Body HONDA CIVIC 2003 7.G Workshop Manual

Brake System Indicator Gircuit Troubleshooting
Brake system indicator does not come on
'1. Discon nect the m ultiplex contro I unit l3Pconnector
and the ABS control unit 31P connector.
2. Check for continuity between the ABS control unit
3l P connector terminal No,21 and bodyground.
ABS CONTROL UNIT 31P CONNECTOR
Wire side of female terminals
ls there continuity?
YES Repair short to body ground in the wire
between the multiplex control unit and the ABS
control unit.l
NO Go to multiplex control system
trou bleshooting lsee page 22''172).a
Brake system indicator does not go off
1. Turn the ignition switch ON {ll).
2. Release the parking brake.
Does the brake system indicatot go ofl after
several seconds?
YES The system is OK at this time.l
NO Go to step 3.
3. Check the brake fluid level.
ls the level OK?
YES Go to step 4.
NO Refill the brake fluid, and recheck.l
4. Check the ABS indicator.
Does the ABS indicator stay on?
YES Read the ABS DTC (see step 1 on page 19-32).
and do the applicable troubleshooting for the DTC
NO Go to step 5.
5. Turn the ignition switch OFF.
6. Disconnect the ABS control unit3lPconnector.
7. Connect the ABS control unit 31P connector
terminal No. 21 and body ground with a jumper
ABS CONTROL UNIT 31P CONNECTOR
(cont'd )
Wire srde of lemale lerminals
19-55

ABS Components
8.
9.
10.
11.
12.
13.
Brake System Indicator Gircuit Troubleshooting (cont'd)
Turn the ignititon switch ON (ll).
Check the brake system indicator.
Does the brake system indicatot go off?
YES-Replace the ABS modulator-control unit.l
NO-Go to step 10.
Turn the ignition switch OFF.
Connect the multiplex control unit 13P connector
terminal No. 'l and body ground with a jumper wire.
MULTIPLEX CONTROL UNIT 13P CONNECTOR
JUMPERWIRE
Wire side of female terminals
Turn the ignition switch ON (ll).
Check the brake system indicator.
Does the btake system indicatot go off?
YES Repair open in the wire between the
multiplex control unit and the ABS control unit.l
NO Go to multiplex control system
troubleshootin g (see page 22-17 2). a
19-56
\

Body
DoorsComponent Location Index ...........Door Panel Removal/lnstallation .....,..........Door Outer Handle ReplacementDoor Latch ReplacementDoor Glass and RegulatorReplacementDoor Sash Trim Replacement .......................
Door Glass Outer WeatherstripReplacement
Door Weatherstrip Beplacement
Door Glass Adjustment .................................Door Position Adjustment .............................Door Striker Adiustment ................................MirrorsComponent Location Index ...........................Power Mirror Replacement ...........................Mirror Holder Replacement ...........................Rearview Mirror Rep1acement ......................
GlassComponent Location Index ...........................Windshield Replacement
Bear Window Rep1acement ...........................
Ouarter Glass Replacement ..........................MoonroofComponent Location Index ...........................Symptom Troubleshooting Index
Glass Height Adjustment ...............................
Glass ReplacementWind Def lector 8ep1acement ........................Drain Channel Rep1acement ..........................Sunshade Replacement .................................Motor ReplacementFrame and Drain Tube Replacement ............Drain Channel Slider and Cable AssemblyReplacementLimit Switch Adjustment ...............................Closino Force and ODenina Draq Check ......lnterioi TrimComponent Location Index ...........................Trim Removal/lnstallation DoorArea ..........Trim Removal/lnstallation-Rear Side AreaTrim Removal/lnstallation-Cargo Floor AreaTrim Removal/lnstallation-Hatch Area .........Headliner Removal/lnstallation* Carpet Rep1acement .......................................ConsolesConsoles, Front and RearRemova l/lnsta llationFront Console Disassembly/Reassembly .....
20-220,420-620-7
20-920 t0
20- 10
20-1120-1120-1220 13
20-1420-1520-1520-16
20 1120-1920-2520-29
20,3520-3620-3720-3120-3820 3920-4020-4120,42
20 4420-4620,44
20-4920 50
20-51
DashboardInstrument Panel Removal/lnstallation ........Driver's Dashboard Lower CoverRemovat InstallationDriver's Dashboard Under CoverRemova t Insta llation
Oriver's Pocket Removal/lnstallation ............Shift Lever Trim Removal/lnstallation ..........Center Panel Removal/lnstallation ...............Passenger's Dashboard Lower CoverRemova l/lnsta llat ionx Glove Box Removal/lnstallationDashboard Side VentRemoval/lnstallation .................................. 20-64Beverage Holder Removal/lnstallation ........ 20-64Driver'sTray Removal/lnstallation ............... 20-65Passenger's Tray Removal/lnstallation ........ 20 65* Dashboard Removal/lnstallation .................. 20-66Steerinq Hanqer Beam Reolacement ........... 20-68Seats "
Component Location Index ........................... 20-10* Front Seat Removal/lnstallation ................... 20-11* Front Seat Disassembly/Reassembly-Driver's .................................. 20-73* Front Seat Disassembly/Reassembly-Passenger's ........................... 20-74* Front Seat Cover Replacement ..................... 2O-75Rear Seat Removal/1nsta11ation ..................... 20-80Rear Seat-back Latch Replacement .............. 20-81Rear Seat-backStriker Replacement ............ 20-81
20-59
20-59
Rear Seat-back Cover Replacement ............. 20-82Rear Seat Cushion Cover Replacement ....... 20.84BumpersFront Bumper Removal/lnstallation .............Rear Bumoer Removal/lnstallation ...............HoodAdjustmentHood Seal ReplacementHood Insulator Rep1acement .........................Hatch
20-6020,6020 6120-62
20-63
20-63
20,8520-86
20-4720,8820,89
20-5220-5320-5420-55
20-5720-58
Adjustment ................... 20-90Hatch Suppon Strut Replacement ................ 20-91Hatch WeatherstriD Reo1acement ................. 20-92
Fuel Fill DoorAdiustment ................... 20-93Exterior TrimFront Grille Replacement ..............Cowl Covers Replac"rn""t .. . .....................A pillar Corner Trim Replacement ................Roof lMolding Replacement ...........................Rear License Trim ReplacementHatch Spoiler 8ep1acement ...........................Emblem Rep1acement .........................
20-9420-9520-9620-9720,9820-9920-100

Doors
Door Glass Adiustment {cont'd)
6. Raise the glass fully, and check for gaps. Check that
the glass (A) contacts the glass run channel (B)
evenrv.
7.Check for water leaks. Run water over the roof and
on the sealing area as shown, and note these items:
. Use a 12 mm (1/2 in.) diameter hose (A).. Adjust the rate of water flow as shown {B).. Do not use a nozzle.. Hold the hose about 300 mm (12 in.) awayfrom
the door (C).
12mm1112in,l !
\e
Attach the plastic cover, and installthe door panel(see page 20-4).
9. Test-drive and check for wind noise.
300 mm {12 in.l
20-12
Door Position Adiustment\
NOTE; Check for equal gaps between the front, rear,
and bottom door edges and the body. Check that the
door and body edges are parallel.
1. Place the vehicle on a firm, level surface when
adjusting the door.
2. Adjust at the hinges {A):
. Remove the front inner fender (see page 20-102)
and front fender fairing (see page 20-103).
Loosen the hinge mounting bolts (B) slightly, and
move the door backward or forward, uD or down
as necessary to equalize the gaps.. Place a shop towel (C) on the jack (D) to prevent
damage to the door when adjusting the door.
t, 8x1.25mm29 N.m (3.0 kgf.m,22 tbt.trl
\

3. Check that the door and body edges are parallel. lf
necessary, adjust the door cushions (A) to make the
rear of the door flush with the bodv.
Apply body paint to the hinge mounting bolts and
around the hinges.
Check for water leaks (see step 7 on page 20-12).
Test-drive and check for wind noise.
5.
Door Striker Adjustment
Make sure the door latches securely without slamming
it. lf necessary, adjust the striker (A): The striker nuts
are fixed, but the striker can be adjusted slightly up or
down, and in or out.
1. Loosen the screws (B), rhen insert a shop towel (C)
between the body and striker.
Lightly tlghten the screws.
Wrap the striker with a shop towel, then adjust the
striker by tapping it with a plastic hammer (D). Do
not tap the striker too hard.
Loosen the screws, and remove the shop towel.
Lightly tighten the screws.
Hold the outer handle out, and push the door
against the body to be sure the striker allows a
flush fit, lf the door latches properly, tighten the
screws and recheck.
5.
6.
8 x 1.25 mm18 N.m 11.8 kgf m, 13 lbf.ft)
20-13

Windshield Replacement
NOTE:. Put on gloves to protect your hands,. Wear eye protection while cutting the glass adhesive
with piano wire.. Use seat covers to avoid damaging the seats.
1. Remove these items:
. Rearview mirror (see page 20-16). Windshield wiper arms (see page 22-145)
2. Pull up the side trim (A) to release the clips (B) from
the retainers (C), and pull the trim rearward to
release it from the cliD (D) then remove the trim
from each side of the windshield.
4.
Remove the cowl covers (see page 20-95).
Remove the molding (A) from the upper edge of the
windshield (B). lf necessary, cut the molding with a
utility knife.
lf the old windshield is to be reinstalled, make
alignment marks across the glass and body with a
grease pencil.
Pull down the front portion of the headliner (see
page 20-54). Take care not to bend the headliner
excessively, or you may crease or break it.
Apply protective tape along the edge of the
dashboard and body. Using an awl, make a hole
through the rubber dam, adhesive. and dashboard
seal from inside the vehicle at the corner ponion ot
the windshield. Push a piece of piano wire through
the hole, and wrap each end around a piece of
wood.
(cont'd)
7.
20-19

Glass
Windshield Replacement (cont'd)
With a helper on the outside, pullthe piano wire {A)back and forth in a sawing motion. Hold the piano
wire as close to the windshield (B) as possible toprevent damage to the body and dashboard.
Carefully cut through the rubber dam and adhesive(C) around the entire windshield.
-A\, ,.-
,,t""""""""',-\i-.. -1:-, -
-=-.--
20-20
10. With a knife, scrape the old adhesive smooth to a
thickness of about 2 mm (0.08 in.) on the bonding
surface around the entire windshield opening
flange:
. Do not scrape down to the painted surface ofthe
body; damaged paint will interfere with proper
bonding.. Remove the rubber dam and fasteners from the
oooy.
1 1. Clean the body bonding surface with a sponge
dampened in alcohol. After cleaning, keep oil,grease and water from getting on the clean surface.
12. lf the old windshield is to be reinstalled, use a puttv
knife to scrape off all of the old adhesive, the
fasteners and the rubber dam from the windshield.
Clean the inside face and the edge of the
windshield with alcohol where new adhesive is to
be applied. Make sure the bonding surface is kept
free of water, oil, and grease.
\

t5.Glue the side rubber dams (A) and lower rubber
dam (B) with adhesive tape (NITTO 501M, or
equivalent). Glue the fasteners (C)with adhesive
tape (3M 4215, or equivalent) to the inside face of
the windshield {D) as shown:
. Be sure the rubber dams and fasteners line uD
with the alignment marks (E).
. Be careful not to touch the windshield where
adhesive will be aoolied.
t3.
14. Glue the molding (A)with adhesive tape {B)(3M 4212, or equivalent)to the upper edge ofthe
windshield (C);
. Be sure the alignment mark (D) of the molding
lines up with the alignment mark (E) of the
windshield.. Be careful not to touch the windshield where
adhesive will be applied.
Install the fasteners (A), retalners (B, C), and clips
(D) to lhe body.
Fastener Locations
A>:Fastener.2B>:Retainer,2
q\
C >: Retainer,6 O > : Clip,2
(cont'd)
20-21

Glass
to.
Windshield Replacement (cont'dl
Set the windshield in the opening, and center it.
Make alignment marks (A) across the windshield
and body with a grease pencil at the four points
shown. Be careful not to touch the windshield
where adhesive will be applied.
17. Remove the windshield.
20-22
18. With a sponge, apply a light coat of glass primer
around the edge of the windshield (A) between the
dams (B) and molding {C) as shown, then lightly
wipe it off with gauze or cheesecloth:
. Apply glass primer to the molding.. Do not apply body primer to the windshield, and
do not get body and glass primer sponges mixed
up.. Never touch the primed surfaces with your hands.
lf you do, the adhesive may not bond to the
windshield properly. causing a leak afterthe
windshield is installed.. Keep water. dust, and abrasive materials away
from the primed surface.
'l',,1r- r Apply glass primer here.
)-'
G1)'r'llol
,,/ ll\B tl -A
lnside

19. With a sponge, apply a light coat of body primer to
the original adhesive remaining around the
windshield opening flange, Let the body primer dry
for at least 10 minutes:
. Do not apply glass primer to the body, and be
careful not to mix up glass and body primer
sponges.. Never touch the primed surfaces with your hands.. l\4ask off the dashboard before paintingthe
flange.
20 mm(0.79 in.l
Before filling a cartridge, cut a "V" in the end of the
nozzle (A) as shown.
20.
12 mm (0.47 in.)
7 mm {0.27 in.)
21. Pack adhesive into the cartridge without air pockets
to ensure continuous delivery. Put the cartridge in a
caulking gun, and run a bead of adhesive (A)
around the edge of the windshield (B) between the
dams (C) and molding (D) as shown. Apply the
adhesive within 30 minutes after applying the glass
primer. Make a slightly thicker bead at each corner.
l'1fifr.,1:?mm n10.28 in.l ,..-A.. )t
$?I.",x1"u.80.".,trl
.,r []\"Inside
-'
A
Use suction cups to hold the windshield over the
opening, align it with the alignment marks made in
step 16, and set it down on the adhesive. Lightly
push on the windshield until its edges are fully
seated on the adhesive allthe way around. Do not
open or close the doors until the adhesive is dry.
c.. N\F12mm I nl{0.08 in.} I 'Z l
./"
(cont'd)
20-23