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How to Use This Manual

How to Use This Manual


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

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

Special Information

WARNING

Indicates a strong possibility of server


Personal Injury or death if instructions are not
followed.

CAUTION

Indicates a possibility of personal injury or


equipment damage if instructions are not
followed.
NOTE: Gives helpful information.

CAUTION

Detailed description of standard workshop


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

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How to Use This Manual

Fist Edition
8/2000

192 pages HONDA MOTOR CO., LTD.

All Rights Reserved

Service Publication Office

Sections with * include SRS components; Special Caution is required


when servicing.

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Index - Index

Index
4-door General Information

1-3

5-door General Information

1-15

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4-door General Information

4-door General Information


Supplemental Restraint System (SRS)

1-4

Identification Number Locations

1-5

Lift and Support Points

1-6

Body Specifications/Wheel Alignment

1-7

Exterior Parts Removal/Installation

1-8

Construction

1-9

Door and Bumper Reinforcement Beams

1-10

Zinc-plated Steel Plate Repair

1-11

Colour Chart Paint Specifications

1-12

Types and Materials of Exterior Plastic Parts

1-14

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Index - General Information

General Information

1-4

Supplemental Restraint System (SRS)

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

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Index - General Information

General Information

Identification Number Locations

15
1. Built Data and Vehicle Type
Except KK, KX, KY models
2. Vehicle Identification
Number (VIN)
3. Engine Number
4. Transmission Number
(Manual)
5. Transmission Number
(Automatic)
6. Transmission Number
(Honda Multi Matic)

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Index - General Information

General Information

1-6

Lift and Support Points

NOTE: If you are going to remove heavy components such as suspension or the fuel
tank from the rear of the vehicle, first support the front of the vehicle with a tall safety
stands. When substantial weight is removed from the rear of the vehicle, the centre of
gravity can change and cause the vehicle to tip forward on the hoist.
Frame Hoist
Position the hoist lift blocks, or safety stands, under the vehicle's front support points
and rear support points.

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

1. FRONT SUPPORT POINT


2. HOIST LIFT BLOCKS
3. REAR SUPPORT POINT

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

1.
2.
3.
4.

FRONT JACKING BRACKET


JACK LIFT PLATFORM
JACK LIFT PLATFORM
REAR JACKING BRACKET

5. Position the safety stands under the support points and adjust them so the vehicle
will level.
6. Lower the vehicle onto the stands.

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Index - General Information

General Information

1-7

Body Specifications/Wheel Alignment


Unit : mm(in.)

*1: Eurpoean model


*2: Australian model
*3: Saudi Arabia model
*4: Hong Kong model

Front Wheel Alignment:


Camber

000'45'

Caster

1'33'1

Total toe

03 (00.12)

Wheel turning angle

in

4000'2 (D15B engine)


3800'2 (D17A engine)

out

3100' (D15B engine: Reference)


3000' (D17A engine: Reference)

Rear Wheel Alignment:


Camber

-045'45'

Total toe

IN 2 3 (0.08 0.12)

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General Information

1-8

Exterior Parts Removal/Installation

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

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1-9

General Information
Construction

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


No.

Part Name

No.

Part Name

Hood (Hss, Zn)

22

Centre Pillar Stiffener (Sp)

Front Fender (Sp, Zn)

23

Side Sill Reinforcement (Hss, Zn)

Front Door (Hss, Zn)

24

Front Pillar Inner Lower (Hss)

Rear Door (Hss, Zn)

25

Front Pillar Inner Upper (Hss, Zn)

Trunk Lid (Sp, Zn)

26

Centre Inner Pillar (Hss, Zn)

Bulkhead Side (Sp, Zn)

27

Roof Side Rail (Hss)

Bulkhead Side Stray (Sp, Zn)

28

Roof Panel (Sp)

Bulkhead Upper Frame (Sp, Zn)

29

Rear Inner Panel (Sp, Zn)

Front Lower Cross-member (Hss, Zn)

30

Wheel Arch Extension (Sp, Zn)

10

Wheelhouse Upper Member (Sp)

31

Rear Wheelhouse (Sp, Zn)

11

Front Wheelhouse (Sp, Zn)

32

Inside Sill (Hss, Zn)

12

Front Damper Extension (Hss, Zn)

33

Front Floor (Sp, Zn)

13

Damper Housing (Hss, Zn)

34

Middle Floor Cross-member (Hss, Zn)

14

Front Side Frame (Hss, Zn)

35

Rear parcel Self (Sp)

15

Side Frame Extension Rear/Front Side Outrigger (Hss, Zn)

36

Rear Floor Upper Cross-member (Sp)

16

Dashboard Lower (Sp, Zn)

37

Rear Floor (Sp, Zn)

17

Dashboard Upper (Sp, Zn)

38

Rear Panel (Sp, Zn)

18

Outer Panel (Sp, Zn)

39

Rear Panel Side Stiffener (Sp)

19

Rear Combination Adaptor (Sp, Zn)

40

Rear Frame A (Sp, Zn)

20

Front Pillar Lower Stiffener (Sp, Zn)

41

Rear Frame B (Hss, Zn)

21

Front Pillar Upper Stiffener (Hss)

42

Rear Floor Cross-member (Sp, Zn)

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General Information

Door and Bumper Reinforcement Beams

110

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

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111

General Information

Zinc-plated Steel Plate Repair

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

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

WARNING

To prevent eye injury, wear goggles or safety glassed whenever sanding, cutting or grinding.
NOTE: Seal the sanded surface thoroughly to prevent rust.
2. The electric continuity properties of zinc-plated steel plate is different from the ordinary steel plate. When spot welding, increase the current by 10-20%.
NOTE: The MIG welding procedures for Zinc-plated steel plate are the same an for ordinary steel plate.

WARNING

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

SPECIAL BOLT
GROUND WIRE
GROUND WIRE MOUNTING HOLE
PLUG

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112

General Information

Colour Chart Paint Specifications

P.: Pearl Paint / M.: Metallic Paint


NH-578
Taffeta
White
KE
KG

KB
KQ
KY

NH623M
Stain
Silver M.

B-92P
Night
Hawk
Black P.

B-96P
Eternal
Blue P.

G-95P
Clover
Green P.

R-81
Mirano
Red

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

YR-525M
Titanium
M.

1.4S

1.6SE

1.4S

1.6LS

1.6ES

1.4S

1.6ES

GLi

VTi

LXi

EXi

VTi

KW

EXi

KT

LXi

EXi

EXi

VTi

VTi-S

LXi

EXi

VTi

DX

LX

EX

EXi

VTi

EXi

LXi

150I

170I

LX

EX

KU

KV

KK

KH
KF
KN
KX

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General Information

Colour Chart Paint Specifications (cont'd)

113
1. FRONT GRILLE
Body Colour
2. HOOD MOLDING BASE
Chrome plated or body
colour
3. DOOR MIRROR BASE
Black (NH-70 Gloss 20)
4. DOOR MIRROR
Body colour or black (NH70 Gloss 20)
5. DOOR OUTER HANDLE
Body colour or black (NH72 Gloss 30)
6. PROTECTER
MOULDINGS
Body colour or BP, Dark
grey (NH-533)
7. FRONT BUMPER
Body colour
8. ROOF MOULDING
Black (NH-70 Gloss 20)
9. DRIP MOULDING
Chrome plated or black
(NH-70 Gloss 20)
10. LICENSE TRIM
Chrome plated or body
colour
11. REAR BUMPER
Body Colour
12. DOOR MOULDING
Chrome plated or black
(NH-70 Gloss 20)
13. DOOR SASH TRIM
Black (NH-70 Gloss 20)
14. FRONT UNDER SPOILER
Black (NH-68 Gloss 10)
15. GRILLE
BP. Dark grey (NH-533)

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General Information

Type and Materials of Exterior Plastic Parts

114

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

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

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5-door General Information

5-door General Information


Supplemental Restraint System (SRS)

1-16

Identification Number Locations

1-17

Lift and Support Points

1-18

Body Specifications/Wheel Alignment

1-19

Exterior Parts Removal/Wheel Alignment

1-20

Construction

1-21

Door and Bumper Reinforcement Beams

1-22

Zinc-plated Steel Plate Repair

1-23

Colour Chart Paint Specifications

1-24

Types and Materials of Exterior Plastic Parts

1-26

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General Information

Supplemental Restraint System (SRS)

116

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

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General Information

Identification Number Locations

117
1. Built Data and Vehicle Type
2. Vehicle Identification
Number (VIN)
3. Engine Number
4. Transmission Number
(Manual)
5. Transmission Number
(Automatic)

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Index - General Information

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 a tall safety
stands. When substantial weight is removed from the rear of the vehicle, the centre of
gravity can change and cause the vehicle to tip forward on the hoist.
Frame Hoist
Position the hoist lift blocks, or safety stands, under the vehicle's front support points
and rear support points.

118
Floor Jack
1. Set the parking brake.
2. Block the wheels that are not being lifted.
3. When lifting the rear of the vehicle, put the gearshift lever in reverse (or automatic
transmission in Park position).
4. Position the floor jack under the front jacking bracket or rear jacking bracket, centre
the jacking bracket in the jack lift platform, and jack up the vehicle high enough to fit
the safety stands under it.

1. FRONT SUPPORT POINT


2. HOIST LIFT BLOCKS
3. REAR SUPPORT POINT

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

1.
2.
3.
4.

FRONT JACKING BRACKET


JACK LIFT PLATFORM
JACK LIFT PLATFORM
REAR JACKING BRACKET

5. Position the safety stands under the support points and adjust them so the vehicle
will level.
6. Lower the vehicle onto the stands.

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General Information

Body Specifications/Wheel Alignment

119
Unit : mm(in.)

*1: With Roof Antenna


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

Front Wheel Alignment:


Camber

000'45'

Caster

1'33'1

Total toe

03 (00.13)

Wheel turning angle

in

4000'2 (D15B engine)


3800'2 (D17A engine)

out

3100' (D15B engine: Reference)


3000' (D17A engine: Reference)

Rear Wheel Alignment:


Camber

-045'45'

Total toe

IN 2 3 (0.08 0.12)

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General Information

Exterior Parts Removal/Installation

120

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

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121

General Information
Construction

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


No.

Part Name

No.

Part Name

Hood (Hss, Zn),/p>

22

Front Pillar Upper Stiffener (Hss)

Front Fender (Sp, Zn)

23

Centre Pillar Stiffener (Sp)

Front Door (Hss, Zn)

24

Side Sill Reinforcement (Hss, Zn)

Rear Door (Hss, Zn)

25

Front Pillar Inner Lower (Hss)

Trunk Lid (Sp, Zn)

26

Front Pillar Inner Upper (Hss, Zn)

Bulkhead Side (Sp, Zn)

27

Centre Inner Pillar (Hss, Zn)

Bulkhead Side Stray (Sp, Zn)

28

Roof Side Rail (Hss)

Bulkhead Upper Frame (Sp, Zn)

29

Roof Panel (Sp)

Front Lower Cross-member (Hss, Zn)

30

Rear Inner Panel (Sp, Zn)

10

Wheelhouse Upper Member (Sp)

31

Wheel Arch Extension (Sp, Zn)

11

Front Wheelhouse (Sp, Zn)

32

Rear Wheelhouse (Sp, Zn)

12

Front Damper Extension (Hss, Zn)

33

Inside Sill (Hss, Zn)

13

Damper Housing (Hss, Zn)

34

Front Floor (Sp, Zn)

14

Front Side Frame (Hss, Zn)

35

Middle Floor Cross-member (Hss, Zn)

15

Side Frame Extension Rear/Front Side Outrigger (Hss, Zn)

36

Rear Floor Upper Cross-member (Sp)

16

Dashboard Lower (Sp, Zn)

37

Rear Floor (Sp, Zn)

17

Dashboard Upper (Sp, Zn)

38

Rear Panel (Sp, Zn)

18

Outer Panel (Sp, Zn)

39

Rear Frame A (Sp, Zn)

19

Rear Pillar Gutter Lower (Sp, Zn)

40

Rear Frame B (Hss, Zn)

20

Rear Pillar Gutter Upper (SP, Zn)

41

Rear Floor Cross-member (Sp, Zn)

21

Front Pillar Lower Stiffener (Sp, Zn)

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Index - General Information

General Information

Door and Bumper Reinforcement Beams

122

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

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Index - General Information

123

General Information

Zinc-plated Steel Plate Repair

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

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

WARNING

To prevent eye injury, wear goggles or safety glassed whenever sanding, cutting or grinding.
NOTE: Seal the sanded surface thoroughly to prevent rust.
2. The electric continuity properties of zinc-plated steel plate is different from the ordinary steel plate. When spot welding, increase the current by 10-20% or increase the resistance
welding time.Also increase the number of weld spots by 10-20%.
NOTE: The MIG welding procedures for Zinc-plated steel plate are the same an for ordinary steel plate.

WARNING

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

SPECIAL BOLT
GROUND WIRE
GROUND WIRE MOUNTING HOLE
PLUG

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Index - General Information

124

General Information

Colour Chart Paint Specifications

P.: Pearl Paint / M.: Metallic Paint


NH-578 NH-623M
Taffeta Stain
White
Silver M.
KE

KQ
KT

B-92P
Night
Hawk
Black P.

G-502M
Aqua
Green M.

PB-77M
Lavender
Mist M.

R-81
Mirano
Red

R504P
Ruby
Red P.

B-96P
Eternal
Blue P.

G95P
Clover
Green P.

1.4S

1.6S

1.4SE

1.6LSE

Vi

VTi

EXi

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Index - General Information

General Information

Colour Chart Paint Specifications (cont'd)

125
1. DOOR MIRROR BASE
Black (NH-70 Gloss 20)
2. DOOR MIRROR
Body colour or black (NH-70
Gloss 20)
3. CHANNEL TAPE
Black (NH-70 Gloss 20)
4. DOOR OUTER HANDLE
Body colour or black (NH-72
Gloss 30)
5. CORNER TRIM
Black (NH-70 GLOSS 20)
6. ROOF MOULDING
Black (NH-70 Gloss 20)
7. LICENSE TRIM
Body colour or black (NH-72
Gloss 30)
8. REAR BUMPER
Body Clour
9. DOOR MOULDING
Black (NH-70 Gloss 20)
10. DOOR SASH TRIM
Black (NH-70 Gloss 20)
11. FRONT BUMPER
Body Colour
12. GRILLE
BP. Dark grey (NH-533)

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Index - General Information

General Information

Type and Materials of Exterior Plastic Parts

126

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

1. FRONT WINDSHIELD MOULDING


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

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Preparation of Work - Preparation of Work

Preparation of Work
General Safety Precaution

2-3

Accurate Inspection of Damaged Parts (Visual)


Description

2-4

Measurement

2-5

Reshaping
Correction of the Damaged Area

2-6

Replacement
Removal

2-7

Installation

2-8

Rust Prevention/Paint

2-10

Installation and Inspection

2-11

Repair Tools
Measurement Equipment

2-12

Protective Tools

2-12

Processing Tools

2-13

Cutting Tools

2-13

Shaping Tools

2-14

Fixing Tools

2-15

Welders

2-16

Sanding Tools

2-16

Welding Methods
Spot Welding

2-17

Carbon Dioxide Arc Welder (MIG Arc Weld)

2-19

Gas Welding

2-20

Outline of Body Repair

2-2

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Outline of Body Repair

2-2

Outline of Body Repair

The contents described in this section are the basic processes of repair procedures needed to cut and replace welded parts. Reshape the light damage, outer panel with filler after
repair by the washer welder, the hammer and dolly.
The table below shows information to this model.
Processes

Repair Procedures

Accurate inspection of Damaged Parts. (Visual)


Measurement

Information

Reshape

1.
2.
3.
4.

Remove any related parts.


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

Rust Prevention

1. Cut off and separate the damaged area.


2. Straighten any related parts.
3. Check the repair part installation and alignment with
the body.
4. Clean and degrease to the welded surfaces.
5. Weld in the repair part.
6. Finish the welded areas.
1. Apply the sealer.
2. Apply the undercoating.
3. Apply anti-rust agent to the inside of the outer panel
and frames.

Installation and
Inspection

see section 1
see section 4
see section 1

Paint

see section 1

Shop Manual

Replacement

Wheelbase
Wheel Alignment
Body Dimensional Drawings

Reference

Body Dimensional Drawings


Mass Production Body Welding
Diagram
Removal
Body Dimensional Drawings
Installation

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

Cross Section of Body and Sealants. see section 5


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

Apply the paint

see section 6

1.
2.
3.
4.

Shop Manual

Adjust the hood, door, tailgate.


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

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General Safety Precaution

2-3

General Safety Precaution

Disconnect the battery to reduce the possibility of damage caused by


electrical shorts.
Check for fuel leaks and repair as necessary.
Use standard safety equipment when spraying paint, welding, cutting,
sanding, or grinding (see page 2-12).
Always attach a safety cable when using a hydraulic ram or a frame
straightening table; do not stand in direct line of the chains used on
such equipment.

Remove the fuel tank and/or fuel lines if welding equipment is to be


used near the fuel system.

1. FUEL TANK

1. SAFETY CABLES

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

The vehicle identification number is stamped on the dashboard upper


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

1. VEHICLE IDENTIFICATION NUMBER (VIN)


2. DASHBOARD UPPER

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

Accurate Inspection of Damaged Parts


(Visual)

2-4

Description

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

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

2-5

Accurate Inspection of Damaged Parts


(Visual)
Measurement

Whenever possible, make judgements and conclusions based on


measurements.

Measure the wheel alignment to prevent uneven tyre wear or incorrect


steering wheel alignment.
If there are any deviations, use a tram-tracking gauge and measure
the body parts.

To measure body dimensions, use a universal tram gauge and convex


tool.
Body Measuring Dimension/Opening Repair Chart:

Frame Repair Chart:

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


gauge.

Diagonal measurement:

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Reshape

Reshape

2-6

Correction of the Damaged Area

1. Remove any related parts.


NOTE: See the Shop Manual.
2. Connect the frame straightener to the vehicle body.
The side sill is flangeless to allow reshaping by pulling it out.
Use the horizontal pinch welds for anchoring the vehicle.

4. Check that the part of the body is more or less restored to its original
shapes. Check the original positions using the body dimensional
drawings.

1. SUPPORT POINTS
(Jack-up stiffener)

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

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Preparation of Work - Replacement

2-7

Replacement
Removal

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

2. Peel off the undercoat.

CAUTION

Be careful not to burn the fittings inside the


passenger compartment when heating.

3. Remove the damaged parts.

WARNING

To prevent eye injury, wear goggles or safety


glasses whenever sanding, cutting or grinding.
Centre punch around the spot weld imprints on the welded flange
and drill holes using the spot cutter.
NOTE: Make a drill hole so that the installation of the repair parts may
become easy.

Remove the MIG weld flange with a disc sander.


Pry off the welded flange with a chisel.

Cut off the outer panel with an airsaw.


NOTE: Be careful not to cut the inner section.

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

1. STIFFENER
2. OUTER PANEL

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Preparation of Work - Replacement

2-8

Replacement
Installation

1. Straighten any damaged parts.

WARNING

To prevent eye injury and burns when welding,


wear an approved welding helmet, gloves and
safety shoes.

Where new panels cannot be spot welded, make holes for plug
welding.
Make holes to the size which corresponds to the thickness of the
welded plate (see page 2-19).
The position and the point by which holes are made, refer to the old
parts or Mass Production Body Welding Diagram (see section 3).

Fill any holes by MIG welding and even out with a hammer and
dolly.

WARNING

To prevent eye injury, wear goggles or safety


glasses whenever sanding, cutting or grinding.

Level and finish the burns on the welding flanges with a disc sander
or belt sander.

1. NEW PART
2. OLD PART
3. Apply rust prevention processing on welded surface.

WARNING

To prevent eye injury, wear goggles of safety


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

2. Preparations of new parts.


Cut the new outer panel so it will overlap by 20-30mm (0.8-1.2 in.)
to the panel of the body side.

1. OVERLAP

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Preparation of Work - Replacement

2-9

Replacement
Installation

4. Check the tack weld at positions of the new parts.


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

WARNING

To prevent eye injury and burns when welding,


wear an approved welding helmet, gloves and
safety shoes.

Make 20% to 30% more spot welds than there were holes drilled.
A new welding position should avoid an old position as much as
possible.
NOTE: If there is not room for spot welds, compensate by using MIG
welds

The electric continuity property of zinc-plated steel plate is different


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

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

5. Check the alignment of the exterior body parts.


Temporary install the exterior body parts, windshield and rear
window glass, and check for differences in level and clearances.
NOTE: Check the fit of the front fender, door and the rear fender, and
make sure the body lines flow smoothly.

6. Main weld the repair parts.


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

WARNING

To prevent eye injury and burns when welding,


wear an approved welding helmet, gloves and
safety shoes.

1. BUTT WELD
2. PATCH
3. FILLET WELD

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Preparation of Work - Replacement

210

Replacement

Installation (cont'd)

7. Finishing the welded areas.


Level the MIG welded areas with a disc sander.

WARNING

To prevent eye injury, wear goggles or safety


glasses whenever sanding, cutting or grinding.

1. Applying the sealer. Seal the overlapped areas of the outer panel, and
the welded surfaces of the new parts. Seal gaps completely.
2. Apply the paint.

WARNING

NOTE: Take care not to grind excessively.

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

Rust Prevention/Paint

Ventilate when spraying paint. Most paint


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

3. Apply undercoat to the wheelhouse and under-floor.


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

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Installation and Inspection

Installation and Inspection

211

1. Check the clearance of the door, hood, tailgate and adjust if necessary.
Check the operation of the parts and make sure the doors lock
securely.
2. Apply the sealer to the hinges of the hood, door and tailgate.

1. HOOD HINGE
2. DOOR HINGE
3. TAILGATE HINGE

3. Adjust the wheel alignment.


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

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Preparation of Work - Repair Tools

212

Repair Tools

Measurement Equipment

TRAM TRACKING GAUGE

Protective Tools

OPERATOR:
1

Protective goggles

Protective apron

Cap

Welding glove

Ear plugs

Foot protector

Shield for eyes

10

Safety shoes

Overalls with long sleeves

11

Work glove

Dust-proof mask

12

Splatter guard

FRAME CENTRING GAUGE

UNIVERSAL TRAM GAUGE

CONVEX TOOL

VEHICLE BODY:
Heat-resistant protective cover

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Preparation of Work - Repair Tools

Repair Tools

Processing Tools

213

SPOT CUTTER

AIRSAW

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

Cut the outer panel.

Cutting Tools

AIR CHUCK GRINDER


AIR DRILL
The rotation speed can be adjusted, and an adequate hole opening can
work.

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

AIR IMPACT CUTTER


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

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

SPOT WELD CUTTER


Pry off the spot welded flange.

HAND NIBBLER

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Preparation of Work - Welding Methods

219

Welding Methods

Carbon Dioxide Arc Welder (MIG Arc Weld)

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

CAUTION

Disconnect the negative battery cable before arc welding.


Welding Methods:
Butt welding

Fillet welding

Spot welding

Plug welding

Plug Welding Conditions:


Plate thickness and weld holes
Unit: mm (in.)
Plate thickness

~1.0 (0.04)

1.0 (0.04) ~ 1.5 (0.06)

1.5 (0.06)~

Weld hole diameter

5 (0.2)

6.5 (0.26)

8 (0.3)

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Preparation of Work - Welding Methods

220

Welding Methods
Gas Welding

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

Gas regulator
Gas regulator
Welder
Cutter
Oxygen/Acetylene tanks

Welding Methods:
Butt welding

Fillet welding or soldering

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Index - Index

Index
4-door Replacement

3-3

5-door Replacement

3-35

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4-door Replacement

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

3-4

Removal

3-5

Installation

3-5

*Front Wheelhouse/Damper Housing


Mass Production Body Welding Diagram

3-6

Removal

3-7

Installation

3-9

*Front Side Frame Outrigger


Mass Production Body Welding Diagram

3-11

Removal

3-12

Installation

3-14

*Front Pillar Outer Panel


Mass Production Body Welding Diagram

3-16

Removal

3-17

Installation

3-18

*Side Sill Outer Panel


Mass Production Body Welding Diagram

3-19

Removal

3-20

Installation

3-21

Roof Panel
Mass Production Body Welding Diagram

3-24

Removal

3-24

Installation

3-25

Rear Side Outer Panel


Mass Production Body Diagram

3-26

Removal

3-27

Installation

3-28

Rear Panel
Mass Production Body Welding Diagram

3-29

Removal

3-30

Installation

3-31

Rear Floor
Mass Production Body Welding Diagram

3-32

Removal

3-33

Installation

3-34

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

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4-door Replacement

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Index - Front Bulkhead

Front Bulkhead

Mass Production Body Welding Diagram

34
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.

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Front damper extension


Bulkhead upper frame
Bulkhead side stay
Wheelhouse upper
member
Front wheelhouse
Front side frame
4-Plate welding
Front lower cross-member
Bulkhead side
Bulkhead bracket

Index - Front Bulkhead

Front Bulkhead

3-5

Installation

Removal

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

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

BULKHEAD UPPER FRAME


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

1.
2.
3.
4.
5.
6.
7.
8.
9.

BULKHEAD UPPER FRAME


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

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Index - Front Wheelhouse/Damper Housing

Front Wheelhouse/Damper Housing


Mass Production Body Welding Diagram

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

Front side frame


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

Passenger compartment side:


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

Dashboard upper side member


Damper housing extension
Front damper extension
Damper housing
Front wheelhouse

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Index - Front Wheelhouse/Damper Housing

Front Wheelhouse/Damper Housing

3-7

Removal

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

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

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Index - Front Wheelhouse/Damper Housing

Front Wheelhouse/Damper Housing

3-8

Removal (cont'd)

Replace the front damper extension, damper housing and damper housing extension as an assembly.
Passenger compartment side:

1. FRONT DAMPER
EXTENSION
2. DASHBOARD UPPER
SIDE MEMBER
3. DAMPER HOUSING
4. FRONT DAMPER
EXTENSION
5. ENGINE MOUNT BRACKET
6. FRONT SIDE FRAME
7. DAMPER HOUSING
EXTENSION
8. DAMPER HOUSING
EXTENSION

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Index - Front Wheelhouse/Damper Housing

3-9

Front Wheelhouse/Damper Housing


Installation

1. Set the new damper housing assembly, front wheelhouse and front
bulkhead into position, and measure the front compartment diagonally.
Check the body dimensions (see section 4).

From the passenger compartment side, plug the holes in the


dashboard lower, damper housing extension and front damper
extension.

2. Tack weld the clamped position.


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

1. FRONT DAMPER EXTENSION


2. DAMPER HOUSING EXTENSION

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

1. DAMPER HOUSING EXTENSION

1.
2.
3.
4.

FRONT DAMPER EXTENSION


DASHBOARD UPPER SIDE MEMBER
FRONT SIDE FRAME
DAMPER HOUSING

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Index - Front Wheelhouse/Damper Housing

Front Wheelhouse/Damper Housing


Installation (cont'd)

Weld the front wheelhouse, damper housing and front side frame.

1.
2.
3.
4.

310

DAMPER HOUSING
FRONT DAMPER EXTENSION
FRONT WHEELHOUSE
ENGINE MOUNT BRACKET

Weld the wheelhouse upper member.


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

1. FRONT DAMPER EXTENSION


2. Butt Welding
3. WHEELHOUSE UPPER MEMBER

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Index - Front Side Frame/Outrigger

Front Side Frame/Outrigger

Mass Production Body Welding Diagram

311
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.

Front side frame


Sub-frame rear bracket
4-Plated welding
Side frame extension rear
Inside sill extension
Outrigger
Side frame bulkhead rear
4-Plate welding
Inside sill extension
Side frame extension rear
Side frame bulkhead rear
and front side frame
l. Front wheelhouse

VIEW (Y)
a. Inside sill extension

VIEW (Z)

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Index - Front Side Frame/Outrigger

Passenger compartment side:

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Index - Front Side Frame/Outrigger

Front Side Frame/Outrigger


Removal

312

Passenger compartment side:


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

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FRONT SIDE FRAME


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

Index - Front Side Frame/Outrigger

Front Side Frame/Outrigger


Removal (cont'd)

313

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

If necessary, replace the side frame extension rear, outrigger and sub-frame rear bracket as an assembly.
NOTE: When removing the outrigger, leave the inside sill extension attached to the inside sill, if possible.

Passenger compartment side:


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

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Index - Front Side Frame/Outrigger

314

Front Side Frame/Outrigger


Installation

1. Tack weld the new side frame bulkhead rear to the side frame
extension rear.

Plug weld the inside sill extension and floor frame.

1. SIDE FRAME BULKHEAD REAR

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

1. INSIDE SILL EXTENSION


2. FLOOR FRAME

From passenger compartment, plug weld the dashboard lower and


front floor.

1. SIDE FRAME BULKHEAD REAR


2. FRONT SIDE FRAME
3. SIDE FRAME EXTENSION REAR

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

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Index - Roof Panel

Roof Panel
Removal

324
1.
2.
3.
4.
5.
6.
7.

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

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Index - Roof Panel

Roof Panel
Installation

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

325
5. From inside the vehicle, plug weld the front pillar inner upper, rear
inner panel and front and rear roof rails.

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

VIEW (Z)

1.
2.
3.
4.

FRONT INNER UPPER PILLAR


FRONT ROOF RAIL
REAR INNER PANEL
REAR ROOF RAIL

1. ROOF ARCH GUSSET

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Index - Rear Side Outer Panel

Rear Side Outer Panel

Mass Production Body Welding Diagram

326
a.
b.
c.
d.
e.
f.
g.

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Rear damper stiffener


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

Index - Rear Side Outer Panel

Rear Side Outer Panel


Removal

327

Cut and pry off rear side outer panel.


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

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Index - Rear Side Outer Panel

Rear Side Outer Panel


Installation

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

328

Weld the rear combination adaptor and rear panel.

1. REAR COMBINATION ADAPTOR

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

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

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Index - Rear Panel

Rear Panel

Mass Production Body Welding Diagram

329
a.
b.
c.
d.
e.
f.

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Rear panel side stiffener


Rear combination adaptor
Trunk compartment side:
Rear panel
Jack-up stiffener
4-Plate welding

Index - Rear Panel

Rear Panel
Removal

330

Cut and pry off the rear panel.


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

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Index - Rear Panel

331

Rear Panel
Installation

1. Set the new rear panel and rear combination adaptor into position and
clamp them.
Check the body dimensions (see section 4).

1. REAR COMBINATION ADAPTOR


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

1. NEW REAR COMBINATION ADAPTOR


2. NEW REAR PANEL

2. Tack weld the clamped position.


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

In the case of leave the rear panel side stiffener and rear combination
adopter and replace rear panel.
Remove the new panel side stiffener from the new rear panel.
Weld the rear panel side lower stiffener and rear panel side stiffener.

Weld the rear panel and rear floor.

1. NEW REAR PANEL

1.
2.
3.
4.

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

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Index - Rear Floor

Rear Floor

Mass Production Body Welding Diagram

332
a.
b.
c.
d.
e.
f.
g.

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Rear floor cross-member


Rear floor
Rear panel gusset
Rear frame A
Rear frame B
Rear floor
Include (A)

Index - Rear Floor

Rear Floor
Removal

333

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

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Index - Rear Floor

Rear Floor
Installation

1.
2.
3.
4.

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

1. NEW REAR FLOOR


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

334
8. Set the new rear floor, and plug weld the rear floor cross-member, rear
frame B and rear frame A.

1.
2.
3.
4.
5.

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

9. Perform the main welding to the rear floor.

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

1. REAR FLOOR CROSS MEMBER


1. Filler welding

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5-door Replacement

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

3-36

Removal

3-37

Installation

3-37

*Front Wheelhouse/Damper Housing


Mass production Body Welding Diagram

3-38

Removal

3-39

Installation

3-41

*Front Side Frame/Outrigger


Mass Production Body Welding Diagram

3-43

Removal

3-44

Installation

3-46

*Front Pillar Outer Panel


Mass Production Body Welding Diagram

3-48

Removal

3-49

Installation

3-50

*Side Sill Outer Panel


Mass Production Body Welding Diagram

3-51

Removal

3-52

Installation

3-53

Roof Panel
Mass Production Body Welding Diagram

3-55

Removal

3-56

Installation

3-57

Rear Side Outer Panel


Mass Production Body Welding Diagram

3-58

Removal

3-59

Installation

3-60

Rear Panel
Mass Production Body Welding Diagram

3-61

Removal

3-62

Installation

3-62

Rear Floor
Mass Production Body Welding Diagram

3-63

Removal

3-64

Installation

3-65

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

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5-door Replacement

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Index - Front Bulkhead

Front Bulkhead

Mass Production Body Welding Diagram

336
a. Front wheelhouse
b. Wheelhouse upper
extension
c. Front side frame
d. Wheelhouse upper
member
e. Front lower cross-member
f. Bulkhead side
g. Front side frame
h. 4-Plate welding
i. 4-Plate welding
j. Front lower cross-member
k. Bulkhead side stay
l. Bulkhead centre stay
m. Bulkhead upper frame

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Index - Front Bulkhead

Front Bulkhead
Removal

337

Installation

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

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

BULKHEAD UPPER FRAME


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

1.
2.
3.
4.
5.
6.
7.
8.
9.

BULKHEAD UPPER FRAME


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

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Front/Wheelhouse/Damper Housing

Front/Wheelhouse/Damper Housing
Mass Production Body Welding Diagram

338
a.
b.
c.
d.
e.
f.
g.

Front side frame


Engine mount bracket dashboard upper
Damper housing extension
Wheelhouse upper extension
Wheelhouse upper member
Dashboard upper side member
Front wheelhouse

Wheelhouse upper member removed:


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

Passenger compartment side:


a. Wheelhouse upper member

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Front/Wheelhouse/Damper Housing

VIEW (X)

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Index - Front Wheelhouse/Damper Housing

Front Wheelhouse/Damper Housing


Removal

339

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

Check the wheelhouse upper extension and damper housing for position and damage. If Necessary, remove the wheelhouse upper member and replace the damper housing and
wheelhouse upper extension as an assembly. If possible.
1.
2.
3.
4.

DAMPER HOUSING
WHEELHOUSE UPPER EXTENSION
WHEELHOUSE UPPER MEMBER EXTENSION
WHEELHOUSE UPPER MEMBER Reused.

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Index - Front Wheelhouse/Damper Housing

Front Wheelhouse/Damper Housing


Removal (cont'd)

340

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


Passenger compartment side:

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

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Index - Front Wheelhouse/Damper Housing

341

Front Wheelhouse/Damper Housing


Installation

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

From passenger compartment side, plug weld the holes in the


dashboard lower damper housing extension and wheelhouse upper
extension.

1. WHEELHOUSE UPPER EXTENSION


2. DAMPER HOUSING EXTENSION

Weld the dashboard upper and damper housing.

1. DASHBOARD UPPER

1.
2.
3.
4.

WHEELHOUSE UPPER EXTENSION


DASHBOARD UPPER SIDE MEMBER
FRONT SIDE FRAME
DAMPER HOUSING

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Index - Front Wheelhouse/Damper Housing

Front Wheelhouse/Damper Housing


Installation (cont'd)

Weld the front wheelhouse, damper housing and front side frame.

1.
2.
3.
4.

342

DAMPER HOUSING
WHEELHOUSE UPPER EXTENSION
FRONT WHEELHOUSE
ENGINE MOUNT BRACKET

Weld the wheelhouse upper member.


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

1.
2.
3.
4.

WHEELHOUSE UPPER EXTENSION


WHEELHOUSE UPPER MEMBER EXTENSION
Butt welding
WHEELHOUSE UPPER MEMBER

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Index - Front Side Frame/Outrigger

Front Side Frame/Outrigger

Mass Production Body Welding Diagram

343
a.
b.
c.
d.
e.
f.
g.
h.

Front side frame


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

a. Inside sill extension

VIEW (Y)
Passenger compartment side:

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Index - Front Side Frame/Outrigger

Front Side Frame/Outrigger


Removal

344

Passenger compartment side:


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

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FRONT SIDE FRAME


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

Index - Front Side Frame/Outrigger

Front Side Frame/Outrigger


Removal (cont'd)

345

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

If necessary, replace the side frame extension rear, outrigger and sub-frame rear bracket as an assembly.
NOTE: When removing the outrigger, leave the inside sill extension attached to the inside sill, if possible.

Passenger compartment side:


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

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Index - Front Side Frame/Outrigger

346

Front Side Frame/Outrigger


Installation

1. Tack weld the new side frame bulkhead rear to the side frame
extension rear.

Plug weld the inside sill extension and floor frame.

1. SIDE FRAME BULKHEAD REAR

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

1. INSIDE SILL EXTENSION


2. FLOOR FRAME

From passenger compartment, plug weld the dashboard lower and


front floor.

1. SIDE FRAME BULKHEAD REAR


2. FRONT SIDE FRAME
3. SIDE FRAME EXTENSION REAR

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

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Index - Front Side Frame/Outrigger

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Index - Front Side Frame/Outrigger

Front Side Frame/Outrigger


Installation (cont'd)

347

Weld the damper housing, front wheelhouse and front side frame.

1. DAMPER HOUSING
2. FRONT WHEELHOUSE

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Index - Front Pillar Outer Panel

Front Pillar Outer Panel

Mass Production Body Welding Diagram

348
a. Wheelhouse upper
member (see page 338)
b. Front pillar lower
stiffener
c. Inner lower
d. Front pillar upper
stiffener
e. VIEW (Z)
f. Side sill reinforcement
g. Front pillar stiffener
h. 4-Plate welding
i. Front pillar separator

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Index - Front Pillar Outer Panel

Front Pillar Outer Panel


Removal

349

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

FRONT PILLAR UPPER STIFFENER


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

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Index - Front Pillar Outer Panel

Front Pillar Outer Panel


Installation

1. Glue the insulator to the inner lower at the front pillar lower separator
mounted position.
Insulator: P/N. 74416-SF1-000
Adhesive: Cemedine 366 or equivalent

350
6. Clamp the repair part and recheck the clearance and alignment of the
front door, front fender and windshield.
7. Perform the main welding:
Attach the patch at the cut the section of the front pillar outer panel
and plug weld it.

1. INNER LOWER
2. INSULATOR

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

1.
2.
3.
4.
5.

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

8. Weld the wheelhouse upper member.

1. FRONT PILLAR UPPER STIFFENER


2. FRONT PILLAR LOWER STIFFENER
3. INSULATOR

1. WHEELHOUSE UPPER MEMBER EXTENSION


2. WHEELHOUSE UPPER MEMBER

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Index - Side Sill Outer Panel

Side Sill Outer Panel

Mass Production Body Welding Diagram

351
a. Center pillar stiffener
reinforcement
b. Centre pillar stiffener
c. 4-Plate welding
d. Centre pillar separator
e. VIEW (Y)
f. Side sill reinforcement
g. VIEW (Z)
h. Centre pillar stiffener
i. VIEW (W)
j. VIEW (Y)
k. 4-Plate welding

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Index - Side Sill Outer Panel

Side Sill Outer Panel


Removal

352

Cut and pry off the side sill outer panel.


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

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Index - Side Sill Outer Panel

Side Sill Outer Panel


Installation

353

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

1. NEW SIDE SILL REINFORCEMENT


2. INSIDE SILL
3. CENTRE INNER PILLAR

1. CENTRE INNER PILLAR


2. INSULATOR

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

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

1.
2.
3.
4.
5.

FRONT PILLAR OUTER PANEL


OUTER PANEL
SIDE SILL REINFORCEMENT
INSIDE SILL
REINFORCEMENT STIFFENER

1. NEW CENTRE PILLAR STIFFENER


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

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Index - Side Sill Outer Panel

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Index - Side Sill Outer Panel

Side Sill Outer Panel


Installation (cont'd)

354

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

1.
2.
3.
4.
5.

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

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Index - Roof Panel

Roof Panel

Mass Production Body Welding Diagram

355

Without roof panel:


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

Front inner upper pillar


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

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Index - Roof Panel

Roof Panel
Removal

356
1. ROOF PANEL
2. REAR INNER PANEL
3. REAR PILLAR GUTTER
UPPER
4. ROOF ARCH GUSSET
5. REAR INNER PANEL
6. REAR ROOF RAIL
7. FRONT ROOF RAIL
8. FRONT INNER UPPER
PILLAR
9. FRONT INNER UPPER
PILLAR

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Index - Roof Panel

Roof Panel
Installation

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

357
5. From inside the vehicle, plug weld the front pillar inner upper, rear
inner panel and front and rear roof rail.

VIEW (Z)
1. OUTER PANEL
2. ROOF PANEL
3. ROOF SIDE RAIL

1.
2.
3.
4.

FRONT INNER UPPER PILLAR


FRONT ROOF RAIL
REAR INNER PANEL
REAR ROOF RAIL

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

1. REAR PILLAR GUTTER UPPER


1. ROOF ARCH GUSSET

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Index - Rear Side Outer Panel

Rear Side Outer Panel

Mass Production Body Welding Diagram

358
a.
b.
c.
d.
e.
f.
g.
h.
i.

Quarter pillar inner


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

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Index - Rear Side Outer Panel

Rear Side Outer Panel


Removal

359

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

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WHEEL ARCH EXTENSION


QUARTER PILLAR INNER
REAR PILLAR INNER
REAR PILLAR GUTTER
UPPER
REAR PILLAR GUTTER
LOWER
REAR INNER PANEL
REAR PILLAR GUTTER
LOWER
REAR PANEL
REAR PILLAR GUTTER
UPPER
REAR PANEL GUSSET
VIEW (Z)
REAR GUTTER LOWER
STIFFENER
OUTER PANEL

Rear Side outer Panel

360

Rear Side outer Panel


Installation

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

Weld the rear pillar gutter lower, gutter upper and rear panel.

1. REAR GUTTER LOWER STIFFENER


2. REAR PILLAR GUTTER LOWER

1.
2.
3.
4.
5.

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

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Index - Rear Panel

Rear Panel

Mass Production Body Welding Diagram

361
a.
b.
c.
d.
e.
f.

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Rear pillar gutter lower


Rear gutter lower stiffener
Rear panel
Rear panel
Jack-up stiffener
Rear pillar gutter lower

Index - Rear Panel

Rear Panel
Removal

Cut and pry off the rear panel.


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

362

Installation

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

1. REAR PANEL
2. REAP PILLAR GUTTER LOWER

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

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

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Index - Rear Floor

Rear Floor

Mass Production Body Welding Diagram

363
a.
b.
c.
d.
e.
f.
g.
h.

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

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Index - Rear Floor

Rear Floor
Removal

364

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

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Index - Rear Floor

Rear Floor
Installation

1.
2.
3.
4.

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

1. NEW REAR FLOOR


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

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

365
8. Set the new rear floor and plug weld the rear floor cross-member, rear
frame B and rear frame A.

1.
2.
3.
4.
5.

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

9. Perform the main welding to the rear floor.

1. REAR FLOOR CROSS MEMBER

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Index - Rear Floor

1. Fillet welding

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Index - Index

Index
4-door Body Dimensional Drawings

4-3

5-door Body Dimensional Drawings

4-13

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4-door Body Dimensional Drawings

4-door Body Dimensional Drawings


Upper Body Measuring Dimensions
Engine Compartment

4-4

Engine/Transmission Mount Positions and


Passenger Compartment

4-5

Under Body Measuring Dimensions


Engine Compartment and Front Floor Under View 4-6
Middle and Rear Floor Under View

4-7

Frame Repair Chart


Top View

4-8

Side View

4-10

Opening Repair Chart

4-12

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Index - Upper Body Measuring Dimensions

Upper Body Measuring Dimensions

4-4

Engine Compartment

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

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Index - Upper Body Measuring Dimensions

Upper Body Measuring Dimensions

4-5

Passenger Compartment

Engine/Transmission Mount Positions

Unit: mm (in.)

Unit: mm (in.)

1. E
Front Damper Mount Hole 11.5 (0.45)
2. H
AT/MT Transmission Bracket Mount Holed 13 (0.51)
3. I
Engine Bracket Mount Hole 13 (0.51)
4. J
Honda Multi Matic Transmission Bracket Mount Hole 13 (0.51)

AT/MT:

Honda Multi Matic:

1. K, k
Front Seat Rear Side Bracket Point 9 (0.35)
2. L, l
Rear Damper Mount Hole 11 (0.43)
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Index - Upper Body Measuring Dimensions

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Index - Under Body Measuring Dimensions

Under Body Measuring Dimensions

Engine Compartment and Front Floor Under View

46
Unit: mm (in.)
1. A, a
Radiator Mount Hole 15
(0.59)
2. B, b
Front Sub-frame Mount
Hole 15 (0.59) Forward
3. C, c
Front Sub-frame Mount
Hole 15 (0.59) Rearward
4. D, d
Front Floor Frame Point 20
(0.79)

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Index - Under Body Measuring Dimensions

Under Body Measuring Dimensions

4-7

Middle and Rear Floor Under View

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

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Index - Frame Repair Chart

48

Frame Repair Chart


Top View

Unit: mm (in.)

For sub-frame o15 (0.59)

For damper mount o 11.5 (0.45)

: Inner diameter

b1

For engine mount o13 (0.51)

Damper centre o 78 (3.07)

b2

For engine mount o 13 (0.51)

For damper mount o 11.5 (0.45)

b3

For engine mount o 13 (0.51)

For damper mount o 11.5 (0.45)

c1

For transmission mount o13 (0.51)

For sub-frame o 11.5 (0.45)

c2

For transmission mount o13 (0.51)

For sub-frame o 11.5 (0.45)

c3

For transmission mount o13 (0.51)

Locate hole o 25 (0.98)

d1

For transmission mount o13 (0.51)

Locate hole o 50 (1.97)

d2

For transmission mount o13 (0.51)

d3

For transmission mount o13 (0.51)

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Index - Frame Repair Chart

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Index - Frame Repair Chart

49

Frame Repair Chart


Top View (cont'd)

Locate hole o 25 (0.98)

For upper arm bracket center o 15 (0.59)

For trailing arm o 13 (0.51)

v1, v2

Locate hole o 13 (0.51)

Locate hole o 25 (0.98)

For upper arm o 13 (0.51)

Locate hole o 20 (0.79)

For rear lower arm centre

Trailing arm centre

Locate hole o 50 (1.97)

Rear damper center 73 x 68 (slot)

Locate hole o 20 (0.79)

For upper arm o 13 (0.51)

For trailing arm o 13 (0.51)

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Index - Frame Repair Chart

410

Frame Repair Chart


Side View

Unit: mm (in.)
o: Inner diameter

For sub-frame o 15 (0.59)

For damper mount o 11.5 (0.45)

b1

For engine mount o 13 (0.51)

Damper centre o 78 (3.07)

b2

For engine mount o 13 (0.51)

For damper mount o 11.5 (0.45)

b3

For engine mount o 13 (0.51)

For damper mount o 11.5 (0.45)

c1

For transmission mount o 13 (0.51)

For sub-frame o 11.5 (0.45)

c2

For transmission mount o 13 (0.51)

For sub-frame o 11.5 (0.45)

c3

For transmission mount o 13 (0.51)

Locate hole o 25 (0.98)

d1

For transmission mount o 13 (0.51)

Locate hole o 50 (1.97)

d2

For transmission mount o 13 (0.51)

d3

For transmission mount o 13 (0.51)

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Index - Frame Repair Chart

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Index - Frame Repair Chart

411

Frame Repair Chart


Side View (cont'd)

Locate hole o 25 (0.98)

For upper arm bracket center o15 (0.59)

For trailing arm o 13 (0.51)

v1, v2

Locate hole o 13 (0.51)

Locate hole o 25 (0.98)

For upper arm o 13 (0.51)

Locate hole o 20 (0.79)

For rear lower arm centre

Trailing arm centre

Locate hole o 50 (1.97)

Rear damper center 73 x 68 (slot)

Locate hole o 20 (0.79)

For upper arm o 13 (0.51)

For trailing arm o 13 (0.51)

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Index - Opening Repair Chart

Opening Repair Chart

412

Door and Windshield Openings:


Unit: mm (in.)

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

Rear Window and Trunk Lip Openings:

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

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Index - Opening Repair Chart

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5-door Body Dimensional Drawings

5-door Body Dimensional Drawings


Upper Body Measuring Dimensions
Engine Compartment

4-14

Engine/Transmission Mount Positions and


Passenger Compartment

4-15

Under Body Measuring Dimensions


Engine Compartment and Front Floor Under View 4-16
Middle and Rear Floor Under View

4-17

Frame Repair Chart


Top View

4-18

Side View

4-20

Opening Repair Chart

4-22

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Index - Upper Body Measuring Dimensions

Upper Body Measuring Dimensions


Engine Compartment

414

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

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Index - Upper Body Measuring Dimensions

Upper Body Measuring Dimensions


Engine/Transmission Mount Positions

Unit: mm (in.)

415

Passenger Compartment

Unit: mm (in.)

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

1. J, j
Front seat Rear Side Bracket Point 9 (0.35)
2. K, k

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Index - Upper Body Measuring Dimensions

Rear Damper Mount hole 11 (0.43)

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Index - Upper Body Measuring Dimensions

Upper Body Measuring Dimensions

Engine Compartment and Front Under View

416

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

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Index - Upper Body Measuring Dimensions

Upper Body Measuring Dimensions


Middle and Rear Floor Under View

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

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Index - Frame Repair Chart

418

Frame Repair Chart


Top View

Unit: mm (in.)

For sub-frame o 15 (0.59)

Damper centre o 78 (3.07)

: Inner diameter

b1

For engine mount o 13 (0.51)

For damper mount o 11.5 (0.45)

b2

For engine mount o 13 (0.51)

For damper mount o 11.5 (0.45)

b3

For engine mount o 13 (0.51)

For sub-frame o 11.5 (0.45)

c1

For transmission mount o 13 (0.51)

For sub-frame o 11.5 (0.45)

c2

For transmission mount o 13 (0.51)

Locate hole o 25 (0.98)

c3

For transmission mount o 13 (0.51)

Locate hole o 50 (1.97)

For damper mount o 11.5 (0.45)

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Index - Frame Repair Chart

419

Frame Repair Chart


Top View (cont'd)

Locate hole o 25 (0.98)

For upper arm bracket center o 15 (0.59)

For trailing arm o 13 (0.51)

u1, u2

Locate hole o 13 (0.51)

Locate hole o 25 (0.98)

For upper arm o 13 (0.51)

Locate hole o 20 (0.79)

Locate hole o 25 (0.98)

Trailing arm centre

For rear lower arm centre

Rear damper center 73 x 68 (slot)

Locate hole o 50 (1.97)

For upper arm o 13 (0.51)

Locate hole o 20 (0.79)

For trailing arm o 13 (0.51)

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Index - Frame Repair Chart

420

Frame Repair Chart


Side View

Unit: mm (in.)

For sub-frame o 15 (0.59)

Damper centre o 78 (3.07)

: Inner diameter

b1

For engine mount o 13 (0.51)

For damper mount o 11.5 (0.45)

b2

For engine mount o 13 (0.51)

For damper mount o 11.5 (0.45)

b3

For engine mount o 13 (0.51)

For sub-frame o 11.5 (0.45)

c1

For transmission mount o 13 (0.51)

For sub-frame o 11.5 (0.45)

c2

For transmission mount o 13 (0.51)

Locate hole o 25 (0.98)

c3

For transmission mount o 13 (0.51)

Locate hole o 50 (1.97)

For damper mount o 11.5 (0.45)

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Index - Frame Repair Chart

421

Frame Repair Chart


Side View (cont'd)

Locate hole o 25 (0.98)

For upper arm bracket center o 15 (0.59)

For trailing arm o 13 (0.51)

u1, u2

Locate hole o 13 (0.51)

Locate hole o 25 (0.98)

For upper arm o 13 (0.51)

Locate hole o 20 (0.79)

Locate hole o 13 (0.51)

Trailing arm centre

For rear lower arm centre

Rear damper center 73 x 68 (slot)

Locate hole o 50 (1.97)

For upper arm o 13 (0.51)

Locate hole o 20 (0.79)

For trailing arm o 13 (0.51)

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Index - Opening Repair Chart

Opening Repair Chart

422

Door and Windshield Openings:


Unit: mm (in.)

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

Tailgate Opening:

1. L
Roof lower Rail Flange notch
2. M
Rear Gutter Lower Stiffener flange end (2 places)

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Index - Opening Repair Chart

3. N
Rear panel upper stiffener water drain notch

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Index - Index

Index
4-door Rust Prevention

5-3

5-door Rust Prevention

5-17

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4-door Rust Prevention

4-door Rust Prevention


Cross Section of Body and Sealants
General

5-4

Engine Compartment, Front Wheelhouse and


Damper Housing

5-5

Dashboard Upper, Dashboard Lower and Roof


Panel

5-6

Front Floor and Rear Floor

5-7

Rear Side Outer Panel and Rear Panel

5-8

Under Floor

5-9

Soft Chipping Guard Primer Coat


General

5-10

Coating Diagram

5-11

Rust-preventive Treatments
General

5-12

Undercoating Diagram

5-13

Area to be Covered by Anti-rust Agents

5-14

Materials and Tools

5-15

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Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants

5-4

General

NOTE: Following the sealer manufacturer's instructions.


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

5. Apply sealer on any area that the replacement part will cover. Smooth
the sealer with a brush is necessary.

4. Finish sealing the engine compartment, the door opening, the truck
gutter and the tailgate gutter. Wipe of the excess sealer.

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Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants

Engine Compartment, Front Wheelhouse and


Damper Housing

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

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Bulkhead Upper Frame


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

Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants

Dashboard Upper, Dashboard Lower and Roof Panel

56
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.

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

Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants


Front Floor and Rear Floor

57
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.

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

Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants


Rear Side Outer Panel and Rear Panel

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

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

Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants


Under Floor

59
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.

(A): No need seal areas.


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

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

Index - Soft Chipping Guard Primer Coat

510

Soft Chipping Guard Primer Coat


General

The removal of paint and undercoating by stones chips


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

2. Air blowing/degreasing

Sectional View of Paint Coats:

4. Spraying primer surface


Spray 4~5 coats to get 20 microns of thickness.
One coat deposits 5~7 microns
Do not try to cover the surface with one heavy coat.
Apply several thin coats.

Top coat
Intermediate coat

Chipping guard primer


Electrodeposition of primer
Base metal

Use alcohol, wax and grease remover.


3. Making
Use masking tape and paper.

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


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

The soft chipping guard primer coat is applied over the E.D.
(Electrostatically Despotised) primer. It is followed by guide
coating and top coating.
The soft chipping guard primer produces a smooth surface
when dry. It should be sprayed so the thickness of the
protective film is 20 microns.
Basic Rules for Repairing a Soft Chipping
Guard Primer Coat:

Soft chipping guard primer coat is then applied to the most


susceptible area (see page 5-11).
Spray the primer surface (2-part urethane primer surface) on
the soft chipping guard primer coating areas when you replaced
parts using soft chipping guard primer coat.

WARNING

Wear goggles or safety glasses to


prevent eye injury.
Ventilate when spraying undercoat.

1. Sanding the replacement part.


NOTE:

Do not oversand the edges or corners of the part.


Do not expose base metal.

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

Use a double action sander and #400 disc sandpaper.

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Index - Soft Chipping Guard Primer Coat

Soft Chipping Guard Primer Coat


Coating Diagram

511

Indicates chipping guard primer coating area.


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

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

Index - Rust-preventive Treatments

512

Rust-preventive Treatments
General

Anti-rust Agents:

Undercoat:

WARNING

WARNING

Wear goggles or safety glasses to prevent


eye injury.
Ventilate when spraying undercoat.

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

Anti-rust agents contain substances that are


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

NOTE:
Do not spray an anti-rust agent on the brake system, exhaust system
and its related parts, emission control devices in the engine
compartment, ball joint cover, fuel strainer and exterior and interior
parts.
Wipe the excess agent with a clean rag dampened with light oil.
Follow the anti-rust agent manufacturer's instructions.
1. Before applying an anti-rust agent, thoroughly clean the area to be
coated with a steam cleaner, etc., and let it dry. Waxoyl may be
applied to wet surface.
2. Apply anti-rust agent from the installation hole and the access hole of
parts in the outer panel and the frame (see page 5-14). Spray an antirust agent sufficiently unit the excess amount oozes out when filling
the side sill.

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Index - Soft Chipping Guard Primer Coat

513

Soft Chipping Guard Primer Coat


Undercoating Diagram

Indicated PVC coating area.


NOTE:

Coating thickness 0.4mm (0.16 in.) MIN.


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

SECTION AA

SECTION BB

SECTION CC

FRONT SIDE DAMPER


DAMPER HOUSING
OUTER PANEL
FRONT FLOOR CENTRE
CROSS-MEMBER

SECTION DD

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

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

SECTION FF
1.
2.
3.
4.

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

VIEW (Z)

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Index - Rust-prevention Treatments

Rust-prevention Treatments

Area to be Covered by Anti-rust Agents

514

Indicates anti-rust agents.


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

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Index - Materials and Tools

515

Materials and Tools

SEALER

SPRAY GUNS

Use urethane sealer.

Use the correct gun toe the agent being used.

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

Use of a pressure type spray gun is recommended


when work involves a considerable number of
vehicles.

TOOLS

Cartridge type

For nox-rust 409-20S/solton 1000S

For rustop

For deox #100

For waxoyl

Tube type

Sealing gun

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

ANTI-RUST AGENT
To be applied to weld joints inside the body panel.
Rustop
Deox #100
Waxoyl
or equivalent.

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5-door Rust Prevention

5-door Rust Prevention


Cross Section of Body and Sealants
General

5-18

Engine Compartment, Front Wheelhouse and


Damper Housing

5-19

Dashboard Upper, Dashboard Lower and Roof


Panel

5-20

Front Floor and Rear Floor

5-21

Rear Side Outer Panel and Rear Panel

5-22

Under Floor

5-23

Soft Chipping Guard Primer Coat


General

5-24

Coating Diagram

5-25

Rust-preventive Treatments
General

5-26

Undercoating Diagram

5-27

Area to be Covered by Anti-rust Agents

5-28

Materials and Tools

5-29

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Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants


General

NOTE: Following the sealer manufacturer's instructions.


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

518
5. Apply sealer on any area that the replacement part will cover. Smooth
the sealer with a brush is necessary.

4. Finish sealing the engine compartment, the door opening, the truck
gutter and the tailgate gutter. Wipe of the excess sealer.

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Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants

Engine Compartment, Front Wheelhouse and


Damper Housing

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

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Bulkhead Upper Frame


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

Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants

Dashboard Upper, Dashboard Lower and Roof Panel

520
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.

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

Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants


Front Floor and Rear Floor

521
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.

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

Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants


Rear Side Outer Panel and Rear Panel

522
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.

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

Index - Cross Section of Body and Sealants

Cross Section of Body and Sealants


Under Floor

523
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.

(A): No need seal areas.


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

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

Index - Soft Chipping Guard Primer Coat

524

Soft Chipping Guard Primer Coat


General

The removal of paint and undercoating by stones chips


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

2. Air blowing/degreasing

Sectional View of Paint Coats:

4. Spraying primer surface


Spray 4~5 coats to get 20 microns of thickness.
One coat deposits 5~7 microns
Do not try to cover the surface with one heavy coat.
Apply several thin coats.

Top coat
Intermediate coat

Chipping guard primer


Electrodeposition of primer
Base metal

Use alcohol, wax and grease remover.


3. Making
Use masking tape and paper.

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


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

The soft chipping guard primer coat is applied over the E.D.
(Electrostatically Despotised) primer. It is followed by guide
coating and top coating.
The soft chipping guard primer produces a smooth surface
when dry. It should be sprayed so the thickness of the
protective film is 20 microns.
Basic Rules for Repairing a Soft Chipping
Guard Primer Coat:

Soft chipping guard primer coat is then applied to the most


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

WARNING

Wear goggles or safety glasses to


prevent eye injury.
Ventilate when spraying undercoat.

1. Sanding the replacement part.


NOTE:

Do not oversand the edges or cornres of the part.


Do not expose base metal.

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

Use a double action sander and #400 disc sandpaper.

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Index - Soft Chipping Guard Primer Coat

Soft Chipping Guard Primer Coat


Coating Diagram

525

Indicates chipping guard primer coating area.


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

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

Index - Rust-preventive Treatments

526

Rust-preventive Treatments
General

Anti-rust Agents:

Undercoat:

WARNING

WARNING

Wear goggles or safety glasses to prevent


eye injury.
Ventilate when spraying undercoat.

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

Anti-rust agents contain substances that are


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

NOTE:
Do not spray an anti-rust agent on the brake system, exhaust system
and its related parts, emission control devices in the engine
compartment, ball joint cover, fuel strainer and exterior and interior
parts.
Wipe the excess agent with a clean rag dampened with light oil.
Follow the anti-rust agent manufacturer's instructions.
1. Before applying an anti-rust agent, thoroughly clean the area to be
coated with a steam cleaner, etc., and let it dry. Waxoyl may be
applied to wet surface.
2. Apply anti-rust agent from the installation hole and the access hole of
parts in the outer panel and the frame (see page 5-28). Spray an antirust agent sufficiently unit the excess amount oozes out when filling
the side sill.

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Index - Soft Chipping Guard Primer Coat

527

Soft Chipping Guard Primer Coat


Undercoating Diagram

Indicated PVC coating area.


NOTE:

Coating thickness 0.4mm (0.16 in.) MIN.


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

SECTION AA

SECTION BB

SECTION CC

FRONT SIDE DAMPER


DAMPER HOUSING
OUTER PANEL
FRONT FLOOR CENTRE
CROSS-MEMBER

SECTION DD

SECTION EE
1.
2.
3.
4.

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

SECTION FF
1.
2.
3.
4.

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

VIEW (Z)

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Index - Rust-prevention Treatments

Rust-prevention Treatments

Area to be Covered by Anti-rust Agents

528

Indicates anti-rust agents.


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

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Index - Materials and Tools

529

Materials and Tools

SEALER

SPRAY GUNS

Use urethane sealer.

Use the correct gun toe the agent being used.

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

Use of a pressure type spray gun is recommended when work involves a


considerable number of vehicles.

For nox-rust 409-20S/solton 1000S

For rustop

For deox #100

For waxoyl

TOOLS

Cartridge type

Tube type

Sealing gun

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

ANTI-RUST AGENT
To be applied to weld joints inside the body panel.
Rustop
Deox #100
Waxoyl
or equivalent.

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Paints - Paints

Paints
General Safety Precautions

6-2

Body Paint
General

6-3

Refinishing Processes

6-4

Pre-processing of Painting

6-5

Treatment of Metal Surface

6-6

Undercoating

6-7

Intermediate Coating

6-8

Top Coating

6-9

Plastic Parts Paint


Features of Plastic Material

6-11

Use of the Repair Material (reference)

6-13

Refinishing Processes

6-14

Pre-processing of Painting

6-15

Undercoating

6-15

Intermediate Coating

6-17

Top Coating

6-18

Glossary

6-19

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General Safety Precautions

General Safety Precautions


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

6-2
4. Read the paint label before opening the container. Cover spilled paint
with sand, or wipe it up at once.

5. If paint gets in your mouth or your skin, rinse or wash thoroughly with
water. If paint gets in your eyes, flush with water and get prompt
medical attention.
2. Wear approved gloves, appropriate clothing when painting. Avoid
contact with skin.

6. After the painting work is finished, wash face and gargle with water.

3. Spray paint only in a well ventilated area.

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


sparks, flames or cigarettes.

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Paints - Body Paint

Body Paint

6-3

General

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

WARNING

Most paints contain substances that are harmful if inhaled or swallowed. Read the paint label
before opening the container. Spray paint only in a well ventilated area.
Cover spilled paint with sand, or wipe it up at once.
Wear an approved respirator, gloves, eye protection and appropriate clothing when painting.
Avoid contact with skin.
If paint gets in your mouth or on your skin, rinse or wash thoroughly with water. If paint gets in
your eyes, flush with water and get prompt medical attention.
Paint is flammable. Store it in a safe place, and keep it away from sparks, flames or cigarettes.

Basic Rules for Repairing a Paint Finish


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

Features in Each Work Process


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

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Paints - Body Paint

Body Paint

6-4

Refinishing Processes

Paint damage can appear in any form. Before making a repair, check the damaged area carefully, and determine the best procedure for repairing the damage. The following shows
you refinishing methods for various types of paint damage or defects.

: Indicates the best method depending on the degree of damage.

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Paints - Body Paint

6-5

Body Paint

Pre-processing of Painting

1. Featheredging
NOTE

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

If double action sander is not available, use a rubber pad and wet or
dry sandpaper.

Use the flexible block and #280,


#340, #400, #600 sandpaper.
Damage to undercoat, intermediate coat and
top coat:
Sand the damage area flat and smooth
Use the double action sander and
#180~#240~#320 disc paper.

Damage to metal surface:


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

2. Preparation of metal surface


Remove all corrosion from the damaged area.
Use a product that removes
corrosion.

1.
2.
3.
4.

Top coat
Intermediate coat
Undercoat
Metal surface

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

Use the double action sander and


#60~#80 disc paper.

Sand the area larger than the damaged area.

Use the double action sander and


#180~#240 disc paper.

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Paints - Body Paint

6-6

Body Paint

Treatment of Metal Surface

1. Filling/drying
Small cracks or pinholes in the sheet metal should be repaired with a
body filler and sanded flat and smooth.

Use the 2-part polyester resin


putty.
Mix the putty with the hardener
in the correct ratio.
Follow the body filler
manufacturer's instructions.

Mix the body filler and hardener quickly.

After applying the body filler, allow 5~6 minutes of normal drying time,
then force dry it with infrared lamps or other industrial dryer at 50C
(122F)~60C (140F).
NOTE: Follow the body filler manufacturer's instructions for drying time.

2. Polishing
When the body filler is dry a white mark appears when the surface is
scratched with your finger nail.
1. Thoroughly sand the body filler surface.
Use the double action sander and
#80~#120 disc paper.

2. Sand the surface evenly, particularly the area that was filled.

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

Use the flexible block and #120~#180 sandpaper.

1. Body Filler

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Paints - Body Paint

6-7

Body Paint

Undercoating

Treatment of Metal Surface (cont'd)


3. Featheredge the paint coat.

Sand the body filler surface until the proper dimensions are met.
Use the double action sander and
#240~#320#~400 disc papers.

1. Masking
Mask the area surrounding the damage to prevent over spray from the
primer surfacer.
Use the masking tape and paper.
2. Spraying primer surfacer
Spray the primer surfacer over a wider area than the body filler and
the exposed surface of the paint film.
Spray 2~3 coats to get 30 microns of thickness.

Use the 2-part urethane primer


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

1. Body Filler
2. Featheredging

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

1. Primer Surfacer

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

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Paints - Body Paint

6-8

Body Paint

Intermediate Coating

Undercoating (cont'd)

4. Polishing
Check that the primer surfacer has dried thoroughly, then sand the
primer surfacer.
Use the double action sander and
#320~#400~#600 disc papers.

1. Masking
Mask the area surrounding the damage to prevent over spray from the
intermediate coat.
Use masking tape and paper.
2. Spraying top coat enamel
Spray the top coat enamel over the surface until the primer surfacer is
fully covered.
NOTE: For the 3-coat pearl paint, spray the colour base over the
surface.

Use the 2-part polyester


urethane top coat enamel and
a spray gun.
Mix the top coat enamel with
the additive and solvent, and in
the correct ratio.
Follow the top coat
manufacturer's instructions.

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

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

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Paints - Body Paint

6-9

Body Paint

Top Coating

Intermediate Coating (cont'd)

4. Polishing
Check that the top coat enamel has dried thoroughly, then sand the
top coat enamel.
Use the double action sander and
#600~#800 disc papers.
NOTE: Be careful not to polish down to the primer surfacer.

1. Masking
Mask the area surrounding the damage to prevent over spray from the
top coat.
Use masking tape and paper.
2. Spraying top coat enamel/clear coat
Spray 2~3 double coat until the intermediate coat is fully covered.
NOTE: See pages 6-11, 6-12 for the painting repair (gradation) of the
3-coat pearl paint.

Use the 2-part polyester


urethane top coat enamel and
spray gun.
Mix the top coat enamel with
the additive and solvent, and in
the correct ratio.
Follow the top coat
manufacturer's instructions.

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

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

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Paints - Body Paint

Body Paint

Top Coating (cont'd)


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

610
4. After buffing, remove the masking paper and tape, and thoroughly
wash the entire vehicle.

NOTE: Follow the top coat manufacturer's instructions for drying times.
3. Polishing/buffing
Check that the clear coat has dried thoroughly.
The clear coat is cooled.
1. Any adhesion or roughness on the top coat should be wet sanded
and repaired.
Use the #1200~#2000 and crystal block.

2. Polish any roughness caused by sanding.


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

Do not use a power buffer.


Do not polish too much; use light hand pressure.

Use the buffing sponge, fine compound, very fine


compound, then ultra fine compound.

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Paints - Plastic Parts Paint

611

Plastic Parts Paint

Features of Plastic Material

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

Name

Heat Resistance
Temperature C (
F)

AAS

Acrylonitrile acrylic styrene

80
(176)

A small amount of alcohol is acceptable


for a short time. (Degreasing)

An organic solvent such as gasoline is not recommended.

Acrylonitrile butadiene
styrene

80
(176)

A small amount of alcohol is acceptable


for a short time. (Degreasing)

An organic solvent such as gasoline is not recommended.

Acrylonitrile ethylene
styrene

80
(176)

A small amount of alcohol is acceptable


for a short time. (Degreasing)

An organic solvent such as gasoline is not recommended.

Acrylonitrile / ethylene
propylene diene rubber /
styrene

80
(176)

A small amount of alcohol is acceptable


for a short time. (Degreasing)

An organic solvent such as gasoline is not recommended.

Acrylonitrile styrene
acrylate

80
(176)

A small amount of alcohol is acceptable


for a short time. (Degreasing)

An organic solvent such as gasoline is not recommended.

Cellulose acetate butylate

80
(176)

A small amount of alcohol is acceptable


for a short time. (Degreasing)

An organic solvent such as gasoline is not recommended.

Ethylene-vinyl acetate

80
(176)

A small amount of alcohol and gasoline


are acceptable for a short time.
(Degreasing)

Soaking with an organic solvent such as gasoline and


alcohol is not recommended.

PA

Polyamide

80
(176)

Alcohol and gasoline are acceptable.

Battery acid (sulphuric acid) is not recommended.

PBT

Polybutylene terephtalate

160
(320)

Alcohol and gasoline are acceptable.

Solvent is not recommended.

PC

Polycarbonate plastics

120
(248)

A small amount of alcohol is acceptable


for a short time.

Brake fluid, and wax and grease remover not


recommended.

PE

Polyethylene

80
(176)

Alcohol and gasoline are acceptable.

Solvent is not recommended.

PF

Phenol formaldehyde

80
(176)

A small amount of alcohol is acceptable


for a short time. (Degreasing)

Soaking with an organic solvent such as gasoline and


alcohol, is not recommended.

PMMA

Polymethyl methacrylate

80
(176)

A small amount of alcohol is acceptable


for a short time. (Degreasing)

Soaking with an organic solvent such as gasoline and


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

POM

Polyoxymethylene
polyacetal

100
(212)

Alcohol and gasoline are acceptable.

Solvent is not recommended.

ABS
AES
A/EPDM/S

ASA
CAB
E/VAC

Solvent Resistance

Note

An aroma product is not recommended.


An aroma product is not recommended.
An aroma product is not recommended.
An aroma product is not recommended.

An aroma product is not recommended.


An aroma product is not recommended.

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Paints - Plastic Parts Paint

612

Plastic Parts Paint

Features of Plastic Material (cont'd)

Standard
Symbol
PP

Name

Heat Resistance
Temperature C (
F)

Solvent Resistance

Note

Polypropylene

80
(176)

Alcohol and gasoline are acceptable.

Solvent is not recommended.

Polyphenylene oxide

100
(212)

A small amount of alcohol is acceptable


for a short time.

Soaking with an organic solvent such as gasoline and


alcohol is not recommended.

PS

Polystyrene

60
(140)

A small amount of alcohol is acceptable


for a short time.

Soaking with an organic solvent such as gasoline and


alcohol is not recommended.

PUR

Polyurethane

80
(176)

A small amount of alcohol is acceptable


for a short time. (Degreasing)

Soaking with an organic solvent such as gasoline and


alcohol is not recommended.

PVC

Polyvinylchloride

80
(176)

A small amount of alcohol and gasoline


are acceptable for a short time.
(Degreasing)

Soaking with an organic solvent such as gasoline and


alcohol is not recommended.

SAN

Styrene acrylonitrile

80
(176)

Wiping alcohol off in a short time can be


allowed.

Soaking with an organic solvent such as gasoline and


alcohol is not recommended.

SMC

Sheet moulding
compound

180
(356)

Alcohol and gasoline are acceptable.

Solvent is not recommended.

TPE

Thermoplastic polyester
elastomer

80
(176)

Alcohol is acceptable and wiping gasoline Soaking with an organic solvent such as gasoline and
for a short time can be allowed.
alcohol is not recommended. Wash remover off with
(Degreasing)
water thoroughly.

TPS

Thermoplastic styrene
elastomer

80
(176)

A small amount of alcohol and gasoline


are acceptable for a short time.
(Degreasing)

TPO

Thermoplastic olefin /
elastomer

80
(176)

Alcohol is acceptable and wiping gasoline Soaking with an organic solvent such as gasoline and
for a short time can be allowed.
alcohol is not recommended. Wash remover off with
(Degreasing)
water thoroughly.

TPU

Thermoplastic /
urethane / elastomer

80
(176)

A small amount of alcohol and gasoline


are acceptable for a short time.
(Degreasing)

Soaking with an organic solvent such as gasoline and


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

UP

Polyester

110
(230)

Alcohol and gasoline are acceptable.

Alkali is not recommended.

PPO
(PPE)

Soaking with an organic solvent such as gasoline and


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

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Paints - Plastic Parts Paint

Plastic Parts Paint

Use of the Repair Material (reference)

NOTE: Follow the materials manufacturer's instructions.

613
Mixing Ratio:

The use of a special polyester putty for PP bumper is described here:


1. Filler
Mixing Ratio:

4. Intermediate coat and top coat


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

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

NOTE: Use a spray gun to apply the paint. Do not use a brush.
Drying time:
Air dry 20C (68F)

6~10 minutes Touch dry

Almost hardened

12~24 hours

Thoroughly hardened

96 hours

Force dry the intermediate coat and top coat.


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

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Paints - Plastic Parts Paint

Plastic Parts Paint

Refinishing Processes

614

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

A:

Hole/Deep Gouge

B:

Deep Abrasion 3 mm (0.12 in.) approx.

C:

Shallow Scratch 1 mm (0.04 in.) approx.

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Paints - Plastic Parts Paint

615

Plastic Parts Paint

Pre-processing of Painting

1. Sanding
Sand the damage area flat and smooth.

Undercoating

1. Spraying primer
Primer is used to fill cavities in the putty and primer surfacer.

Shallow Scratch:

Use a flexible block and


#240~#400~#600 sandpaper.

Spray primer on the exposed area.


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

Bumper primer (Reference)


Warm the primer if the ambient
temperature is below 10C (50
F).
Follow the bumper primer
manufacturer's instructions.
Use the spray gun and brush.

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

2. Air blowing/degreasing
Clean the damaged area thoroughly.
Use alcohol, and wax and grease
remover.

Drying
NOTE: Take care not to let the heat lamp deform the bumper during
the drying process.
Dry the bumper primer thoroughly with an infrared dryer or other
suitable method.
Drying Time:
Air dry 20C (68 20 minutes
F)
Force dry 60C
(140F)

10 minutes

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Paints - Plastic Parts Paint

616

Plastic Parts Paint

Undercoating (cont'd)

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

Apply the putty on the damaged are in 2~3 steps.


Glue aluminium tape on the outside of the bumper, and apply putty
from the other side of the bumper.
Remove the aluminium tape after the putty dries, apply putty from
the outside, and fill the hole.

Use a special polyester putty


(Reference) and a putty knife.

5. Spraying primer surfacer


NOTE: Spray the bumper primer (see page 6-17) on the area where
the PP material was exposed and around the putty.

Spray the primer surface wider than the putty and painted surfaces
of bumper primer.
Spray 2~3 coats to get 20~30 microns of thickness.

Use the 2-component type


primer surfacer (grey) and a
spray gun.
Follow the materials
manufacturer's instructions.

Drying
1. Aluminium Tape
2. Outside

3. Sanding
Sand the surface evenly, particularly at the area where the PP material
and putty meet.
Use a flexible block and
#240~#400~#600 sandpaper.

NOTE: Take care not to let the heat lamp deform the bumper during
the drying process.
6. Sanding
After drying, wet sand the area of the intermediate coat.
Use the #600 sandpaper.
NOTE: Do not use less than #600.

7. Air blowing/degreasing
1. Featheredging

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

Use alcohol, a tack cloth, and wax


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

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Paints - Plastic Parts Paint

Plastic Parts Paint


Intermediate Coating

NOTE: You must do this procedure on the PP parts of the bumper and
side sill panel.
1. Masking
Mask the area surrounding the damage to prevent overspray from the
intermediate coat.
Use masking tape and paper.
2. Spraying top coat enamel
Spray the top coat enamel over the surface until the primer surfacer
is fully covered.
Spray 2~3 coats to get 15~25 microns of thickness.

617
3. Polishing
Check the top coat enamel has dried thoroughly, then sand the top
coat enamel.
Use a flexible block and
#600~#800~#1000 sandpapers.
NOTE: Be careful not to sand down to the primer surfacer.

Use the 2-part polyester


urethane top coat enamel and
a spray gun.
Mix the top coat enamel with
the additive and solvent, and in
the correct ratio.
Follow the top coat
manufacturer's instructions.
When the painting repair is almost complete, polish the top coat.
Use #1500 sandpaper and
compound.

Drying
NOTE: Take care not to let the heat lamp deform the bumper during
the drying process.
After spraying the top coat enamel, allow for 5~10 minutes of normal
drying, then force dry it with infrared lamps or other industrial dryer.

1.
2.
3.
4.
5.

Material
Putty
Intermediate Coat
Sanding
Paint Coat

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

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Paints - Plastic Parts Paint

Plastic Parts Paint


Top Coating

1. Masking
Mask the area surrounding the damage to prevent overspray of the top coat
Use masking tape and paper.
2. Spraying top coat enamel / clear coat
Spray 2~3 coats in double coat until the intermediate coat is fully covered.
NOTE:

618

Using a buffer and compound, remove any polishing marks


made from the sandpaper.

Use a buffing sponge, and buffing


wool and compounds.
Finish up with buffing:
1. Wet sands with #2000 sandpaper and soapy water.

Do not cover the surface with one heavy coat.


Apply several thin coats.

Use the 2-part polyester urethane top coat enamel and a spray gun.
Mix the top coat enamel with the additive and solvent, and in the correct
ratio.
Follow the top coat manufacturer's instructions.
After spraying the top coat enamel, allow for 5~10 minutes drying time before
you spray the clear coat.

2. Remove moisture using compressed air.


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

Drying

4. Check the finished area at an angle, and make sure there are
no polishing marks.
5. Polish with ultra fine compound and a buffing sponge.

NOTE: Take care not to let the heat lamp deform the bumper during the drying
process.
After spraying the clear coat, allow for 5~10 minutes drying time before you
force dry it with infrared lamps or other industrial dryer.
3. Polishing/buffing
Check that the clear coat has dried thoroughly.
Wet sand to remove any imperfections.
Use a flexible block soap and #2000 sandpaper.

6. Wax the finished area.

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Paints - Glossary

619

Glossary

All paint

Painting of complete surface.

Compressed air

Use compressed air to blow away dust and debris.

Block paint

Painting a section only, such as a door

Clear paint (clear coat)

Clear paint without dye (pigment).

Double coat

Application of two paint coats.

Dry film

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

Dust coat

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

ED painting

Electrostatic discharge painting.

Enamel

Finishing paint pigmented with dye.

Featheredging

Smoothing out the edges of painted surface.

Flash off

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

Ford cup

A type of viscosity meter.

Gun stroke

Movement of the paint gun.

Hardener

Harding agent of two-liquid type paint or fillers.


Polycyanated and oxides are used for hardeners.

Heat-hardening acrylic resin paint

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

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Paints - Glossary

620

Glossary
Cont'd

Lacquer

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

Meramine resin

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

Metallic-base paint

Paint with aluminium power for metallic tone.

Mist coat

Painting for fade-in sections. A small amount of paint may be dissolved with slow-evaporating thinner, or thinner alone may
be applied with low pressure.
150-200kPa (1.5-2.0kgf/cm, 21.3-28.4 psi)

Mixing scale

Colour mixing device.

Overlap

Blending of spray patterns.

Overspray

Spraying other than the area that needs painting.

Paddle

A tool to mix paint.

Paint dust

Dust of paint formed by spraying.

Paper dispenser

A paper posting device (masker) that combines tape and paper.

Scrapes

Traces of scratches.

Scuffing

Particles on the painted surface are lightly polished with fine emery paper (#600 or over).

Set (setting)

Evaporation time of solvent in the paint, before drying the layer forcefully or by banking. (May be considered the same as
flash-off time).

Single coat

Application of paint in single layer.

Spot paint

Painting of small section, such as for touch-up.

Undercoat

Undercoat paint (such as primer and surface).


May be applied to lower section of car for moist prevention and rust proofing.

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Paints - Glossary

621

Glossary
cont'd

Wet coat

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

Wet film

Paint which has not dried completely.

Wet on wet

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

Wool bonnet

Wood grinder for compound polishing.

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Introduction

Introduction

How to Use This Manual

This manual covers the repairs of 2001 model series CIVIC 3-door that
have been involved in an accident and it describes the work related to the
replacement of damage body parts.
Please read through these instructions and familiarise yourself with them
before actually using this manual.
NOTE: Refer to the 2001 CIVIC 4-door/CIVIC 5-door Body Repair Manual
(P/N. 62S5A30), CIVIC Shop Manual (P/N. 62S5A00) and CIVIC Shop
Manual supplement (P/N. 62S5A20) on this CD for specifications, wire
harness locations, safety stand support points, etc.

1 General Info
3 *Replacement
4 Body Dimensional Drawings
5 Rust Prevention
Sections with an * include SRS
components; special caution is
required when servicing.

Special Information

WARNING

Indicates a strong possibility of severe


personal injury or death if instructions are
not followed.

CAUTION

Indicates a possibility of personal injury or


equipment damage if instructions are not
followed.
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
themselves thoroughly that neither personal
safety or vehicle safety will be jeopardised.
All information contained in this manual is based on the latest product information
available at the time of printing. We reserve the right to make changes at any time
without notice. No part of this publication may be reproduced, stored in retrieval
system, or transmitted, in any form by an means, electronic, mechanical,
photocopying, recording or otherwise, without the prior written permission of the
publisher. This includes text, figures and tables.
HONDA MOTOR CO., LTD.
Service Publication Office
Fist Edition 3/2001 40 pages
All Rights Reserved

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1-1

General Information
Supplemental Restraint System (SRS)

1-2

Body Specifications/Wheel Alignment

1-3

Body Construction

1-4

Colour Chart Paint Specifications

1-5

Types and Materials of Exterior Plastic Parts

1-7

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1-2

General Information

1-2

Supplemental Restraint System (SRS)

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

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1-3

1-3

General Information

Body Specifications/Wheel Alignment


Unit: mm (in.)

Front Wheel Alignment:


Camber

000' 45'

Caster

133' 1

Total toe

0 3 (0 0.12)

Wheel turning angle

in

4000' 2

out

3100' (Reference)

Rear Wheel Alignment:


Camber

-045' 45'

Total toe

IN 2 3 (0.08 0.12)

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1-4

1-4

General Information
Body Construction

Sp: Steel plate

Hss: High strength steel plate

No.

Zn: Zinc-plated

Part Name

No.

Part Name

Hood (Hss, Zn)

23

Centre Pillar Stiffener Lower (Sp)

Front Fender (Sp, Zn)

24

Side Sill Reinforcement (Hss, Zn)

Door (Hss, Zn)

25

Front Pillar Inner Lower (Hss, Zn)

Tailgate (Sp, Zn)

26

Front Pillar Inner Upper (Hss)

Bulkhead Side (Sp, Zn)

27

Centre Inner Pillar (Hss, Zn)

Bulkhead Side Stay (Sp, Zn)

28

Roof Side Rail (Hss)

Bulkhead Upper Frame (Sp, Zn)

29

Roof Panel (Sp)

Front Lower Cross-member (Hss, Zn)

30

Rear Inner Pillar (Sp)

Wheelhouse Upper Member (Sp)

31

Rear Inner Panel (Sp, Zn)

10

Front Wheelhouse (Sp, Zn)

32

Wheel Arch Extension (Sp, Zn)

11

Wheelhouse Upper Extension (Hss, Zn)

33

Rear Wheelhouse (Sp, Zn)

12

Damper Housing (Hss, Zn)

34

Inside Sill (Hss, Zn)

13

Front Side Frame (Hss, Zn)

35

Front Floor (Sp, Zn)

14

Side Frame Extension Rear/Front Side Outrigger (Hss, Zn)

36

Middle Floor Cross-member (Hss, Zn)

15

Dashboard Lower (Sp, Zn)

37

Middle Floor Gusset (Sp)

16

Dashboard Upper (Sp, Zn)

38

Rear Floor Upper Cross-member (Sp)

17

Outer Panel (Sp, Zn)

39

Rear Floor (Sp, Zn)

18

Rear Pillar Gutter Lower (Sp, Zn)

40

Rear Panel (Sp, Zn)

19

Rear Pillar Gutter Upper (Sp, Zn)

41

Rear Gutter Lower Stiffener (Sp)

20

Front Pillar Lower Stiffener (Hss)

42

Rear Frame A (Sp, Zn)

21

Front Pillar Upper Stiffener (Hss)

43

Rear Frame B (Hss, Zn)

22

Centre Pillar Stiffener upper (Sp)

44

Rear Floor Cross-member (Sp, Zn)

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1-5

1-5

General Information

Colour Chart Paint Specifications


P.: Pearl Paint / M.: Metallic Paint

Paint Code Colour Name NH-623M Satin


Silver M.
KE

1.4 B

B-92P Night
Hawk Black P.

B-94 Midnight
Blue

B-96P Eternal
Blue P.

R-81 Mirano
Red

R-504P Ruby
Red P.

G-503P
Amazon
Green P.

YR-62 Corona
Gold P.

1.4 S
1.4 SE
1.6 S
1.6 SE
1.6 SEE
KG

1.4 S
1.4 LS
1.6 S
1.6 LS
1.6 ES

KR

1.4 S
1.4 LS
1.6 S
1.6 LS
1.6 ES

KS

1.4 S
1.4 LS
1.6 LS

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1-6

General Information

1-6

Colour Chart Paint Specifications (cont'd)


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

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1-7

General Information

1-7

Type and Materials of Exterior Plastic Parts

NOTE: A standard symbol is stamped on the underside of each resin part to show the type of material of used.
Example:
1. FRONT WINDSHIELD
MOULDING
Acrylonitrile ethylene
propylene diene rubber
styrene (A/EPDM/S)
2. DOOR OUTER HANDLE
Polycarbonate (PC)
3. DOOR MIRROR
Painted: Acrylonitrile
butadiene styrene (ABS)
Unpainted: Acrylonitrile
styrene acrylate (ASA)
4. TAILGATE SPOILER
Acrylonitrile butadiene styrene
(ABS)
5. LICENSE TRIM
Painted: Acrylonitrile
butadiene styrene (ABS)
Unpainted: Acrylontirile
ethylene styrene (AES)
6. REAR BUMPER
Polypropylene (PP)
7. DOOR SASH TRIM
Acrylontrile styrene acrylate
(ASA)
8. ROOF MOULDING
Polyvinyl chloride (PVC)
9. FRONT BUMPER
Polypropylene (PP)

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3-2

Side Sill Outer Panel

3-2

Mass Production Body Welding Diagram

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3-3

Side Sill Outer Panel

3-3

Removal

Cut and pry off the side sill outer panel.


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

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3-4

Side Sill Outer Panel

3-4

Installation

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

Passenger's side
When replacing the side sill reinforcement, cut the new side sill reinforcement so it
overlaps the body side reinforcement by 20 mm (1.8 in.) and fillet weld it.

1. Fillet welding Overlap


20 mm (1.8 in.)

VIEW (Z)

1. NEW SIDE SILL REINFORCEMENT

5. Clamp the repair part and recheck the clearance and alignment of the door and
front fender.
6. Perform the main welding:
Attach a patch at the cut section of the front pillar (driver's side), side sill
(passenger's side) and wheel arch and plug weld them.
Driver's side

1.
2.
3.
4.
5.

PATCH
Butt welding
Butt welding
PATCH
OUTER PANEL

Passenger's side:

1. PATCH
2. Butt welding
3. OUTER PANEL

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3-5

Roof Panel

3-5

Mass Production Body Welding Diagram

Without roof panel:

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3-6

Rear Side Outer Panel

3-6

Mass Production Body Welding Diagram

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3-7

Rear Side Outer Panel

3-7

Removal

Cut and pry off the rear side outer panel.


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

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3-8

Rear Side Outer Panel

3-8

Installation

1. Glue the insulator to the centre inner pillar as shown.


Insulator: P/N. 774416-SF1-000
Adhesive: Cemedine 366, or equivalent.

3. Set the new repair part (outer panel) and rear pillar gutter lower into position and
clamp them.
Check the body dimensions (see section 4).

Remove the repair part (outer panel) and weld the centre pillar stiffener lower.

1. CENTRE INNER PILLAR


2. INSULATOR

2. Set the new centre pillar stiffener lower into position and install the middle floor
gusset.

1. NEW CENTRE PILLAR STIFFENER LOWER


2. CENTRE PILLAR STIFFENER UPPER

4. Tack weld the outer panel and rear pillar gutter lower.
5. Temporarily install the door, tailgate and rear bumper and check for differences in
level and clearance.
Make sure the body lines flow smoothly.

1. NEW CENTRE PILLAR STIFFENER LOWER


2. MIDDLE FLOOR GUSSET

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3-9

Rear Side Outer Panel

3-9

Installation (cont'd)

6. Do the main welding:


Attach a patch at the cut section of the side sill, centre pillar, rear pillar and plug
weld them.

VIEW (Z)

1. NEW REAR GUTTER LOWER STIFFENER


2. REAR INNER PILLAR

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

Butt welding
PATCH
Butt welding
PATCH
Butt welding
NEW OUTER PANEL
PATCH
NEW REAR GUTTER LOWER

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3-10

Rear Panel

Mass Production Body Welding Diagram

310

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3-11

Rear Panel
Removal

Cut and pry off the rear panel.


Check the rear pillar gutter lower position and check it for damage.
If necessary, replace the rear pillar gutter lower (see page 3-7)

311

Installation

1. Set the new rear panel and check the body dimensions (see section 4).
2. Tack weld the clamped position.
3. Temporarily install the tailgate, taillight, rear bumper and check for differences in
level and clearance. Check for operation of the tailgate.
4. Do the main welding.

1. NEW REAR PANEL

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

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

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4-1

Body Dimensional Drawings


Upper Body Measuring Dimensions
Engine/Transmission Mount Positions and Passenger Compartment

4-2

Under Body Measuring Dimensions


Middle and Rear Floor Under View

4-3

Frame Repair Chart


Top View

4-4

Side View

4-6

Opening Repair Chart

4-8

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4-2

Upper Body Measuring Dimensions

4-2

Passenger Compartment

Engine/Transmission Mount Positions

Unit: mm (in.)

Unit: mm (in.)

AT/MT:

Honda Multi Matic:

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4-3

Under Body Measuring Dimensions

4-3

Middle and Rear Floor Under View

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4-4

Frame Repair Chart

4-4

Top View

Unit: mm (in.)
: Inner diameter

For sub-frame 15 (0.59)

Damper centre 78 (3.07)

b1

For engine mount 13 (0.51)

For damper mount 11.5 (0.45)

b2

For engine mount 13 (0.51)

For damper mount 11.5 (0.45)

b3

For engine mount 13 (0.51)

For sub-frame 11 (0.43)

c1

For transmission mount 15 (0.59)

For sub-frame 15 (0.59)

c2

For transmission mount 15 (0.59)

Locate hole 25 (0.98)

c3

For transmission mount 13 (0.51)

Locate hole 50 (1.97)

For damper mount 11.5 (0.45)

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4-5

4-5

Frame Repair Chart


Top View (cont'd)
Locate hole 25 (0.98)

For upper arm bracket center 15 (0.59)

For trailing arm 13 (0.51)

u1, u2

Locate hole 13 (0.51)

Locate hole 25 (0.98)

For upper arm 13 (0.51)

Locate hole 20 (0.79)

Locate hole 25 (0.98)

Trailing arm centre

For rear lower arm centre

Rear damper center 73 x 68 (Slot)

Locate hole 50 (1.97)

For upper arm 13 (0.51)

Locate hole 20 (0.79)

For trailing arm 13 (0.51)

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4-6

4-6

Frame Repair Chart


Side View

Unit: mm (in.)
: Inner diameter

For sub-frame 15 (0.59)

Damper centre 78 (3.07)

b1

For engine mount 13 (0.51)

For damper mount 11.5 (0.45)

b2

For engine mount 13 (0.51)

For damper mount 11.5 (0.45)

b3

For engine mount 13 (0.51)

For sub-frame 11 (0.43)

c1

For transmission mount 15 (0.59)

For sub-frame 15 (0.59)

c2

For transmission mount 15 (0.59)

Locate hole 25 (0.98)

c3

For transmission mount 13 (0.51)

Locate hole 50 (1.97)

For damper mount 11.5 (0.45)

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4-7

4-7

Frame Repair Chart


Side View (cont'd)
Locate hole 25 (0.98)

For upper arm bracket center 15 (0.59)

For trailing arm 13 (0.51)

u1, u2

Locate hole 13 (0.51)

Locate hole 25 (0.98)

For upper arm 13 (0.51)

Locate hole 20 (0.79)

Locate hole 25 (0.98)

Trailing arm centre

For rear lower arm centre

Rear damper center 73 x 68 (Slot)

Locate hole 50 (1.97)

For upper arm 13 (0.51)

Locate hole 20 (0.79)

For trailing arm 13 (0.51)

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How to Use This Manual


This manual covers the repairs of 2001 model series CIVIC 2-door that
have been involved in an accident, and it describes the work related to
the replacement of damage body parts.

1 General Info

Please read through these instructions and familiarise yourself with


them before actually using this manual.

5 Rust Prevention

NOTE: Refer to the 2001 CIVIC 4-door/CIVIC 5-door Body Repair


Manual (P/N. 62S5A30), CIVIC Shop Manual (P/N. 62S5A00) and
CIVIC Shop Manual supplement (P/N. 62S5A20) for specifications,
wire harness locations, safety stand support points, etc.

3 *Replacement
4 Body Dimensional Drawings
Sections with * include SRS
components; special caution is
required when servicing.

Special Information

WARNING

Indicates a strong possibility of severe


personal Injury or death if instructions are not
followed.

CAUTION

Indicates a possibility of personal injury or


equipment damage if instructions are not
followed.
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
jeopardised.
All information contained in this manual is based on the latest product
information available at the time of printing. We reserve the right to make
changes at any time without notice. No part of this publication may be
reproduced, stored in retrieval system, or transmitted, in any form by an
means, electronic, mechanical, photocopying, recording, or otherwise,
without the prior written permission of the publisher. This included text,
figures and tables.
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HONDA MOTOR CO., LTD.


Service Publication Office
First Edition 10/2000

32 pages

All Rights Reserved

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General Information - General Information

General Information
Supplemental Restraint System (SRS)

1-2

Body Specifications/Wheel Alignment

1-3

Construction

1-4

Colour Chart Paint Specifications

1-5

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General Information - General Information

General Information

1-2

Supplemental Restraint System (SRS)

This model has an SRS which includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above the glove box, seat belt tensioners in the front seat
belt retractors and side airbags in the front seat backs. The SRS unit is separate from the airbag assembly and has built-in sensors. The following precautions should be observed
when performing sheet metal work, paint work and repair work around the locations of the SRS components.
1. The SRS unit (including the safing sensor and the impact sensor) is located under the dashboard and the side impact sensors are located in each side sill. The front impact
sensors are located behind the right and left end of the front bumper. Avoid any strong impact with a hammer or other tools when repairing the front side frame, the lower part of
the dashboard and the side sill. Do not apply heat to these areas with a torch, etc.
2. Take extra care when painting or doing body work in the area below the centre pillar. Avoid direct exposure of the seat belt retractor and tensioner to heat guns, welding or
spraying equipment.
3. SRS electrical wiring harnesses and connectors are identified with yellow colour coding. Care should be taken not to damage the harness when repairing this area.
4. Do not apply heat of more than 100C (212F) when drying painted surfaces anywhere around the locations of SRS components.
5. If strong impact or high temperature needs to be applied to the areas around the locations of SRS components, remove the components before performing the repair work.
6. If any of the SRS related components are damaged or deformed, be sure to replace them.
NOTE: Refer to the Restraints section of the Shop Manual for after deployment procedures, and removal and replacement of SRS related components.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

FRONT IMPACT SENSOR


DRIVER'S AIRBAG ASSEMBLY
FRONT IMPACT SENSOR
CABLE REEL
FRONT PASSENGER'S AIRBAG ASSEMBLY
SIDE AIRBAG
SEAT BELT TENSIONERS
SIDE IMPACT SENSOR
SIDE IMPACT SENSOR
SIDE AIRBAG
SRS UNIT
(with built-in sensor)
12. UNDER-DASH FUSE/RELAY BOX

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General Information - General Information

General Information

1-3

Body Specifications/Wheel Alignment


Unit : mm(in.)

Front Wheel Alignment:


Camber

000' 45'

Caster

133' 1

Total toe

0 2 (0 1/16)

Wheel turning angle in

4000' 2

out

3100' (Reference)

Rear Wheel Alignment:


Camber

-045' 45'

Total toe

2 +2 -1 (1/16 +1/16 -1/32)

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General Information - General Information

1-4

General Information
Construction

Sp: Steel plate / Hss: High strength steel plate / Zn: Zinc-plating
No.

Part Name

No.

Part Name

(1)

Hood (Hss, Zn)

(22)

Side Sill Reinforcement (Hss, Zn)

(2)

Front Fender (Sp, Zn)

(23)

Front Pillar Inner Lower (Hss)

(3)

Door (Hss, Zn)

(24)

Front Pillar Inner Upper (Hss, Zn)

(4)

Trunk Lid (Sp, Zn)

(25)

Roof Side Rail (Hss)

(5)

Bulkhead Side (Sp, Zn)

(26)

Roof Panel (Sp)

(6)

Bulkhead Side Stay (Sp, Zn)

(27)

Rear Inner Panel (Sp, Zn)

(7)

Bulkhead Upper Frame (Sp, Zn)

(28)

Wheel Arch Extension (Sp, Zn)

(8)

Front Lower Cross-member (Hss, Zn)

(29)

Rear Wheelhouse (Sp, Zn)

(9)

Wheelhouse Upper Member (Sp)

(30)

Inside Sill (Hss, Zn)

(10)

Front Wheelhouse (Sp, Zn)

(31)

Front Floor (Sp, Zn)

(11)

Front Damper Extension (Hss, Zn)

(32)

Middle Floor Cross-member (Hss, Zn)

(12)

Damper Housing (Hss, Zn)

(33)

Middle Floor Gusset (Hss)

(13)

Front Side Frame (Hss, Zn)

(34)

Rear parcel Shelf (Sp)

(14)

Side Frame Extension Rear/Front Side Outrigger (Hss, Zn)

(35)

Rear Floor Upper Cross-member (Sp)

(15)

Dashboard Lower (Sp, Zn)

(36)

Rear Floor (Sp, Zn)

(16)

Dashboard Upper (Sp, Zn)

(37)

Rear Panel (Sp, Zn)

(17)

Outer Panel (Sp, Zn)

(38)

Rear Panel Side Stiffener (Sp)

(18)

Rear Combination Adapter (Sp, Zn)

(39)

Rear Frame A (Sp, Zn)

(19)

Front Pillar Lower Stiffener (Sp, Zn)

(40)

Rear Frame B (Hss, Zn)

(20)

Front Pillar Upper Stiffener (Hss)

(41)

Rear Floor Cross-member (Sp, Zn)

(21)

Centre Pillar Stiffener (Sp)

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General Information - General Information

1-5

General Information

Colour Chart Paint Specifications

P.: Pearl Paint / M.: Metallic Paint


Paint Code Colour
Name
KE

NH-578
NH-623M Stain
Taffeta White
Silver M.

B-92P Night
Hawk Black P.

B-96P Eternal
Blue P.

G-95P Clover
Green P.

R-513 Rallye
Red

Y-61P Inca P.

YR-525M
Titanium M.

SE

SE EXEC

LS

LSG

ES

ESG

KK

EX

KY

VTi

KX

EX

KB

LS

ES

KG

NOTE: In case of vehicles painted with NH-578, NH-623M, Y-61P and YR-525M and apply black (NH-70 Gloss 20) to the lower surface of the side sill (A) section.
1. FRONT BUMPER
Body colour
2. FRONT GRILLE
Body colour
3. HOOD MOULDING
Body colour
4. DOOR MIRROR
Body colour or black (NH-72 Gloss 30)
5. DOOR OUTER HANDLE
Body colour or black (NH-72 Gloss 30)
6. SIDE SILL
7. ROOF MOULDING
Black (NH-70 Gloss 20)
8. LICENSE PLATE TRIM
Body colour or black (NH-70 Gloss 20)
9. REAR BUMPER
Body colour
10. DOOR MOULDING
Black (NH-70 Gloss 20)
11. DOOR SASH TRIM
Black (NH-70 Gloss 20)
12. FRONT UNDER SPOILER
Black (NH-68 Gloss 10)

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Replacement - Replacement

Replacement
*Side Sill Outer Panel
Mass Production Body Welding Diagram

3-2

Removal

3-3

Installation

3-4

Roof Panel
Mass Production Body Welding Diagram

3-5

Rear Side Outer Panel


Mass Production Body Welding Diagram

3-6

Removal

3-7

Installation

3-8

Rear Panel
Mass Production Body Welding Diagram

3-9

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

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Replacement - Side Sill Outer Panel

Side Sill Outer Panel

Mass Production Body Welding Diagram

32
a.
b.
c.
d.
e.

VIEW (Y)
Centre pillar stiffener
Outer panel stiffener
Side sill reinforcement
VIEW (Z)

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Replacement - Side Sill Outer Panel

Side Sill Outer Panel

3-3

Removal

Cut and pry off the side sill outer panel.


Check the centre pillar stiffener and side sill reinforcement position and check for damage. If necessary replace the side sill reinforcement.
Replace the driver's side sill reinforcement as an assembly because of the way the stiffener is attached inside the side sill reinforcement.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

OUTER PANEL
SIDE SILL REINFORCEMENT
REINFORCEMENT STIFFENER (Driver side)
INSIDE SILL
REAR INNER PANEL
SIDE SILL REINFORCEMENT
VIEW (Z)
CENTRE PILLAR STIFFENER
OUTER PANEL STIFFENER
WHEEL ARCH EXTENSION
SIDE SILL REINFORCEMENT
OUTER PANEL
FRONT PILLAR LOWER STIFFENER

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Replacement - Side Sill Outer Panel

Side Sill Outer Panel

3-4

Installation

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

Passenger's side
When replacing the side sill reinforcement, cut the new side sill reinforcement so it
overlaps the body side reinforcement by 20 mm (1.8 in.), and fillet weld it.

1. Fillet welding
Overlap
20 mm (1.8 in.)

1. NEW SIDE SILL REINFORCEMENT

VIEW (Z)

5. Clamp the repair part and recheck the clearance and alignment of the door and
front fender.
6. Perform the main welding:
Attach a patch at the cut section of the front pillar (driver's side) center pillar and
wheel arch and plug weld them.
Driver's side

1. NEW SIDE SILL REINFORCEMENT


1.
2.
3.
4.
5.

PATCH
Butt welding
Butt welding
PATCH
OUTER PANEL

Passenger's side:

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Replacement - Side Sill Outer Panel

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

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Roof Panel

Roof Panel

3-5

Mass Production Body Welding Diagram

Without roof panel:


a.
b.
c.
d.

Outer panel
Roof panel
Front roof rail
Rear roof rail

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Replacement - Rear Side Outer Panel

Rear Side Outer Panel

Mass Production Body Welding Diagram

36
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.

Rear parcel shelf


Rear damper stiffener
Rear gutter
Inner panel
Rear panel
Rear Combination adaptor
Rear gutter
Outer panel stiffener
VIEW (Z)
Wheel arch extension
Side sill reinforcement
Centre pillar stiffener

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Replacement - Rear Side Outer Panel

Rear Side Outer Panel

3-7

Removal

Cut and pry off the rear side outer panel.


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

CENTRE PILLAR STIFFENER


INNER PANEL
REAR DAMPER STIFFENER
PARCEL SHELF
REAR COMBINATION ADAPTOR
REAR GUTTER
REAR PANEL
REAR COMBINATION ADAPTOR
OUTER PANEL
REAR FLOOR
SIDE SILL REINFORCEMENT

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Replacement - Rear Side Outer Panel

Rear Side Outer Panel

3-8

Installation

1. Cut and set the new centre pillar stiffener into position, and install the middle floor
gusset.

8. Temporarily install the door, rear window, trunk lid and rear bumper, and check for
differences in level and clearance.
Make sure the body lines flow smoothly.
9. Do the main welding:
Attach a patch at the cut section of the rear pillar and plug weld it.

1. MIDDLE FLOOR GUSSET


2. NEW CENTRE PILLAR STIFFENER

2. Set the new repaired part (outer panel) and rear combination adaptor into position
and clamp them.
Check the body dimensions (see section 4).

Remove the repaired part (outer panel) and weld the centre pillar stiffener.

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

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

Weld the rear combination adaptor and rear panel.

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

7. Tack weld the outer panel and rear combination adaptor.

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Replacement - Rear Side Outer Panel

1. REAR COMBINATION ADAPTOR

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Rear Panel

Rear Panel

Mass Production Body Welding Diagram

39
a.
b.
c.
d.
e.

Rear combination adaptor


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

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Body Dimensional Drawings - Body Dimensional Drawings

Body Dimensional Drawings


Upper Body Measuring Dimensions
Passenger Compartment

4-2

Opening Repair Chart

4-3

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Upper Body Measuring Dimensions

Upper Body Measuring Dimensions

4-2

Passenger Compartment

Unit: mm (in.)

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

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Opening Repair Chart

Opening Repair Chart

4-3

Unit: mm (in.)
Door and Windshield Openings:
1. A
Windshield lower dashboard guide pin
2. B, C
Windshield opening flange notch (2 places)
3. D, E, F, G
Door opening flange notch (8 places)

Rear Window and Trunk Lid Openings:


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

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Rust Prevention - Rust Prevention

Rust Prevention
Cross Section of Body and Sealants
General

5-2

Rear Side Outer Panel and Rear Panel

5-3

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Rust Prevention - Cross Section of Body and Sealants

Cross Section of Body and Sealants

5-2

General

NOTE: Following the sealer manufacturer's instructions.


1. Clean the areas to be sealed with the white gasoline.
2. Wipe off any excess spot sealer with thinner. After the primer is sprayed, sealer will
fill in the area where spot sealer was wiped off.
3. Make sure you can see the sealant when the sealed part is in its proper location.
Refer to page 5-3 of this manual, refer to the 2001 CIVIC 4-door/CIVIC 5-door
Body Repair Manual (P/N. 62S5A30) on this CD for the items not shown in this
manual.

5. Apply sealer on any area that the replacement part will cover. Smooth the sealer
with a brush is necessary.

4. Finish sealing the engine compartment, the door opening, the truck gutter and the
tailgate gutter. Wipe of the excess sealer.

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Rust Prevention - Cross Section of Body and Sealants

Cross Section of Body and Sealants


Rear Side Outer Panel and Rear Panel

53
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

Rear gutter
Outer Panel
Outer Panel
Parcel Shelf
Rear combination adaptor
Outer Panel
Rear gutter
Rear combination adaptor
Rear combination adaptor
Rear panel
Rear combination adaptor
Outer Panel
Rear combination adaptor
Rear gutter extension
Rear combination adaptor
Rear gutter
Gutter extension
Rear gutter
Quarter lower extension
Outer panel

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