Honda Accord 2008 Body Repair Manual
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Honda Accord 2008 Body Repair Manual

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See also: Navigation Manual , Owner's Manual
2008-
How to Use This Manual
This manual covers the repairs of a 2008
an accident, and it d
escribes 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 Accord 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 10/2007
144 pages
All Rights Reserved
20 2
1 ACCORD Body Repair Manual

INTRODUCTION

-2012
model-series Accord that has been involved in
WARNING
CAUTION
CAUTION
HONDA MOTOR CO., LTD.
Service Publication Office
Sections with an * include SRS
components; special caution is
required when servicing.
1
Information
2
Paint
Information
3
Body Dimensional
4
Drawings
Rust
5
Prevention
General Safety
Precautions
Reference

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Summary of Contents for Honda Accord 2008

  • 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 there If you need to replace a part, use Honda parts with the is any doubt, put on eye protection. 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 Main Menu 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 sketches. : 2-Plate spot welding Black dots: Measuring point : 3-Plate spot welding Black Dot...

  • Page 5: Table Of Contents

    Main Menu General Information General Information Supplemental Restraint System (SRS) 1–2 • • • • • • • • • • • • • • • • • SRS Component Replacement/Inspection After Deployment 1–4 • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Battery Terminal Disconnection/Reconnection 1–5 •...

  • Page 6: Supplemental Restraint System (Srs) • • • • • • • • • • • • • • • • •

    Table of Contents Main Menu General Information Supplemental Restraint System (SRS) This model has an SRS which includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above the glove box, the seat belt tensioners in the front seat belt retractors, the side airbags in the front seat-backs, and the side curtain airbags in the sides of the roof.
  • Page 7 Table of Contents Main Menu 2-door PASSENGER’S AIRBAG CUTOFF INDICATOR DRIVER’S AIRBAG FRONT PASSENGER’S AIRBAG ODS UNIT CABLE REEL OPDS SENSOR/ SEAT-BACK COVER/PAD DATA LINK CONNECTOR (DLC) FRONT PASSENGER’S SIDE AIRBAG FRONT PASSENGER’S SEAT BELT TENSIONER RIGHT SIDE SRS UNIT IMPACT SENSOR (FIRST) FRONT PASSENGER’S WEIGHT SENSORS...
  • Page 8 Main Menu Table of Contents General Information SRS Component Replacement/Inspection After Deployment NOTE: SRS unit ● Before doing any SRS repairs, use the HDS SRS menu Deployed side curtain airbag(s) ● ● method to check for DTCs; refer to the DTC Seat belt tensioner(s) for the side(s) that deployed ●...

  • Page 9: Battery Terminal Disconnection/Reconnection • • • • • • •

    Table of Contents Main Menu Battery Terminal Disconnection/Reconnection Disconnection Reconnection NOTE: Some system store data in memory is lost when NOTE: Some system store data in memory is lost when the battery is disconnected. Do the following procedures the battery is disconnected. Do the following procedures before disonnecting the battery.

  • Page 10: Identification Number Locations

    Table of Contents Main Menu General Information Identification Number Locations 4-door L4 Engine Models 4-door Vehicle Identification Vehicle Identification Number (VIN) Number (VIN) Automatic Transmission Number Engine Number Manual Transmission Number 2-door 2-door Vehicle Identification Vehicle Identification Number (VIN) Number (VIN) Automatic Transmission Number...
  • Page 11 Main Menu Table of Contents 4-door V6 Engine Models 4-door Vehicle Identification Vehicle Identification Number (VIN) Number (VIN) Engine Number Automatic Transmission Number 2-door 2-door Vehicle Identification Vehicle Identification Number (VIN) Number (VIN) Automatic Engine Manual Transmission Transmission Number Number Number (cont'd)
  • Page 12 Main Menu Table of Contents General Information Identification Number Locations Parts Marking (cont'd) 4-door To deter vehicle theft, certain major components are marked with the vehicle identification number (VIN). Vehicle Identification Original parts have self-adhesive labels. Replacement Number, Federal Motor body parts have generic self-adhesive labels.

  • Page 13: Lift And Support Points

    Table of Contents Main Menu Lift and Support Points NOTE: If you are going to remove heavy components Floor Jack such as the suspension or the fuel tank from the rear of the vehicle, first support the front of the vehicle with tall 1.

  • Page 14: Body Specifications/Wheel Alignment • • • • • • • • • • • • • • • • •

    Table of Contents Main Menu General Information Body Specifications/Wheel Alignment V6 Engine Model 4-door 1,590 mm (62.6 in.) 1,845 mm (72.6 in.) 2,800 mm (110.2 in.) 1,590 mm (62.6 in.) 4,930 mm (194.1 in.) Front Wheel Alignment: 17 inch wheels: 0 ° 00 ’ ＋30 ’...
  • Page 15 Main Menu Table of Contents 2-door 1,580 mm (62.2 in.) 1,848 mm (72.8 in.) 2,740 mm (107.9 in.) 1,580 mm (62.2 in.) 4,849 mm (190.9 in.) Front Wheel Alignment: 17 inch wheels: 0 ° 00 ’ ＋30 ’ Camber －45 ’ 18 inch wheels: －0 °...

  • Page 16: Table Of Contents

    Table of Contents Main Menu General Information Exterior Parts Removal/Installation NOTE: To adjust the alignment of the hood, the doors, and the tailgate, refer to the Accord Service Manual. ● When adjusting the door in or out, replace the mounting bolts (A) (90102-SFA-305). ●...

  • Page 17: Table Of Contents

    Main Menu Table of Contents 10 x 1.25 mm 38 N·m (3.9 kgf·m, 28 lbf·ft) MIDDLE FLOOR CROSS-MEMBER GUSSET (2-door) 14 x 1.5 mm 65 N·m 14 x 1.5 mm (6.5 kgf·m, 47 lbf·ft) 65 N·m (6.5 kgf·m, 47 lbf·ft) REAR BUMPER SIDE BRACKET 6 x 1.0 mm...
  • Page 18 Main Menu Table of Contents General Information Front Body Construction ꐆ ꐀ ꐅ Rear Front ꐇ Lower Rear Upper Front ꐃ ꐄ ꐂ ꐁ 1-14...
  • Page 19 Main Menu Table of Contents 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-tension steel sheet: Tensioner strength 340 to 590 MPa.

  • Page 20: Roof And Side Panel Construction • • • • • • • • • • • • • • • • • • • • • •

    Main Menu Table of Contents General Information Roof and Side Panel Construction 4-door ꐀ ꐌ ꐊ ꐈ ꐋ ꐉ ꐇ ꐃ ꐄ ꐂ ꐅ ꐆ Rear Front ꐁ ꐎ Rear Front ꐍ 1-16...
  • Page 21 Table of Contents Main Menu 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-tension steel sheet: Tensioner strength 340 to 590 MPa.
  • Page 22 Main Menu Table of Contents General Information Roof and Side Panel Construction (cont'd) 2-door ꐀ ꐊ ꐉ ꐈ ꐃ ꐄ ꐅ ꐇ ꐂ ꐆ ꐁ Rear ꐋ Front 1-18...
  • Page 23 Table of Contents Main Menu 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-tension steel sheet: Tensioner strength 340 to 590 MPa.

  • Page 24: Floor And Rear Body Construction • • • • • • • • • • • • • • • • • • • • • •

    Table of Contents Main Menu General Information Floor and Rear Body Construction ꐉ ꐈ ꐇ ꐂ ꐃ ꐁ ꐅ ꐀ ꐆ ꐄ 1-20...
  • Page 25 Table of Contents Main Menu 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-tension steel sheet: Tensioner strength 340 to 590 MPa.

  • Page 26: Door And Bumper Reinforcement Beams • • • • • • • • • • • • • •

    Main Menu Table of Contents General Information Door and Bumper Reinforcement Beams The door and bumper reinforcement beams used on Accord vehicles are made from a metal equivalent to high-strength steel. If high-strength steel is heated, the strength of the steel will be reduced. If high-strength steel is damaged, for example. In an accident, and the door and bumper reinforcement beams are bent, the beams may crack when attempting to straighten them.

  • Page 27: Zinc-Plated Steel Plate Repair

    Main Menu Table of Contents Zinc-Plated Steel Plate Repair The zinc-plated steel plate used in some panels of the Accord require different repair techniques than ordinary steel plate. Refer to ‘‘Front Body Construction’’ (see page 1-14), ‘‘Roof and Side Panel Construction (4-door)’’ (see page 1-16), ‘‘Roof and Side Panel Construction (2-door)’’...

  • Page 28: High-Tension Steel Sheet Framed Area • • • • • • • • • • • • • • • •

    Table of Contents Main Menu General Information High-Tension Steel Sheet Framed Area The new high-tension steel sheet has greater tensioner strength than the conventional high-tension steel sheet. Although it's a thinner sheet, it maintains the same strength capacity as the previous thicker ones. Because the manufacturing press process has improved, the usage area has expanded.
  • Page 29 Table of Contents Main Menu Precautions for High-Tension Steel Headlight Bracket Replacement Parts Area Repair The new high-tension steel parts of the frame are all NOTE: Put on gloves to protect your hands. ● spot welded together. In order to disassemble, drill a When the upper bracket (A) and/or side bracket (B) of the hole in the sections that are spot welded together with headlight assembly (C) are broken, it can be reinstalled...
  • Page 30 Main Menu Table of Contents General Information Headlight Bracket Replacement (cont'd) 4. Install the upper repair bracket (A) on the bosses of 6. Install the side repair bracket (A) on the bosses of the the headlight housing (B), then fasten it with the headlight housing (B), then fasten it with the screws screws (C) provided with the repair bracket.
  • Page 31 Main Menu Paint Information Paint Information Paint Safety Precautions 2–2 • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • General 2–3 •...
  • Page 32 Main Menu Table of Contents 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 33 Main Menu Table of Contents General The 3-coat·3-bake (3C·3B) paint finish gives the Accord a deep gloss and 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.
  • Page 34 Main Menu Table of Contents Paint Information Color Chart Paint Specifications 4-door NOTE: For model year paint code infomation, refer to the appropriate service manual. WINDSHIELD MOLDING DOOR OUTER MOLDING Black (NH-70 Gloss 20) Chrome plated COWL COVER Black (NH-696) FRONT GRILLE MOLDING Chrome plated DOOR GLASS OUTER...
  • Page 35 Table of Contents Main Menu 2-door NOTE: For model year paint code infomation, refer to the appropriate service manual. DOOR OUTER MOLDING WINDSHIELD MOLDING Chrome plated Black (NH-70 Gloss 20) QUARTER GLASS MOLDING Chrome plated COWL COVER Black (NH-696) FRONT GRILLE MOLDING Chrome plated DOOR GLASS OUTER WEATHERSTRIP...
  • Page 36 Table of Contents Main Menu Paint Information 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. ●...
  • Page 37 Table of Contents Main Menu Types and Materials of Exterior Plastic Parts 4-door NOTE: For the full plastic name, refer to the features of plastic materials (see page 2-6). ● A standard symbol is stamped on the underside of each resin part to show the type of material used. ●...
  • Page 38 Table of Contents Main Menu Paint Information Types and Materials of Exterior Plastic Parts (cont'd) 2-door NOTE: For the full plastic name, refer to the features of plastic materials (see page 2-6). ● A standard symbol is stamped on the underside of each resin part to show the type of material used. ●...
  • Page 39 Main Menu Table of Contents 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 the process continues unchecked.
  • Page 40 Table of Contents Main Menu Soft Chipping Guard Primer Coat Coating Diagram indicates chipping guard primer coating area. NOTE: Make sure to coat the flange on front and rear wheel arch. Unit: mm (in.) ROOF PANEL 100 (3.9) MOONROOF OPENING FLANGE OUTER PANEL 4-door (3.9)
  • Page 41 Main Menu Replacement Front Bulkhead Removal 3–2 • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Installation 3–4 •...
  • Page 42 Main Menu Table of Contents Front Bulkhead Removal Mass production body welding position and number NOTE: Welding symbols ● : MIG fillet or butt : 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ welding L= Welding length Unit: mm (in.) ( ): The number of welds ●...
  • Page 43 Table of Contents Main Menu Construction Replace the bulkhead upper center frame and side frame as an assembly. ● If necessary, replace the bulkhead side stay and bulkhead lower cross member. ● BULKHEAD UPPER SIDE FRAME BULKHEAD UPPER WHEELHOUSE CENTER FRAME UPPER MEMBER BULKHEAD SIDE STAY FRONT SIDE FRAME...
  • Page 44 Main Menu Table of Contents Front Bulkhead Installation NOTE: 6. Do the main welding. Welding symbols Weld the front side frame (A) and bulkhead side ● ● stay (B). : 2-Plate spot welding Weld the bulkhead side stay and bulkhead lower ●...
  • Page 45 Main Menu Table of Contents 7. Weld the bulkhead upper center frame (A) and side 8. Weld the bulkhead upper side frame (A) to the frame (B) to the bulkhead side stay (C). wheelhouse upper inner (B) and wheelhouse upper member (C).
  • Page 46 Main Menu Table of Contents Front Wheelhouse/Damper Housing Removal Mass production body welding position and number (Wheelhouse upper member and wheelhouse upper inner) NOTE: Welding symbols ● : MIG fillet or butt : 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ welding L= Welding length Unit: mm (in.) ( ): The number of welds ●...
  • Page 47 Main Menu Table of Contents Mass production body welding position and number (Front wheelhouse and damper housing) NOTE: Welding symbols ● : MIG fillet or butt : 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ welding L= Welding length Unit: mm (in.) ( ): The number of welds ●...
  • Page 48 Main Menu Table of Contents Front Wheelhouse/Damper Housing Removal (cont'd) Construction Remove the wheelhouse upper member. ● Replace the wheelhouse upper inner and lower member as an assembly, and check the wheelhouse lower member ● support position for damage. If necessary, replace it. Check the damper position for damage.

  • Page 49: N·m

    Table of Contents Main Menu Installation NOTE: 6. Do the main welding. Welding symbols Weld the damper housing (A), damper housing ● ● lower extension (B) to the front side frame (C). : 2-Plate spot welding Weld the damper housing and dashboard upper ●...
  • Page 50 Main Menu Table of Contents Front Wheelhouse/Damper Housing Installation (cont'd) 8. Weld the wheelhouse upper inner (A) and dashboard 10. Weld the front wheelhouse (A) to the damper housing upper side member (B). (B), front side frame (C), and wheelhouse upper inner (D).
  • Page 51 Table of Contents Main Menu 11. Weld the wheelhouse upper inner (A), lower member 12. Weld the wheelhouse upper member (A). (B), and lower member support (C). (5) L=10 (0.4) 3-11...
  • Page 52 Table of Contents Main Menu Front Side Frame/Outrigger Removal Mass production body welding position and number (Front side frame) NOTE: Welding symbols ● : MIG fillet or butt : 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ welding L= Welding length Unit: mm (in.) ( ): The number of welds ●...
  • Page 53 Main Menu Table of Contents Mass production body welding position and number (Outrigger and side frame rear end) NOTE: Welding symbols ● : MIG fillet or butt : 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ welding L= Welding length Unit: mm (in.) ( ): The number of welds ●...

  • Page 54: Kgf·m

    Main Menu Table of Contents Front Side Frame/Outrigger Removal (cont'd) Construction When removing the front side frame, leave the side frame rear end, outrigger, and subframe rear bracket in place. ● Check the side frame rear end, outrigger, and subframe rear bracket position for damage. If necessary, replace them ●...
  • Page 55 Main Menu Table of Contents Installation NOTE: 6. Do the main welding. Welding symbols Weld the subframe rear bracket (A), side frame rear ● ● end (B), and outrigger (C) to the dashboard lower : 2-Plate spot welding (D) and inside sill (E). : 3-Plate spot welding Weld the front side frame (F) and middle mounting ●...
  • Page 56 Main Menu Table of Contents Front Side Frame/Outrigger Installation (cont'd) 7. From the passenger's side, plug weld the holes in the 9. Weld the wheelhouse upper inner (A), lower member dashboard lower (A), front floor (B), and floor frame (B), and lower member support (C). (C).
  • Page 57 Table of Contents Main Menu Front Pillar Outer Panel Removal Mass production body welding position and number (Outer panel and front pillar lower stiffener) NOTE: Welding symbols ● : MIG fillet or butt : 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ welding L= Welding length Unit: mm (in.) ( ): The number of welds ●...
  • Page 58 Main Menu Table of Contents Front Pillar Outer Panel Removal (cont'd) Mass production body welding position and number (Outer panel and front pillar lower stiffener) NOTE: Welding symbols ● : MIG fillet or butt : 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ welding L= Welding length Unit: mm (in.) ( ): The number of welds ●...
  • Page 59 Main Menu Table of Contents Construction Remove the wheelhouse upper member (see page 3-6). ● Cut and pry off the outer panel at the front pillar and side sill portion. ● NOTE: Select the cutting positions in consideration of the front side outer panel repair part. Refer to ‘‘Roof and Side Panel Construction (4-door)’’...
  • Page 60 Main Menu Table of Contents Front Pillar Outer Panel 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 side sill reinforcement (C). : 2-Plate spot welding : 3-Plate spot welding : 4-Plate spot welding : MIG plug welding...
  • Page 61 Main Menu Table of Contents 8. Install the new front pillar outer separator (A) on the front pillar lower stiffener (B). 4-door: L=200 (7.87) NOTE: Apply the sealer (C) all the way around the 2-door: L=185 (7.28) separator and inside the outer panel repair part (D) without gaps.
  • Page 62 Main Menu Table of Contents Side Sill Outer Panel Removal Mass production body welding position and number NOTE: Welding symbols ● : MIG fillet or butt : 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ welding L= Welding length Unit: mm (in.) ( ): The number of welds ●...
  • Page 63 Main Menu Table of Contents Construction Cut and pry off the side sill outer panel, and replace it. ● NOTE: Select the cutting positions in consideration of the side sill outer panel repair part. Replace the front pillar outer separator and center pillar outer separator. ●...
  • Page 64 Table of Contents Main Menu Side Sill Outer Panel Installation NOTE: Center pillar section Welding symbols ● : 2-Plate spot welding 40 mm : 3-Plate spot welding (1.6 in.) : 4-Plate spot welding : MIG plug welding 40 mm : MIG fillet or butt welding (1.6 in.) L= Welding length Unit: mm (in.) ( ): The number of welds...
  • Page 65 Table of Contents Main Menu 7. Recheck the clearance and alignment of the door and 2-door front fender. L=330 (13.0) 8. Do the main welding. Weld the outer panel repair part (A) and patch (B). 4-door L=315 (12.4) (12) (11) (19) L=350 (13.8) (24)
  • Page 66 Main Menu Table of Contents Center Pillar Outer Panel Removal Mass production body welding position and number (Outer panel, center pillar stiffener and side sill reinforcement) NOTE: Welding symbols ● : MIG fillet or butt : 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ welding L= Welding length Unit: mm (in.) ( ): The number of welds ●...
  • Page 67 Main Menu Table of Contents 2-door Refer to the front pillar outer panel. CENTERPILLAR Front side outer panel STIFFNER repair part rear edge SIDE SILL REINFORCEMENT Refer to the side sill outer panel. Refer to the rear side outer panel. (cont'd) 3-27...
  • Page 68 Main Menu Table of Contents Center Pillar Outer Panel Removal (cont'd) 4-door construction If there is any damage to the center pillar, cut the (A) position and pry off the outer panel, and replace it. ● NOTE: Select the cutting positions in consideration of the front side outer panel repair part. Check the side sill reinforcement and center pillar stiffener position for damage.
  • Page 69 Table of Contents Main Menu Installation NOTE: 4. Clamp the center pillar stiffener, and tack weld it into Welding symbols position. ● : 2-Plate spot welding 5. Install the new front pillar inner separator (see step 1 : 3-Plate spot welding on page 3-20), and tack weld the front pillar lower : 4-Plate spot welding stiffener into position.
  • Page 70 Main Menu Table of Contents Center Pillar Outer Panel Installation (cont'd) 11. From inside the passenger's compartment, plug weld the hole in the inner lower pillar (A) and the front of side sill reinforcement (B). (2) L=10 (0.4) 14. Weld the front pillar lower stiffener (see step 6 on page 3-20).
  • Page 71 Main Menu Table of Contents 19. Do the main welding. Weld the outer panel repair part Front pillar section (A) and patch (B). 40 mm (1.6 in.) (36) (33) Side sill section 40 mm (1.6 in.) ［Z］ 16. Install the new center pillar outer separator (A) on the center pillar stiffener (B).
  • Page 72 Main Menu Table of Contents Center Pillar Outer Panel Installation (cont'd) Center pillar upper portion L=285 (11.2) L=125 (4.92) L=125 (4.92) L=140 (5.51) (28) (30) Side sill lower flange (14) L=360 (14.2) 3-32...
  • Page 73 Main Menu Table of Contents Roof Panel Removal Mass production body welding position and number NOTE: Welding symbols ● : MIG fillet or butt : 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ welding L= Welding length Unit: mm (in.) ( ): The number of welds ●...
  • Page 74 Main Menu Table of Contents Roof Panel Removal (cont'd) Construction Remove the mounting bolts and roof arch gusset, and drill the welded flange of the roof panel and rear rail. REAR ROOF RAIL ROOF PANEL ROOF ARCH GUSSET 6 x 1.0 mm 6 x 1.0 mm 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft) 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
  • Page 75 Table of Contents Main Menu Installation NOTE: 4-door Welding symbols ● : 2-Plate spot welding : 3-Plate spot welding : 4-Plate spot welding : MIG plug welding : MIG fillet or butt welding L= Welding length Unit: mm (in.) ( ): The number of welds ●...
  • Page 76 Main Menu Table of Contents Rear Side Outer Panel Removal 4-door mass production body welding position and number (Outer panel and rear gutter) NOTE: Welding symbols ● : MIG fillet or butt : 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ welding L= Welding length Unit: mm (in.) ( ): The number of welds ●...
  • Page 77 Main Menu Table of Contents 2-door mass production body welding position and number (Door opening, side sill, quarter glass opening, and center pillar lower stiffener) NOTE: Welding symbols ● : MIG fillet or butt : 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ welding L= Welding length Unit: mm (in.) ( ): The number of welds ●...
  • Page 78 Main Menu Table of Contents Rear Side Outer Panel Removal (cont'd) 2-door mass production body welding position and number (Wheel arch, rear window glass opening, and rear gutter) NOTE: Welding symbols ● : MIG fillet or butt : 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ welding L= Welding length Unit: mm (in.) ( ): The number of welds ●...
  • Page 79 Main Menu Table of Contents 4-door construction Cut and pry off the rear side outer panel, and replace it. ● NOTE: Select the cutting positions in consideration of the rear side outer panel repair part. Check the rear gutter position for damage. If necessary, replace it. ●...
  • Page 80 Main Menu Table of Contents Rear Side Outer Panel Removal (cont'd) 2-door construction Cut and pry off the rear side outer panel, and replace it. ● NOTE: Select the cutting positions in consideration of the rear side outer panel repair part. Check the rear gutter position for damage.
  • Page 81 Main Menu Table of Contents Check the side sill reinforcement and center pillar lower stiffener position for damage. If necessary, replace them. ● When replacing the side sill reinforcement, cut the front pillar position at the outer panel, and carefully remove the ●...
  • Page 82 Main Menu Table of Contents Rear Side Outer Panel Installation NOTE: 5. Clamp the center pillar lower stiffener (A), and install the middle floor cross-member gusset (B). Tack weld Welding symbols ● the center pillar lower stiffener into position. : 2-Plate spot welding : 3-Plate spot welding : 4-Plate spot welding : MIG plug welding...
  • Page 83 Table of Contents Main Menu 2-door 13. Weld the center pillar lower stiffener (A) to the center pillar upper stiffener (B), side sill reinforcement (C), 10. From inside the passenger's compartment, plug weld and inner panel (D). the hole in the inner lower pillar (A) and the front of side sill reinforcement (B).
  • Page 84 Main Menu Table of Contents Rear Side Outer Panel Installation (cont'd) 4-door/2-door 4-door 15. Weld the patch (A) at the cut section of the body side 16. Install the new wheel arch outer separator (A) on the outer panel (B). wheel arch extension (B).
  • Page 85 Main Menu Table of Contents 4-door/2-door 4-door rear window opening and trunk gutter area 19. Clamp the outer panel repair part, and recheck the clearance and alignment of the door, rear window glass, and trunk lid. 20. Do the main welding. Weld the outer panel repair part (A), rear gutter (B), and patch (C).
  • Page 86 Table of Contents Main Menu Rear Side Outer Panel Installation (cont'd) 4-door rear gutter and outer panel rear area 2-door side sill, door opening, and quarter glass area L=190 (7.48) L=150 (5.91) (14) (11) (18) 4-door wheel arch portion (14) L=350 (13.8) 3-46...
  • Page 87 Main Menu Table of Contents 2-door rear window opening and trunk gutter area 2-door rear gutter and outer panel rear area (14) 2-door wheel arch portion 3-47...
  • Page 88 Table of Contents Main Menu Rear Panel Removal Mass production body welding position and number NOTE: Welding symbols ● : MIG fillet or butt : 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ welding L= Welding length Unit: mm (in.) ( ): The number of welds ●...
  • Page 89 Table of Contents Main Menu Construction Cut and pry off the rear panel, and replace it. ● If necessary, replace the rear panel gusset. ● 4-door REAR INNER PILLAR REAR PANEL REAR GUTTER SPARE TIRE PAN REAR FLOOR SIDE PANEL REAR PANEL GUSSET 2-door REAR PANEL...

  • Page 90: Rear Panel

    Table of Contents Main Menu Rear Panel Installation NOTE: 2-door Welding symbols ● : 2-Plate spot welding (2) L=10 (0.4) : 3-Plate spot welding : 4-Plate spot welding : MIG plug welding : MIG fillet or butt welding L= Welding length Unit: mm (in.) ( ): The number of welds ●...
  • Page 91 Main Menu Table of Contents Spare Tire Pan/Rear Frame Removal Mass production body welding position and number (Spare tire pan and rear floor side panel) NOTE: Welding symbols ● : MIG fillet or butt : 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ welding L= Welding length Unit: mm (in.) ( ): The number of welds ●...
  • Page 92 Main Menu Table of Contents Spare Tire Pan/Rear Frame Removal (cont'd) Mass production body welding position and number (Rear frame and rear floor cross-member) NOTE: Welding symbols ● : MIG fillet or butt : 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ welding L= Welding length Unit: mm (in.) ( ): The number of welds ●...
  • Page 93 Main Menu Table of Contents Construction Remove the spare tire pan and rear floor side panel, and replace them. ● If there is any damage to the rear frame, replace the rear frame C, and repair the rear upper frame B if possible. ●...
  • Page 94 Main Menu Table of Contents Spare Tire Pan/Rear Frame Removal (cont'd) Construction Check the rear upper frame B, rear frame B and rear floor cross-member position for damage. If necessary, replace ● them. When replacing the rear upper frame B and rear frame B, carefully remove the rear bulkhead lower cross-member and ●...
  • Page 95 Table of Contents Main Menu Installation 5. Set the rear upper frame B, and clamp the rear floor NOTE: side panel (A), and spare tire pan (C). Welding symbols ● : 2-Plate spot welding : 3-Plate spot welding : 4-Plate spot welding : MIG plug welding : MIG fillet or butt welding L= Welding length Unit: mm (in.)
  • Page 96 Main Menu Table of Contents Spare Tire Pan/Rear Frame Installation (cont'd) 10. Remove the spare tire pan, and weld the rear floor 8. Plug weld the rear frame B, and rear frame stiffener cross-member (A) to the rear frame B and rear floor (C) to the rear frame A.
  • Page 97 Table of Contents Main Menu 12. Weld the rear floor side panel (A) to the rear 11. Drill the holes for welding the overlaps with the rear floor (A) of the rear upper frame B. Weld the rear wheelhouse (B) and outer panel (C). frame B (D), rear upper frame B, rear frame C, rear floor side panel (E) and rear floor.
  • Page 98 Table of Contents Main Menu Spare Tire Pan/Rear Frame Installation (cont'd) 15. Set the rear upper frame C and tack weld it into 17. Weld the rear upper frame C and rear bulkhead lower position. cross-member (B). (51) 16. Set the rear bulkhead lower cross-member (A), temporarily install the rear bulkhead lower gusset (B), (1) L=10 (0.4) and check the rear bulkhead lower cross-member...
  • Page 99 Table of Contents Main Menu Floor Insulators Insulator Locations Japan-produced models Cut new insulators, and apply as indicated. NOTE: Before applying, clean and degrease the floor. ꐄ REAR FLOOR ꐇ REAR FLOOR SIDE ꐀ FRONT FLOOR SIDE FRONT INSULATOR FRONT INSULATOR REAR INSULATOR ［Y］...
  • Page 100 Main Menu Table of Contents Floor Insulators Insulator Sizes Unit: mm (in.) ꐀ FRONT FLOOR SIDE FRONT INSULATOR 440 (17.3) ꐁ FRONT FLOOR TUNNEL SIDE INSULATOR 15 (0.6) 460 (18.1) 65 (2.6) 275 (10.8) 100 (3.94) 30 (1.2) 75 (3.0) 175 (6.89) 475 (18.7) 3-60...
  • Page 101 Main Menu Table of Contents Unit: mm (in.) ꐂ FRONT FLOOR SIDE REAR INSULATOR 220 (8.66) 195 (7.68) 475 (18.7) ꐃ MIDDLE FLOOR CROSS-MEMBER INSULATOR (1.8) (1.4) (1.4) 107 (4.21) 79 (3.1) (2.2) (0.9) 90 (3.5) (1.8) R30 (1.2) (2.3) 30 (1.2) 168 (6.61) 262 (10.3)
  • Page 102 Main Menu Table of Contents Floor Insulators Insulator Sizes (cont'd) Unit: mm (in.) ꐄ REAR FLOOR FRONT INSULATOR 429 (16.9) 367 (14.4) 57 (2.2) 124 (4.88) 186 (7.32) 10 (0.4) 89 (3.5) 133 (5.24) 158 (6.22) 182 (7.17) 562 (22.1) 3-62...
  • Page 103 Table of Contents Main Menu Unit: mm (in.) ꐅ REAR FLOOR REAR INSULATOR R55 (2.2) 75 (3.0) 137 (5.39) 93 (3.7) R55 (2.2) 112 (4.41) 150 (5.91) 262 (10.3) ꐆ REAR WHEELHOUSE INSULATOR (1.7) (1.7) (2.9) (1.8) (2.9) 318 (12.5) (cont'd) 3-63...
  • Page 104 Main Menu Table of Contents Floor Insulators Insulator Sizes (cont'd) Unit: mm (in.) ꐇ REAR FLOOR SIDE REAR INSULATOR 66 (2.6) (1.6) 198 (7.8) 100 (3.94) 106 (4.17) ø45 (1.8) (1.3) 371 (14.6) 404 (15.9) ꐈ SPARE TIRE PAN INSULATOR R60 (2.4) 333 (13.1) 159 (6.26)
  • Page 105 Main Menu Table of Contents Insulator Coating U.S.A.-produced models NOTE: When replacing the insulator, refer to the Japan-produced models information (see page 3-59). : indicates insulator coating area. 4-door REAR FLOOR SIDE REAR FLOOR FRONT FRONT FLOOR SIDE REAR INSULATOR INSULATOR FRONT INSULATOR ［Z］...
  • Page 106 Main Menu Body Dimensional Drawings Upper Body Measuring Dimensions Front Fender Position 4–2 • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Engine Compartment 4–3 •...
  • Page 107 Main Menu Table of Contents Upper Body Measuring Dimensions Front Fender Position NOTE: The front grille cover and front fender trim are removed in the illustrations. Unit: mm (in.) A, a B, b Bulkhead Upper Center Frame Fender Trim Mount Hole 10 (0.39) font Locating Hole 15 (0.59) 4-door 2-door...
  • Page 108 Table of Contents Main Menu Engine Compartment Unit: mm (in.) A, a B, b C, c D, d Bumper Beam Radiator Upper Bulkhead Upper Front Fender Mount Mount Hole 9 (0.35) Bracket Mount Side Frame Locating Hole 7 (0.28) front Hole 11 (0.43) Hole 7 (0.28) 4-door...
  • Page 109 Main Menu Table of Contents Upper Body Measuring Dimensions Engine/Transmission Mount Position Unit: mm (in.) A, a E, e Bumper Beam Front Damper Mount Mount Hole 9 (0.35) Hole 11.5 (0.45) H, h I, i Engine Side Mount Transmission Mount Hole 15 (0.59) Hole 11 (0.43) 1006...
  • Page 110 Main Menu Table of Contents Front Wheelhouse Lower Member Position Unit: mm (in.) Front Fender Front Mount Hole 7 (0.28) Front Fender Upper Mount Hole 9 (0.35) Front Fender Lower Mount Hole 7 (0.28) 2-door 4-door ꐀ 979 (38.5) 984 (38.7) ꐁ...
  • Page 111 Table of Contents Main Menu Upper Body Measuring Dimensions Door Hinge Positions Unit: mm (in.) Front Door Upper Hinge Front Door Lower Hinge Rear Door Upper Hinge Mount Hole 13 (0.51) Mount Hole 13 (0.51) Mount Hole 13 (0.51) 4-door Door Switch Rear Door Lower Hinge Mount Hole 13 (0.51) 4-door...
  • Page 112 Main Menu Table of Contents Passenger's Compartment Unit: mm (in.) R, r S, s Front Floor Cross-member Rear Damper Locating Hole 20 (0.79) Mount Hole 13 (0.51) 4-door 2-door ꐀ 1790 (70.47) 1734 (68.27) ꐁ 2094 (82.44) 2047 (80.59) 1094 (43.07) ꐀ...
  • Page 113 Main Menu Table of Contents Upper Body Measuring Dimensions Windshield/Door and Rear Window/Trunk Lid Opening 4-door Unit: mm (in.) Windshield Lower Dashboard Guide Pin B, C 1334 Outer Panel and (52.52) 1500 (59.06) Roof Panel Windshield Opening Flange Notch (3 places) 1519 (59.80) (28.7) (28.2)
  • Page 114 Main Menu Table of Contents 2-door Unit: mm (in.) Windshield Lower Dashboard Guide Pin 1318 B, C (51.89) Outer Panel and Roof Panel Windshield 1521 (59.88) Opening Flange (27.7) Notch (3 places) (30.8) (39.3) D, E, F, G 1122 Outer Panel Door (44.17) 1523 Opening Flange...
  • Page 115 Table of Contents Main Menu Upper Body Measuring Dimensions External Parts Fitting Positions Unit: mm (in.) 4-door Outer Panel Rear Side Hood Front Fender Rear Door Front Door Outer Panel 2 (0.08) 4 (0.16) 3 (0.12) Front Fender 3.5 (0.14) 3.5 (0.14) Front Fender 2 (0.08)
  • Page 116 Main Menu Table of Contents Under Body Measuring Dimensions Front Subframe Position Unit: mm (in.) A, a Front Subframe Front Mount Bolt (Center of the bolt) B, b Front Subframe Rear Mount Bolt (Center of the bolt) C, c Front Side Frame Rear End Locating Hole 15 (0.59) 1020 (40.16)
  • Page 117 Main Menu Table of Contents Under Body Measuring Dimensions Engine Compartment and Front Floor, Under View Unit: mm (in.) B, b A, a Front Subframe Mount C, c Front Subframe Stay Hole 20 (0.98) front Front Subframe Mount Mount Hole 15 (0.59) Hole 15 (0.59) middle D, d E, e...
  • Page 118 Table of Contents Main Menu Front Floor and Rear Floor, Under View Unit: mm (in.) H, h F, f G, g Floor Tunnel Frame Rear Subframe Mount Side Sill Extension Locating Hole 13 (0.51) Hole 14.4 (0.567) front Locating hole 20 (0.98) rear I, i J, j...
  • Page 119 Main Menu Table of Contents Frame Repair Chart Repair Chart, Top View Unit: mm (in.) ø: Inner diameter For transmission mount ø11 (0.43) middle For front subframe mount ø20 (0.79) front For front subframe mount ø16 (0.63) rear For transmission mount ø11 (0.43) rear Front side frame locating hole ø25 (0.98) front For upper arm mount ø11 (0.43) front Front side frame locating hole ø15 (0.59) rear...
  • Page 120 Table of Contents Main Menu Front floor locating hole ø25 (0.98) rear For rear subframe mount ø26.2 (1.03) front Front floor tunnel frame locating hole ø13 (0.51) rear For rear subframe mount ø26.2 (1.03) rear Rear frame A locating hole ø25 (0.98) Rear damper center hole ø52 (2.05) Rear floor locating hole ø25 (0.98) ꐄ...
  • Page 121 Table of Contents Main Menu Frame Repair Chart Repair Chart, Side View Unit: mm (in.) ø: Inner diameter For front subframe mount ø20 (0.79) front For tower bar mount ø10 (0.39) For front subframe mount ø16 (0.63) rear Front side frame locating hole ø25 (0.98) front Front side frame locating hole ø15 (0.59) rear Front side frame rear end locating hole ø25 (0.98) 120 °...
  • Page 122 Table of Contents Main Menu Front floor locating hole ø25 (0.98) rear Front floor tunnel frame locating hole ø13 (0.51) rear Rear frame A locating hole ø25 (0.98) Rear floor locating hole ø25 (0.98) For rear subframe mount ø26.2 (1.03) front For rear subframe mount ø26.2 (1.03) rear Rear damper center hole ø52 (2.05) m1 Rear floor cross-member locating hole ø15 (0.59) right side...
  • Page 123 Main Menu Rust Prevention Cross Section of Body and Sealants General 5–2 • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Engine Compartment and Damper Housing 5–3 •...
  • Page 124 Table of Contents Main Menu Cross Section of Body and Sealants General NOTE: Follow the sealer manufacturer's instructions, and apply the sealer. Note the following items: Clean the areas to be sealed with wax and grease ● remover. Wipe off any excess spot sealer with thinner. After the ●...
  • Page 125 Main Menu Table of Contents Engine Compartment and Damper Housing OUTER PANEL OUTER PANEL INNER UPPER DASHBOARD UPPER INNER UPPER SIDE MEMBER DASHBOARD UPPER WINDSHIELD LOWER SIDE MEMBER DASHBOARD UPPER SIDE MEMBER DAMPER HOUSING LOWER EXTENSION INNER UPPER WHEELHOUSE DASHBOARD UPPER MEMBER UPPER SIDE MEMBER...
  • Page 126 Main Menu Table of Contents Cross Section of Body and Sealants Front Wheelhouse and Front Side Frame WHEELHOUSE LOWER DAMPER HOUSING UPPER MEMBER EXTENSION DAMPER HOUSING REINFORCEMENT WHEELHOUSE UPPER INNER DASHBOARD DAMPER INNER LOWER LOWER HOUSING UPPER WHEELHOUSE DAMPER UPPER HOUSING UPPER UPPER ARM ARM REAR...
  • Page 127 Table of Contents Main Menu Dashboard Upper, Dashboard Lower, and Front Floor DASHBOARD UPPER CROSS-MEMBER FRONT PILLAR INNER UPPER/LOWER DASHBOARD UPPER FRONT PILLAR INNER UPPER FRONT PILLAR DASHBOARD INNER LOWER UPPER SIDE DASHBOARD LOWER MEMBER DASHBOARD DASHBOARD WINDSHIELD LOWER FRONT PILLAR UPPER UPPER DASHBOARD...
  • Page 128 Main Menu Table of Contents Cross Section of Body and Sealants Middle Floor SIDE SILL SIDE SILL FRAME JOINT REINFORCEMENT REINFORCEMENT CENTER PILLAR EXTENSION REAR UPPER LOWER INNER FRAME A FRAME JOINT SIDE SILL EXTENSION INSIDE SILL SIDE SILL REINFORCEMENT SIDE SILL EXTENSION REAR WHEELHOUSE INSIDE SILL...
  • Page 129 Main Menu Table of Contents Rear Floor and Spare Tire Pan/Roof Panel REAR PANEL REAR PANEL REAR PANEL OUTER PANEL GUSSET UPPER ROOF PANEL STIFFENER REAR FLOOR SIDE PANEL REAR FRAME B PATCH REAR FLOOR SIDE PANEL REAR FRAME C REAR PANEL SPARE CENTER STIFFENER...
  • Page 130 Main Menu Table of Contents Cross Section of Body and Sealants Rear Side Outer Panel and Rear Panel OUTER PANEL FUEL FILL LID REAR GUTTER OUTER PANEL PARCEL SHELF REAR GUTTER REAR COMBINATION ADAPTOR OUTER PANEL LID STIFFENER LID STIFFENER REAR GUTTER REAR GUTTER HINGE...
  • Page 131 Table of Contents Main Menu Rear Wheelhouse INNER PANEL DAMPER DAMPER STIFFENER STIFFENER BULKHEAD DAMPER STIFFENER BULKHEAD INNER PILLAR STIFFENER INNER PANEL INNER INNER DAMPER PANEL PANEL STIFFENER INNER PILLAR INNER PANEL DAMPER BASE WHEELHOUSE DAMPER STIFFENER INNER PANEL WHEELHOUSE DAMPER STIFFENER INNER PANEL WHEEL ARCH...
  • Page 132 Main Menu Table of Contents 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 133 Main Menu Table of Contents Undercoating Diagram 1. Apply undercoat to the areas shown. NOTE: Coating thickness: 0.4 mm (0.016 in.) MIN. Front wheelhouse, rear wheelhouse, and dashboard lower coating thickness 0.5 mm (0.02 in.). : indicates coating area. Unit: mm (in.) REAR FLOOR INSIDE SILL REAR WHEELHOUSE...
  • Page 134 Main Menu Table of Contents Rust-Preventive Treatments Undercoating Diagram (cont'd) 2. Spray the soundproof coating to the areas shown. NOTE: Coating thickness: 2.0 mm (0.08 in.) MIN. : indicates soundproof coat coating area. Unit: mm (in.) REAR WHEELHOUSE OUTER PANEL FRONT FENDER REAR FLOOR INSIDE SILL...
  • Page 135 Table of Contents Main Menu Areas to be Covered by Internal Anti-Rust Agents : indicates anti-rust agents. HOOD TRUNK LID MIDDLE FLOOR CROSS-MEMBER REAR FLOOR HOOD HINGE CROSS-MEMBER FLOOR TUNNEL JACK-UP STIFFENER FRAME INSIDE SILL FUEL FILL DOOR HINGE DASHBOARD UPPER FRONT SIDE FRAME REAR WHEEL ARCH...

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