMEMBER
[D]
3-52
Installation
NOTE:
● Welding symbols
: 2-Plate spot welding
: 3-Plate spot welding
: 4-Plate spot welding
: MAG plug welding
: MAG welding
L=Welding length unit: mm (in)
● ( ): The number of welds
4. Apply the sealer (A) to the left crossmember separator
(B) on the body side.
Left side
Right side
C
B
1. Cut the left side of the inner crossmember (A), and
remove the floor crossmember extensions (B) from
both sides of the the new floor rear crossmember (C).
A
Front
A
C
5. Apply the sealer on the right side rear inner panel (C)
at the separator location.
B
A
B
6. Bend the lower edge of the right rear combination
adapter (A) and the rear pillar stiffener (B). Bend the
weld flange of the new outer crossmennber (C)
inward.
Insert the right side of the outer crossmember inside
of the rear pillar stiffener, and insert the left side of the
outer crossmember (D) inside of the left rear
combination adapter from the bottom, then set the
floor rear crossmember (E) in the body.
A
2. Install the new crossmember separator (A) on the
right side inner crossmember (B).
B
NOTE: Apply the sealer (C) all the way around the
separator and to the right side outer crossmember (D)
without gaps.
Right side
C
Left side
B
C
A
E
D
C
D
E
3. Apply the sealer on the left side outer crossmember
(E) at the body side separator location.
(cont'd)
3-53
Floor Rear Crossmember
Installation (cont'd)
7. Temporarily install the rear bumper beam, and
tighten the mounting bolts.
12. Right side: Weld the inner crossmember (A) to the
rear inner pillar (B) and the rear inner panel (C).
(5)
L=5 (0.20)
8. Check the body dimensions.
Rear pillar gutter and floor rear crossmember
positions (see page 4-12)
● Tailgate opening (see page 4-14)
● Front floor and rear floor, under view (see page
4-18)
B
(1)
●
9. Temporarily install the tailgate, then check for
differences in level and clearance.
Check the external parts fitting positions (see page
4-15). If necessary, check the taillight and the rear
bumper positions. Make sure the body lines flow
smoothly.
10. Do the main welding.
Right side: Weld the inner crossmember (A) to the
crossmember extension (B) and the third-seat pan (C).
(2)
A
(5)
C
13. Left side: Weld the body side inner crossmember (A)
and the new inner crossmember (B).
A
(4)
L=180 (7.09)
B
(6)
A
B
(2)
L=40 (1.57)
C
11. Right side: Weld floor rear extension B.
(3)
B
(3)
(4)
(6)
(10)
(2)
3-54
14. Weld the outer crossmember (A) to the crossmember
extension (B) , the bumper beam bracket (C), and the
outer panel (D).
Left side: Weld the outer crossmember and the body
side inner crossmember (E).
MOUNTING BOLTS
6 x 1.0 mm
18 N·m
(18 kgf·m, 1.3 lbf·ft)
B
A
(3)
Left side only
(8)
16. With BSI radar unit: If necessary, remove the
damaged rivnuts, then install the new rivnuts (A) with
a rivnut tool, and check the BSI radar unit mounting
holes position. Install 6 mm bolts (B), 45－60 mm
long, in the BSI radar unit mounting holes (C, D, E).
Tape the plumb line (F) against the outer panel (G)
directly above each mounting hole, and thread each
bolt in or out until the head of the bolt just touches the
plumb line. At each bolt, measure the distance from
the head to the end of the threaded insert in the outer
panel. If any of the distances are out of specification,
adjust the hole positions of the outer panel in order of
C, D, E.
Hole C: 22.6 mm (0.890 in)
Hole D: 47.5 mm (1.870 in)
Hole E: 44.3 mm (1.744 in)
F
B
A
D
C
E
(5)
D
15. Weld the outer crossmember (A) and the third-seat
pan (B).
C
A
E
A
B
G
(25)
B
3-55
Third-Seat Pan/Rear Frame
Removal
Mass production body welding positions and numbers (Third-seat pan)
NOTE:
● Welding symbols
: 2-Plate spot welding; : 3-Plate spot welding;
L=Welding length Unit: mm (in)
● ( ): The number of welds
: 4-Plate spot welding;
: MAG plug welding;
: MAG welding
With floor rear crossmember removed
(11)
(20)
THIRD ROW SEAT
MOUNT PANEL
THIRD-SEAT PAN
FLOOR PANEL
(7)
(11)
(5)
REAR FRAME
FLOOR REAR
EXTENSION A
FLOOR REAR
EXTENSION B
3-56
Mass production body welding positions and numbers (Floor rear extension A and B)
NOTE:
● Welding symbols
: 2-Plate spot welding; : 3-Plate spot welding;
L=Welding length Unit: mm (in)
● ( ): The number of welds
: 4-Plate spot welding;
: MAG plug welding;
: MAG welding
With third-seat pan removed
[VIEW: Z]
(3)
(8)
(4)
L=10 (0.39)
(7)
REAR WHEELHOUSE
FLOOR REAR EXTENSION A
Front
FLOOR PANEL
(9)
[Z]
(6)
FLOOR REAR EXTENSION A
FLOOR REAR EXTENSION B
(2)
[X]
(9)
REAR WHEELHOUSE
REAR FLOOR
CROSSMEMBER
EXTENSION
(1)
(3)
L=5 (0.20)
(12)
REAR FLOOR
CROSSMEMBER
EXTENSION
(3)
[VIEW: X]
REAR FRAME
FLOOR REAR EXTENSION B
(cont'd)
3-57
Third-Seat Pan/Rear Frame
Removal (cont'd)
Mass production body welding positions and numbers (Rear frame)
NOTE:
● Welding symbols
: 2-Plate spot welding; : 3-Plate spot welding;
L=Welding length Unit: mm (in)
● ( ): The number of welds
: 4-Plate spot welding;
With floor rear extension removed
FLOOR MIDDLE
CROSSMEMBER C
: MAG plug welding;
: MAG welding
Right side
FLOOR MIDDLE
CROSSMEMBER D
FLOOR FRONT
EXTENSION
FLOOR PANEL
REAR FRAME
(8)
(12)
(9)
(11)
FLOOR FRONT
EXTENSION
FLOOR MIDDLE
CROSSMEMBER C
RIGHT
THIRD-SEAT
PLATE
(8)
(4)
REAR FRAME
FLOOR PANEL
REAR FLOOR
CROSSMEMBER
EXTENSION
MOUNTING BOLTS
6x 1.0 mm
Outside (8)
Inside (8)
(1)
(10)
REAR FRAME
FLOOR FRONT
EXTENSION
3-58
REAR WHEELHOUSE
(3)
REAR FLOOR
CROSSMEMBER
EXTENSION
Construction (Third-seat pan)
NOTE:
● This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer
to the appropriate Service Manual.
● The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to
the area and the degree of damage on the body.
●
●
Cut and pry off the third-seat pan, and replace it.
If necessary, replace the third row seat mount panel.
FLOOR PANEL
THIRD ROW SEAT
MOUNT PANEL
REAR FRAME
FLOOR MIDDLE
CROSSMEMBER D
FLOOR REAR
EXTENSION A
FLOOR MIDDLE
CROSSMEMBER D
THIRD-SEAT PAN
FLOOR REAR
EXTENSION B
THIRD ROW SEAT
MOUNT PANEL
THIRD-SEAT PAN
(cont'd)
3-59
Third-Seat Pan/Rear Frame
Removal (cont'd)
Construction (Floor rear extension A and B, and rear frame)
NOTE:
● This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer
to the appropriate Service Manual.
● The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to
the area and the degree of damage on the body.
If necessary, remove the rear floor crossmember extension from the rear frame, and replace it.
Check the rear frame and floor middle crossmember D positions for damage. If necessary, replace them..
● When replacing the rear frame, remove floor rear extensions A and B.
● When drilling the five spot welded points [A] at the joints for the rear frame and the floor front extension, cut and peel
back the floor panel to vertically access each welded point from the top.
●
●
FLOOR REAR
EXTENSION B
REAR FRAME
55 mm
(2.17 in)
225 mm
(8.86 in)
FLOOR
PANEL
FLOOR REAR
EXTENSION A
MOUNTING BOLTS
6 x 1.0 mm
FLOOR FRONT
EXTENSION
[A]
FLOOR FRONT
EXTENSION
FLOOR PANEL
REAR FLOOR
CROSSMEMBER
EXTENSION
3-60
REAR FRAME
FLOOR MIDDLE
CROSSMEMBER D
Installation
2. Check the body dimensions.
NOTE:
● Welding symbols
: 2-Plate spot welding
: 3-Plate spot welding
: 4-Plate spot welding
: MAG plug welding
: MAG welding
L=Welding length unit: mm (in)
● ( ): The number of welds
Front floor and rear floor, under view (see page
4-18)
● Inside sill positions (see page 4-19)
● Repair chart, top view (see page 4-20)
● Repair chart, side view (see page 4-22)
●
3. Tack weld the new parts into position, and check the
rear suspension position.
1. Set the new rear frame (A) and the floor middle
crossmember (B).
Both sides: Secure the new rear frame and the rear
inner panel (C) with the mounting bolts (D).
Right side: Secure the new rear frame and the floor
front extension (E) with the mounting bolt (F) from
under the rear frame.
Measure the rear frame diagonally.
4. Weld the rear floor crossmember extension (A).
(1)
C
A
(4)
5. Set the third row seat mount panel (A), secure it with
the bolts (B), and set the third-seat pan (C).
C
D
6 x 1.0 mm
A
B
10 x 1.25 mm
A
B
Right side
E
Front
F
6 x 1.0 mm
A
6. Clamp the floor rear crossmember, and temporarily
install the rear bumper beam. Set floor rear
extensions A and B.
7. Check the body dimensions.
Passenger's compartment (see page 4-9)
Rear pillar gutter and floor rear crossmember
positions (see page 4-12)
● Tailgate opening (see page 4-14)
●
●
(cont'd)
3-61
Third-Seat Pan/Rear Frame
Installation (cont'd)
8. Temporarily install the tailgate, then check for
differences in level and clearance.
Check the external parts fitting positions (see page
4-15). If necessary, check the taillight and the rear
bumper positions. Make sure the body lines flow
smoothly.
11. Weld the rear frame outrigger (A) to the rear side
outer panel (B).
B
9. Remove the floor rear crossmember, floor rear
extensions A and B, the third-seat pan, and the third
row seat mount panel.
(3)
10. Do the main welding.
Weld the rear frame (A) to the floor front extension
(B), floor middle crossmember C, and the rear
wheelhouse (D).
A
6 x 1.0 mm
18 N·m
(1.8 kgf·m, 13 lbf·ft)
(10)
A
12. From the passenger's compartment side, weld the
rear frame (A) to the floor front extension (B) and the
floor panel (C).
(8)
(5)
B
A
D
B
C
Front
(8)
C
(2)
C
Front
B
(4)
L=225
(8.86)
A
(2)
3-62
13. Weld the rear frame (A) to floor middle crossmember
C, floor middle crossmember D and the floor panel
(B).
Right side: Weld the right third-seat plate (E) to the
rear frame and the floor panel.
(2)
15. Weld the lower flange of the rear floor inner
crossmember (A) to the rear floor crossmember
extension (B) and the rear frame (C).
A
B
(5)
C
(11)
A
C
D
B
16. Set the third row seat mount panel (A) and the
third-seat pan (B), and weld them.
A
Right side
(4)
B
A
Front
E
(11)
C
(5)
(2)
B
14. Clamp the floor rear crossmember, recheck the
clearance and alignment of the tailgate, and install the
rear bumper beam.
(20)
17. Set floor rear extensions A and B, and recheck each
part's position.
(cont'd)
3-63
Third-Seat Pan/Rear Frame
Installation (cont'd)
18. Weld floor rear extension A to the rear wheelhouse
(B), the third-seat pan (C), the third row seat mount
panel (D), and the floor panel (E).
(4)
L=5 (0.20)
[VIEW: Z]
B
(1)
A
A
[Z]
B
Hole C: 22.6 mm (0.890 in)
Hole D: 47.5 mm (1.870 in)
Hole E: 44.3 mm (1.744 in)
(3)
(2)
L=5 (0.20)
21. With BSI radar unit: If necessary, remove the
damaged rivnuts, then install the new rivnuts (A) with
a rivnut tool, and check the BSI radar unit mounting
holes position. Install 6 mm bolts (B), 45－60 mm
long, in the BSI radar unit mounting holes (C, D, E).
Tape the plumb line (F) against the outer panel (G)
directly above each mounting hole, and thread each
bolt in or out until the head of the bolt just touches the
plumb line. At each bolt, measure the distance from
the head to the end of the threaded insert in the outer
panel. If any of the distances are out of specification,
adjust the hole positions of the outer panel in order of
C, D, E.
(7)
F
B
(8)
(19)
A
(12)
D
C
(1)
(6)
D
C
E
A
19. Weld floor rear extension B to the rear inner panel (C),
the third-seat pan (D), the rear floor inner
crossmember (E), and floor rear extension A.
E
B
C
E
(3)
(1)
L=5 (0.20)
(6)
G
(9)
(1)
B
A
(10)
(2)
D
20. Weld the floor rear crossmember (see page 3-53).
3-64
Floor Insulators
Insulator Locations
Cut new insulators, and apply as indicated.
NOTE: Before applying, clean and degrease the floor.
ᫎ RIGHT-FRONT FLOOR
FRONT INSULATOR
᫐ RIGHT-FRONT FLOOR
REAR INSULATOR
᫓ RIGHT-MIDDLE FLOOR
FRONT INSULATOR
᫕ RIGHT-MIDDLE FLOOR
REAR INSULATOR
᫗ RIGHT-REAR FLOOR
SIDE INSULATOR
[X]
᫙ REAR
FLOOR
INSULATOR
[Z]
[Y]
᫏ LEFT-FRONT FLOOR
FRONT INSULATOR
᫒ LEFT-FRONT FLOOR
REAR INSULATOR
᫖ LEFT-MIDDLE FLOOR
REAR INSULATOR
᫔ LEFT-MIDDLE FLOOR
FRONT INSULATOR
᫘ LEFT-REAR FLOOR
SIDE INSULATOR
[VIEW: Z]
᫑ SPARE TIRE PAN INSULATOR
[VIEW: X]
176 mm (6.93 in)
᫜ OUTER PANEL INNER
INSULATOR
[VIEW: Y]
20 mm
(0.79 in)
᫚ RIGHT-REAR WHEELHOUSE
INSULATOR
164 mm (6.46 in)
᫛ LEFT-REAR WHEELHOUSE
INSULATOR
3-65
Floor Insulators
Insulator Sizes
Unit: mm (in)
735 (28.94)
ᫎ RIGHT-FRONT FLOOR FRONT INSULATOR
962 (37.87)
᫏ LEFT-FRONT FLOOR FRONT INSULATOR
681 (26.81)
882 (34.72)
3-66
Unit: mm (in)
309 (12.17)
᫐ RIGHT-FRONT FLOOR REAR INSULATOR
598 (23.54)
548 (21.57)
᫑ SPARE TIRE PAN INSULATOR
573 (22.56)
239 (9.41)
᫒ LEFT-FRONT FLOOR REAR INSULATOR
438 (17.24)
(cont'd)
3-67
Floor Insulators
Insulator Sizes (cont'd)
Unit: mm (in)
᫓ RIGHT-MIDDLE FLOOR FRONT INSULATOR
323 (12.72)
430 (16.93)
᫔ LEFT-MIDDLE FLOOR FRONT INSULATOR
379 (14.92)
562 (22.13)
3-68
Unit: mm (in)
469 (18.46)
᫕ RIGHT-MIDDLE FLOOR REAR INSULATOR
764 (30.08)
642 (25.28)
᫕ LEFT-MIDDLE FLOOR REAR INSULATOR
778 (30.63)
(cont'd)
3-69
Floor Insulators
Insulator Sizes (cont'd)
Unit: mm (in)
212 (8.35)
᫗ RIGHT-MIDDLE FLOOR SIDE INSULATOR
428 (16.85)
213 (8.39)
᫘ LEFT-REAR FLOOR SIDE INSULATOR
428 (16.85)
1189 (46.81)
᫙ REAR FLOOR INSULATOR
498 (19.61)
3-70
Unit: mm (in)
᫚ RIGHT-REAR WHEELHOUSE INSULATOR
468 (18.43)
963 (37.91)
᫛ LEFT-REAR WHEELHOUSE INSULATOR
486 (19.13)
1154 (45.43)
120
(4.72)
᫜ OUTER PANEL INNER INSULATOR
250 (9.84)
3-71
Body Dimensional Drawings
Upper Body Measuring Dimensions
Front Fender Positions • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 4–2
Front Bulkhead Position • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 4–3
Engine Compartment • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 4–4
Engine Side Mount Position • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 4–5
Bulkhead Side Member Position • • • • • • • • • • • • • • • • • • • • • • • • 4–6
Door Hinge Positions • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 4–7
Sliding Door Female Guide and Striker Positions • • • • • 4–8
Passenger's Compartment • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 4–9
Sliding Door Rail Lower Support Positions • • • • • • • • • • • • 4–10
Roof Rail Positions • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 4–11
Rear Pillar Gutter and Floor Rear Crossmember
Positions • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 4–12
Windshield and Door Openings • • • • • • • • • • • • • • • • • • • • • • • • 4–13
Tailgate Opening • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 4–14
External Parts Fitting Positions • • • • • • • • • • • • • • • • • • • • • • • • • • 4–15
Under Body Measuring Dimensions
Front Subframe Position • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 4–16
Engine Compartment and Front Floor, Under View • • 4–17
Front Floor and Rear Floor, Under View • • • • • • • • • • • • • • • 4–18
Inside Sill Positions • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •4–19
Frame Repair Chart
Repair Chart, Top View • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 4–20
Repair Chart, Side View • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 4–22
Upper Body Measuring Dimensions
Front Fender Positions
NOTE: The air intake duct and the front bulkhead cover are removed in the illustrations.
Unit: mm (in)
A, a
Bulkhead Upper Center Frame A
Locating Hole ø20 (0.78)
B, b
Front Fender Bracket Mounting
Bolt (Center of the bolt)
C
C, c
Front Fender Rear Mounting
Bolt (Center of the bolt)
F
C
F
C
1644
(64.72)
c
C
802
(31.57)
1322
(52.05)
1460
(57.48)
b
B
435
(17.13)
1082
(42.60)
a
4-2
A
F
Front Bulkhead Position
Unit: mm (in)
A1, a1
Front Bulkhead Lower
Crossmember Locating
Hole ø10 (0.39)
A3, a3
Corner Upper Beam Mounting
Hole ø7 (0.28)
A4, a4
Radiator Mounting
Hole ø9 (0.35)
F
C
C
C
F
F
A2, a2
Front Bumper Beam
Mounting Hole ø11 (0.43)
752
(29.61)
a4
360
(14.17)
1000
(39.37)
A4
863
(33.98)
236
(9.29)
916
(36.06)
a3
a2
875
(34.45)
359
(14.13)
832
(32.76)
a1
A3
A2
551
(21.69)
A1
614
(24.17)
1159
(45.63)
4-3
Upper Body Measuring Dimensions
Engine Compartment
Unit: mm (in)
B5
Windshield Lower Locating
Hole ø7 (0.28)
B3, b3
Front Damper Mounting
Hole ø11.5 (0.453)
B1, b1
Bulkhead Upper Center Frame A
Locating Hole ø20 (0.79)
C
C
F
B2, b2
Front Fender Mounting
Hole ø9 (0.35) front
B4, b4
Hood Hinge
Mounting
Hole ø7 (0.28) rear
F
C
F
B4
b4
1618
(63.70)
253
(9.96)
1414
(55.67)
b3
B3
1196
(47.09)
B5
b4
484
(19.06)
b4
b3
B4
747
(29.41)
793
(31.22)
591
(23.27)
842
(33.15)
1011
(39.80)
1402
(55.20)
680
(26.77)
B3
1125
(44.29)
896
(35.28)
471
(18.54)
727
(28.62)
1457
(57.36)
b2
1078
(42.44)
B4
b1
B1
1374
(54.09)
B1
1645
(64.76)
b2
4-4
B2
431
(16.97)
Engine Side Mount Position
Unit: mm (in)
C3
Battery Set Base Mounting
Hole ø9 (0.35)
B3, b3
Front Damper Mounting
Hole ø11.5 (0.453)
C2
Engine Side Mounting Hole ø13 (0.51)
Wheelhouse side
F
C
C
F
C
F
C1
Engine Side Mounting
Hole ø15 (0.59)
Side frame side
B3
b3
411
(16.18)
535
(21.06)
1243
(48.94)
502
(19.76)
1265
(49.80)
1249
(49.17)
C2
1143
(45.00)
C1
1073
(42.24)
C3
4-5
Upper Body Measuring Dimensions
Bulkhead Side Member Position
Unit: mm (in)
D3
Front Fender Mounting
Hole ø9 (0.35) upper
D2
Front Fender Mounting
Hole ø7 (0.28) front
E2
Front Door Lower Hinge Mounting
Hole ø13 (0.51) upper
C
F
C
C
F
F
D1
Bulkhead Side
Member A
Locating
Hole ø13 (0.51)
D4
Front Fender Mounting
Hole ø7 (0.28) lower
995
(39.17)
D3
1101
(43.35)
730
(28.74)
D2
D1
1010
(39.76)
1060
(41.73)
E2
1015
(39.96)
D4
4-6
Door Hinge Positions
Unit: mm (in)
E1
Front Door Upper Hinge
Mounting Hole ø13 (0.51) front
E2
Front Door Lower Hinge
Mounting Hole ø13 (0.51) upper
E3
Front Door Switch
Mounting Hole ø8 (0.32)
C
F
C
C
F
F
E1
367
(14.45)
E2
1031
(40.59)
992
(39.06)
E3
4-7
Upper Body Measuring Dimensions
Sliding Door Female Guide and Striker Positions
Unit: mm (in)
F1, f1
Sliding Door Sub-Seal
Mounting Hole ø5 (0.20)
F3, f3
Sliding Door Lower Female Guide
Mounting Hole ø10 (0.39) upper
F2, f2
Sliding Door Upper Female Guide
Mounting Hole ø10 (0.39) upper
C
F
F
F
C
F5, f5
Sliding Door Rear Striker
Mounting Hole
14 (0.55) x 14 (0.55) square
F4
Sliding Door Center Rail
Mounting Hole ø6.3 (0.248)
C
F
f1
1429
(56.26)
F1
f2
1118
(44.02)
1737
(68.39)
1097
(43.19)
f5
1188
(46.77)
f3
F2
F4
1848
(72.76)
982
(38.66)
1183
(46.57)
F3
4-8
1802
(70.94)
1040
(40.94)
F5
C
Passenger's Compartment
Unit: mm (in)
G1, g1
Front Seat Mounting
Hole ø15 (0.59) front
G2, g2
Second-Seat Striker Cover A
Mounting Hole ø7 (0.28)
C
G3, g3
Second Row Seat Belt Lower Anchor
Mounting Hole ø12 (0.47)
C
F
F
C
F
g3
2277
(89.65)
1070
(42.13)
g2
1204
(47.40)
2585
(101.77)
1207
(47.52)
2596
(102.20)
g1
G3
1314
(51.73)
1777
(69.96)
1295
(50.98)
1652
(65.04)
1768
(69.61)
G2
1194
(47.01)
2263
(89.09)
G1
4-9
Upper Body Measuring Dimensions
Sliding Door Rail Lower Support Positions
Unit: mm (in)
H2, h2
Sliding Door Sill Trim Clip
Mounting Hole ø8.5 (0.335)
H1, h2
Front Floor Panel Locating
Hole ø26.3 (1.035)
H3, h3
CESS Articulated Harness
Mounting Hole ø9 (0.35)
F
C
F
F
C
C
H4, h4
Floor Rear Extension A Locating
Hole ø20 (0.79)
C
F
h4
h3
1058
(41.65)
h2
1741
(68.54)
1670
(65.75)
1582
(62.28)
1852
(72.91)
H4
812
(31.97)
h1
1113
(43.82)
H1
4-10
H3
1525
(60.04)
650
(25.59)
H2
723
(28.46)
Roof Rail Positions
Unit:: mm (in)
I1, i1
Roof Front Rail Locating
Hole ø15 (0.59)
I2, i2
Center Inner Pillar Locating
Hole ø13 (0.51)
I3, i3
Quarter Inner Upper Pillar
Locating Hole ø13 (0.51)
C
C
C
F
F
F
I4, i4
Rear Roof Trim Clip Mounting
Hole ø8.5 (0.335)
C
F
i4
I4
1274
(50.16)
i3
1085
(42.72)
2057
(80.98)
i2
1487
(58.54)
2161
(85.08)
2081
(81.93)
I3
i1
1706
(67.17)
1355
(53.35)
1459
(57.44)
954
(37.56)
I2
I1
667
(26.26)
4-11
Upper Body Measuring Dimensions
Rear Pillar Gutter and Floor Rear Crossmember Positions
Unit: mm (in)
J2, j2
Sliding Door Center Rail Cover
Mounting Hole ø7 (0.28)
J1, j1
Tailgate Support Strut
Mounting Hole ø11 (0.43)
J3, j3
Rear Bumper Mounting
Hole ø7 (0.28)
F
C
F
F
C
C
J4, j4
Rear Trim Panel Clip Mounting
Hole ø8.5 (0.335)
H4, h4
Floor Rear Extension A Locating
Hole ø20 (0.79)
F
F
C
C
J1
j1
1320
(51.97)
1595
(62.80)
926
(36.46)
H4
J2
1463
(57.60)
491
(19.33)
h4
j2
1438
(56.61)
876
(34.49)
1434
(56.46)
J3
1335
(52.56)
J4
960
(37.80)
1277
(50.28)
4-12
469
(18.46)
j4
j3
Windshield and Door Openings
Unit: mm (in)
D, E, F, G, H, I, J, K
Outer Panel and Roof Side
Outer Door Opening
Flange Notch (16 places)
B, C
Outer Panel and Roof Panel
Windshield Opening
Flange Notch (3 places)
A
Windshield Lower
Dashboard Front Installing Pin
F
C
938
(36.93)
A
1514
(59.61)
950
(37.40)
1714
(67.48)
1681
(66.18)
B
H
D
828
(32.60)
935
(36.81)
811
(31.93)
1126
(44.33)
1669
(65.71)
K
G
I
845
(33.27)
E
1277
(50.28)
599
(23.58)
J
F
819
(32.24)
4-13
Upper Body Measuring Dimensions
Tailgate Opening
Unit: mm (in)
M
Rear Combination Adapter
Flange End (2 places)
F
L
Rear Roof Lower Rail
Flange Notch
F
N
Floor Rear Crossmember
Scribe Marks
C
L
832
(32.76)
1107
(43.58)
1349
(53.11)
M
918
(36.14)
N
4-14
F
External Parts Fitting Positions
Unit: mm (in)
Outer Panel
Front Fender
0.5
(0.020)
3.0
(0.118)
Tailgate Roof
Spoiler
Panel
6.0
Side Trim
0.7
(0.236)
Outer
(0.028)
Panel
Tailgate
7.0
Spoiler Trim
(0.276) 1.0
(0.039)
3.0
(0.118)
Hood
Outer Panel
6.9
(0.272)
Outer Panel
5.5
(0.217)
5.8
(0.228)
Front Door
Sliding Door
Front Fender
4.5
(0.177)
Front Door
Sliding Door
Front Door
5.5
(0.217)
Sliding Door
5.0
(0.197)
Rear Side
Outer Panel
4-15
Under Body Measuring Dimensions
Front Subframe Position
Unit: mm (in)
B, b
Front Subframe Rear
Mounting Bolt
(Center of the bolt)
A, a
Front Subframe Front
Mounting Bolt
(Center of the bolt)
C
C
Left Front Floor
Extension Locating
Hole ø11 (0.43)
C
c
Right Front Floor Frame
Locating Hole ø10 (0.39)
C
F
F
C
F
F
a
A
1045
(41.14)
1203
(47.36)
883
(34.76)
2382
(93.78)
2134
(84.02)
B
639
(25.16)
b
1298
(51.10)
1538
(60.55)
c
4-16
1068
(42.05)
C
Engine Compartment and Front Floor, Under View
Unit: mm (in)
A, a
Front Bumper Beam
Mounting Hole ø11 (0.43)
C, c
Front Subframe Mounting
Hole ø15 (0.59) front
B, b
Front Bulkhead Lower
Crossmember Locating
Hole ø13 (0.51)
F
C
F
F
C
C
D, d
Front Subframe Mounting
Hole ø15 (0.59) rear
E, e
Front Side Frame Gusset
Locating Hole ø28 (1.10)
F, f
Left Floor Front Extension
Locating Hole ø32 (1.26)
Right Floor Front Frame
Locating Hole ø32 (1.26)
F
F
C
F
ø32
(1.26)
C
C
D
B
349
(13.74)
1029
(40.51)
Left side
342
(13.46)
A
1186
(46.69)
C
883
(34.76)
B
1036
(40.79)
1045
(41.14)
798
(31.42)
Right side
D
1530
(60.24)
b
1478
(58.19)
833
(32.80)
639
(25.16)
1173
(46.18)
1203
(47.36)
a
F
E
895
(35.24)
1392
(54.80)
1779
(70.04)
1096
(43.15)
d
c
1129
(44.45)
e
f
4-17
Under Body Measuring Dimensions
Front Floor and Rear Floor, Under View
Unit: mm (in)
F, f
Left Floor Front Extension
Locating Hole ø32 (1.26)
Right Floor Front Frame
Locating Hole ø32 (1.26)
G, g
Rear Subframe Mounting
Hole ø17 (0.67) front
H, h
Floor Middle Crossmember D
Locating Hole
Left: ø15 (0.59)/Right: ø20 (0.79)
F
F
C
C
ø32
(1.26)
I, i
Rear Subframe Mounting
Hole ø17 (0.67) rear
F
C
602
(23.70)
J, j
Trailer Hitch Mounting
Hole ø15 (0.59)
F
F
C
C
1096
(43.15)
1697
(66.81)
J
Left side
I
1159
(45.63)
G
F
1227
(48.31)
1096
(43.15)
1100
(43.31)
H
1430
(56.30)
1213
(47.76)
F
Right side
874
(34.41)
1657
(65.24)
1237
(48.70)
f
1084
(42.68)
1092
(42.99)
h
884
(34.80)
g
1011
(39.80)
i
2108
(82.99)
1108
(43.62)
1280
(50.39)
g
j
4-18
J
1635
(64.37)
j
Inside Sill Positions
Unit: mm (in)
E, e
Front Side Frame Gusset Locating
Hole ø28 (1.10)
K, k
Front Inside Sill B Locating
Hole ø20 (0.79) front
F
F
C
C
L, l
Front Inside Sill B Locating
Hole ø20 (0.79) rear
I, i
Rear Subframe Mounting
Hole ø17 (0.67)
F
C
F
C
678
(26.69)
Left side
K
L
1157
(45.55)
935
(36.81)
I
E
1390
(54.72)
Right side
895
(35.24)
1644
(64.72)
2006
(78.98)
1634
(64.33)
1722
(67.80)
1280
(50.39)
e
i
k
l
4-19
Frame Repair Chart
Repair Chart, Top View
Unit: mm (in)
φ: Inner diameter
a1, a2
For bumper beam φ11 (0.43)
b1, b2
For front subframe φ15 (0.59) forward
c
d1, d2
e1, e2
f1, f2
For engine mount φ13 (0.51)
Front damper center φ80 (3.15)
For front subframe φ15 (0.59) rearward
Locating hole φ28 (1.1)
c
d1
f1
268 (10.55)
e2
895 (35.24)
e1
639 (25.16)
1319 (51.93)
1036 (40.79)
CENTER LINE
1045 (41.14)
b1
598 (23.54)
a1
b2
a2
d2
481 (18.94)
728 (28.66)
34 (1.34)
374 (14.72)
705 (27.76)
BASE LINE
4-20
f2
For rear subframe φ17 (0.67) forward
o1, o2
r1, r2
For rear spring φ25 (0.98)
For rear subframe φ17 (0.67) rearward
j1, j2
k1, k2
For trailing arm φ16 (0.63) outrigger side
For trailing arm φ20 (0.79) floor frame side
s1, s2
Locating hole φ25 (0.98)
l1, l2
Locating hole φ25 (0.98)
m1, m2
For fuel tank φ13 (0.51) rearward
n1
m1
D
o1
1058 (41.65)
404 (15.91)
234 (9.21)
l1
544 (21.42)
1113 (43.82)
1096 (43.15)
k1
1072 (42.20)
j1
1430 (56.30)
i1
233 (9.17)
h1
544 (21.42)
D
233 (9.17)
g1
r1
s1
1410 (55.51)
n1, n2
Locating hole φ25 (0.98)
For fuel tank φ11 (0.43) middle
1280 (50.39)
For fuel tank φ13 (0.51) forward
h1, h2
i1, i2
1011 (39.80)
g1, g2
m2
i2
j2 k2
l2
n2
o2
r2
s2
2022 (79.61)
2178 (85.75)
2322 (91.42)
2384 (93.86)
g1
2421 (95.31)
2650 (104.33)
2743 (107.99)
2771 (109.09)
i1
m1
42
(1.65)
BASE
LINE
3111 (122.48)
3325 (130.90)
52
(2.05)
h2
42
(1.65)
g2
3620 (142.52)
[SECTION: DD]
4-21
Frame Repair Chart
Repair Chart, Side View
Unit: mm (in)
ø: Inner diameter
a1, a2
b1, b2
For bumper beam ø11 (0.43)
For front subframe ø15 (0.59) forward
c
For engine mount ø13 (0.51)
d1, d2
e1, e2
f1, f2
Front damper center ø80 (3.15)
For front subframe ø15 (0.59) rearward
Locating hole ø28 (1.1)
3-ø11.5 (0.453)
80 (3.15)
130°
115°
d1, d2
115°
7°
[SECTION: AA]
d1, d2
3°
A
c
M10 x 1.25
4-22
88 (3.46)
a1, a2
M8 x 1.25 b1, b2
M12 x 1.5
69 (2.72)
12 (0.47)
93 (3.66)
331 (13.03)
BASE LINE
639 (25.16)
A
BASE LINE
e1, e2
M14 x 1.5
f1, f2
h1, h2
Locating hole ø25 (0.98)
j1, j2
k1, k2
For trailing arm ø16 (0.63) outrigger side
For trailing arm ø20 (0.79) floor frame side
l1, l2
n1, n2
Locating hole ø25 (0.98)
For rear subframe ø17 (0.67) forward
o1, o2
p
For rear spring ø25 (0.98)
For rear damper ø12 (0.47) forward
q
r1, r2
s1, s2
For rear damper ø12 (0.47) rearward
For rear subframe ø17 (0.67) rearward
Locating hole ø25 (0.98)
CENTER LINE
CENTER LINE
673.5 (26.516)
673.5 (26.516)
q
313 (12.32)
319 (12.56)
p
BASE
LINE
BASE
LINE
[SECTION: B1B1]
[SECTION: B2B2]
3046 (119.92)
2947 (116.02)
p
q
B1
n1, n2
k1, k2
B2
s1, s2
j1, j2
B2
h1, h2
l1, l2
o1, o2
55.6 (2.189)
51 (2.01)
118 (4.65)
8 (0.31)
19.4 (0.764)
43.5 (1.713)
43.5 (1.713)
14.4 (0.567)
B1
r1, r2
4-23
Rust Prevention
Sealing Areas
General • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 5–2
Front Wheelhouse and Damper Housing • • • • • • • • • • • • • • 5–3
Dashboard Upper and Dashboard Lower • • • • • • • • • • • • • • 5–4
Front Floor and Rear Floor • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •5–5
Roof Panel and Side Outer Panel • • • • • • • • • • • • • • • • • • • • • • • 5–6
Rear Pillar Gutter • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 5–7
Rear Wheelhouse • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 5–8
Rust-Preventive Treatments
General • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 5–9
Undercoating Areas • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 5–10
Areas to be Covered by Internal Anti-Rust Agents • • • • 5–13
Sealing Areas
General
NOTE: Follow the sealant manufacturer's instructions,
and apply the sealant. Note the following items:
● Clean the areas to be sealed with wax and grease
remover.
● Wipe off any excess spot sealant with thinner. After
the primer is sprayed, sealant will fill the area where
the spot sealant was wiped.
● Make sure you can see the sealant when the sealed
part is in its proper location. For the details, refer to
front wheelhouse and damper housing (see page 5-3),
dashboard upper and dashboard lower (see page 5-4),
front floor and rear floor (see page 5-5), roof panel and
side outer panel (see page 5-6), rear pillar gutter (see
page 5-7), and rear wheelhouse (see page 5-8).
● When applying sealant to the engine compartment,
the door opening, and the rear gutter, try to match the
appearance of the factory sealant. Wipe off any excess
sealant.
● Apply sealant to any area that a replacement part will
cover. Smooth the sealant with a brush if necessary.
5-2
Front Wheelhouse and Damper Housing
DASHBOARD UPPER
Do not apply the sealer to
the mounting holes. If necessary,
wipe off the excess sealer from the
mounting nut flange seating areas.
DAMPER BASE
FRONT PILLAR
LOWER STIFFENER
DASHBOARD LOWER
DASHBOARD LOWER
FRONT INNER
LOWER PILLAR
OUTER PANEL
OUTRIGGER
FRONT PILLAR LOWER
STIFFENER
FRONT JACK-UP BASE
5-3
Sealing Areas
Dashboard Upper and Dashboard Lower
FRONT INNER
UPPER PILLAR
OUTER PANEL
DASHBOARD
LOWER
FRONT PILLAR INNER
UPPER EXTENSION
WINDSHIELD LOWER
FRONT INNER
LOWER PILLAR
STEERING
JOINT COVER
[Z]
FRONT PILLAR INNER
UPPER EXTENSION
[VIEW: Z]
DASHBOARD LOWER
FRONT INNER
UPPER PILLAR
INSIDE SILL A
FLOOR PANEL
FRONT INNER
MIDDLE PILLAR
DASHBOARD LOWER
5-4
FRONT INNER
LOWER PILLAR
Front Floor and Rear Floor
CENTER INNER
PILLAR
[DETAIL: A]
[A]
FRONT INNER
UNDER FLOOR PAN
ELR STIFFENER
INSIDE
SILL B
FRONT SEAT REAR
OUTER BRACKET
FLOOR PANEL
QUARTER
PILLAR
STIFFENER
EXTENSION
FRONT SEAT
REAR OUTER
BRACKET
[DETAIL: B]
INSIDE SILL A
Do not apply the sealer to
the mounting holes.
FLOOR
PANEL
PATCH
INSIDE
SILL B
THIRD-SEAT PAN
THIRD-SEAT PLATE
[B]
REAR FLOOR INNER
CROSSMEMBER
[Z]
REAR FLOOR OUTER
CROSSMEMBER
SECOND-SEAT
PLATE B
FLOOR PANEL
FLOOR REAR
EXTENSION B
[VIEW: Z]
FRONT SECOND-SEAT
PLATE A
SECOND-SEAT PLATE B
REAR
FLOOR REAR
EXTENSION A
FLOOR PANEL
SECOND-SEAT
PLATE B
THIRD ROW SEAT
MOUNT PANEL
HOLE CAP
5-5
Sealing Areas
Roof Panel and Side Outer Panel
Do not apply the sealer to the roof rail
brackets. If necessary, wipe off the
excess sealer from the stud bolt.
[V]
[VIEW: Z]
[Z]
[DETAIL: V]
OUTER PANEL
REAR PILLAR
GUTTER
[V]
ROOF
PANEL
REAR ROOF
UPPER RAIL
[Y]
[W]
TAILGATE
HINGE AREA
[VIEW: X]
FUEL CAP
ADAPTER
REAR DOOR
STRIKER STIFFENER
ROOF PANEL
CENTER PILLAR
LOWER EXTENSION
OUTER PANEL
[X]
[VIEW: Y]
ROOF SIDE OUTER UPPER
ROOF SIDE
OUTER UPPER
[VIEW: W]
OUTER PANEL
ROOF SIDE OUTER PANEL
OUTER PANEL
5-6
SLIDE RAIL EXTENSION A
REAR DOOR
RAIL SUPPORT
Rear Pillar Gutter
[VIEW: Z]
OUTER PANEL
REAR PILLAR
GUTTER
[Z]
[X]
REAR COMBINATION
ADAPTER
[VIEW: X]
REAR PILLAR
GUTTER
REAR
COMBINATION
ADAPTER
REAR INNER
PANEL
OUTER PANEL
FLOOR REAR
CROSSMEMBER
OUTER PANEL
COMBINATION ADAPTER
EXTENSION
5-7
Sealing Areas
Rear Wheelhouse
REAR WHEELHOUSE
WHEELHOUSE STIFFENER
REAR INNER PANEL
REAR WHEEL ARCH
EXTENSION
[Z]
[X]
REAR FRAME
[VIEW: X]
[VIEW:Z]
REAR INNER PANEL
REAR INNER
PANEL
OUTER PANEL
OUTER PANEL
REAR WHEEL ARCH
EXTESION
5-8
Rust-Preventive Treatments
General
Undercoat
Wear goggles or safety glasses to prevent eye
injury.
● Ventilate when spraying undercoat.
●
NOTE:
● Mask the exhaust system, the oxygen sensors, and the
suspension mounting areas to protect them from the
undercoat overspray.
● Follow the undercoating manufacturer's instructions.
● Clean the body with wax and grease remover before
the undercoat is sprayed.
● Apply the undercoat to the front wheelhouse, the rear
wheelhouse, and the undersides of the front and rear
floors; refer to undercoating areas (see page 5-10).
● Coat the bottom of the fuel tank.
Anti-Rust Agents
Anti-rust agents contain substances that are
harmful if you breathe or swallow them, or get
them on your skin. Wear coveralls, gloves, eye
protection, and an approved respirator while using
such agents.
● Ventilate when spraying an anti-rust agent as 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
components, exhaust system components and related
parts, emission control devices in the engine
compartment, ball joint covers, the fuel strainer, or
exterior and interior parts.
● Wipe the excess agent with a clean rag dampened
with light oil.
● Follow the anti-rust agent manufacturer's instructions.
● 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 a wet surface.
● Apply the anti-rust agent from the installation holes
and the access holes to parts in the outer panels and
the frame (see page 5-13). Spray the anti-rust agent
sufficiently until the excess amount oozes out when
filling the side sill.
5-9
Rust-Preventive Treatments
Undercoating Areas
Apply undercoat to the areas shown.
NOTE:
● Coating thickness: 0.4 mm (0.016 in) MIN.
● Front wheelhouse and dashboard lower coating thickness 0.5 mm (0.020 in).
● Apply the undercoat 10 mm (0.39 in) from the edge of the welded flanges.
: Indicates undercoating area.
UNDER FLOOR PAN
INSIDE SILL
THIRD-SEAT PAN
[U]
DASHBOARD LOWER
Left side
H
H
[W]
[Y]
A
A
E
D
C
F
G
Right side
B
I
I
C
B
[V]
FLOOR PANEL
FRONT DAMPER BASE
E
D
[X]
F
G
[Z]
FRONT DAMPER BASE
DASHBOARD LOWER
FRONT DAMPER
HOUSING
FRONT DAMPER
HOUSING
78 mm
(3.07 in)
78 mm
(3.07 in)
FRONT SIDE FRAME
FRONT SIDE FRAME
[VIEW: U]
5-10
[VIEW: V]
: Indicates undercoating area.
FRONT FLOOR FRAME
EXTENSION
Front
FRONT FLOOR FRAME
TRAILING ARM
OUTRIGGER B
INSIDE SILL
[VIEW: W]
REAR WHEELHOUSE
Front
[VIEW: X]
REAR FRAME
REAR FRAME
FLOOR MIDDLE
CROSSMEMBER D
THIRD-SEAT PAN
[VIEW: Y]
Right side only
[VIEW: Z]
(cont'd)
5-11
Rust-Preventive Treatments
Undercoating Areas (cont'd)
: Indicates undercoating area.
FLOOR MIDDLE
CROSSMEMBER D
FLOOR PANEL
DASHBOARD LOWER
THIRD-SEAT PAN
UNDER FLOOR PAN
Apply undercoat to
the flange end of the
crossmember A.
Apply undercoat to the flange
end of the under floor pan.
FLOOR
CROSSMEMBER A
[SECTION: AA]
FRONT
DAMPER BASE
Apply undercoat to the flange
end of the crossmember D
and the rear frame.
REAR
WHEELHOUSE
FRONT FLOOR FRAME
FRONT
DAMPER
HOUSING
UNDER
FLOOR PAN
FRONT
SIDE FRAME
Coating
thickness:
0.5 mm
(0.020 in)
FLOOR REAR
EXTENSION A
INSIDE SILL
[SECTION: CC]
REAR FRAME
[SECTION: BB]
[SECTION: DD]
THIRD-SEAT
PAN
REAR FRAME
REAR FRAME
[SECTION: EE]
FLOOR REAR
EXTENSION B
THIRD-SEAT
PAN
[SECTION: GG]
REAR FLOOR
CROSSMEMBER
EXTENSION
30 mm
(1.18 in)
REAR UNDERCOVER
[SECTION: HH]
5-12
Round end
point
REAR FRAME
[SECTION: FF]
REAR FRAME
THIRD-SEAT
PAN
THIRD-SEAT
PAN
Round end
point
REAR FLOOR
OUTRIGGER
[SECTION: II]
REAR FRAME
OUTRIGGER
Areas to be Covered by Internal Anti-Rust Agents
: Indicates anti-rust agents.
[DETAIL: X]
(8 places)
ROOF RAIL
BRACKET
TAILGATE FRAME
HOOD FRAME
[X]
FLOOR MIDDLE
CROSSMEMBER C
HOOD HINGE
[X]
FLOOR MIDDLE
CROSSMEMBER B
FLOOR MIDDLE
CROSSMEMBER D
[X]
REAR
FRAME
TAILGATE HINGE
FLOOR FRONT FRAME
FLOOR FRONT
CROSSMEMBER B
FUEL FILL DOOR
DASHBOARD UPPER
WHEEL
ARCH
FLOOR FRONT
EXTENSION
FRONT SIDE FRAME
TRAILING ARM
BRACKET
INSIDE SILL
FLOOR MIDDLE
CROSSMEMBER A
OUTRIGGER
FLOOR FRONT
CROSSMEMBER A
BULKHEAD LOWER
CROSSMEMBER
WHEELHOUSE
UPPER MEMBER
SLIDING DOOR PANEL
BULKHEAD SIDE
MEMBER
FRONT DOOR PANEL
FRONT DOOR HINGE
FRONT FENDER
5-13
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