Body Repair News
Applies To: 2016 Civic Model Series – ALL

March 2016

2016 Civic: New Model Body Repair Information
(Supersedes original publication issued November 2015. Revised to add 2-door model information)
DISCLAIMER: This publication contains a summary of new body and vehicle technology that may affect
collision and other body repairs. Always refer to the appropriate electronic service information for complete
repair information. A subscription may be purchased at: techinfo.honda.com
TABLE OF CONTENTS
New Model Body Technology

Page 2

Body Repair Information

Page 8

Welding Precautions and Information

Page 9

Airbag System Components and Repairs

Page 11

Electrical & Driver Support Systems Repair Information

Page 13

OVERVIEW OF BODY FEATURES

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•
•
•
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Next-Generation Advanced Compatibility Engineering™ (ACE™) body structure
Body construction using extensive amounts of high-tensile-strength steel (HSS) and ultra-high-strength
steel (UHSS - 980 MPa and higher)
Weight-saving 1,500 MPa steel center pillar stiffener and rear frame with soft zones for crash performance
on 4-Door models
Bolt-on resin composite lower front bulkhead assembly
Introduction of the Honda Sensing™ suite of advanced safety and driver-assistive technologies, including:
Adaptive Cruise Control with Low Speed Follow, Lane Keeping Assist System, Road Departure Mitigation,
and Collision Mitigation Braking System™ with pedestrian sensing capability
© 2016 American Honda Motor Co., Inc. – All Rights Reserved

ABN 02539 (1603)

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New Model Body Technology
BODY CONSTRUCTION AND HIGH-STRENGTH STEEL CONTENT (4-DOOR MODELS)
• Steel parts are color coded based on their tensile strength in megapascals (MPa).
• High-strength steel (HSS) is defined as any steel with a tensile strength of 340 MPa or higher.
• Ultra-high-strength steel (UHSS) is defined as any steel with a tensile strength of 980 MPa or higher.
• Steel repair and welding procedures vary depending on the tensile strength of the parts involved.

4-Door Upper View

270 MPa
440 MPa
590 MPa
Aluminum

780 Mpa
980 MPa
1,500 MPa
Steel Tensile
Strength Legend

4-Door Lower View
Aluminum

Important Information
These illustrations are for general reference only.
Some body parts are constructed from multiple
layers of different tensile strength steels. Refer to the
body service information’s body construction section
for specific steel tensile strength information.
© 2016 American Honda Motor Co., Inc. – All Rights Reserved

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BODY CONSTRUCTION AND HIGH-STRENGTH STEEL CONTENT (2-DOOR MODELS)
• Steel parts are color coded based on their tensile strength in megapascals (MPa).
• High-strength steel (HSS) is defined as any steel with a tensile strength of 340 MPa or higher.
• Ultra-high-strength steel (UHSS) is defined as any steel with a tensile strength of 980 MPa or higher.
• Steel repair and welding procedures vary depending on the tensile strength of the parts involved.

2-Door Upper View

270 MPa
440 MPa
590 MPa
Aluminum

780 Mpa
980 MPa
1,500 MPa
Steel Tensile
Strength Legend
2-Door Lower View
Aluminum

Important Information
These illustrations are for general reference only.
Some body parts are constructed from multiple
layers of different tensile strength steels. Refer to the
body service information’s body construction section
for specific steel tensile strength information.
© 2016 American Honda Motor Co., Inc. – All Rights Reserved

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1,500 MPa (HOT STAMP) STEEL LOCATIONS
1,500 MPa steel is stronger than ordinary steel, so it can help protect vehicle occupants while reducing overall
vehicle weight to improve fuel efficiency.
The numbered parts in the diagram below are constructed of 1,500 MPa steel:
4-Door 1,500 MPa Locations

5

6

1
2

8
7
4
3
Civic 2 & 4 Door Models
1

Front Inner Upper Pillar

5

Roof Side Stiffener

2

Front Pillar Upper Stiffener

6

Roof Front Rail (4-Door)

3

Front Side Frame Extension

7

Center Pillar Stiffener (4-Door)

4

Side Sill Reinforcement

8

Rear Frame (4-Door)

2-Door 1,500 MPa Locations

5
1
2

3

© 2016 American Honda Motor Co., Inc. – All Rights Reserved

4

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1,500 MPa STEEL REAR FRAME (4-DOOR MODELS)
4-door models utilize weight-saving 1,500 MPa steel rear frame rails with soft zones for impact crush control.
• If rear frame damage is suspected, measure the entire
vehicle using a three-dimensional measuring system.
• If the rear frame is damaged, replace the affected
rear frame(s) as a complete assembly only.
• The traditional replacement of only the rear portion
of the frame (Rear Frame B) is not possible because
the 1,500 MPa rear frame cannot be sectioned.
• For further repair information, refer to the following:
– “Repairing 1,500 MPa Steel Parts” on
page 7 of this publication.
– “Rear Floor/Rear Frame Replacement” in the
body service information.

1,500 MPa Steel Rear Frame Rails

ALUMINUM PARTS & REPAIRABILITY
The front bumper beam uses 6000 series aluminum alloy construction.
Repairability Issues
• Do not repair damaged bumper beams.
• To help prevent galvanic corrosion, some
fasteners for aluminum parts are considered
one-time use and must be replaced if removed.

Front Bumper Beam

RESIN COMPOSITE FRONT BULKHEAD
This vehicle has a lower bulkhead assembly constructed of resin composite material.
• The upper bulkhead frame is constructed of 270 MPa
mild steel.
• The front upper and lower bulkheads are only sold
as a complete assembly.
• The bulkhead design improves engine compartment
access during factory assembly and service.
• The cooling fans, radiator, A/C condenser, hood lock,
outside air temperature sensor, and related
piping/components are attached to the front bulkhead.
• The bulkhead is attached to the body with 20 bolts.
• A damaged bulkhead must be replaced.
• For more information, refer to “Front Bulkhead
Replacement” in the body service information.
Lower
Bulkhead

Upper
Bulkhead

Resin Composite Front Bulkhead

© 2016 American Honda Motor Co., Inc. – All Rights Reserved

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FRONT BRACE COLLAR BOLTS
This front brace is located under the front bumper directly ahead of the front subframe.
• The front brace is attached to the body using special
collar bolts that compensate for body dimensional variations.
• A special removal and installation procedure is required
• For more information, refer to “Front Brace Removal
and Installation” in the service information.

ACOUSTIC SEPARATOR LOCATIONS
A combination of molded, extruded, and tape acoustic separators are applied in various body locations.
• Locations are shown in the diagram below.
• These are applied within the body pillars.
• They are designed to block noise paths into the cabin from hollow body cavities.
• Repairs are similar to previous models using commercially-available products.
• Refer to the Replacement section of the body service information for specific procedures.

4-Door Separator Locations Shown - 2-Door Similar
© 2016 American Honda Motor Co., Inc. – All Rights Reserved

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CAPLESS FUELING SYSTEM
This vehicle uses a capless fueling system. It does not have a conventional fuel fill cap.
• A backup fuel door open cable is located under the parcel shelf.
• If you need to refuel the vehicle from a portable fuel container,
a funnel is located in the trunk’s spare tire well tool case.
• The fueling system can be damaged by directly inserting the
nozzle of a portable fuel container or by using any funnel
other than the one provided with the vehicle.
• For more information, refer to “Refueling From a
Portable Fuel Container” in the owner’s guide.
Capless Fueling System

TOWING AND LIFTING PRECAUTIONS
• Flat bed towing equipment is the preferred method to
transport this vehicle.
• Front wheel lift towing equipment may also be used
to tow this vehicle.
For more information, refer to “Emergency Towing”
in the owner’s guide or service information.
• Lift or jack only at the specified points to avoid damaging
the vehicle.
• Do not lift or tow this vehicle by its bumpers, or serious
damage will result.
For more information, refer to “Lift and Support Points” in the
service information.

© 2016 American Honda Motor Co., Inc. – All Rights Reserved

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Body Repair Information
NOTE: The following content is intended only to highlight new/special concerns. No body repairs should be
attempted without first referencing the appropriate body service information.
USE OF HEAT DURING BODY STRAIGHTENING AND REPAIR
When you are doing body straightening and repair procedures,
follow these guidelines:
• Do not apply heat to any body part during straightening.
This may compromise the internal structure and strength
of high-strength steel parts.
• Any part that has heat applied to it during straightening
must be replaced with new parts.
• Ignoring these instructions may significantly reduce
occupant protection in any subsequent collision.
Do not heat during straightening
SECTIONING (CUT AND JOINT) GUIDELINES
Various high-strength steel materials with different sheet
thicknesses and strengths are applied in many places that
vary by body design in order to increase collision safety
performance, body stiffness, and weight reduction.
Stiffening members inside each part (patch, stiffener, etc.)
are also specified in detail.
Follow these guidelines to avoid an unsafe repair:
• Sectioning (cut and joint) should usually be avoided except
for mild steel outer panels and floor panels unless a specific
procedure is provided in the body service information.
• However, depending on the type of vehicle damage,
steel parts with a tensile strength ≤ 780 MPa may be
sectioned provided all of the following conditions are met:
– Sectioning must be done in a single-layer area of the part.
– Multi-layer internal steel reinforcements and stiffeners
must not be cut.
– The repair is not in a load-bearing area such as engine,
transmission, or suspension mounting points.
• Replace body structural components such as
stiffeners, reinforcements, and other multi-layered
steel parts as assemblies that match the replacement
parts configuration.
• Approved welding methods are listed in the table on
the right.
• Refer to the body service information for complete
information.

Sectioning Area Examples

Welding Method

Steel Part
Tensile Strength
(MPa)

Spot
Weld

Plug

Butt