BODY Repair Manual

SERVICE
MANUAL
CIVIC
CIVIC COUPE
BODY REPAIR MANUAL 01
How to Use This Manual
This manual covers the repairs of 2001 model series CIVIC 1 General Info
2-door that have been involved in an accident, and it 3 *Replacement
describes the work related to the replacement of damage 4 Body Dimensional Drawings
body parts.
5 Rust Prevention
Please read through these instructions and familiarise
Sections with * include SRS
yourself with them before actually using this manual.
components; special caution is
NOTE: Refer to the 2001 CIVIC 4-door/CIVIC 5-door Body
Repair Manual (P/N. 62S5A30), CIVIC Shop Manual (P/N. required when servicing.
62S5A00) and CIVIC Shop Manual supplement (P/N.
62S5A20) for specifications, wire harness locations, safety
stand support points, etc.
Special Information
WARNING
Indicates a strong possibility of severe personal
Injury or death if instructions are not followed.
CAUTION
Indicates a possibility of personal injury or
equipment damage if instructions are not followed.
NOTE: Gives helpful information.
CAUTION
Detailed descriptions of standard workshop
procedures, safety principles and service
operations are not included. Please note that this
manual does contain warnings and cautions
against some specific service methods which
could cause PERSONAL INJURY, damage a vehicle,
or make it unsafe. Please understand that these
warnings cannot cover all conceivable ways in
which service, whether or not recommended by
Honda, might be done or of the possible hazardous
consequences of each conceivable way, nor could
Honda investigate all such ways. Anyone using
service procedures or tools, whether or not
recommended by Honda, must satisfy himself
thoroughly that neither personal safety or vehicle
safety will be jeopardised.
All information contained in this manual is based on the latest

product information available at the time of printing. We
reserve the right to make changes at any time without notice.
No part of this publication may be reproduced, stored in
retrieval system, or transmitted, in any form by an means,
electronic, mechanical, photocopying, recording, or otherwise,
without the prior written permission of the publisher. This
included text, figures and tables.
HONDA MOTOR CO., LTD.
Service Publication Office
First Edition 10/2000 32 pages
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General Information - General Information

General Information
Supplemental Restraint System (SRS) 1-2
Body Specifications/Wheel Alignment 1-3
Construction 1-4
Colour Chart Paint Specifications 1-5

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

1-3
General Information
Body Specifications/Wheel Alignment
Unit : mm(in.)
Front Wheel Alignment:

Camber 0°00' ± 45'
Caster 1°33' ± 1°
Total toe 0 ± 2 (0 ± 1/16)
Wheel turning in 40°00' ± 2°
angle
out 31°00' (Reference)
Rear Wheel Alignment:

Camber -0°45' ± 45'
Total toe 2 +2 -1 (1/16 +1/16 -1/32)

1-4
General Information
Construction
Sp: Steel plate / Hss: High strength steel plate / Zn: Zinc-plating
No. Part Name No. Part Name
(1) Hood (Hss, Zn) (22) Side Sill Reinforcement (Hss, Zn)
(2) Front Fender (Sp, Zn) (23) Front Pillar Inner Lower (Hss)
(3) Door (Hss, Zn) (24) Front Pillar Inner Upper (Hss, Zn)
(4) Trunk Lid (Sp, Zn) (25) Roof Side Rail (Hss)
(5) Bulkhead Side (Sp, Zn) (26) Roof Panel (Sp)
(6) Bulkhead Side Stay (Sp, Zn) (27) Rear Inner Panel (Sp, Zn)
(7) Bulkhead Upper Frame (Sp, Zn) (28) Wheel Arch Extension (Sp, Zn)
(8) Front Lower Cross-member (Hss, Zn) (29) Rear Wheelhouse (Sp, Zn)
(9) Wheelhouse Upper Member (Sp) (30) Inside Sill (Hss, Zn)
(10) Front Wheelhouse (Sp, Zn) (31) Front Floor (Sp, Zn)
(11) Front Damper Extension (Hss, Zn) (32) Middle Floor Cross-member (Hss, Zn)
(12) Damper Housing (Hss, Zn) (33) Middle Floor Gusset (Hss)
(13) Front Side Frame (Hss, Zn) (34) Rear parcel Shelf (Sp)
(14) Side Frame Extension Rear/Front Side Outrigger (Hss, Zn) (35) Rear Floor Upper Cross-member (Sp)
(15) Dashboard Lower (Sp, Zn) (36) Rear Floor (Sp, Zn)
(16) Dashboard Upper (Sp, Zn) (37) Rear Panel (Sp, Zn)
(17) Outer Panel (Sp, Zn) (38) Rear Panel Side Stiffener (Sp)
(18) Rear Combination Adapter (Sp, Zn) (39) Rear Frame A (Sp, Zn)
(19) Front Pillar Lower Stiffener (Sp, Zn) (40) Rear Frame B (Hss, Zn)
(20) Front Pillar Upper Stiffener (Hss) (41) Rear Floor Cross-member (Sp, Zn)
(21) Centre Pillar Stiffener (Sp)

1-5
General Information
Colour Chart Paint Specifications
P.: Pearl Paint / M.: Metallic Paint

Paint Code Colour NH-578 NH-623M B-92P B-96P G-95P R-513 Y-61P Inca YR-525M
Name Taffeta Stain Silver Night Hawk Eternal Blue Clover Green Rallye Red P. Titanium M.
White M. Black P. P. P.
KE SE O O O O O O O O
SE EXEC O O O O O O O O
KG LS O O O O O O O O
LSG O O O O O O O O
ES O O O O O O O O
ESG O O O O O O O O
KK EX O O O O
KY VTi O O O O O O
KX EX O O O O O
KB LS O O O O O O O O
ES O O O O O O O O
NOTE: In case of vehicles painted with NH-578, NH-623M, Y-61P and YR-525M and apply black (NH-70 Gloss 20) to the lower
surface of the side sill (A) section.
1. FRONT BUMPER
Body colour
2. FRONT GRILLE
Body colour
3. HOOD MOULDING
Body colour
4. DOOR MIRROR
Body colour or black (NH-72 Gloss
30)
5. DOOR OUTER HANDLE
30)
6. SIDE SILL
7. ROOF MOULDING
Black (NH-70 Gloss 20)
8. LICENSE PLATE TRIM
20)
9. REAR BUMPER
Body colour
10. DOOR MOULDING
11. DOOR SASH TRIM
12. FRONT UNDER SPOILER

Replacement - Replacement

Replacement
*Side Sill Outer Panel

Mass Production Body Welding Diagram 3-2
Removal 3-3
Installation 3-4
Roof Panel
Rear Side Outer Panel

Removal 3-7
Installation 3-8
Rear Panel
Items marked with and asterisk (*) include SRS components; special caution is required when servicing.

Replacement - Side Sill Outer Panel
3-2
Side Sill Outer Panel
Mass Production Body Welding Diagram
a. a. VIEW (Y)
b. Centre pillar stiffener
c. Outer panel stiffener
d. Side sill reinforcement
e. VIEW (Z)

3-3
Removal
Cut and pry off the side sill outer panel.

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

3-4
Installation
1. 1. Cut and set the new side sill reinforcement into Passenger's side
position, and tack weld the clamped position.
When replacing the side sill reinforcement, cut the new side sill
2. Cut the repaired part (outer panel) and set it into
reinforcement so it overlaps the body side reinforcement by 20
position. Clamp the repair part and check the body
mm (1.8 in.), and fillet weld it.
dimensions (see section 4).
3. Temporarily install the door and front fender and
check for differences in level and clearance. Make
sure the body lines flow smoothly.
4. Remove the repaired part and weld the centre pillar
stiffener, side sill reinforcement and front pillar lower
stiffener (driver's side).
Driver's side
1. 1. Fillet welding
Overlap
20 mm (1.8 in.)
2. 5. Clamp the repair part and recheck the clearance and

alignment of the door and front fender.
6. Perform the main welding:
Attach a patch at the cut section of the front pillar
(driver's side) center pillar and wheel arch and plug
2. 1. NEW SIDE SILL REINFORCEMENT
weld them.
VIEW (Z) Driver's side
3. 1. NEW SIDE SILL REINFORCEMENT
3. 1. PATCH
2. Butt welding
3. Butt welding
4. PATCH
5. OUTER PANEL
Passenger's side:

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

Roof Panel
3-5
Roof Panel
Without roof panel:

a. a. Outer panel
b. Roof panel
c. Front roof rail
d. Rear roof rail

Replacement - Rear Side Outer Panel
3-6
a. Rear parcel shelf
b. Rear damper stiffener
c. Rear gutter
d. Inner panel
e. Rear panel
f. Rear Combination adaptor
g. Rear gutter
h. Outer panel stiffener
i. VIEW (Z)
j. Wheel arch extension
k. Side sill reinforcement
l. Centre pillar stiffener

3-7
Removal
Cut and pry off the rear side outer panel.

Check the rear combination adaptor position, and check it for damage. If necessary, replace the rear combination
adopter and rear gutter as an assembly.
Check the centre pillar stiffener position and check it for damage. If necessary, cut and replace it.
1. CENTRE PILLAR STIFFENER
2. INNER PANEL
3. REAR DAMPER STIFFENER
4. PARCEL SHELF
5. REAR COMBINATION ADAPTOR
6. REAR GUTTER
7. REAR PANEL
8. REAR COMBINATION ADAPTOR
9. OUTER PANEL
10. REAR FLOOR

3-8
Installation
1. 1. Cut and set the new centre pillar stiffener into 1. 8. Temporarily install the door, rear window, trunk lid and
position, and install the middle floor gusset. rear bumper, and check for differences in level and
clearance.
Make sure the body lines flow smoothly.
9. Do the main welding:
Attach a patch at the cut section of the rear pillar
and plug weld it.
2. 1. MIDDLE FLOOR GUSSET

2. NEW CENTRE PILLAR STIFFENER
3. 2. Set the new repaired part (outer panel) and rear

combination adaptor into position and clamp them.
Check the body dimensions (see section 4).
Remove the repaired part (outer panel) and weld
the centre pillar stiffener.
2. 1. OUTER PANEL
2. PARCEL SHELF
3. REAR GUTTER
4. Butt welding
5. PATCH
6. Butt welding
7. NEW OUTER PANEL
8. Fillet welding
Overlap
30 mm (1.2 in.)
4. 1. Fillet welding 9. PATCH
Overlap
20 mm (0.8 in.) Weld the rear combination adaptor and rear panel.
2. NEW CENTRE PILLAR STIFFENER
5. 7. Tack weld the outer panel and rear combination

adaptor.

3. 1. REAR COMBINATION ADAPTOR

Rear Panel
3-9
Rear Panel
a. Rear combination adaptor
b. Passenger's compartment
c. Rear panel
d. Jack-up stiffener
e. 4-plate welding

Body Dimensional Drawings - Body Dimensional Drawings

Body Dimensional Drawings
Upper Body Measuring Dimensions

Passenger Compartment 4-2
Opening Repair Chart 4-3

4-2
Passenger Compartment
Unit: mm (in.)
1. 1. K, k
Front Seat Rear Side Bracket Point 7 (0.3)

2. L, l
Rear Damper Mount Hole 11 (0.43)

Opening Repair Chart
4-3
Opening Repair Chart
Unit: mm (in.)
Door and Windshield Openings:
1. A
Windshield lower dashboard guide
pin
2. B, C
Windshield opening flange notch (2
places)
3. D, E, F, G
Door opening flange notch (8 places)
Rear Window and Trunk Lid Openings:

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

Rust Prevention - Rust Prevention

Rust Prevention
Cross Section of Body and Sealants

General 5-2
Rear Side Outer Panel and Rear Panel 5-3

Rust Prevention - Cross Section of Body and Sealants
5-2
General
NOTE: Following the sealer manufacturer's instructions. 1. 5. Apply sealer on any area that the replacement part
will cover. Smooth the sealer with a brush is
1. 1. Clean the areas to be sealed with the white gasoline.
necessary.
2. Wipe off any excess spot sealer with thinner. After
the primer is sprayed, sealer will fill in the area where
spot sealer was wiped off.
3. Make sure you can see the sealant when the sealed
part is in its proper location. Refer to page 5-3 of this
manual, refer to the 2001 CIVIC 4-door/CIVIC 5-door
Body Repair Manual (P/N. 62S5A30) on this CD for
the items not shown in this manual.
2. 4. Finish sealing the engine compartment, the door

opening, the truck gutter and the tailgate gutter. Wipe
of the excess sealer.

Rust Prevention - Cross Section of Body and Sealants
5-3
Rear Side Outer Panel and Rear Panel
1. Rear gutter
2. Outer Panel
3. Outer Panel
4. Parcel Shelf
5. Rear combination adaptor
6. Outer Panel
7. Rear gutter
10. Rear panel
12. Outer Panel
14. Rear gutter extension
16. Rear gutter
17. Gutter extension
18. Rear gutter
19. Quarter lower extension
20. Outer panel

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SERVICE

NOTE: Gives helpful information.

All information contained in this manual is based on the latest

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Front Wheel Alignment:

Rear Wheel Alignment:

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P.: Pearl Paint / M.: Metallic Paint

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*Side Sill Outer Panel

Rear Side Outer Panel

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Cut and pry off the side sill outer panel.

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2. 5. Clamp the repair part and recheck the clearance and

3. 1. NEW SIDE SILL REINFORCEMENT

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Without roof panel:

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Cut and pry off the rear side outer panel.

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2. 1. MIDDLE FLOOR GUSSET

3. 2. Set the new repaired part (outer panel) and rear

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

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3. 1. REAR COMBINATION ADAPTOR

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Upper Body Measuring Dimensions

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Rear Window and Trunk Lid Openings:

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Cross Section of Body and Sealants

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2. 4. Finish sealing the engine compartment, the door

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