Honda 2011 Odyssey Body Repair Manual
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Honda 2011 Odyssey Body Repair Manual

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See also: Manual
2011–2015 Odyssey
How to Use This Manual
This manual covers the repairs of the 2011– – – - 2015 model-series Odyssey that has been involved
in a collision, and it describes the work related to the replacement of damaged body parts.
Please read through these instructions and familiarize yourself with them before actually
using this manual.
NOTE: Refer to the appropriate Odyssey Service Manual for specifications, wire harness
locations, safety stand support points, etc.
Special Information
You CAN be KILLED or SERIOUSLY HURT if you don't follow instructions.
You CAN be HURT if you don't follow instructions.
NOTE: Gives helpful information.
Detailed descriptions of standard workshop procedures, safety principles and service operations are
not included. Please note that this manual does contain warnings and cautions against some specific
service methods which could cause PERSONAL INJURY, damage a vehicle, or make it unsafe.
Please understand that these warnings cannot cover all conceivable ways in which service, whether
or not recommended by Honda, might be done or of the possible hazardous consequences of each
conceivable way, nor could Honda investigate all such ways. Anyone using service procedures or
tools, whether or not recommended by Honda, must satisfy himself thoroughly that neither personal
safety or vehicle safety will be jeopardized.
All information contained in this manual is based on the latest product information available at the time of
printing. We reserve the right to make changes at any time without notice. No part of this publication may be
reproduced, stored in retrieval system, or transmitted, in any form by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes
text, figures and tables.
First Edition 09/2010
All Rights Reserved
Body Repair Manual
INTRODUCTION
WARNING
CAUTION
CAUTION
Honda Motor Co., Ltd.
Customer Service Technology
Development Division
General
1
Information
2
Paint
Information
3
*Replacement
Body Dimensional
4
Drawings
Rust
5
Prevention
General Safety
Precautions
Reference
Sections with an * include SRS
components; special caution is
required when servicing.

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Summary of Contents for Honda 2011 Odyssey

  • Page 1 Please understand that these warnings cannot cover all conceivable ways in which service, whether Rust or not recommended by Honda, might be done or of the possible hazardous consequences of each Prevention conceivable way, nor could Honda investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda, must satisfy himself thoroughly that neither personal safety or vehicle safety will be jeopardized.

  • Page 2: A Few Words About Safety

    If you need to replace a part, use Honda parts with the Protect your eyes by using proper safety glasses, correct part number, or an equivalent part. We strongly...
  • Page 3 PERSONAL INJURY, damage a vehicle, or make it unsafe. Please understand that these warnings cannot cover all conceivable ways in which service, whether or not recommended by Honda, might be done or of the possible hazardous consequences of each conceivable way, nor could Honda investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda, must satisfy himself thoroughly that neither personal safety or vehicle safety will be jeopardized.
  • Page 4 Reference Symbols Replacement Body Dimensional Drawings The welding symbols in the removal/installation have Body measuring dimensions show the distance these meanings. between the forward or upper edge of positioning bosses and/or holes shown in the detail illustration. : 2-Plate spot welding Black dots: Measuring point : 3-Plate spot welding Black Dot...

  • Page 5: Table Of Contents

    General Information General Information Supplemental Restraint System (SRS) 1–2 SRS Component Replacement/Inspection After Deployment 1–4 Battery Terminal Disconnection and Reconnection 1–5 Identification Number Locations 1–6 Parts Marking 1–7 Lift and Support Points 1–8 Body Specifications/Wheel Alignment 1–9 Exterior Parts Removal/Installation 1–10 Front Body Construction 1–12...

  • Page 6: General Information

    General Information Supplemental Restraint System (SRS) This model has an SRS which includes a driver's airbag in the steering wheel hub, a front passenger's airbag in the dashboard above the glove box, front seat belt tensioners in the front seat belt retractors, driver's seat belt outer lap tensioner in the front seat belt lower anchor, side airbags in the front seat-backs, and side curtain airbags in the sides of the roof.
  • Page 7 LEFT SIDE CURTAIN AIRBAG RIGHT SIDE CURTAIN AIRBAG LEFT FRONT RIGHT SIDE IMPACT IMPACT SENSOR SENSOR (THIRD) RIGHT FRONT IMPACT SENSOR LEFT SIDE IMPACT SENSOR (SECOND) REAR SAFING SENSOR LEFT SIDE IMPACT SENSOR RIGHT SIDE IMPACT SENSOR (THIRD) (SECOND) SIDE AIRBAG CUTOFF SRS INDICATOR (RED) INDICATOR (AMBER) Canada...

  • Page 8: Srs Component Replacement/Inspection After Deployment

    General Information SRS Component Replacement/Inspection After Deployment NOTE: After a collision where the side airbag has deployed, replace the items for the side(s) that deployed: Before doing any SRS repairs, check for DTCs with the ● HDS; refer to the appropriate Odyssey Service SRS unit ●...

  • Page 9: Battery Terminal Disconnection And Reconnection

    Battery Terminal Disconnection and Reconnection Disconnection Reconnection NOTE: Some systems store data in memory (including NOTE: Some systems store data in memory (including seat position, mirror position, etc) that is lost when the seat position, mirror position, etc) that is lost when the battery is disconnected.

  • Page 10: Identification Number Locations

    General Information Identification Number Locations Vehicle Identification Vehicle Identification Number (VIN) Number (VIN) Vehicle Identification Number, Federal Motor Vehicle Safety Standard Certification, and Paint Code Label. Vehicle Identification Number, Canadian Motor Vehicle Safety Standard Certification, and Paint Code Label. Transmission Number Engine Number (5-speed A/T model) PAINT CODE...

  • Page 11: Parts Marking

    Parts Marking To deter vehicle theft, certain major components are marked with the vehicle identification number (VIN). Original parts have self-adhesive labels. Replacement body parts have generic self-adhesive labels. These labels should not be removed. The original engine or transmission VIN plates are not transferable to the replacement engine or transmission.

  • Page 12: Lift And Support Points

    General Information Lift and Support Points NOTE: If you are going to remove heavy components Floor Jack such as suspension or the fuel tank from the rear of the vehicle, first support the front of the vehicle with tall 1. When lifting the front of the vehicle, set the parking safety stands.

  • Page 13: Body Specifications/Wheel Alignment

    Body Specifications/Wheel Alignment Body Specifications 1,730 mm (68.1 in) 1,997 mm (78.6 in) 3,000 mm (118.1 in) 1,732 mm (68.2 in) 5,153 mm (202.9 in) Front Wheel Alignment 0 ° 00 ’ ᤣ45 ’ Camber 2 ° 36 ’ ᤣ36 ’ Caster Total toe-in 0ᤣ2 mm (0ᤣ0.08 in)

  • Page 14: Exterior Parts Removal/Installation

    General Information Exterior Parts Removal/Installation NOTE: When removing the front fender, do not deform its upper portion (A). ● When reinstalling the front fender, apply the sealer all the way around the front pillar end block and the front fender ●...
  • Page 15 REAR ENTERTAINMENT SYSTEM BRACKET (For some models) 6 x 1.0 mm 9.3 N·m (0.95 kgf·m, 6.9 lbf·ft) 10 x 1.25 mm 38 N·m (3.9 kgf·m, 28 lbf·ft) 8 x 1.25 mm 22 N·m (2.2 kgf·m, 16 lbf·ft) 8 x 1.25 mm 22 N·m BATTERY (2.2 kgf·m,...

  • Page 16: Front Body Construction

    General Information Front Body Construction NOTE: To confirm which parts are sold as repair parts, refer to the appropriate Parts Catalog. ᫔ ᫎ ᫓ ᫕ Rear Upper Front Lower Rear Front ᫖ ᫑ ᫒ ᫏ ᫐ 1-12...
  • Page 17 NOTE: The parts marked with numbers are sold as repair parts. ● The parts marked with letters are not sold separately and are shown only for reference. ● [ ]: Thickness unit: mm (in) ● High-strength steel sheet: Tensile strength 340 to 590 MPa. ●...

  • Page 18: Roof And Side Panel Construction

    General Information Roof and Side Panel Construction NOTE: To confirm which parts are sold as repair parts, refer to the appropriate Parts Catalog. ᫎ ᫞ ᫑ ᫐ ᫜ ᫏ ᫝ ᫛ ᫕ Upper ᫚ ᫔ Lower ᫖ ᫓ ᫙ ᫗ ᫘...
  • Page 19 NOTE: The parts marked with numbers are sold as repair parts. ● The parts marked with letters are not sold separately and are shown only for reference. ● [ ]: Thickness unit: mm (in) ● High-strength steel sheet: Tensile strength 340 to 1500 MPa. ●...

  • Page 20: Floor And Rear Body Construction

    General Information Floor and Rear Body Construction NOTE: To confirm which parts are sold as repair parts, refer to the appropriate Parts Catalog. ᫝ ᫜ ᫐ ᫏ ᫒ ᫎ ᫓ ᫑ ᫘ ᫗ ᫖ ᫛ ᫕ ᫔ ᫙ ᫚ 1-16...

  • Page 21: Frame [0.6 (0.024)]

    NOTE: The parts marked with numbers are sold as repair parts. ● The parts marked with letters are not sold separately and are shown only for reference. ● [ ]: Thickness unit: mm (in) ● High-strength steel sheet: Tensile strength 340 to 980 MPa. ●...

  • Page 22: Door And Bumper Reinforcement Beams, And High-Strength Steel (1500 Mpa) Parts

    General Information Door and Bumper Reinforcement Beams, and High-Strength Steel (1500 MPa) Parts The door and bumper reinforcement beams are made from high-strength steel. The roof side front rail and roof arch D are made from the high-strength steel (1500 MPa) parts. If high-strength steel is heated, the strength of the steel is reduced.

  • Page 23: Zinc-Plated Steel Plate Repair

    Zinc-Plated Steel Plate Repair The zinc-plated steel plate used in some panels of the Odyssey require different repair techniques than ordinary steel plate. Refer to Front Body Construction (see page 1-12), Roof and Side Panel Construction (see page 1-14), and Floor and Rear Body Construction (see page 1-16) for the locations of the zinc-plated panels.

  • Page 24: High-Strength Steel Sheet Framed Areas

    General Information High-Strength Steel Sheet Framed Areas The new high-strength steel sheet has greater tensile strength than conventional high-strength steel sheet. Although it's a thinner sheet, it is as strong as the previous thicker ones. Because the manufacturing press process has improved, its usage has expanded.

  • Page 25: Precautions For High-Strength Steel Parts Area Repair

    Precautions for High-Strength Steel Parts Replacement Description Parts Area Repair The new high-strength steel parts of the frame are all Because of changes in body structure to improve ● spot welded together. To disassemble, drill a hole in collision safety and body rigidity, the materials and the sections that are spot welded together with a very thickness of steel sheets and internal reinforcements sharp spot weld bit.

  • Page 26: Mag Welding Specifications For High-Strength Steel Parts 590 Mpa Or Higher (Except 1500 Mpa)

    590 MPa or higher (except 1500 MPa) BEAD NOTE: This wire is available from the Honda Tool & Equipment Program http://honda.snapon.com or Approx. 4 mm (0.16 in) 1-866-346-8858 [SECTION: AA] Example: Bosch Automotive Service...

  • Page 27: High-Strength Steel (1500 Mpa) Parts Welding Specifications

    High-Strength Steel (1500 MPa) Parts Welding Specifications High-Strength Steel (1500 MPa) Parts Welding Spot welding specifications Specifications Current: 9000 A ● The high-strength steel (1500 MPa) material is used for Pressure: 3432 N (350 kgf, 772 lbf) ● the front pillar area, the roof side area, the center pillar Welding cycle: 26 ●...
  • Page 28 Paint Information Paint Information Paint Safety Precautions 2–2 General 2–3 Color Chart Paint Specifications 2–4 Features of Plastic Materials 2–5 Types and Materials of Exterior Plastic Parts 2–7 Soft Chipping Guard Primer Coat General Safety Precautions 2–8 Coating Areas 2–9...

  • Page 29: Paint Information

    Paint Information Paint Safety Precautions Most paints contain substances that are harmful if inhaled or swallowed. Read the paint label before opening the container. Observe the following precautions to maintain a safe painting work area. Wear an approved respirator and eye protection when ●...

  • Page 30: General

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

  • Page 31: Color Chart Paint Specifications

    Paint Information Color Chart Paint Specifications NOTE: For model year paint code information, refer to the appropriate service manual. ● Apply black paint to the visible surface of the front wheelhouse and the rear wheelhouse after repairing and painting ● (except vehicles painted with black color).

  • Page 32: Features Of Plastic Materials

    Features of Plastic Materials Check each of the plastic parts for solvent resistance and heat resistance before you do any repair work. ● Select the repair material according to materials of the plastic parts. ● Alcohol can be used for degreasing in small amounts, and for short periods of time. Do not soak. ●...
  • Page 33 Paint Information Features of Plastic Materials (cont'd) Standard Name Heat Note Symbol Resistance Temperature °F (°C) Polystyrene (60) Polyurethane (80) Polyvinyl chloride (80) Styrene acrylonitrile (80) Sheet molding compound Solvent can damage the material. (180) Thermoplastic polyester Wash remover off with water thoroughly. elastomer (80) Thermoplastic styrene...

  • Page 34: Types And Materials Of Exterior Plastic Parts

    Types and Materials of Exterior Plastic Parts NOTE: For the full plastic name, refer to the features of plastic materials (see page 2-5). ● A standard symbol is stamped on the underside of each plastic part to show the type of material used. ●...

  • Page 35: Soft Chipping Guard Primer Coat

    Soft Chipping Guard Primer Coat General Safety Precautions The removal of paint and undercoating by stone chips 2. Air blowing/degreasing. immediately exposes metal to the atmosphere, causing Use alcohol, and wax and grease remover. it to oxidize. The thickness of this oxidation increases if 3.

  • Page 36: Coating Areas

    Coating Areas : Indicates chipping guard primer coating area. OUTER PANEL NOTE: Make sure to coat the flanges on the front and rear wheel arches. Unit: mm (in) HOOD SKIN 300 (11.81) 100 (3.94) FRONT PILLAR HOOD OUTER PANEL SLIDING DOOR 200 (7.87) FRONT DOOR FRONT FENDER...
  • Page 37 Replacement Front Bulkhead Removal 3–2 Installation 3–4 Front Wheelhouse/Damper Housing Removal 3–6 Installation 3–10 Front Side Frame/Side Frame Gusset Removal 3–13 Installation 3–16 Front Pillar Outer Panel Removal 3–19 Installation 3–21 Side Sill Outer Panel Removal 3–23 Installation 3–25 Center Pillar Outer Panel Removal 3–28 Installation...

  • Page 38: Front Bulkhead

    Front Bulkhead Removal Mass production body welding positions and numbers NOTE: Welding symbols ● : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MAG plug welding; : MAG welding L=Welding length unit: mm (in) ( ): The number of welds ●...
  • Page 39 This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer ● to the appropriate Service Manual. The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to ● the area and the degree of damage on the body.

  • Page 40: Installation

    Front Bulkhead Installation NOTE: [VIEW: Z] Welding symbols ● : 2-Plate spot welding : 3-Plate spot welding : 4-Plate spot welding : MAG plug welding : MAG welding L=Welding length unit: mm (in) ( ): The number of welds ● 1.
  • Page 41 7. Weld the bulkhead upper frame (A) to the bulkhead side member (B).

  • Page 42: Front Wheelhouse/Damper Housing

    Front Wheelhouse/Damper Housing Removal Mass production body welding positions and numbers (Wheelhouse upper member and bulkhead side member) NOTE: Welding symbols ● : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MAG plug welding; : MAG welding L=Welding length unit: mm (in) ( ): The number of welds ●...
  • Page 43 Mass production body welding positions and numbers (Damper housing) NOTE: Welding symbols ● : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MAG plug welding; : MAG welding L=Welding length unit: mm (in) ( ): The number of welds ●...
  • Page 44 This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer ● to the appropriate Service Manual. The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to ● the area and the degree of damage on the body.
  • Page 45 This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer ● to the appropriate Service Manual. The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to ● the area and the degree of damage on the body.

  • Page 46: Installation

    Front Wheelhouse/Damper Housing Installation NOTE: 6. Do the main welding. Weld the damper housing (A) and wheelhouse lower Welding symbols ● gusset B to the front side frame (C). : 2-Plate spot welding : 3-Plate spot welding : 4-Plate spot welding : MAG plug welding : MAG welding L=Welding length unit: mm (in)
  • Page 47 8. From the passenger's compartment, plug weld the 10. Weld the damper housing extension (A) and the front damper stiffener (A), the damper housing extension inner lower pillar (B). (C), wheelhouse lower gusset B, and the damper housing (D) to the dashboard lower (E). 11.
  • Page 48 Front Wheelhouse/Damper Housing Installation (cont'd) 12. Weld the side frame end outrigger (A) and the 13. Weld the wheelhouse upper member (A). When bulkhead side member (B). reusing the wheelhouse upper member, weld it with Weld the bulkhead side stay (C) and the bulkhead MIG plug welding.

  • Page 49: Front Side Frame/Side Frame Gusset

    Front Side Frame/Side Frame Gusset Removal Mass production body welding positions and numbers (Front side frame) NOTE: Welding symbols ● : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MAG plug welding; : MAG welding L=Welding length unit: mm (in) ( ): The number of welds ●...
  • Page 50 Front Side Frame/Side Frame Gusset Removal (cont'd) Mass production body welding positions and numbers (Outrigger and side frame gusset) NOTE: Welding symbols ● : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MAG plug welding; : MAG welding L=Welding length unit: mm (in) ( ): The number of welds ●...
  • Page 51 This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer ● to the appropriate Service Manual. The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to ● the area and the degree of damage on the body.

  • Page 52: Installation

    Front Side Frame/Side Frame Gusset Installation NOTE: 4. Tack weld the new parts and the front bulkhead into position. Welding symbols ● : 2-Plate spot welding 5. Temporarily install the front subframe, and check the : 3-Plate spot welding front side frame and the side frame gusset positions. : 4-Plate spot welding 6.
  • Page 53 9. Weld the outrigger (A) to the side frame gusset (B) [VIEW: Z] and the inside sill (C). (14) (14) Front (18) (18) Front 8. Weld the outrigger gusset (A) to the side frame gusset (B) and the inside sill (C). L=95 (3.74) 10.
  • Page 54 Front Side Frame/Side Frame Gusset Installation (cont'd) 11. When only replacing the front side frame (A), main 13. Weld side frame gusset B. weld the side frame gusset (B) and the front side [X] area: Drill the three holes for welding the new front frame.

  • Page 55: Front Pillar Outer Panel

    Front Pillar Outer Panel Removal Mass production body welding positions and numbers (Outer panel and front pillar lower stiffener) NOTE: Welding symbols ● : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MAG plug welding; : MAG welding L=Welding length unit: mm (in) ( ): The number of welds ●...
  • Page 56 This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer ● to the appropriate Service Manual. The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to ● the area and the degree of damage on the body.

  • Page 57: Installation

    Installation NOTE: 6. Remove the outer panel repair part, and weld the front pillar lower stiffener (A) to the upper stiffener (B) Welding symbols ● and the side sill reinforcement (C). : 2-Plate spot welding : 3-Plate spot welding NOTE: When welding position [X], do not burn the sealer (D) behind the front pillar lower stiffener.
  • Page 58 Front Pillar Outer Panel Installation (cont'd) 8. Apply the sealer (A) on the front pillar lower stiffener (B) at the outer separator location. Sealer thickness: 10 mm (0.39 in) (16) L=195 (7.68) A A A 9. Clamp the outer panel repair part, and recheck the clearance and alignment of the door, the front fender, and the windshield.

  • Page 59: Side Sill Outer Panel

    Side Sill Outer Panel Removal Mass production body welding positions and numbers (Outer panel and side sill reinforcement) NOTE: Welding symbols ● : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MAG plug welding; : MAG welding L=Welding length unit: mm (in) ( ): The number of welds ●...
  • Page 60 This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer ● to the appropriate Service Manual. The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to ● the area and the degree of damage on the body.

  • Page 61: Installation

    Installation NOTE: NOTE: When welding position [X], do not burn or melt the inner separator (C) behind the front pillar lower Welding symbols ● stiffener. : 2-Plate spot welding : 3-Plate spot welding : 4-Plate spot welding : MAG plug welding : MAG welding L=Welding length unit: mm (in) ( ): The number of welds...
  • Page 62 Side Sill Outer Panel Installation (cont'd) 9. Weld the patches (A) at the cut sections of the body 10. Install new center pillar outer separator A on the side outer panel (B). center pillar stiffener (C). Front pillar section NOTE: Apply the sealer (D) all the way around the separator and inside the outer panel repair part (E) without gaps.
  • Page 63 13. Do the main welding. Lower center pillar and side sill rear areas Weld the outer panel repair part (A) and the patches (B). [VIEW: Z] L=360 (14.17) [X] Portion: Excessive heat from welding can burn or melt the inner separator (C) behind the front pillar lower stiffener (D).

  • Page 64: Center Pillar Outer Panel

    Center Pillar Outer Panel Removal Mass production body welding positions and numbers (Outer panel and side sill reinforcement) NOTE: Welding symbols ● : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MAG plug welding; : MAG welding L=Welding length unit: mm (in) ( ): The number of welds ●...
  • Page 65 This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer ● to the appropriate Service Manual. The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to ● the area and the degree of damage on the body.

  • Page 66: Installation

    Center Pillar Outer Panel Installation NOTE: 5. Check the body dimensions. Welding symbols ● Bulkhead side member position (see page 4-6) : 2-Plate spot welding ● Door hinge positions (see page 4-7) : 3-Plate spot welding ● Sliding door female guide and striker positions (see ●...
  • Page 67 9. Weld the top of the center pillar stiffener (A) to the 10. Weld the patches (A) at the cut sections of the body front pillar upper stiffener (B), the roof side rail side outer panel (B). extension (C), and the roof side front rail (D). Front pillar and side sill section (see step 9 on page (ᤝ)*: Welding position with the roof side front rail, the 3-26)
  • Page 68 Center Pillar Outer Panel Installation (cont'd) 13. Do the main welding. In case of outer panel replacement only. Weld the outer panel repair part (A) and the patches (B). L=180 (7.09) Lower front pillar and side sill areas (see step 13 on page 3-27) (ᤝ)*: Welding position with the roof side front rail (C), the high-strength steel (1500 MPa).

  • Page 69: Inside Sill, Rear

    Inside Sill, Rear Removal Mass production body welding positions and numbers NOTE: Welding symbols ● : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MAG plug welding; : MAG welding L=Welding length unit: mm (in) ( ): The number of welds ●...
  • Page 70 This section explains the procedures after removal of all related parts. For the related parts’ removal procedure, refer ● to the appropriate Service Manual. The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to ● the area and the degree of damage on the body.
  • Page 71 4. Drill the eight spot welded points on inside sill B, the Front portion removal procedure under floor pan upper crossmember (C), and the floor 1. Carefully drill the seven spot welded points at the joint panel (D). for the under floor pan upper crossmember (A) and NOTE: Drill through the two welding nuggets (1, 2).

  • Page 72: Installation

    Inside Sill, Rear Installation NOTE: 3. While inserting inside sill B into inside sill A, push the tip of inside sill B to the side sill reinforcement side Welding symbols ● (C), and align inside sill B in inside sill A. : 2-Plate spot welding : 3-Plate spot welding : 4-Plate spot welding...
  • Page 73 7. Tack weld the new parts, and check the rear 12. Weld side sill B, side sill A, and the side sill stiffener suspension position. (C). 8. Rough-cut the side sill outer panel repair part and the (Left side only) rear side outer panel repair part, and clamp them to the body.
  • Page 74 Inside Sill, Rear Installation (cont'd) 16. Plug weld inside sill B to inside sill A, the floor panel 14. From the passenger’s compartment side, weld the (C), the under floor pan upper crossmember (D), and ELR stiffener (A) and the center inner pillar (B). the front seat rear bracket (E).
  • Page 75 18. Plug weld inside sill B to the floor panel (A) and the second seat plate (C). (1) L=5 (0.20) 22. Weld the patch (A) at the cut sections of the body side outer panel (B). Front pillar and center pillar cut section (see step 9 on page 3-26) 30 mm (1.18 in) 19.
  • Page 76 Inside Sill, Rear Installation (cont'd) 24. Weld the rear side outer panel repair part (A) and the patches (B). Side sill outer panel repair part (see step 13 on page 3-27) L=280 (11.02) L=155 (6.10) (11) 3-40...

  • Page 77: Roof Panel

    Roof Panel Removal Mass production body welding positions and numbers NOTE: Welding symbols ● : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MAG plug welding; : MAG welding L=Welding length unit: mm (in) ( ): The number of welds ●...
  • Page 78 Roof Panel Removal (cont'd) Construction NOTE: This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer to the appropriate Service Manual. Remove the mounting bolts, drill the welded flange of the roof panel, and remove it. ●...

  • Page 79: Installation

    Installation NOTE: 5. Remove the roof panel, and weld the roof front rail (A), roof arch D, and the rear roof rail (B). Welding symbols ● : 2-Plate spot welding (ᤝ)*: Welding position with roof arch D (USIBOR : 3-Plate spot welding 1500).
  • Page 80 Roof Panel Installation (cont'd) 6. Apply a soft type sealer (A) to the mating surfaces of 9. Do the main welding. Weld the front, rear, and side flanges of the roof panel the roof panel and the roof front rail (B), roof arch D, and the rear roof rail (C).

  • Page 81: Rear Side Outer Panel

    Rear Side Outer Panel Removal Mass production body welding positions and numbers (Outer panel and rear gutter) NOTE: Welding symbols ● : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MAG plug welding; : MAG welding L=Welding length unit: mm (in) ( ): The number of welds ●...
  • Page 82 This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer ● to the appropriate Service Manual. The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to ● the area and the degree of damage on the body.

  • Page 83: Installation

    Installation NOTE: 6. Weld the patches (A) at the cut sections of the body side outer panel (B). Welding symbols ● : 2-Plate spot welding Quarter pillar section : 3-Plate spot welding : 4-Plate spot welding : MAG plug welding : MAG welding 40 mm (1.57 in)
  • Page 84 Rear Side Outer Panel Installation (cont'd) 8. Install the new wheel arch outer separator (A) on the Door opening and side sill area wheel arch extension (B). L=150 (5.91) NOTE: Apply the sealer (C) all the way around the separator and inside the outer panel repair part (D) without gaps.
  • Page 85 Wheel arch area 10. Weld the rear combination adapter (A) and the rear pillar gutter (B). (13) (16) 6 x 1.0 mm 18 N·m (1.8 kgf·m, 13 lbf·ft) Rear end area (13) (cont'd) 3-49...
  • Page 86 Rear Side Outer Panel Installation (cont'd) 11. With BSI radar unit: Check the BSI radar unit mounting holes position. Install 6 mm bolts (A), 45－60 mm long, in the BSI radar unit mounting holes (B, C, D). Tape the plumb line (E) against the outer panel (F) directly above each mounting hole, and thread each bolt in or out until the head of the bolt just touches the plumb line.

  • Page 87: Floor Rear Crossmember

    Floor Rear Crossmember Removal Mass production body welding positions and numbers NOTE: Welding symbols ● : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MAG plug welding; : MAG welding L=Welding length unit: mm (in) ( ): The number of welds ●...
  • Page 88 This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer ● to the appropriate Service Manual. The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to ● the area and the degree of damage on the body.

  • Page 89: Installation

    Installation NOTE: 4. Apply the sealer (A) to the left crossmember separator Welding symbols (B) on the body side. ● : 2-Plate spot welding Left side Right side : 3-Plate spot welding : 4-Plate spot welding : MAG plug welding : MAG welding L=Welding length unit: mm (in) ( ): The number of welds...
  • Page 90 Floor Rear Crossmember Installation (cont'd) 7. Temporarily install the rear bumper beam, and 12. Right side: Weld the inner crossmember (A) to the tighten the mounting bolts. rear inner pillar (B) and the rear inner panel (C). 8. Check the body dimensions. L=5 (0.20) Rear pillar gutter and floor rear crossmember ●...
  • Page 91 14. Weld the outer crossmember (A) to the crossmember 16. With BSI radar unit: If necessary, remove the extension (B) , the bumper beam bracket (C), and the damaged rivnuts, then install the new rivnuts (A) with outer panel (D). a rivnut tool, and check the BSI radar unit mounting Left side: Weld the outer crossmember and the body holes position.

  • Page 92: Third-Seat Pan/Rear Frame

    Third-Seat Pan/Rear Frame Removal Mass production body welding positions and numbers (Third-seat pan) NOTE: Welding symbols ● : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MAG plug welding; : MAG welding L=Welding length Unit: mm (in) ( ): The number of welds ●...
  • Page 93 Mass production body welding positions and numbers (Floor rear extension A and B) NOTE: Welding symbols ● : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MAG plug welding; : MAG welding L=Welding length Unit: mm (in) ( ): The number of welds ●...
  • Page 94 Third-Seat Pan/Rear Frame Removal (cont'd) Mass production body welding positions and numbers (Rear frame) NOTE: Welding symbols ● : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MAG plug welding; : MAG welding L=Welding length Unit: mm (in) ( ): The number of welds ●...
  • Page 95 This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer ● to the appropriate Service Manual. The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to ● the area and the degree of damage on the body.
  • Page 96 This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer ● to the appropriate Service Manual. The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to ● the area and the degree of damage on the body.

  • Page 97: Installation

    Installation NOTE: 2. Check the body dimensions. Welding symbols ● Front floor and rear floor, under view (see page : 2-Plate spot welding ● 4-18) : 3-Plate spot welding Inside sill positions (see page 4-19) ● : 4-Plate spot welding Repair chart, top view (see page 4-20) ●...
  • Page 98 Third-Seat Pan/Rear Frame Installation (cont'd) 8. Temporarily install the tailgate, then check for 11. Weld the rear frame outrigger (A) to the rear side differences in level and clearance. outer panel (B). Check the external parts fitting positions (see page 4-15).
  • Page 99 13. Weld the rear frame (A) to floor middle crossmember 15. Weld the lower flange of the rear floor inner C, floor middle crossmember D and the floor panel crossmember (A) to the rear floor crossmember (B). extension (B) and the rear frame (C). Right side: Weld the right third-seat plate (E) to the rear frame and the floor panel.
  • Page 100 Third-Seat Pan/Rear Frame Installation (cont'd) 18. Weld floor rear extension A to the rear wheelhouse 21. With BSI radar unit: If necessary, remove the (B), the third-seat pan (C), the third row seat mount damaged rivnuts, then install the new rivnuts (A) with panel (D), and the floor panel (E).

  • Page 101: Floor Insulators

    Floor Insulators Insulator Locations Cut new insulators, and apply as indicated. NOTE: Before applying, clean and degrease the floor. ᫓ RIGHT-MIDDLE FLOOR FRONT INSULATOR ᫎ ᫐ ᫗ RIGHT-FRONT FLOOR RIGHT-FRONT FLOOR RIGHT-REAR FLOOR ᫕ FRONT INSULATOR REAR INSULATOR RIGHT-MIDDLE FLOOR SIDE INSULATOR REAR INSULATOR ᫙...

  • Page 102: Insulator Sizes

    Floor Insulators Insulator Sizes Unit: mm (in) ᫎ RIGHT-FRONT FLOOR FRONT INSULATOR 962 (37.87) ᫏ LEFT-FRONT FLOOR FRONT INSULATOR 882 (34.72) 3-66...
  • Page 103 Unit: mm (in) ᫐ RIGHT-FRONT FLOOR REAR INSULATOR 598 (23.54) ᫑ SPARE TIRE PAN INSULATOR 573 (22.56) ᫒ LEFT-FRONT FLOOR REAR INSULATOR 438 (17.24) (cont'd) 3-67...
  • Page 104 Floor Insulators Insulator Sizes (cont'd) Unit: mm (in) ᫓ RIGHT-MIDDLE FLOOR FRONT INSULATOR 430 (16.93) ᫔ LEFT-MIDDLE FLOOR FRONT INSULATOR 562 (22.13) 3-68...
  • Page 105 Unit: mm (in) ᫕ RIGHT-MIDDLE FLOOR REAR INSULATOR 764 (30.08) ᫕ LEFT-MIDDLE FLOOR REAR INSULATOR 778 (30.63) (cont'd) 3-69...
  • Page 106 Floor Insulators Insulator Sizes (cont'd) Unit: mm (in) ᫗ RIGHT-MIDDLE FLOOR SIDE INSULATOR 428 (16.85) ᫘ LEFT-REAR FLOOR SIDE INSULATOR 428 (16.85) ᫙ REAR FLOOR INSULATOR 498 (19.61) 3-70...
  • Page 107 Unit: mm (in) ᫚ RIGHT-REAR WHEELHOUSE INSULATOR 963 (37.91) ᫛ LEFT-REAR WHEELHOUSE INSULATOR 1154 (45.43) ᫜ OUTER PANEL INNER INSULATOR 250 (9.84) 3-71...
  • Page 108 Body Dimensional Drawings Upper Body Measuring Dimensions Front Fender Positions 4–2 Front Bulkhead Position 4–3 Engine Compartment 4–4 Engine Side Mount Position 4–5 Bulkhead Side Member Position 4–6 Door Hinge Positions 4–7 Sliding Door Female Guide and Striker Positions 4–8 Passenger's Compartment 4–9 Sliding Door Rail Lower Support Positions...

  • Page 109: Upper Body Measuring Dimensions

    Upper Body Measuring Dimensions Front Fender Positions NOTE: The air intake duct and the front bulkhead cover are removed in the illustrations. Unit: mm (in) A, a B, b C, c Bulkhead Upper Center Frame A Front Fender Bracket Mounting Front Fender Rear Mounting Locating Hole ø20 (0.78) Bolt (Center of the bolt)

  • Page 110: Front Bulkhead Position

    Front Bulkhead Position Unit: mm (in) A1, a1 A3, a3 A4, a4 Front Bulkhead Lower Corner Upper Beam Mounting Radiator Mounting Crossmember Locating Hole ø7 (0.28) Hole ø9 (0.35) Hole ø10 (0.39) A2, a2 Front Bumper Beam Mounting Hole ø11 (0.43) (29.61) 1000 (39.37)

  • Page 111: Engine Compartment

    Upper Body Measuring Dimensions Engine Compartment Unit: mm (in) B1, b1 B3, b3 Bulkhead Upper Center Frame A Front Damper Mounting Windshield Lower Locating Locating Hole ø20 (0.79) Hole ø11.5 (0.453) Hole ø7 (0.28) B4, b4 B2, b2 Hood Hinge Front Fender Mounting Mounting Hole ø9 (0.35) front...

  • Page 112: Engine Side Mount Position

    Engine Side Mount Position Unit: mm (in) B3, b3 Battery Set Base Mounting Engine Side Mounting Hole ø13 (0.51) Front Damper Mounting Hole ø9 (0.35) Wheelhouse side Hole ø11.5 (0.453) Engine Side Mounting Hole ø15 (0.59) Side frame side 1243 (48.94) (16.18) (19.76)

  • Page 113: Bulkhead Side Member Position

    Upper Body Measuring Dimensions Bulkhead Side Member Position Unit: mm (in) Front Fender Mounting Front Fender Mounting Front Door Lower Hinge Mounting Hole ø9 (0.35) upper Hole ø13 (0.51) upper Hole ø7 (0.28) front Bulkhead Side Member A Locating Front Fender Mounting Hole ø13 (0.51) Hole ø7 (0.28) lower (39.17)

  • Page 114: Door Hinge Positions

    Door Hinge Positions Unit: mm (in) Front Door Upper Hinge Front Door Lower Hinge Front Door Switch Mounting Hole ø13 (0.51) front Mounting Hole ø13 (0.51) upper Mounting Hole ø8 (0.32) 1031 (40.59) (14.45) (39.06)

  • Page 115: Sliding Door Female Guide And Striker Positions

    Upper Body Measuring Dimensions Sliding Door Female Guide and Striker Positions Unit: mm (in) F1, f1 F2, f2 F3, f3 Sliding Door Sub-Seal Sliding Door Upper Female Guide Sliding Door Lower Female Guide Mounting Hole ø5 (0.20) Mounting Hole ø10 (0.39) upper Mounting Hole ø10 (0.39) upper F5, f5 Sliding Door Rear Striker...

  • Page 116: Passenger's Compartment

    Passenger's Compartment Unit: mm (in) G1, g1 G2, g2 G3, g3 Front Seat Mounting Second-Seat Striker Cover A Second Row Seat Belt Lower Anchor Hole ø15 (0.59) front Mounting Hole ø7 (0.28) Mounting Hole ø12 (0.47) 2277 1070 (89.65) (42.13) 1204 (47.40) 1652...

  • Page 117: Sliding Door Rail Lower Support Positions

    Upper Body Measuring Dimensions Sliding Door Rail Lower Support Positions Unit: mm (in) H1, h2 H2, h2 H3, h3 Front Floor Panel Locating Sliding Door Sill Trim Clip CESS Articulated Harness Hole ø26.3 (1.035) Mounting Hole ø8.5 (0.335) Mounting Hole ø9 (0.35) H4, h4 Floor Rear Extension A Locating Hole ø20 (0.79)

  • Page 118: Roof Rail Positions

    Roof Rail Positions Unit: mm (in) I1, i1 I2, i2 I3, i3 Roof Front Rail Locating Center Inner Pillar Locating Quarter Inner Upper Pillar Hole ø15 (0.59) Hole ø13 (0.51) Locating Hole ø13 (0.51) I4, i4 Rear Roof Trim Clip Mounting Hole ø8.5 (0.335) 1274 (50.16)

  • Page 119: Rear Pillar Gutter And Floor Rear Crossmember Positions

    Upper Body Measuring Dimensions Rear Pillar Gutter and Floor Rear Crossmember Positions Unit: mm (in) J1, j1 J2, j2 J3, j3 Sliding Door Center Rail Cover Tailgate Support Strut Rear Bumper Mounting Mounting Hole ø7 (0.28) Mounting Hole ø11 (0.43) Hole ø7 (0.28) J4, j4 H4, h4...

  • Page 120: Windshield And Door Openings

    Windshield and Door Openings Unit: mm (in) B, C D, E, F, G, H, I, J, K Windshield Lower Outer Panel and Roof Panel Outer Panel and Roof Side Dashboard Front Installing Pin Windshield Opening Outer Door Opening Flange Notch (3 places) Flange Notch (16 places) 1514 (59.61)

  • Page 121: Tailgate Opening

    Upper Body Measuring Dimensions Tailgate Opening Unit: mm (in) Rear Roof Lower Rail Rear Combination Adapter Floor Rear Crossmember Flange Notch Flange End (2 places) Scribe Marks 1107 (32.76) (43.58) 1349 (53.11) (36.14) 4-14...

  • Page 122: External Parts Fitting Positions

    External Parts Fitting Positions Tailgate Unit: mm (in) Roof Tailgate Outer Panel Spoiler Panel Spoiler Trim (0.276) Side Trim (0.236) (0.039) Outer (0.028) Front Fender (0.118) Panel (0.118) (0.020) Hood Outer Panel Outer Panel (0.272) (0.217) (0.228) Front Door Sliding Door Front Fender Front Door (0.177)

  • Page 123: Under Body Measuring Dimensions

    Under Body Measuring Dimensions Front Subframe Position Unit: mm (in) A, a B, b Front Subframe Front Front Subframe Rear Left Front Floor Right Front Floor Frame Mounting Bolt Mounting Bolt Extension Locating Locating Hole ø10 (0.39) (Center of the bolt) (Center of the bolt) Hole ø11 (0.43) 1045...

  • Page 124: Engine Compartment And Front Floor, Under View

    Engine Compartment and Front Floor, Under View Unit: mm (in) C, c A, a B, b Front Subframe Mounting Front Bumper Beam Front Bulkhead Lower Hole ø15 (0.59) front Mounting Hole ø11 (0.43) Crossmember Locating Hole ø13 (0.51) D, d E, e F, f Front Subframe Mounting...

  • Page 125: Front Floor And Rear Floor, Under View

    Under Body Measuring Dimensions Front Floor and Rear Floor, Under View Unit: mm (in) F, f G, g H, h Left Floor Front Extension Rear Subframe Mounting Floor Middle Crossmember D Locating Hole ø32 (1.26) Hole ø17 (0.67) front Locating Hole Right Floor Front Frame Left: ø15 (0.59)/Right: ø20 (0.79) Locating Hole ø32 (1.26)

  • Page 126: Inside Sill Positions

    Inside Sill Positions Unit: mm (in) E, e K, k Front Side Frame Gusset Locating Front Inside Sill B Locating Hole ø28 (1.10) Hole ø20 (0.79) front L, l I, i Front Inside Sill B Locating Rear Subframe Mounting Hole ø20 (0.79) rear Hole ø17 (0.67) (26.69) 1157...

  • Page 127: Frame Repair Chart

    Frame Repair Chart Repair Chart, Top View Unit: mm (in) φ: Inner diameter For bumper beam φ11 (0.43) a1, a2 For front subframe φ15 (0.59) forward b1, b2 For engine mount φ13 (0.51) Front damper center φ80 (3.15) d1, d2 For front subframe φ15 (0.59) rearward e1, e2 Locating hole φ28 (1.1)
  • Page 128 For fuel tank φ13 (0.51) forward For rear subframe φ17 (0.67) forward g1, g2 n1, n2 Locating hole φ25 (0.98) For rear spring φ25 (0.98) h1, h2 o1, o2 For fuel tank φ11 (0.43) middle For rear subframe φ17 (0.67) rearward i1, i2 r1, r2 For trailing arm φ16 (0.63) outrigger side...

  • Page 129: Repair Chart, Side View

    Frame Repair Chart Repair Chart, Side View Unit: mm (in) ø: Inner diameter a1, a2 For bumper beam ø11 (0.43) b1, b2 For front subframe ø15 (0.59) forward For engine mount ø13 (0.51) d1, d2 Front damper center ø80 (3.15) e1, e2 For front subframe ø15 (0.59) rearward f1, f2...
  • Page 130 h1, h2 Locating hole ø25 (0.98) j1, j2 For trailing arm ø16 (0.63) outrigger side For trailing arm ø20 (0.79) floor frame side k1, k2 l1, l2 Locating hole ø25 (0.98) n1, n2 For rear subframe ø17 (0.67) forward o1, o2 For rear spring ø25 (0.98) For rear damper ø12 (0.47) forward For rear damper ø12 (0.47) rearward...
  • Page 131 Rust Prevention Sealing Areas General 5–2 Front Wheelhouse and Damper Housing 5–3 Dashboard Upper and Dashboard Lower 5–4 Front Floor and Rear Floor 5–5 Roof Panel and Side Outer Panel 5–6 Rear Pillar Gutter 5–7 Rear Wheelhouse 5–8 Rust-Preventive Treatments General 5–9 Undercoating Areas...

  • Page 132: Sealing Areas

    Sealing Areas General NOTE: Follow the sealant manufacturer's instructions, and apply the sealant. Note the following items: Clean the areas to be sealed with wax and grease ● remover. Wipe off any excess spot sealant with thinner. After ● the primer is sprayed, sealant will fill the area where the spot sealant was wiped.

  • Page 133: Front Wheelhouse And Damper Housing

    Front Wheelhouse and Damper Housing DASHBOARD UPPER Do not apply the sealer to the mounting holes. If necessary, wipe off the excess sealer from the mounting nut flange seating areas. DAMPER BASE FRONT PILLAR LOWER STIFFENER DASHBOARD LOWER DASHBOARD LOWER OUTER PANEL FRONT INNER LOWER PILLAR...

  • Page 134: Dashboard Upper And Dashboard Lower

    Sealing Areas Dashboard Upper and Dashboard Lower FRONT INNER OUTER PANEL UPPER PILLAR DASHBOARD LOWER FRONT PILLAR INNER UPPER EXTENSION WINDSHIELD LOWER FRONT INNER STEERING LOWER PILLAR JOINT COVER FRONT PILLAR INNER UPPER EXTENSION [VIEW: Z] DASHBOARD LOWER FRONT INNER UPPER PILLAR INSIDE SILL A FLOOR PANEL...

  • Page 135: Front Floor And Rear Floor

    Front Floor and Rear Floor UNDER FLOOR PAN CENTER INNER FRONT INNER [DETAIL: A] PILLAR ELR STIFFENER INSIDE SILL B FLOOR PANEL FRONT SEAT REAR OUTER BRACKET FRONT SEAT QUARTER REAR OUTER PILLAR BRACKET [DETAIL: B] STIFFENER EXTENSION INSIDE SILL A Do not apply the sealer to the mounting holes.

  • Page 136: Roof Panel And Side Outer Panel

    Sealing Areas Roof Panel and Side Outer Panel Do not apply the sealer to the roof rail brackets. If necessary, wipe off the [VIEW: Z] excess sealer from the stud bolt. OUTER PANEL [DETAIL: V] REAR PILLAR GUTTER ROOF PANEL REAR ROOF TAILGATE HINGE AREA...

  • Page 137: Rear Pillar Gutter

    Rear Pillar Gutter [VIEW: Z] OUTER PANEL REAR PILLAR GUTTER REAR COMBINATION ADAPTER REAR PILLAR [VIEW: X] GUTTER REAR COMBINATION REAR INNER ADAPTER PANEL OUTER PANEL FLOOR REAR CROSSMEMBER COMBINATION ADAPTER OUTER PANEL EXTENSION...

  • Page 138: Rear Wheelhouse

    Sealing Areas Rear Wheelhouse REAR WHEELHOUSE WHEELHOUSE STIFFENER REAR INNER PANEL REAR WHEEL ARCH EXTENSION REAR FRAME [VIEW: X] [VIEW:Z] REAR INNER PANEL REAR INNER PANEL OUTER PANEL OUTER PANEL REAR WHEEL ARCH EXTESION...

  • Page 139: Rust-Preventive Treatments

    Rust-Preventive Treatments General Undercoat Anti-Rust Agents Wear goggles or safety glasses to prevent eye Anti-rust agents contain substances that are ● ● injury. harmful if you breathe or swallow them, or get them on your skin. Wear coveralls, gloves, eye Ventilate when spraying undercoat.

  • Page 140: Undercoating Areas

    Rust-Preventive Treatments Undercoating Areas Apply undercoat to the areas shown. NOTE: Coating thickness: 0.4 mm (0.016 in) MIN. ● Front wheelhouse and dashboard lower coating thickness 0.5 mm (0.020 in). ● Apply the undercoat 10 mm (0.39 in) from the edge of the welded flanges. ●...
  • Page 141 : Indicates undercoating area. FRONT FLOOR FRAME EXTENSION FRONT FLOOR FRAME Front TRAILING ARM OUTRIGGER B INSIDE SILL [VIEW: W] REAR WHEELHOUSE Front [VIEW: X] REAR FRAME REAR FRAME FLOOR MIDDLE CROSSMEMBER D Right side only THIRD-SEAT PAN [VIEW: Y] [VIEW: Z] (cont'd) 5-11...
  • Page 142 Rust-Preventive Treatments Undercoating Areas (cont'd) : Indicates undercoating area. FLOOR MIDDLE CROSSMEMBER D FLOOR PANEL DASHBOARD LOWER THIRD-SEAT PAN UNDER FLOOR PAN Apply undercoat to Apply undercoat to the flange the flange end of the end of the under floor pan. crossmember A.

  • Page 143: Areas To Be Covered By Internal Anti-Rust Agents

    Areas to be Covered by Internal Anti-Rust Agents : Indicates anti-rust agents. [DETAIL: X] (8 places) ROOF RAIL BRACKET TAILGATE FRAME HOOD FRAME FLOOR MIDDLE CROSSMEMBER C HOOD HINGE FLOOR MIDDLE CROSSMEMBER B FLOOR MIDDLE CROSSMEMBER D REAR FRAME TAILGATE HINGE FLOOR FRONT FRAME FLOOR FRONT CROSSMEMBER B...

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