CRV Daftar Isi Body Repair

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NOTE: Gives helpful information.

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.

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6HUYLFH3XEOLFDWLRQ2IILFHFirst Edition 12/2001 124 pagesAll Rights Reserved

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This manual covers the repairs of 2002 CR-V that have been involved in an accident, 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 2002 CR-V Shop Manual, P/N. 62S9A00 for specifications, wire harness locations,safety stand support points, etc.

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You CAN be KILLED or SERIOUSLY HURT if you dont follow instructions.

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You CAN be HURT if you dont follow instructions.

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Detailed descriptions of standard workshop procedures, safety principles and service operations are notincluded. Please note that this manual does contain warnings and cautions against some specific servicemethods which could cause PERSONAL INJURY, damage a vehicle, or make it unsafe. Please understandthat these warnings cannot cover all conceivable ways in which service, whether or not recommended byHonda, might be done or of the possible hazardous consequences of each conceivable way, nor couldHonda investigate all such ways. Anyone using service procedures or tools, whether or not recommendedby Honda, must satisfy himself thoroughly that neither personal safety or vehicle safety will be jeopardized.


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Frame Hoist ...................................................................................................................................... 1-5Safety Stands ................................................................................................................................... 1-5

Floor Jack ......................................................................................................................................... 1-5

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Description........................................................................................................................................ 2-4Measurement.................................................................................................................................... 2-5

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Correction of the Damaged Area ...................................................................................................... 2-6

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Removal............................................................................................................................................ 2-7

Installation......................................................................................................................................... 2-8

Rust Prevention / Paint ................................................................................................................... 2-10

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Measurement Equipment................................................................................................................ 2-12

Protective Tools .............................................................................................................................. 2-12
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Processing Tools ............................................................................................................................ 2-13

Cutting Tools................................................................................................................................... 2-13

Shaping Tools ................................................................................................................................. 2-14

Fixing Tools..................................................................................................................................... 2-15

Welders........................................................................................................................................... 2-16

Sanding Tools ................................................................................................................................. 2-16

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Spot Welding................................................................................................................................... 2-17

Carbon Dioxide Arc Welder (MIG Arc Weld)................................................................................... 2-19

Gas Welding ................................................................................................................................... 2-20

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Mass Production Body Welding Diagram ......................................................................................... 3-2

Removal ........................................................................................................................................... 3-3

Installation......................................................................................................................................... 3-3

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Removal............................................................................................................................................ 3-5

Installation......................................................................................................................................... 3-7

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Removal.......................................................................................................................................... 3-10

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Mass Production Body Welding Diagram ....................................................................................... 3-14

Removal.......................................................................................................................................... 3-15

Installation....................................................................................................................................... 3-16

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Removal.......................................................................................................................................... 3-18

Installation....................................................................................................................................... 3-19

5RRI3DQHO Mass Production Body Welding Diagram ....................................................................................... 3-20

Removal.......................................................................................................................................... 3-21

Installation....................................................................................................................................... 3-22

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Mass Production body Welding Diagram ........................................................................................ 3-23

Removal.......................................................................................................................................... 3-25

Installation....................................................................................................................................... 3-27

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Removal.......................................................................................................................................... 3-30

Installation....................................................................................................................................... 3-31

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Removal.......................................................................................................................................... 3-33

Installation....................................................................................................................................... 3-34

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Engine Compartment........................................................................................................................ 4-2

Engine / Transmission Mount Positions............................................................................................ 4-3

Passengers Compartment ............................................................................................................... 4-3

Rear Panel / Rear Pillar Gutter Positions ......................................................................................... 4-4

Tailgate Hinge Mount Position.......................................................................................................... 4-4

Opening Repair Chart....................................................................................................................... 4-5

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Engine Compartment and Front Floor Under View ........................................................................... 4-6

Middle and Rear Floor Under View................................................................................................... 4-7

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Top View........................................................................................................................................... 4-8

Side View........................................................................................................................................ 4-10

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General ............................................................................................................................................. 5-2

Engine Compartment, Front Wheelhouse, and Damper Housing .................................................... 5-3

Dashboard Upper, Dashboard Lower, and Roof Panel .................................................................... 5-4

Front Floor and Rear Floor ............................................................................................................... 5-5

Rear Side Outer Panel, and Rear Panel........................................................................................... 5-6

Under Floor, and Rear Wheelhouse ................................................................................................. 5-7

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General ............................................................................................................................................. 5-8

Coating Diagram............................................................................................................................... 5-9

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General ........................................................................................................................................... 5-10

Undercoating Diagram.................................................................................................................... 5-11Area to be Covered by Anti-rust Agents ......................................................................................... 5-12

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General ............................................................................................................................................. 6-3

Refinishing Processes ...................................................................................................................... 6-4

Preprocessing of Painting................................................................................................................. 6-5

Treatment of Metal Surface .............................................................................................................. 6-6

Undercoating .................................................................................................................................... 6-7

Intermediate Coating ........................................................................................................................ 6-8
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Top Coating ...................................................................................................................................... 6-9

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Coating Procedures ........................................................................................................................ 6-11

Painting Repair (Gradation) ............................................................................................................ 6-12

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Features of Plastic Material ............................................................................................................ 6-15

Use of the Repair Material (reference)............................................................................................ 6-17

Refinishing Processes .................................................................................................................... 6-18

Preprocessing of Painting ............................................................................................................... 6-19

Undercoating................................................................................................................................... 6-19

Intermediate Coating....................................................................................................................... 6-21

Top Coating .................................................................................................................................... 6-22

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Frame Repair Chart ............................................................................................................................... 4-8General Safety Precaution .................................................................................................................... 2-3Inspection of Damaged Part .................................................................................................................. 2-4Installation and Inspection ................................................................................................................... 2-11Opening Repair Chart ............................................................................................................................ 4-5Procedures ............................................................................................................................................ 2-2Replacement of the Damaged Area ...................................................................................................... 2-7Reshaping of the Damaged Area .......................................................................................................... 2-6Tools .................................................................................................................................................... 2-12

Welding Methods ................................................................................................................................. 2-17Zinc-plated Steel Plate ........................................................................................................................ 1-11

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Front Bulkhead ...................................................................................................................................... 3-2Front Pillar Outer Panel ....................................................................................................................... 3-14Front Side Frame / Outrigger ................................................................................................................. 3-9Front Wheelhouse / Damper Housing ................................................................................................... 3-4Rear Floor / Rear Floor Cross-member .......................................................................................... ..... 3-32Rear Panel ........................................................................................................................................... 3-29Rear Side Outer Panel ........................................................................................................................ 3-23Roof Panel ........................................................................................................................................... 3-20

Side Sill Outer Panel ........................................................................................................................... 3-17%RG\6SHFLILFDWLRQV .........................................................................................................................1-

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Under Body .................................................................................................................................4-6

Upper Body .................................................................................................................................4-2

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Installation ...................................................................................................................................1-7

Removal ......................................................................................................................................1-7

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Materials ...................................................................................................................................1-1 4

Types ........................................................................................................................................1-1 4

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Locations ....................................................................................................................................1-4
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Floor Jack ................................................................................................................................... 1-5

Frame Hoist ................................................................................................................................1-5

Safety Stands .............................................................................................................................. 1-5

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Body ........................................................................................................................................... 6-3

Color Chart ............................................................................................................................... 1-1 1

General Safety Precautions ..........................................................................................................6-2

Glossary ...................................................................................................................................6-2 3

Plastic Parts .............................................................................................................................. 6-1 5

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Bumper ..................................................................................................................................... 1-1 0

Door ......................................................................................................................................... 1-1 0

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Cross Sections of Body ................................................................................................................ 5-2

Materials ...................................................................................................................................5-1 3

Primer Coat .................................................................................................................................5-8

Sealants .....................................................................................................................................5-2

Tools ........................................................................................................................................ 5-1 3

Treatments ............................................................................................................................... 5-1 0

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Front ........................................................................................................................................... 1-6

Rear ........................................................................................................................................... 1-6
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CRV Daftar Isi Body Repair

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