Rear Side Outer Panel Replacement
1. Mass Production Body Welding Positions and Numbers - Remove

Outer Panel, Rear Gutter Upper and Rear Combi Adapter


2. Construction - Check

Outer Panel and Rear Gutter Complete

NOTE:
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.
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.
When removing the outer panel, bend the wheel arch flange, and cut the sealer with a putty knife.
Check the rear gutter upper and the rear combi adapter for damage. If necessary, replace it at the same time.
Replace the wheel arch outer separator.


NOTE:
Confirm the sheet thickness, tensile strength, and existence of the zinc treatment of both sides, and set the welder to conform to the welding conditions by referring to Roof and Side Panel Construction and Floor and Rear Body Construction.
Welding symbols (The welding symbols with dashed lines have a meaning of the spot welding of the part which is not visible)
( ) and ( )*: The number of welds

1. Body Dimensions - Check

Positioning the replacement parts.
Clamp or tack weld the new parts into position.

2. External Parts Fitting Positions - Check

Temporarily install the related parts, then check for differences in level and clearance. Check the external parts fitting positions. Make sure the body lines flow smoothly. Remove the clamped part.

3. Outer Panel and Rear Gutter Upper and Rear Combi Adapter - Install
1.
Grinding for better adhesive adherence:
Grind the wheel arch portion of the rear inside panel (A) and the outer panel repair part (B) with a belt sander using P80?P120 sand paper.
Air blow the grinding surfaces, then degrease with a wax and grease remover.
2.
Put the cartridge in a caulking gun, and run a continuous bead of the adhesive (A) on all ground surfaces of the rear inside panel (B) and the outer panel repair part (C).
NOTE: Use care to make sure the adhesive is not applied in areas that will be butt welded when the outer panel is installed.
Adhesive: 3M AUTO MIX Panel Bonding 8115, or equivalent, commercially available
NOTE: See the adhesive manufacturer's instructions for details.
3.
Even out the applied adhesive (A) with a spatula (B).
NOTE:
Use care to make sure the adhesive is not applied in areas that will be butt welded when the outer panel is installed.
Be careful not to entrap air in adhesive.
4.
Body side: Reapply the adhesive (A) on the rear inside panel (B).
NOTE: Use care to make sure the adhesive is not applied in areas that will be butt welded when the outer panel is installed.
5.
Apply the sealer (A) to the fuel fill door adapter mating surface of the rear inside panel (B).
6.
Install the new wheel arch outer separator (A). Apply the sealer (B) without a gap all the way around the separator.
7.
Clamp the outer panel repair part, and recheck the clearance and alignment of the rear door and the trunk lid.
NOTE: Never touch the adhesive surfaces with your hands.
8.
Make a gap evenly with the rear inside panel (A) 1.5 mm (0.059 in) while pushing the wheel arch portion of the outer panel repair part (B).
NOTE: Use a commercially available adhesive remover to remove any excess adhesive.
9.
Do the main welding.
Weld the outer panel repair part (A) and the rear gutter set (B).
( )*: Welding positions with high-strength steel (except 1500 MPa) parts. Confirm the plug welding conditions.


Outer Panel Rear Area

Rear Gutter Upper and Rear Combi Adapter

Rear Window Opening
10.
Drying adhesive.
NOTE: Do not move the body until the adhesive is dry.
Drying time (Reference)
Force drying
60°C (140°F)
90 minutes
Natural drying
25°C (77°F)
24 hours