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Fuel Supply System
Fuel Pressure
11-146
Relieving
Before disconnecting fuel pipes or hoses, release p ressure
from the system by loosening the fuel pulsation dam per on
top of the fuel rail.
Inspection
1. Relieve the fuel pressure.
2. Remove the fuel pulsation damper from the fuel
rail. Attach the fuel pressure gauge attachment
and fuel pressure gauge.
Do not smoke while working on the fuel system.
Keep open flames or sparks away from the work area.
Be sure to relieve the fuel pressure while the igni tion switch
is off.
1. Disconnect the battery negative cable from the ba ttery
negative terminal.
2. Remove the fuel fill cap.
3. Use a wrench on the fuel pulsation damper at the fuel
rail.
4. Place a rag or shop towel over the fuel pulsation damper.
5. Slowly loosen the fuel pulsation damper one compl ete
turn.
1.
2.
1.
2.
3.
4.
FUEL PRESSURE GAUGE, 07406-0040002
CLAMP
FUEL PRESSURE REGULATOR
FUEL PRESSURE GAUGE ATTACHMENT, 07VAJ-0090100
3.
Start the engine. Measure the fuel pressure with
the engine idling and the vacuum hose of the fuel
pressure regulator disconnected from the fuel
pressure regulator and pinched. If the engine will
not start, turn the ignition switch ON (II), wait for
two seconds, turn it off, then back on again and
read the fuel pressure.
Pressure should be:
260 - 310 kPa (2.7 - 3.2 kgf/cm 2, 38 - 46psi)
Reconnect the vacuum hose to the fuel pressure
regulator.
Pressure should be:
200 - 250 kPa (2.0 - 2.5 kgf/cm 2, 28 - 36psi)
If the fuel pressure is not as specified, first check
the fuel pump (See Page 11-147). If the fuel pump
is OK, check the following:
If the fuel pressure is higher than specified,
inspect for:
Pinched or clogged fuel return hose or
line
Faulty fuel pressure regulator
If the fuel pressure is lower than specified,
inspect for:
Clogged fuel filter
FUEL PULSATION DAMPER,
22 Nm (2.2 kgf/m, 16lbf/ft)
SHOP TOWEL
NOTE: Replace the washers whenever the fuel pulsati on
damper is loosened or removed.
4.
Faulty fuel pressure regulator
Leakage in the fuel line.
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Ground Distribution
Circuit Identification (LHD type)
23-B-16
Ground Distribution
Circuit Identification (LHD type) (contd)
23-B-17
Ground Distribution
Circuit Identification (LHD type) (contd)
23-B-18
Ground Distribution
Circuit Identification (RHD type)
23-B-19
Ground Distribution
Circuit Identification (RHD type) (contd)
23-B-20
Ground Distribution
Circuit Identification (RHD type) (contd)
23-B-21
Lighting System
Component Location Index
23-D-2
4D:
NOTE: LHD type is shown, RHD type is similar.
1. REAR FOG LIGHT SWITCH (KG, KE
models)
Test, (See Page 23-D-4)
2. COMBINATION LIGHT SWITCH
3. HIGH BEAM INDICATOR LIGHT
4. REAR FOG LIGHT CONTROL UNIT
(KG, KE models)
5. DASH LIGHTS BRIGHTNESS
CONTROL UNIT (KQ model: 4D)
Input Test, (See Page 23-D-7)
6. HEADLIGHT ADJUSTER SWITCH
(KG, KE models)
Test, (See Page 23-D-5)
DASH LIGHTS BRIGHTNESS
CONTROLLER (KQ model: 4D)
Controller Test, ( See Page 23-D-8)
7. UNDER-DASH FUSE/RELAY BOX
8. TAILLIGHT RELAY
Lighting System
Component Location Index (contd)
23-D-3
Common:
1. HIGH MOUNT BRAKE LIGHT (LED
type)
Replacement, (See Page 23-D-9)
Rear Fog Light (KG and KE models)
Switch Test (4D)
23-D-4
1.
2.
3.
Remove the switch panel from the dashboard.
Disconnect the 6P connector from the rear fog light
switch.
Push the switch out from behind the switch panel.
1.
2.
6P CONNECTOR
SWITCH PANEL
4.
Check for continuity between the terminals in eac h
switch position according to the table.
Headlight Adjuster (KG and KE models)
Headlight Adjuster Switch Test (4D)
23-D-5
1.
2.
Carefully pry the switch out of the rear console.
Disconnect the 5P connector from the switch.
3.
4.
1.
2.
3.
HEADLIGHT ADJUSTER SWITCH
5P CONNECTOR
Not used
Measure the resistance between the No. 1 and No.
3 terminals, and then measure the resistance
between the No. 3 and No. 5 terminals at positions
0, 1, 2, and 3 by moving the knob.
Between No. 1 and No. 3 terminals: Approx.
4.7k ohms
Between No. 3 and No. 5 terminals:
Knob position
0
1
2
3
Resistance
[Approx. (k ohms)]
3.9 3.5 2.8 2.4
Replace the switch if the resistance is not withi n
the specifications.
Dash Lights Brightness Controller (KQ
model)
Circuit Diagram (4D)
23-D-6
Dash Lights Brightness Controller (KQ
model)
23-D-7
Control Unit Input Test (4D)
1.
2.
Disconnect the 6P connector from the control unit.
Inspect the connector terminals to be sure they are all making good contact.
If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system.
If the terminals look OK, make the following input tests at the connector.
If any test indicates a problem, find and correct the cause, then recheck the system.
If all the input tests prove OK, the control unit must be faulty, replace it.
1. DASH LIGHTS BRIGHTNESS
CONTROL UNIT
2. 6P CONNECTOR
3. Wire side of female terminals
| Cavity |
|
|
|
5 |
|
|
|
|
|
|
|
|
|
|
|
1 |
|
|
|
4 |
|
|
|
|
|
|
RED/BLK |
|
|
|
|
|
BLK
|
|
RED
|
|
|
Wire
Test condition |
|
Combination light |
switch ON
|
|
|
|
|
Under all
|
conditions
|
Combination light |
switch ON
|
|
|
|
Check for voltage to ground:
|
There should be battery voltage. |
|
|
|
|
Check for continuity to ground: |
There should be continuity.
|
Connect to ground:
|
Dash lights should come on full |
bright.
|
Test: Desired result
Possible cause if result is not
obtained
Blown No. 46 (7.5 A) fuse in the
under-dash fuse/relay box
Faulty combination light switch
Faulty taillight relay
An open in the wire
Poor ground (G401, G402)
An open in the wire
An open in the wire
|
|
|
|
|
|
|
|
|
|
|
|
|
Dash Lights Brightness Controller (KQ
model)
Controller Test (4D)
23-D-8
1.
2.
Carefully pry the switch out of the rear console.
Disconnect the 5P connector from the switch.
1.
2.
3.
DASH LIGHTS BRIGHTNESS CONTROLLER
5P CONNECTOR
Not used
3.
Measure resistance between the No. 3 and No. 5
terminals.
Resistance: 8,000 - 12,000 ohms
NOTE: Resistance will vary slightly with temperature.
Measure resistance between the No. 4 and No. 5
terminals while rotating the adjusting dial.
Resistance should vary from 0 to 10,000 ohms as the
dial is rotated.
4.
Brake Lights
Circuit Diagram (With LED type High Mount Brake
Light)
23-D-9
High Mount Brake Light
Replacement (LED type)
1.
2.
Remove the four caps and screws.
Disconnect the connectors, then remove the high
mount brake light.
1.
2.
3.
4.
HIGH MOUNT BRAKE LIGHT
CONNECTORS
CAP
SCREW
Interior Lights
Component Location Index
23-D-10
4D:
NOTE: LHD type is shown, RHD type is similar.
1.
2.
3.
4.
5.
6.
7.
8.
9.
FRONT CEILING LIGHT
PASSENGERS DOOR SWITCH
REAR CEILING LIGHT
RIGHT REAR DOOR SWITCH
TAILGATE LATCH SWITCH
CARGO AREA LIGHT
LEFT REAR DOOR SWITCH
DRIVERS DOOR SWITCH
BEVERAGE HOLDER LIGHT
Interior Lights
Circuit Diagram
23-D-11
Power Windows
Component Location Index
23-E-2
4D:
NOTE: LHD type is shown; RHD type is similar
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
POWER WINDOW RELAY
UNDER-DASH FUSE/RELAY BOX
PASSENGERS WINDOW SWITCH
PASSENGERS POWER WINDOW
MOTOR
RIGHT REAR WINDOW MOTOR
Test, (See Page 23-E-11)
RIGHT REAR WINDOW SWITCH
Test, (See Page 23-E-11)
LEFT REAR WINDOW SWITCH
Test, (See Page 23-E-11)
LEFT REAR WINDOW MOTOR
Test, (See Page 23-E-11)
POWER WINDOW MASTER SWITCH
(Has built-in control unit)
Input Test (See Page 23-E-6)
Test, (See Page 23-E-10)
DRIVERS WINDOW MOTOR
Drivers Window Motor Description
The drivers window will stop and automatically ope n if you pinch your hand or something during auto-u p operation.
Power Windows
Circuit Diagram (2D)
23-E-3
Power Windows
Circuit Diagram (4D)
23-E-4
Power Windows
Circuit Diagram (4D) (contd)
23-E-5
Power Windows
Master Switch Input Test (4D)
23-E-6
NOTE: The control unit is built into the power window maste r switch, and only controls drivers door window op erations.
1. Remove the power window master switch and armrest pocket from the door panel.
2. Disconnect the 14P and 7P connectors from the power window master switch.
3. Inspect the connector and socket terminals to be sure they are all making good contact.
If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system.
If the terminals look OK, make the following input tests at the connector.
If a test indicates a problem, find and correct the cause, then recheck the system.
If all the input tests prove OK, the power window master switch must be faulty; replace it.
1.
2.
3.
4.
5.
6.
7P CONNECTOR
POWER WINDOW MASTER SWITCH
14P CONNECTOR
LHD type
RHD type
Wire side of female terminals
Power Windows
Master Switch Input Test (4D) (contd)
23-E-7
Disconnect the connector to the power window master switch.
| Cavity |
|
|
Wire
Test condition
Test: Desired result
|
|
|
|
|
A38 | BLU/BLK | Under all conditions
| Check for voltage to ground:
| [A13] |
|
| There should be battery voltage.
|
|
|
|
|
|
|
|
|
A2 | YEL/BLK | Ignition Switch ON (II) | Check for voltage to ground:
|
[A5] |
|
| There should be battery voltage.
|
|
|
|
|
|
|
|
|
A14 | GRN/BLK | Ignition Switch ON (II) | Check for voltage to ground:
|
[A7] |
|
| There should be battery voltage.
|
|
|
|
|
|
|
|
|
|
|
|
|
B5 | YEL/RED | Ignition Switch ON (II) | Check for voltage to ground:
|
|
|
| There should be battery voltage.
|
|
|
|
|
|
|
|
|
|
|
|
B6 | YEL/BLK | Ignition Switch ON (II) | Check for voltage to ground:
|
|
|
| There should be battery voltage.
|
|
|
|
|
|
|
|
|
|
|
|
|
|
A12 |
BLK
| Under all conditions
| Check for continuity to ground:
|
[A9] |
|
| There should be continuity.
|
B2 |
BLK
| Under all conditions
| Check for continuity to ground:
|
|
|
| There should be continuity:
|
A5 | BLU/YEL | Connect the A13 [A8] | Check for front passengers
|
[A2] |
| terminal to the A14
| window motor:
|
|
| [A7] terminal, and the | It should run. (the window moves
|
|
| A5 [A2] terminal to the | down)
|
|
| A12 [A9] terminal.
|
|
A13 | BLU/ORN | Connect the A13 [A8} | Check for front passengers
|
[A8] |
| terminal to the A14
| window motor:
|
|
| [A7] terminal, and the | It should run. (the window moves
|
|
| A5 [A2] terminal to the | down)
|
|
| A12 [A9] terminal.
|
|
B1 | BRN/WHT | Connect the B4
| Check for left rear window motor.
|
|
| terminal to the B5
| It should run. (the window moves
|
|
| terminal, and the B1
| down)
|
|
| terminal to the B2
|
|
|
| terminal.
|
|
B4 |
BRN
| Connect the B4
| Check for left rear window motor.
|
|
| terminal to the B5
| It should run. (the window moves
|
|
| terminal, and the B1
| down)
|
|
| terminal to the B2
|
|
|
| terminal.
|
|
B3 | BLU/ORN | Connect the B7
| Check for right rear window
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Possible cause if result is |
|
not obtained
Blown No. 52 (20 A) fuse in |
the under-hood fuse/relay
|
box
|
An open in the wire
|
Blown No. 4 (10 A) fuse in |
the under-dash fuse/relay
|
box
|
An open in the wire
|
Blown No. 14, 15 and 16
|
(20 A) fuse in the
|
under-dash fuse/relay box |
Faulty power window relay |
An open in the wire
|
Blown No. 14, 15 and 16
|
(20 A) fuse in the
|
under-dash fuse/relay box |
Faulty power window relay |
An open in the wire
|
Blown No. 14, 15 and 16
|
(20 A) fuse in the
|
under-dash fuse/relay box |
Faulty power window relay |
An open in the wire
|
Poor ground (G401, G402) |
An open in the wire
|
Poor ground (G401, G402) |
An open in the wire
|
Faulty front passengers
|
window motor
|
Faulty front passengers
|
window switch
|
An open in the wire
|
Faulty front passengers
|
window motor
|
Faulty front passengers
|
window switch
|
An open in the wire
|
Faulty left rear window motor |
Faulty left rear window
|
switch
|
An open in the wire
|
|
Faulty left rear window motor |
Faulty left rear window
|
switch
|
An open in the wire
|
|
Faulty right rear window
|
|
|
|
|
|
|
|
|
|
B7 | BRN/YEL
|
|
|
|
|
|
|
|
|
A1 | RED/BLU
|
[A6] |
|
|
|
|
|
|
|
A7 | RED/YEL
| [A14] |
|
|
|
|
|
|
[ ]: RHD type
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
terminal to the B6
terminal, and the B3
terminal to the B2
terminal.
Connect the B7
terminal to the B6
terminal, and the B3
terminal to the B2
terminal.
Connect the A7 [A14]
terminal to the A8
[A13] terminal, and the
A1 [A6] terminal to the
A12 [A9] terminal.
Connect the A7 [A14]
terminal to the A8
[A13] terminal, and the
A1 [A6] terminal to the
A12 [A9] terminal.
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
motor.
|
motor
It should run. (the window moves | Faulty right rear window
down)
|
switch
| An open in the wire
Check for right rear window
| Faulty right rear window
motor.
|
motor
It should run. (the window moves | Faulty right rear window
down)
|
switch
| An open in the wire
Check for drivers window motor. | Faulty drivers power
It should run. (the window moves |
window motor
down)
| An open in the wire
|
|
Check for drivers window motor. | Faulty drivers power
It should run. (the window moves |
window motor
down)
| An open in the wire
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Power Windows
Master Switch Input Test (4D) (contd)
23-E-8
LHD type:
RHD type:
COMMON:
Reconnect the connector to the power window master switch.
| Cavity |
|
|
Wire
Test condition
Test: Desired result
|
|
|
|
|
A9 |
WHT
| Ignition switch ON (II) | Check for voltage to ground:
| [A12] |
|
| There should be battery voltage.
|
|
|
|
|
A3 |
BLK
| Under all conditions
| Check for continuity to ground:
|
[A4] |
|
| There should be continuity.
|
|
|
|
A11 |
BLU
| Ignition switch ON (II), | Check for voltage between the
|
| and the drivers
| A11 [A10] and A12 [A9]
| [A10] |
|
| window switch AUTO | terminals:
|
|
| UP.
| There should be 0 - 5 V or more
|
|
|
| repeatedly.
|
|
A10 |
YEL
| Ignition switch ON (II), | Check for voltage between the
| [A11] |
| and the drivers
| A10 [A11] and A12 [A9]
|
|
| window switch AUTO | terminals:
|
|
| DOWN.
| There should be 0 - 5 V or more
|
|
|
| repeatedly.
[ ]: RHD type
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Possible cause if result is |
|
not obtained
Faulty power window
|
master switch
|
An open in the wire
|
Faulty power window
|
master switch
|
An open in the wire
|
Faulty drivers window motor |
Faulty power window
|
master switch
|
An open in the wire
|
|
Faulty drivers window motor |
Faulty power window
|
master switch
|
An open in the wire
|
|
Power Windows
Master Switch Test (2D)
23-E-9
1.
2.
3.
Remove the armrest pocket.
Disconnect the 14P connector from the power windo w
master switch.
Check for continuity between the terminals in eac h
switch position according to the tables.
Passengers Switch
[ ]: RHD type
4. Check that the switch light comes on when
connecting the battery power to the No. 4 [3]
terminal and ground to the No. 1 [6] terminal.
If it does not come on, replace the master
switch.
1.
POWER WINDOW MASTER SWITCH
Drivers Switch:
The drivers switch is combined with the control un it so you
cannot isolate the switch to test it. Instead, run the master
switch input test procedures.
If the tests are normal, the drivers switch must be faulty.
Power Windows
Master Switch Test (4D)
23-E-10
1.
2.
3.
1.
Remove the armrest pocket (See Page 23-E-6).
Remove the 14P and 7P connectors from the power
window master switch.
Check for continuity between the terminals in eac h
switch position according to the tables.
POWER WINDOW MASTER SWITCH
Drivers Switch:
The drivers switch is combined with the control un it so you
cannot isolate the switch to test it. Instead, run the master
switch input test procedures (See Page 23-E-6).
If the tests are normal, the drivers switch must be faulty.
4.
Check that the switch light comes on when
connecting the battery power to the A2 [A5]
terminal and ground to the A12 [A9] terminal.
If it does not come on, replace the master
switch.
Power Windows
Rear Window Switch Test
23-E-11
Rear Window Motor Test
1.
2.
Remove the armrest pocket (see section 20).
Disconnect the 5P connector then remove the mount ing
screws from the switch.
1.
2.
REAR WINDOW SWITCH
ARMREST POCKET
3.
Check for continuity between the terminals in eac h
switch position according to the table.
1.
2.
Remove the rear door panel (see section 20).
Disconnect the 2P connector from the window
motor.
1.
2.
2P CONNECTOR
Terminal side of male terminals
When the motor stops running, disconnect one
lead immediately.
3. Test the motor in each direction by connecting
battery power and ground according to the table.
4.
If the motor does not run or fails to run smoothly,
replace it.
Power Door Locks
Component Location Index
23-E-12
NOTE: LHD type is shown, RHD type is similar.
1. TAILGATE LOCK ACTUATOR
2. RIGHT REAR DOOR LOCK
ACTUATOR
Test, ( See Page 23-E-15)
3. DRIVERS DOOR LOCK
ACTUATOR (With keyless entry)
DRIVERS DOOR LOCK KNOB
SWITCH (Without keyless entry)
4. UNLOCK BUTTON
5. TRANSMITTER
6. LOCK BUTTON
7. KEYLESS DOOR LOCK
CONTROL UNIT
POWER DOOR LOCK CONTROL
UNIT
8. IGNITION KEY SWITCH
9. PASSENGERS DOOR LOCK
ACTUATOR
10. LEFT REAR DOOR LOCK
ACTUATOR
Test, (See Page 23-E-15)
Power Door Locks
Circuit Diagram (With Keyless Entry System)
23-E-13
Power Door Locks
Circuit Diagram (Without Keyless Entry System)
23-E-14
Power Door Locks
Rear Door Lock Actuator Test
23-E-15
1.
2.
Remove the rear door panel (see section 20).
Disconnect the 2P connector from the actuator.
1.
2P CONNECTOR
To prevent damage to the actuator, apply battery voltage
only momentarily.
3. Check actuator operation by connecting power and
ground according to the table.
Integrated Control Unit
Circuit Diagram
23-E-16
Power Mirrors
Component Location Index
23-F-2
4D:
NOTE: LHD type is shown, RHD type is symmetrical.
1. POWER MIRROR
Function Test, (See Page 23-F-6)
2. POWER MIRROR SWITCH
Power Mirrors
Circuit Diagram (KG model: With Defogger)
23-F-3
Power Mirrors
Circuit Diagram (With Retractable Power Mirror)
23-F-4
Power Mirrors
Circuit Diagram (Without Retractable Power Mirror)
23-F-5
Power Mirrors
Function Test (4D)
23-F-6
1.
2.
3.
Remove the switch panel from the dashboard.
Disconnect the 10P connector from the power mirror
switch.
Push the switch out from behind the switch panel.
1.
2.
3.
10P CONNECTOR
POWER MIRROR SWITCH
Wire side of female terminals
*1: With defogger
*2: With retractable power mirror
Mirror Test
Both inoperative:
1. Check for voltage between the No. 1 terminal and body
ground with the ignition switch ON (II).
There should be battery voltage.
If there is no battery voltage, check for:
blown No. 11 (7.5 A) fuse in the under-dash
fuse/relay box.
an open in the BLK/YEL wire.
If there is battery voltage, go to step 2.
2. Check for continuity between the No. 2 terminal and
body ground.
There should be continuity.
If there is no continuity, check for:
an open in the BLK wire.
poor ground (G401, G402)
If there is continuity, check both mirrors individually
as described in the next column.
Left mirror inoperative:
Connect the No. 1 terminal to the No. 7 terminal, and
the No. 4 (or No. 9) terminal to body ground with jumper
wires. The left mirror should tilt down (or swing left)
with the ignition switch ON (II).
If the mirror does not tilt down (or does not swing
left), check for an open in the No. 4 (or No. 9)
terminal wire between the left mirror and the 10P
connector. If the wire is OK, check the left mirror
actuator.
If the mirror neither tilts down nor swings left, repair
the No. 7 terminal wire.
If the mirror works properly, check the mirror
switch.
Right mirror inoperative:
Connect the No. 1 terminal to the No. 8 terminal, and
the No. 4 (or No. 10) terminal to body ground with
jumper wires. The right mirror should tilt down (or
swing left) with the ignition switch ON (II).
If the mirror does not tilt down (or does not swing
left), check for an open in the No. 4 (or No. 10)
terminal wire between the right mirror and the 10P
connector. If the wire is OK, check the right mirror
actuator.
If the mirror neither tilts down nor swings left, repair
the No. 8 terminal wire.
If the mirror works properly, check the mirror
switch.
Defogger test:
Connect the No. 3 and No. 6 terminals with a jumper
wire, and check for voltage between the No. 3 terminal
and body ground. There should be battery voltage and
both mirrors should warm up with the ignition switc h ON
(II).
If there is no voltage or neither warms up, check
for:
an open in the BLK/YEL and BLU/YEL wires.
blown No. 11 (7.5 A) in the under-dash
fuse/relay box.
poor ground (G401, G402)
If only one fails to warm up, check its defogger.
If both fail to warm up, check the defogger switch.
Retractable mirror inoperative:
Connect the No. 1 (BLK/YEL) terminal of the 10P
connector to the No. 6 (GRN/ORN) terminal and the No.
5 (GRN/YEL) terminal to body ground with jumper
wires. The mirrors should extend when the ignition
switch is turned ON (II).
Connect the No. 1 (BLK/YEL) terminal of the 10P
connector to the No. 5 (GRN/YEL) terminal and the No.
6 (GRN/ORN) terminal to body ground with jumper
wires. The mirrors should retract when the ignition
switch is turned ON (II).
If one of the mirrors does not retract or extend,
check the retractable mirror actuator.
If the mirrors operate properly, replace the switch.
Stereo Sound System
Circuit Diagram
23-F-7
Stereo Sound System
Audio Unit Removal (KY, KT and KQ models)
23-F-8
Audio Unit Connector Terminals
Identification (KY, KT and KQ
models)
1.
2.
Remove the centre panel from the dashboard (see
section 20).
Remove the four screws from the bracket.
1.
2.
3.
4.
5.
6.
7.
CLOCK
ANTENNA LEAD
4P CONNECTOR
20P CONNECTOR
BRACKET
SCREW
AUDIO UNIT
3.
Disconnect the 20P connector and the antenna lead
from the audio unit, and the 4P connector from the clock.
Remove the four screws, then remove the audio unit
from the bracket.
4.
1.
2.
3.
BRACKET
SCREW
AUDIO UNIT
Cavity
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Wire
YEL/BLK
YEL/RED
--------------------------------------------RED/GRN
BLU
RED/BLK
WHT
------------------------------------------------------------------BRN/BLK
GRN/BLK
-----------BLK
Connects to
Roof Antenna
ACC (main power supply)
Not used
Not used
Not used
Not used
Right Front Door Speaker (+)
Left front door speaker (+)
Lights-on signal
Constant power (tuning memory)
Not used
Not used
Not used
Not used
Not used
Not used
Right front door speaker (-)
Left front door speaker (-)
Not used
Ground (G403)
Seat Heaters (KG model)
Circuit Diagram
23-F-9
Seat Heaters (KG model)
Switch Test
1.
2.
23-F-10
Carefully pry the switch out of the rear console.
Disconnect the 10P connector and remove the switch.
1. 10P CONNECTOR
2. SEAT HEATER SWITCH
3. BULBS
3.
Check for continuity between the terminals in each switch position according to the table.
Restraints Index
Seat Belts
Supplemental Restraint System (SRS)
24-1
24-7
NOTE: Refer to the 1999 HR-V Shop Manual, P/N. 62S2H00, for the items not shown in this section.
Outline of Model Change
5-door model has been added. The work of the following items are different against the 3-door model.
Front seat belt
Front seat belt shoulder anchor adjuster (added)
Rear seat belt
Centre belt and seat belt buckles
Seat Belts
Front Seat Belt Replacement
24-2
SRS components are located in this area. Review the SRS component locations, precautions and procedures in the 1999 HR-V
Shop Manual, P/N. 62S2H00, before performing repair s or service.
NOTE: Check the front seat belts for damage, and replace them if necessary. Be careful not to damage them during removal and
installation.
Front seat belt (5D):
1. Disconnect the negative battery cable, and wait at least three minutes before beginning work.
2. Slide the front seat all the way around.
3. Remove (see section 20):
Front side trim
Rear side trim
Centre pillar lower trim
4. Remove the upper anchor cover, and pull the lower anchor cover back.
1. UPPER ANCHOR BOLT 7/16-20UNF
32 Nm (3.3 kgf/m, 24 lbf/ft)
2. SHOULDER ANCHOR ADJUSTER
3. FRONT SEAT BELT
4. RETRACTOR PROTECTOR
5. SEAT BELT TENSIONER
CONNECTOR
6. RETRACTOR BOLT 7/16-20UNF
32 Nm (3.3 kgf/m, 24 lbf/ft)
7. LOWER ANCHOR BOLT 7/16-20UNF
32 Nm (3.3 kgf/m, 24 lbf/ft)
8. LOWER ANCHOR COVER
9. RETRACTOR
10. RETRACTOR MOUNTING SCREW
6 x 1.0 mm 4Nm (0.4 kgf/m, 3 lbf/ft)
11. UPPER ANCHOR COVER
5.
6.
Disconnect the seat belt tensioner connector.
Remove the upper anchor bolt and lower anchor bol t, the retractor mounting screw, and the retractor bolt, and remove the
front seat belt and retractor.
Seat Belts
Front Seat Belt Replacement (contd)
24-3
7.
8.
9.
Remove the front and rear door trim as necessary (see
section 20).
Remove the centre pillar upper trim (see section 20).
Remove the shoulder anchor adjuster.
Upper anchor bolt construction:
1.
2.
3.
4.
5.
BUSHING
UPPER ANCHOR
TOOTHED LOCK WASHER
COLLAR
UPPER ANCHOR BOLT
Lower anchor bolt construction:
1.
SHOULDER ANCHOR ADJUSTER
10. Install in the reverse order of removal, and note these
items:
If the threads on the retractor mounting screw are
worn out, use an oversized screw made specifically
for this application.
Check that the retractor locking mechanism
functions as described (See Page 24-6).
Assemble the washers, collar and bushing on the
upper and lower anchor bolts as shown.
Before installing the anchor bolts, make sure there
are no twists or kinks in the front seat belt.
Make sure the seat belt tensioner connector is
plugged in properly.
1.
2.
3.
4.
5.
6.
7.
8.
BUSHING
COLLAR
SPRING WASHER
COLLAR
TOOTHED LOCK WASHER
WASHER
LOWER ANCHOR
LOWER ANCHOR BOLT
Retractor bolt construction:
1.
2.
3.
RETRACTOR BOLT
RETRACTOR
TOOTHED LOCK WASHER
Seat Belts
Rear Seat Belt Replacement
24-4
Check the rear seat belts for damage, and replace them if necessary. Be careful not to damage them during removal and
installation.
Rear seat belt (5D):
1. Remove:
Rear centre shelf
Spare tyre lid
Rear floor bucket
Rear trim panel
Rear seat cushion (see section 20)
Rear seat-back (see section 20)
Rear side trim (see section 20)
Rear side shelf (see section 20)
Trunk side trim panel (see section 20)
2. Remove the lower anchor bolt.
1. UPPER ANCHOR BOLT 7/16-20UNF
32 Nm (3.3 kgf/m, 24 lbf/ft)
2. GUIDE STAY
3. RETRACTOR PROTECTOR
4. REAR SEAT BELT
5. LOWER ANCHOR BOLT 7/16-20UNF
32 Nm (3.3 kgf/m, 24 lbf/ft)
6. RETRACTOR
7. RETRACTOR BOLT 7/16-20UNF
32Nm (3.3 kgf/m, 24 lbf/ft)
8. RETRACTOR MOUNTING BOLT
6 x 1.0 mm 9.8 Nm (1.0 kgf/m, 7.2
lbf/ft)
9. UPPER ANCHOR COVER
3.
4.
Pull the upper anchor cover back, then remove the upper anchor bolt. Take care not to damage the upper anchor cover.
Remove the retractor mounting bolt and the retractor bolt, and remove the rear seat belt retractor.
Seat Belts
Rear Seat Belt Replacement (contd)
24-5
5.
Install in the reverse order of removal, and note these
items:
Apply liquid thread lock to the upper anchor bolt
before installation.
Check that the retractor locking mechanism
funtions as described (See Page 24-6).
Assemble the collar on the upper anchor bolt as
shown.
Before installing the anchor bolts, make sure there
are no twists or kinks in the rear seat belt.
Upper anchor bolt construction:
1.
2.
3.
4.
Centre belt and seat belt buckles (5D):
1. Slide the front seat forward fully.
2. Remove the rear seat cushion (see section 20).
3. Remove the centre anchor bolts, and remove the
centre belt (for some models) and seat belt
buckles.
GUIDE STAY
TOOTHED LOCK WASHER
COLLAR
UPPER ANCHOR BOLT
Apply liquid thread lock.
Lower anchor bolt construction:
1.
2.
3.
4.
5.
6.
7.
Outside
For some models.
CENTRE ANCHOR BOLT 7/16-20UNF
32 Nm (3.3 kgf/m, 24 lbf/ft)
SEAT BELT BUCKLE
CENTRE BELT BUCKLE (For some models)
CENTRE BELT (For some models)
SEAT BELT BUCKLE
Centre anchor bolt construction:
1.
2.
3.
LOWER ANCHOR BOLT
LOWER ANCHOR
TOOTHED LOCK WASHER
Retractor bolt construction:
1.
2.
3.
RETRACTOR BOLT
RETRACTOR
TOOTHED LOCK WASHER
1.
2.
3.
CENTRE ANCHOR BOLT
CENTRE ANCHOR
TOOTHED LOCK WASHER
4.
Install in the reverse order of removal, and before
installing the centre anchor bolt, make sure there
are no twists or kinks in the centre belt (for some
models).
Seat Belts
Inspection
24-6
SRS components are located in this area. Review the SRS
component locations, precautions and procedures in the
1999 HR-V Shop Manual, P/N. 62S2H00, before perform ing
repairs or service.
Retractor:
1. Before installing the retractor, check that the seat belt
can be pulled out freely.
2. Make sure that the seat belt does not lock when the
retractor is leaned slowly up to 15 from the mounted
position. The seat belt should lock when the retractor is
leaned over 40. Do not attempt to disassemble the
retractor.
Front (5D):
*: Mounted Position
1.
2.
3.
Inside
RETRACTOR
Forward
Rear (5D):
1.
2.
3.
Forward
RETRACTOR
Inside
3.
Replace the seat belt with a new assembly if there is any
abnormality. Do not disassemble any part of the seat
belt for any reason.
In-vehicle:
1. Check that the seat belt is not twisted or caught on
anything.
2. After installing the anchors, check for free
movement on the anchor bolts. If necessary,
remove the anchor bolts and check that the
washers and other parts are not damaged or
improperly installed.
3. Check the seat belts for damage or discolouration.
Clean with a shop towel if necessary. Use only
soap and water to clean.
NOTE: Dirt build-up in the metal loops of the upper
anchors can cause the seat belts to retract slowly.
Wipe the inside of the loops with a clean cloth
dampened in isopropyl alcohol.
4. Check that the seat belt does not lock when pulled
out slowly. The seat belt is designed to lock only
during a sudden impact.
5. Make sure that the seat belt will retract
automatically when released.
6. On the rear shoulder seat belt, make sure that the
locking mechanism in the seat belt retractor will
engage when the seat belt is pulled all the way out.
7. Replace the seat belt with a new assembly if there
is any abnormality. Do not disassemble any part of
the seat belt for any reason.
Supplemental Restraint System (SRS)
24-7
Front Seat Belt
Replacement
24-8
Remove the upper anchor cover and upper anchor
bolt.
1.
2.
UPPER ANCHOR COVER
UPPER ANCHOR BOLT
Remove the two retractor mounting bolts, then
remove the retractor.
1.
2.
3.
MOUNTING BOLT
RETRACTOR
MOUNTING BOLT
Removal of the airbag must be performed according to the
precautions/procedures described before (refer to the Shop
Manual, P/N 62S2H00).
Removal
1. Disconnect the negative battery cable, and wait at least
three minutes before beginning work.
2. Remove the centre pillar lower trim panel.
3. Disconnect the seat belt tensioner 2P connector from
the SRS main harness 2P connector.
4. Remove the lower anchor bolt.
1.
2.
3.
SEAT BELT TENSIONER 2P CONNECTOR
RETRACTOR
SRS MAIN HARNESS 2P CONNECTOR
Front Seat Belt
Replacement (contd)
24-9
Installation
3.
4.
Be sure to install the harness wires so that they are not
pinched or interfering with other parts.
1. Install the new seat belt.
5.
6.
7.
1.
2.
3.
4.
5.
SEAT BELT TENSIONER 2P CONNECTOR
MOUNTING BOLT 9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
RETRACTOR
MOUNTING BOLT 32 Nm (3.3 kgf/m, 24 lbf/ft)
SRS MAIN HARNESS 2P CONNECTOR
2.
Reinstall the upper anchor bolt and upper anchor cover.
1.
2.
UPPER ANCHOR COVER
UPPER ANCHOR BOLT 32 Nm (3.3 kgf/m, 24 lbf/ft)
Reinstall the lower anchor bolt.
Reconnect the seat belt tensioner 2P connector to
SRS main harness 2P connector.
Reinstall the centre pillar lower trim panel.
Reconnect the negative battery cable.
After installing the seat belt, confirm proper system
operation: Turn the ignition switch ON (II); the SRS
indicator light should come on for about six
seconds and then go off.
Preparation of Work Index
Preparation of Work
1-1
Description
1-2
Preparation of Work
Description
1-2
Most monocoque bodies are composed as a single unit 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 as a whole.
Damage to the exterior of the body can be inspected visually, but where there has been an 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 inspected closely.
Unit: mm (in)
Front Wheel Alignment:
Camber:
000 1
Caster
215 1
Total Toe
0 3 (0 0.12)
Wheel turning angle
in
3800 2
Wheel turning angle
out
3000 (Reference)
Rear Wheel Alignment:
Camber
-030 1
Total Toe
IN 2 5 (0.08 0.1)
Replacement
Replacement
4-1
Construction
Exterior Body Parts Removal/Installation
Side Sill (Outer Panel)
Mass Production Body Welding Diagram
Replacement
Roof Panel
Mass Production Body Welding Diagram
Rear Side Outer Panel
Mass Production Body Welding Diagram
Replacement
4-2
4-3
4-4
4-5
4-8
4-9
4-10
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
This model has an SRS which includes a drivers airbag located in the steering wheel hub and some types include a
passengers airbag located in the dashboard above the glove box and seat belt tensioner located in the seat belt retractors.
Information necessary to safely service the SRS is included in the HR-V Shop Manual, P/N 62S2H00. Items marked with an
asterisk (*) on the contents page include, or are located near SRS components. Servicing, disassembling or replacing these
items will require special precautions and tools, and should therefore be done by an authorized Honda dealer.
To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal collision, all
SRS service work must be performed by an authorized Honda dealer.
Improper service procedures, including incorrect removal and installation of the SRS, could lead to personal injury caused by
unintentional deployment of the airbags, side airbags and seat belt tensioners.
All SRS electrical wiring harnesses are indicated with yellow colo r. Related components are located in the steering column, front
console, dashboard, dashboard lower panel, and in the dashb oard above the glove box, front seats and around the floor. Do not use
electrical test equipment on these circuits.
Replacement
Construction
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part Name
Hood
Front Fender
Front Door Panel/Door Skin
Rear Door Panel/Door Skin
Tailgate
Bulkhead Side Stay
Bulkhead Upper Frame
Front Lower Cross-member
Wheelhouse Upper Member
Front Fender Support
Wheelhouse Extension
Front Wheelhouse
Damper Housing
Front Side Frame
Front Side Outrigger/Lower Arm Support
Dashboard Lower
Dashboard Upper
4-2
Zinc-platedNo.
20
O
21
O
22
O
23
O
24
O
25
O
26
O
O
27
28
29
30
O
31
O
32
O
33
O
34
O
35
O
36
Part Name
Centre Pillar Stiffener
Front Pillar Inner Lower
Front Pillar Inner Upper/Roof Side Panel
Side Sill Stiffener
Inside Sill
Roof Panel
Rear Inner Panel
Wheel Arch Extension
Rear Wheelhouse
Rear Pillar Stiffener
Rear Pillar Gutter
Front Floor
Middle Floor Cross-member
Rear Floor
Rear Panel
Side Sill Extension
Rear Frame
Zinc-plated
O
O
O
O
O
O
O
O
O
O
O
O
O
18
19
Outer Panel
Front Pillar Stiffener
O
O
37
Rear Floor Cross-member
Exterior Body Parts
Removal/Installation
4-3
NOTE: To adjust the hood, door and tailgate alignment, refer to the HR-V Shop Manual.
Mounting bolts/nuts Torque:
6 x 1.0 mm: 9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
8 x 1.25 mm: 22 Nm (2.2 kgf/m, 16 lbf/ft)
*8 x 1.25 mm: 28 Nm (2.9 kgf/m, 21 lbf/ft)
10 x 1.25 mm: 38 Nm (3.9 kgf/m, 28 lbf/ft)
: Sealing locations
NOTE: Seal the following areas to prevent water leak and rust.
Mastic sealer: 3M #08654 or equivalent.
1. HOOD HINGE
2. HOOD
3. POP NUT, 4 mm (0.16 in), Staking
stroke: 2.5 mm (0.1 in) (with mast
antenna)
4. TAILGATE HINGE
5. TAILGATE
6. REAR BUMPER EXTENSION
7. FUEL LID
8. REAR DOOR
9. DOOR HINGE
10. REAR FLOOR PIPE
11. FRONT DOOR
12. DOOR HINGE
13. FRONT FENDER
14. UPPER BEAM
15. FRONT BUMPER BEAM
Side Sill (Outer Panel)
Mass Production Body Welding Diagram
4-4
The side sill should, depending on the degree of damage, be repaired as much as possible rather than replaced (Repair by pulling
out with slide hammer with pin and washer welded on).
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
N.
O.
P.
Q.
R.
S.
T.
Roof side rail
Centre pillar upper stiffener
Rear inner panel
Centre pillar stiffener
Outer panel and centre pillar
stiffener
Outer panel and centre pillar
stiffener
VIEW Z1
VIEW X
Centre pillar lower stiffener
extension
Wheel arch extension
Centre pillar lower stiffener
Outer panel, side sill end bulkhead
and centre pillar lower stiffener
extension
Centre pillar lower stiffener, side sill
stiffener and inside sill (passenger
compartment)
Centre pillar stiffener
Side sill stiffener
Outer panel, centre inner panel,
centre pillar lower stiffener and
centre lower anchor (include C)
Outer panel, centre pillar stiffener
and centre pillar lower stiffener
Outer panel, centre pillar lower
stiffener and side sill stiffener
VIEW Z
Outer panel and centre pillar
stiffener
Side Sill (Outer Panel)
Replacement
4-5
1.
2.
3.
1.
2.
3.
4.
Remove the related parts.
Doors (remove according to part damaged).
Side trim panel.
Door opening trim and door sill moldings.
Carpet.
Door switch.
Seat belt.
Pull out and straighten the damaged area.
Damage may extend to the inside sill and floor.
Determine the extent of the damage first, so that the
frame can be pulled out properly.
Cut and pry off the side sill.
Check the damage on the outer side sill, then cut
the repair outer side sill so it will overlap by 30 mm
(1.2 in.) in the front and back.
Cut the side sill with a handsaw.
NOTE: Be careful not to cut the inside sill, side sill
stiffener, centre pillar stiffener and wheel arch extension.
This could result in extensive repair.
REPAIR PART
Overlap 30 mm (1.2 in)
REPAIR PART
Overlap 30 mm (1.2 in)
Centre punch around the spot weld imprints
on the welded flange.
Drill holes using the spot cutter.
Pry of the welded flange with a chisel.
NOTE: Be careful not to let the holes penetrate
down to the inner section.
If the damage involves part of the centre pillar
and rear wheel arch, cut them as shown with
a handsaw.
1.
2.
CENTRE PILLAR UPPER STIFFENER
Cut line
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
WHEEL ARCH EXTENSION
CENTRE PILLAR LOWER STIFFENER
CENTRE PILLAR LOWER STIFFENER
INSIDE SILL
OUTER PANEL
SIDE SILL STIFFENER
OUTER PANEL
SIDE SILL STIFFENER
Cut line
CENTRE PILLAR STIFFENER
4.
Check the side sill stiffener and centre pillar
stiffener for position and damage. If necessary,
replace them.
Side Sill (Outer Panel)
Replacement (contd)
4-6
5.
Straighten the related parts.
Fill any holed areas by MIG or gas welding.
To prevent eye injury and burns when welding, wear an
approved welding helmet, gloves and safety shoes.
Level and finish burrs at welded areas with a disc
sander, then even them out with a hammer and
dolly.
Sand off the undercoat from both sides of the
flange to be welded.
6. Set the new side sill stiffener and centre pillar stiffener.
Cut the new stiffener so it overlaps the body side
stiffener by approximately 20 mm (0.8 in).
Sand off the undercoat from both sides of the
welded flange with a sander to expose the steel
plate.
NOTE: Apply the spot sealer to the welding surface
when spot welding.
Clamp the new side sill stiffener, centre pillar
stiffener and check the position of it using the body
dimensional drawings (see section 6).
Tack weld the new side sill stiffener and centre
pillar stiffener.
Clamp the repair part and temporarily install
the front and rear doors and check the door
hinge mounting position.
Remove the repair parts.
Weld the new side sill stiffener and centre pillar
stiffener.
7.
To prevent eye injury and burns when welding, wear an
approved welding helmet, gloves and safety shoes.
To prevent eye injury and burns when welding, wear an
approved welding helmet, gloves and safety shoes.
1.
2.
8.
Fillet welding
Fillet welding
Set the repair part (outer panel).
Attach the patches at the cut sections of the
centre pillar (body side) and wheel arch (body
side) and plug weld them.
Sand off the undercoat from both sides of the
welded flange on the repair part.
Clamp the repair part in place with vice-grips.
NOTE: Apply the spot sealer to the welding ssurface
when spot welding.
Check the body dimensions.
1.
2.
3.
4.
5.
6.
CENTRE PILLAR UPPER STIFFENER (New parts)
Overlap 20 mm (0.8 in)
CENTRE PILLAR LOWER STIFFENER (New parts)
SIDE SILL STIFFENER (New parts)
Overlap 30 mm (1.2 in)
CENTRE PILLAR STIFFENER (New parts)
Side Sill (Outer Panel)
Replacement (contd)
4-7
9.
Tack weld the repair part.
To prevent eye injury and burns when welding, wear an
approved welding helmet, gloves and safety shoes.
Remove the vice-grips and install the front fender
and door. Check for differences in level and
clearance.
10. Perform main welding.
To prevent eye injury and burns when welding, wear an
approved welding helmet, gloves and safety shoes.
Weld the side sill and rear side outer joints with a
MIG welder.
Spot weld the side sill flanges.
Make 20% to 30% more spot welds than there were
holes drilled.
NOTE: If there is no room for spot welds, compensate
by using MIG welds.
Make 5 mm (0.2 in.) holes in the MIG weld holes
with the new outer panel, and weld the centre pillar
lower stiffener and side sill stiffener with a MIG
welder.
1.
2.
3.
Fillet welding
Butt welding
Butt welding
Level the weld beads at the front and rear with
a disc sander. Hammer down the projections,
then fill with solder or putty to finish it.
11. Apply sealer to the mating surfaces of the floor and
inside sill.
12. Apply the paint. See Paint Repair section.
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.
13. Apply the undercoat.
Undercoat the front floor, and apply an anti-rust
agent to the inside of the side sill and centre pillar.
14. Install the related parts.
Install in the reverse order of removal.
Check the doors for proper installation and
level differences from the fender.
15. Clean the passenger compartment and check for
water leaks.
4.
5.
OUTER PANEL (Repair part)
PATCH
Roof Panel
Mass Production Body Welding Diagram
4-8
Deformation of the roof panel is highly noticeable in terms of the vehicle's outer appearance.
Before replacing the roof rail, make sure that the body is horizontal. Before welding the roof panel, adjust the roof rail flanges so
that they contact the roof panel.
NOTE: When replacing the outer panel, drill holes at the areas where it joins to the roof side rail and rear inner panel as shown.
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
Front roof rail
Roof side rail
Rear pillar stiffener
Rear roof rail
4-plate weldings
4-plate welding
Roof side rail
Rear inner panel
Rear pillar stiffener
Rear pillar gutter
Outer panel
Centre pillar upper stiffener
Rear Side Outer Panel
Mass Production Body Welding Diagram
4-9
The rear side outer panel is a conspicuous part of the vehicle. It is especially important for the body line continuing from the door.
Therefore, pay particular attention to it when conducting work. This part is also next to the trunk lid, door and rear window, and
other parts and must be aligned with them.
A. Roof side rail
B. Rear inner panel
C. Rear pillar gutter, rear inner panel and
rear pillar stiffener
D. Rear pillar gutter and rear pillar stiffener
E. Outer panel and rear pillar gutter
F. Rear pillar stiffener
G. Rear pillar gutter
H. Rear panel
I. 4-plate weldings
J. Outer panel and rear inner panel
K. VIEW Z
L. Outer panel and rear pillar gutter
M. Rear damper stiffener
N. Side sill (outer panel) (see page 4-5)
O. Rear wheel arch extension
P. Rear wheelhouse
Rear Side Outer Panel
Replacement
4-10
1.
Remove the related parts.
Rear bumper.
Tailgate.
Taillight.
Rear seat.
Rear seat belt.
Trim, trim panel and luggage compartment fitting.
Fuel fill pipe (left side only).
Do not smoke while working near the fuel system. Keep
open flame away from the fuel system. If necessary, remove
the fuel tank and/or lines before welding nearby. Drain fuel
into an approved container.
2. Pull out and straighten the damaged area.
4.
Cut and pry off the rear side outer panel.
Cut at the quarter pillar, rear pillar and side sill
with a handsaw.
Cut the panel from the body with a chisel,
leaving the weld flange at the inner panel
intact.
NOTE: Do not cut or damage the centre pillar
lower stiffener, inner panel, rear damper stiffener
and rear pillar gutter.
Cut at the side sill or wheel arch according to
the extent of the damage.
Centre punch around the spot weld imprints
on the remaining flange.
Drill out the spot welds with the spot cutter.
Pry off the welded flange sections using a
chisel.
3.
gutter for position and damage. Pull out the inner panel
by cutting the outer if necessary.
Jack-up the body and place safety stands at the
four designated support points.
Pull out the damaged rear side outer panel with the
frame straightener, then pull out and straighten the
inner panel and rear wheelhouse.
NOTE: Be careful not to pull out more than necessary.
After pulling, check the inner pillar and rear panel
gutter position using the body dimensional drawings
(see section 6).
Peel off the undercoat.
Heat the undercoat at the weld areas of the rear wheel
house with a gas torch and peel off the undercoat with
metal spatula.
Do not smoke while working near the fuel system. Keep
open flame away from the fuel system. If necessary, remove
the fuel tank and/or lines before welding nearby. Drain fuel
into an approved container.
1.
2.
3.
4.
5.
6.
REAR DAMPER STIFFENER
MASTIC SEALERS
REAR PILLAR GUTTER
REAR PILLAR STIFFENER
REAR PANEL
OUTER PANEL
Rear Side Outer Panel
Replacement (contd)
4-11
5.
6.
Check the rear pillar gutter for position and damage.
Replace the rear pillar gutter if necessary.
Cut and drill out the spot welds and pry off the rear pillar
gutter.
Cut the rear pillar gutter at under portion from the
outer panel cut line.
1.
2.
Cut line
REAR PILLAR GUTTER
7.
Straighten the inner panel and related parts.
Use a slide hammer to even out the damaged
areas of the rear wheel arch.
Fill the holes drilled by MIG or gas welding.
To prevent eye injury and burns when welding, wear an
approved welding helmet, gloves and safety shoes.
Level and finish burrs, etc. with a disc sander.
To prevent eye injury and burns when welding, wear an
approved welding helmet, gloves and safety shoes.
8.
Cut the new rear pillar gutter so it overlaps the
body side gutter by approximately 20 mm (0.8 in).
Cut the rear pillar gutter at under portion from
the outer panel cut line.
1.
2.
Overlap 20 mm (0.8 in)
REAR PILLAR GUTTER (New part)
9.
Clamp and check the rear pillar gutter in its correct
position using the body dimensional drawings.
Remove the undercoat from both sides of the
weld flange with a sander to expose the steel
plates.
NOTE: Apply the spot sealer to the weeelding
surface and the clamped positions.
10. Temporarily spot weld the rear pillar gutter at he
clamped positions.
To prevent eye injury and burns when welding, wear an
approved welding helmet, gloves and safety shoes.
Rear Side Outer Panel
Replacement (contd)
4-12
11. Cut and clamp the repair part.
Cut so that the repair part overlaps the side sill by
30 mm (1.2 in.).
Remove the undercoat from both sides of the weld
flange with a sander to expose the steel plate.
12. Check the position of the repair part using the body
dimensional drawings (see section 6).
13. Remove the repair part and weld the new centre pillar
stiffener and the new rear pillar gutter.
To prevent eye injury and burns when welding, wear an
approved welding helmet, gloves and safety shoes.
14. Apply body paint to the back of the repair part.
See Paint Repair section.
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.
15. Apply the reinforcement tape to the inside face of
the repair part as shown (right side only).
NOTE:
Before applying, clean the repair part surface
with a sponge dampened in alcohol.
After applying, heat the reinforcement tape
equally for about 30 minutes with a drier.
1.
1.
2.
Fillet welding
REAR PILLAR GUTTER (New part)
REINFORCEMENT TAPE (P/N 67112-S50-310)
Rear Side Outer Panel
Replacement (contd)
4-13
16. Set and tack weld repair part.
Attach the patch at cut section of the quarter pillar
and rear pillar (body side) and plug weld it.
To prevent eye injury, wear goggles or safety glasses
whenever sanding, cutting or grinding.
NOTE: Apply the spot sealer to the welding surface
when spot welding.
17. Remove the vice-grips and check the alignment of the
taillight, door, rear bumper and tailgate.
NOTE:
Check for flushness of the front fender, door and
the rear fender, taillight, rear bumper and make
sure that the body lines flow smoothly.
18. Perform the main welding.
To prevent eye injury, wear goggles or safety glasses
whenever sanding, cutting or grinding.
Make 20% to 30% more spot welds than there were
holes drilled.
NOTE: If there is not room for spot welds, compensate
by using MIG welds.
Make 5 mm (0.2 in.) holes in the MIG weld hole
with the repair part and the rear pillar gutter with a
MIG welder.
Weld the outer panel at the quarter pillar, rear pillar
and side sill with a MIG welder.
1.
2.
3.
4.
5.
6.
7.
8.
Butt welding
PATCH
OUTER PANEL (Repair part)
Fillet welding
Overlap 30 mm (1.2 in.)
Butt welding
PATCH
OUTER PANEL (Repair part)
Rear Side Outer Panel
Replacement (contd)
4-14
19. Finish the welded areas.
Level the MIG welded areas with a disc sander.
To prevent eye injury, wear goggles or safety glasses
whenever sanding, cutting or grinding.
Even out high areas with a hammer. Be careful not
to deform them.
Even out the spot welded flange areas with a
hammer and dolly.
Fill in deformations and level differences of the
welded areas with solder or putty, then finish.
20. Apply the sealer (see section 5).
Apply sealer to the fuel filler sections, tailgate opening
joint and around the taillight area of the rear pillar gutter.
21. Apply paint. See Paint Repair section.
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.
22. Apply the undercoat.
Apply undercoat to the wheelhouse and apply anti-rust
agent to the inside of the outer panel and rear pillar
gutter.
23. Install the related parts in the reverse order in which they
were removed.
24. Inspect, check and clean.
Adjust the clearance with the door and tailgate then
adjust the level differences and fit.
Check operation.
Test for leaks in the trunk and passenger
compartments.
Check the quarter glass for water leaks.
Clean the trunk floor.
Cross Section of Body and
Sealants
Cross Section of Body and Sealants
5-1
Middle Floor/Rear Floor
Rear Wheelhouse
5-2
5-3
Cross Section of Body and Sealants
Middle Floor/Rear Floor
5-2
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.
Front floor
Middle floor extension
Front floor
Side sill
Side sill
Side sill extension
Side sill
Middle floor
Rear seta centre bracket
Rear floor
Middle floor
Middle floor extension
Middle floor
Rear floor
Front floor
Floor cap
Middle floor extension
Front floor
Front floor
Floor cap
Seat bracket
Rear wheelhouse
Stiffener extension
Rear floor
Side sill extension
Floor cap
Rear floor
Rear frame
Rear floor
Damper base
Rear frame
Rear floor
Stiffener extension
Rear wheelhouse
Cross Section of Body and Sealants
Rear Wheelhouse
5-3
Left side:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Right side:
Wheel arch extension
Wheelhouse
Wheel arch extension
Rear inner
Rear inner
Wheelhouse
Wheelhouse
Damper base
Inner panel
Outer
Wheelhouse
Rear frame
Rear floor
Rear frame
Rear floor
Wheelhouse
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Outer
Inner
Wheelhouse
Damper base
Rear inner
Wheelhouse
Rear inner
Wheel arch extension
Wheelhouse
Wheel arch extension
Wheelhouse
Rear frame
Rear floor
Rear frame
Rear floor
Wheelhouse
Body Dimensional Drawings
Body Dimensional Drawings
6-1
Upper Body Measuring Dimensions
Opening Repair Chart
Under Body Measuring Dimensions
Frame Repair Chart
6-2
6-2
6-3
6-4
Body Dimensional Drawings
Upper Body Measuring Dimensions
6-2
Opening Repair Chart
(Passenger Compartment)
Unit: mm (in.)
1.
2.
(Windshield/Door Opening)
Unit: mm (in.)
FRONT SEAT BRACKET POINT 8 (0.31)
REAR DAMPER MOUNTING HOLE 24 (0.94)
1.
2.
3.
A
Windshield lower cowl cover mounting hole
B, b, C
Windshield opening flange notch
D, E, e, F, G, g, H, h, I, i, J, j, K, k
Door opening flange notch
Body Dimensional Drawings
Under Body Measuring Dimensions
6-3
Unit: mm (in.)
1. A, a
FRONT LOWER CROSS-MEMBER
POINT 14 (0.55)
2. B, b
FRONT SIDE FRAME POINT 16 (0.63)
3. C, c
REAR BEAM MOUNTING HOLE 16
(0.63)
4. D, d
FLOOR FRAME POINT 14 (0.55)
5. E, e
FRONT FLOOR POINT 15 (0.59)
6. F, f
REAR FRAME POINT 20 (0.8)
7. G
PANHARD ROD MOUNTING HOLE
12 (0.47)
8. H
REAR FLOOR CROSS-MEMBER
POINT 20 (0.8)
9. I, i
REAR FRAME POINT 20 (0.8)
10. Left side
11. Right side
Body Dimensional Drawings
Frame Repair Chart
Top View:
Unit: mm (in.)
6-4
Body Dimensional Drawings
Frame Repair Chart (contd)
6-5
Body Dimensional Drawings
Frame Repair Chart (contd)
Side View:
Unit: mm (in.)
O: Inner diameter
6-6
Body Dimensional Drawings
Frame Repair Chart (contd)
6-7
Body Paint Repair
Body Paint Repair
8-1
Colour Chart Paint Specifications
8-2
Body Paint Repair
Colour Chart Painting Specifications
8-2
|
|
|
Type
Body Colour Code Name
|
KG
|
New Vogue Silver Metallic, NH-583M
|
|
|
Starlight Black Pearl, NH-592P
|
|
|
Mirano Red, R-81
|
|
|
Sunburst Yellow Metallic, Y-57M
|
|
|
Super Sonic Blue Pearl, R-90P
|
|
|
Fresh Copper Metallic, YR-532M
|
|
|
Tropic Jade Pearl, R-504P
|
|
KE
|
New Vogue Silver Metallic, NH-583M
|
|
|
Starlight Black Pearl, NH-592P
|
|
|
Mirano Red, R-81
|
|
|
Sunburst Yellow Metallic, Y-57M
|
|
|
Super Sonic Blue Pearl, R-90P
|
|
|
Fresh Copper Metallic, YR-532M
|
|
|
Tropic Jade Pearl, R-504P
|
|
KY
|
Taffeta White, NH-578
|
|
|
Lightening Silver Metallic, NH-617M
|
|
|
Super Sonic Blue Pearl, R-90P
|
|
|
Fresh Copper Metallic, YR-532M
|
|
|
Tropic Jade Pearl, R-504P
|
|
|
Ruby Red Pearl, R-504P
|
|
KN
|
Taffeta White, NH-578
|
|
|
Lightening Silver Metallic, NH-617M
|
|
|
Super Sonic Blue Pearl, R-90P
|
|
|
Fresh Copper Metallic, YR-532M
|
|
|
Tropic Jade Pearl, R-504P
|
|
|
Ruby Red Pearl, R-504P
|
|
KT
|
Taffeta White, NH-578
|
|
|
Lightening Silver Metallic, NH-617M
|
|
|
Super Sonic Blue Pearl, R-90P
|
|
|
Fresh Copper Metallic, YR-532M
|
|
|
Tropic Jade Pearl, R-504P
|
|
|
Ruby Red Pearl, R-504P
|
|
KQ
|
Taffeta White, NH-578
|
|
|
Lightening Silver Metallic, NH-617M
|
|
|
Super Sonic Blue Pearl, R-90P
|
|
|
Fresh Copper Metallic, YR-532M
|
|
|
Tropic Jade Pearl, R-504P
|
|
|
Ruby Red Pearl, R-504P
|
|
KU
|
Lightening Silver Metallic, NH-617M
|
|
|
Super Sonic Blue Pearl, R-90P
|
|
|
Fresh Copper Metallic, YR-532M
|
|
|
Tropic Jade Pearl, R-504P
|
|
|
Ruby Red Pearl, R-504P
|
|
|
Eternal Blue Pearl, B-96P
|
NOTE: Apply NH-86 black (gloss 40) to the front and rear wheelhouses after installing equipment (except vehicle painted with
NH592P, G-95P, B-90P, B-74P and B-96P).
1. FRONT BUMPER
Body colour
2. FRONT GRILLE
BP - Dark Grey, NH-533
3. ROOF MOLDING
Black NH-72 (Gloss 30)
4. DOOR OUTER HANDLE
Body colour
5. DOOR MIRROR
Body colour
6. ROOF SPOILER
Body colour (for some models)
7. REAR LICENSE TRIM
Body colour
8. REAR BUMPER
Body colour
9. REAR UNDER COVER
BP. Medium dark grey NH-590
10. TAILGATE LOWER TRIM
Body colour
11. QUARTER GLASS MOLDING
Black NH-72 (Glass 30)
12. SIDE SILL PANEL
BP. Medium dark grey NH-590
Body colour (for some models)
13. DOOR SASH
Black NH-86 (Gloss 40)
Apply the door channel tape (refer to
the HR-V Shop Manual)
14. ROOF SIDE TRIM
Body colour (for some models)
15. GRILLE
BP - Dark Grey, NH-533
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