Radiator Support: Service and Repair

Front Bulkhead

Removal

Mass production body welding positions and numbers







Construction

NOTE:
- This section explains the procedures after removal of all related parts.
- 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.
- Remove the bulkhead upper center frame and the bulkhead side stay gusset, and replace them.
- Replace the bulkhead side stay and the bulkhead lower crossmember.
- Replace the bulkhead side stay, the side stay plate, and the bulkhead upper side frame as an assembly.







Installation







1. Clamp the new bulkhead parts, and secure the bulkhead upper center frame (A) to the bulkhead side stay (B) and the bulkhead upper side frame (C) with the mounting bolts. Measure the front compartment diagonally.







2. Check the body dimensions.
- Front bulkhead position
- Engine compartment
- Front damper extension position
- Engine compartment and front floor, under view
- Repair chart, top view
- Repair chart, side view

3. Tack weld the new parts into position.
4. Temporarily install the front fender, the hood, and the door(s), then check for differences in level and clearance.
Check the external parts fitting positions; 4-door/2-door. If necessary, check the headlight and the front bumper positions. Make sure the body lines flow smoothly.

5. Do the main welding.
- Weld the bulkhead side stay (A) and the bulkhead lower crossmember (B) to the bumper beam extension flange (C) and the subframe front bracket (D).
- Weld the bulkhead side stay and the bulkhead lower crossmember.







6. Weld the bulkhead upper side frame (A) to front damper extension B.







7. Weld the bulkhead side stay gusset (A).