steering HONDA CIVIC 2002 7.G Repair Manual

Front and Rear Suspension
BallJoint Removal
Special Tools Required
Ball ioint remover.2S mm 07MAC-SL00200
Always use a ball joint remover to disconnect a ball
joint. Do not strike the housing or any other part of
the ball joint connection to disconnect it.
'1, Install a hex nut (A) ontothethreadsoftheballjoint
{B). Make sure the nut is flush with the balljoint pin
end to prevent damage to the threaded end of the
ball ioint oin.
Apply grease to the special tool on the areas shown(A). This will ease installation of the tool and
prevent damage to the pressure bolt {B) threads.
2.
18-10
3. Loosen the pressure bolt (A), and installthe special
tool as shown. Insen the jaws carefully, making
sure not to damage the ball joint boot. Adjust the
jaw spacing by turning the adjusting bolt (B).
10 mm HEX NUT
5.
07MAC-S100200
After adjusting the adjusting bolt, make sure the
head (C) of the adjusting bolt is in the position
shown to allow the jaw to pivot.
With a wrench, tighten the pressure bolt until the
ball ioint pin pops loose from the steering arm or
knuckle. lf necessary. apply penetrating type
lubricant to loosen the ball joint pin
NOTE: Do not use pneumatic or electric tools on
the pressure bolt.
Remove the tool, then remove the nut from the end
ofthe balljoint pin, and pullthe balljoint out ofthe
steering arm or knuckle. Inspectthe balljoint boot,
and replace it if damaged.
6.

Special Tools Required
Ball joint remover,28 mm 07MAC-S100200
Removal
1. Raise the front of the vehicle, and support it with
safety stands in the proper location (see page 1-8).
Remove the front wheels.
Remove the cotter pin (A) from the tie-rod end ball
ioint, and remove the nut (B).
10 mm HEX NUT
07MAC-S1002000
Disconnectthe tie-rod end from the steering arm
on the damper using the specialtool (see page 18-
10 ).
Remove the bolts, and remove the wheel sensor
harness bracket {A) and brake hose bracket (B)
from the damper. Do not disconnect the wheel
4.
sensor connector.
A6x1.0mm
/.8
x 1.25 nm
q
5. Remove the damper pinch bolts (A)while holding
the nuts (B).
6. Remove the flange nuts (A)from the top ofthe
damper,
A10 x 'l.25 mm
7. Lower the lower arm, and remove the damper
assembly (B).
(cont'd)
18-21

3. Position the damper on the knuckle, and installthe
new damper pinch bolts (A) and nuts (B), and
lightly tighten the nuts.
B16x 1,5 mm157 N.m(16.0 kgt m,116 tbt.ftl
4. Place the floor jack under the lower arm balljoint,
and raise the suspension to load it with the vehicle's
weight.
Do not place the jack against the lower arm
balljoint.
Tighten the flange nuts on the top of the damper to
the specified torque.
Tighten the damper pinch nuts to the specified
torque.
Install the brake hose bracket (A) and the wheel
sensor harness bracket (B) onto the damper, and
tighten the bolt to the specified torque.
5.
1.
9.8 N.m11.0 kgf.m, 7.2lbf.ftl22N|rl.12.2 kgI m,16 rbr,ftl
q
8. Connect the tie-rod end to the steering arm, and
tighten the nut (A) to the specified torque. Install
the cotter pin (B) after tightening, and bend lts end
as shown.
9. Clean the mating surface ofthe brake disc and the
inside of the wheel, then install the front wheels.
10. Check the wheel alignment, and adjustitif
necessary {see page 18-4).
18-25

Gonventional Brake Components
ComponentProcedureAlso check for:
l\4aster CylinderLook for damage or signs of fluid leakage at;. Reservoir or reservoir grommets
. Line joints
. Between master cvlinder and booster
Brake HosesLook for damage or signs of fluid leakage at:. Line joints and banjo bolt connections. Hoses and lines. also inspect for twisting or
damaqe
Bulging, twisted or bent lines.
CaliperLook for damage or signs of fluid leakage at:. Piston seal. Banjo bolt connections. Bleeder screw
Seized or sticking caliper pins.
ABS l\ilodulatorLook for damage or signs of fluid leakage at:. Line joints
. Modulator
Brake System Inspection and Tests
Brake System Test
Brake pedal sinks/fades when braking
1. Start the engine, and let it warm up to operating temperature.
2. Attach a 2-inch pieceof masking tape along the bottom of the steering wheel, and draw a horizontal reference
mark across it.
With the transmission in Neutral, press and hold the brake pedal lightly, then release the parking brake.
While still holding the brake pedal, hook the end of the tape measure behind it. Then pull the tape up to the
steering wheel, noting where the tape measure lines up with the reference mark you made on the masking tape.
Apply steady pressure to the brake pedal for 3 minutes.
Watch the tape measure.
. if it moves less than 10 mm, the master cylinder is OK.
. if it moves more than 10 mm replace the master cylinder.
t-
3.
5.
6.
19-4

Dashboard
Instrument Panel Removal/
Installation
NOTE:. When prying with a flat-tip screwdriver, wrap it withprotective tape, and apply protective tape around the
related parts, to prevent damage.. Take care not to scratch the dashboard and related
pa rts.
1. Tilt the steering column down.
2. Remove the steering column upper cover {see page
17,9).
Remove the instrument panel (A).
-1 Gently pull out along the bottom to release the
clips (B) and hooks (C).
-2 Gently pull out the upper portion to release the
clips (D) and hooks (E).
Fastener Locations
B >: clip.2 DD,: Clip,2
^*,
4.Installthe panel in the reverse order of removal,
and push the clip and hook portions into place
securery.
Driver's Dashboard Lower Cover
Removal/lnstallation
NOTE: Take care not to scratch the dashboard and
related Parts.
1. Remove the driver's dashboard lower cover (A).
-1 Turn the lock knob (B) 90".-2 Gently pull out the left side to release the
hooks (C),
-3 Pull out the panelto release the hooks (D).
Installthe cover in the reverse order of removal,
and push the hook portions into place securely.
20-59

Dashboard
Dashboard Side Vent RemovaU
Installation
NOTE:. Take care not to scratch the dashboard.. Put on gloves to protect your hands.
1. Remove the dashboard (see page 20-66).
2. Remove the steering hanger beam from the
dashboard (see page 20-68).
3. Remove the screws, then remove the air duct (A)
from the dashboard (B).
Fastener Locations
):Screw, 7
6hD
t
4.Remove the screws, lhen remove the slde vent (A).
Fastener Locations
):Screw,4
5. lnstallthe side vent in the reverse order of removal.
20-64
Beverage Holder Removal/
lnstallation
NOTE:. Take care not to scratch the dashboard,. Put on gloves to protect your hands.
1. Remove the dashboard (see page 20-66).
2. Remove the screws, then remove the beverage
holder (A).
Fastener Locations
):Screw.2
Installthe beverage holder in the reverse order
removat.
of3.

Driver's Tray Removal/lnstallation
NOTE:. Take care not to scratch the dashboard.. Put on gloves to protect your hands.
1. Remove the dashboard (see page 20-66).
2. Remove the beverage holder (see page 20-64).
3. Remove the screws, then remove the driver's tray(A).
Fastener Locations
):Screw.3
4, lnstall the tray in the reverse order of removal.
Passenger's Tray Removal/
Installation
NOTE:. Take care not to scratch the dashboard.. Put on gloves to protect your hands.
1.
2.
3.
4.
Remove the dashboard (see page 20-66),
Remove the steering hanger beam from the
dashboard (see page 20-68).
Remove the air duct (see step 3 on page 20-64).
Remove the screws, then remove the passenger's
tray (A).
Fastener Locations
):Screw, 8
5. lnstall the trav in the reverse order of removal.
20-65

Dashboard
Dashboard Removal/lnstallation
SRS components are located in this area. Review the
SRS component locations (see page 23-13) and the
precautions and procedures (see page 23-14) in the SRS
section before performing repairs or service.
NOTE:. When prying with a flat-tip screwdriver, wrap it with
protective tape, and apply protective tape around the
related parts to prevent damage.. Have an assistant help you when removing and
installing the dashboa rd.. Take care not to scratch the dashboard, body, and
other related parts.
. Put on gloves to protect your hands.
1. Make sure you have the anti-theft code for the radio,
then write down the frequencies for the preset
buttons.
Disconnect the negative cable from the battery, and
wait at least three minutes before beginning work.
Remove these items:
. Driver's dashboard lower cover (see page 20-59). Driver's dashboard under cover (see page 20-60). Passenger's dashboard lower cover (see page
20-63). Glove box (see page 20-63). Consoles, front and rear (see page 20-57). Shift lever trim {see page 20-61). Center panel (see page 20-62). Kick panels, both sides (see page 20-50). A-pillar trim. both sides (see page 20-50). Steering column (see page 17-9)
20-66
4. From the center panel opening, remove the screws,
then remove the center bracket (A).
Fastener Locations
):Screw,2
Remove the sh ift lever (see page 13-51).
From outside of the passenger's door, gently pull
out along the edge of the dashboard side cover (A)
to release the hooks (B), then release the upper
hook (C), to remove the cover.

Dashboard
Dashboard Removal/lnstallation
(cont'd)
11. From outside the driver's door, remove the caps (A),
then remove the bolts (8, C, D), and lift up on the
dashboard (E) to release it from the guide pins
(F. G) on the body.
Fastener Locations
B>rBolt.3 C>: Bolt,2 D>: Bolt,2
m6[-,,,,",",,-,F6't---'' ffi'!--v{/- Kr* w-
B
$7:
^/761:
/,-,. r:; 8 x 1.25 mm22Nm(2.2 kgf.m, 16lbf.ft)
13.
{2.2 kgf m, 16lbf.ftl
Carefully remove the dashboard through the front
door opening.
lnstall the dashboard in the reverse order of
removal, and note these items:
. Make sure the dashboard fits onto the guide pins
correctly.. Apply liquid thread lock to the dashboard
mounting bolts of the middle portion before
reinstallation.. Before tightening the bolts, make sure each wire
harness and control cables are not pinched.
. Make sure the connectors are plugged in
properly, and the antenna lead is connected
propeny.. Reconnect the negative cable to the battery.. Enter the anti-theft code for the radio, then enter
the customer's radio station presets.
. Reset the clock.. Do the ECM/PCM idle learn procedure isee page
1 '1-139).
20-68
Steering Hanger Beam
Replacement
NOTE: Put on gloves to protect your hands.
1, Remove the dashboard (see page 20-66).
2. Remove these items from the dashboard:
. lnstrument panel (see page 20-59). Driver's pocket (see page 20-60). Gauge assembly (see page 22-64). Passenger's airbag (see page 23-'l 14)
Remove the screws, then remove the glove box
striker (A).
Fastenea Locations
):Screw,4
\

4. Remove the bolts (A) and screws (B) securing the
dashboard (C) and steering hanger beam (D), and
disconnect the power mirror switch connector (E)
and cruise control main switch connector (F).
Separate the dashboard and steering hanger beam.
Faslener Locations
A>rBolt,4 B>:Screw,9
5 N.m {0.5 kgf m,4lbf,ftl
5. Installthe beam in the reverse order of removal,
and note these items:
. N4ake sure the dashboard wire harness (G) is notpinched.
. Make sure the connectors are plugged in
properly.
20-69