limit HONDA CIVIC 2003 7.G Repair Manual

5. Support 4th gear (A) on steel blocks, then use apress and an attachment (B) to press the
countershaft (C) out ofthe 5th gear.
6.Support 2nd gear (A) on steel blocks, then use a
Dress and an attachment {B} to press the
countershaft (C) out of the 3rd gear.
Cou ntershaft lnspection
1. Inspect the gear surface and bearing surface for
wear and damage, then measure the countershaft
at points A, B, and C. lf any part of the countershaft
is less than the service limit, replace it with a new
one.
Standard:
A Ballbearing surface ltransmission housing sidel:
30.020 -30.033 mm {1.1819 1.1824in.)
B Distance collar surface;
39.937- 39.950 mm 11.5723 1.572A in.l
C Needle bearing surface (clutch housing side):
35.000 35.015 mm {r.3780-1.3785 in.)
Service Limit:
A: 29.97 mm {1.180 in.)
B: 39.88 mm {1.570 in.l
C: 34.95 mm {1.376 in.)
lnspect the runout by supporting both ends of lhe
countershaft. Rotate the countershaft two complete
revolutions when measuring the runout. lf the
runout exceeds the service Iimit, replace the
countershaft with a new one.
Standard: 0.02 mm (0.001 in.) max.
Service Limit: 0.05 mm (0.002 in.)
2.
13-33

Manual Transmission
Synchro Ring and Gear Inspection (cont'dl
3. Inspect the thrust surface {D) on each gear hub for
wear.
Inspect the cone surface (E) on each gear hub for
wear ano rougnness.
Inspect the teeth on all gears (F) for uneven wear,
scoring, galling, and cracks.
Coat the cone surface of each gear (E) with oil, andplace its synchro ring on it. Rotate the synchro ring,
making sure that it does not slip.
13-40
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7. Measure the clearance between each gear (A) and
its synchro ring (B) allthe way around. Hold the
synchro ring against the gear evenly while
measuring the clearance. lf the clearance is less
than the service limit, replace the synchro ring andgear.
Synchro Ring.to.Gear Clearance
Standard: 0.70 1.49 mm 10.028 0.059 in.)
Service Limit: 0.4 mm {0.016 in.)
Triple Cone Synchro-to-Gear Clearance
Slandard:
O: Outer Synchro Ring {B}to Synchro Cone (Cl
0-70 1.19 mm (0.028-0.047 in.)
@: Synchro Cone lC) to cear (A)
0.50- 1.04 mm (0.020-0.041 in.)
O: Outer Synchro Ring (B) to Gear (Al
0.95 1.68 mm 10.037 0.066 in.)
Service Limit:
O: 0.3 mm (0.012 in.)
: 0.3 mm (0.012 in.)
O; 0.6 mm 10.024 in.l
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{

Steering
Steering Wheel Rotational Play
Check
1. Turn the front wheels to the straight ahead position.
2. Measure how far you can turn the steering wheel
left and right without moving the front wheels.
. lf the play is within the limit, the gearbox and
linkage are OK.. lf the playexceedsthe limit, adjustthe rack guide
{see page '17-13). lf the play is still excessive after
rack guide adjustment, inspect the steering
linkage and gearbox {see page 17-5).
BOTATIONAL PLAY: 0 10 mm (0-0.39 in.l
+:
17-4
Power Assist Check
Start the engine, and let it idle.
Attach a commercially available spring scale to the
steering wheel. With the engine idling and the
vehicle on a clean, dry floor, pull the scale as
shown, and read it as soon as the tires begin to turn.
\
1.
3. lf the scale reads no morethan 29 N (3.0 kgf,6.6 lbf),
the power assist is OK. lf it reads more, check these
items:
. Front tire pressure. Steering linkage (see page 17-5). Rack gulde adjustment (see page 17-13). EPS system (see page 17-18)

EPS Components
Steering Gearbox Overhaul (cont'd)
'll. Check the slider guide for damage and cracks.Using vernier calipers to measure the thickness ofthe slider guide. lf the thickness is less than servicelimit, replace the slider guide,
f Z,-----:-r-.--------.t.t'E-r
I (fr--', -.----
/i Il il ( t t , ,)))
|i@r
25.3 mm{0.925 in.}
Remove and discard the stop ring {A)on the
cylinder by expanding it with snap ring pliers.
Remove and discard the lock screw {B}.
13. Install the new lock screw on the rack housing.
14. Installthe new stop ring in the groove (C)on thecylinder by expanding it with a snap ring pliers. Becareful not to scratch or damage the housing
surface with the stop ring edges.
25.3 mm{0.925 in.l
12
17-58
15. Apply multipurpose grease to the indicated part
{shaded part) of the outer surface of the rackhousing. Do not apply to the dents and grooves.
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I

Wheel Runout Inspection
1.Raise the vehicle, and support it with safety stands
in the proper location (see page 1-5,.
Check for a bent or deformed wheel.
Set up the dial gauge as shown, and measure the
axial runout by turning the wheel.
Front and rear wheel axial runout:
Standard:
Aluminum wheel: 0-0.7 mm (0-0.03 in.)
Service limit: 2.0 mm {0.08 in.l
4. Reset the dial gaugetothe position shown, and
measure the radial runout.
Front and rear wheel radial runout:
Standard:
Aluminum wheel: 0 0.7 mm (0 0.03 io.)
Service limit: 1.5 mm {0.06 in.}
lf the wheel runout is not within the specification,
checkthe wheel bearing end play (see page 18-8),
and make sure the mating surfaces on the brake
disc and the inside of the wheel are clean.
lf the bearing end play is within the specification
but the wheel runout is more than the service limit.
replace the wheel.
18-9

Frequent inhalation of brake pad dust, regardless of
material composition, could be hazardous to your
Front Brake Pads Inspection and Replacement
. Avoid breathing dust particles.
. Never use an air hose or brush to clean brake
assemblies. Use an OSHA-approved vacuum
cleaner.
lnspection
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.
2. Check the thickness of the inner pad iA) and outer
pad {B). Do not include the thickness of the brake
pad backing plate.
Brake pad thickness:
Standard: 9.5 10.5 mm (0.37 0.41 in.l
Service limit: 1.6 mm (0.06 in.)
Inner pad:
Outer pad:
lf the brake Dad thickness is less than the service
limit, replace allthe pads as a set.
Replacement
1. Remove the bolt (A), and pivot the caliper (B) upout
of the way. Check the hose and pin boots for
damage and deterioration.
'..'
, .a
&
\
A
2. Remove the pad shim iA) andpads{B).
.^h v/
\ tJ I
v ."r------B
(cont'd)
19-11

Front Brake Disc lnspection
Runout
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.
2. Remove the brake pads (see page 19-11).
3. Inspect the disc surface for damage and cracks.
Clean the disc thoroughly, and remove all rust
4. lnstall suita ble flat washers (A) andwheel nuts,and
tighten the nuts to the specified torque to hold the
brake disc securely against the hub.
Set up the dial gauge against the brake disc as
shown, and measure the runout at 10 mm (0 4 in.)
from the outer edge of the disc.
Brake Disc Runout:
Service Limit: 0.10 mm (0.00tt in.l
lf the disc is beyond the service limit, refinish the
brake disc.
Max. Retinish Limit: 19.0 mm (0.75 in.)
NOTE:. lf the brakedisc is beyondtheservice limitfor
refinishing, replace it (see page 18-1 1).
. A new disc should be refinished if its runout is
greater than 0.10 mm (0.004 in.).
Thickness and Parallelism
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.
2. Remove the brake pads (see page 19-11).
3. Using a micrometer, measure disc thickness at
eight points, approximately 45" apart and 10 mm
{0.4 in.) in from the outer edge of the disc.
Brake Oisc Thickness:
Standard: 20.9 21.8 mm {0.82-0.86 in.}
Max. Refinishing Limit: 19.0 mm 10.75 in.)
Brake Disc Parallelism: 0.015 mm 10.0(X)6 in.)
max.
NOTE: This is the maximum allowable difference
between the thickness measurements
10 mm lo.it in.l
lf the smallest measurement is less than the max.
refinishing limit, replace the brake disc (see page
18-11).
lf the disc is beyond the service limit for parallelism,
refinish the brake disc with an on-car brake lathe.
The Kwik-Lathe produced by Kwik-way
Manufacturing Co. and the "Front Brake Disc
Lathe" offered by Snap-on Tools Co. are approved
for this operation.
4.
': . --'t-'"'-
t,.
19-13

Conventional Brake Components
Rear Brake Pads Inspection and Replacement
Frequent inhalation of brake pad dust, regardless ofmaterial composition, could be hazardous to your
hea hh.. Avoid breathing dust particles.. Never use an air hose or brush to clean brake
assemblies, Use an OSHA-approved vacuum
cleaner.
Inspection
'1. Raise the rear of the vehicle, and support jt with
safety stands in the proper location (see page 1-8).Remove the rear wheels,
2. Check the thickness of the inner pad (A) andouterpad (B). Do not include the thickness of the brakepad backing plate.
Brake pad thickness:
Standard: 8.5 9.5 mm {0.33-0.37 in.}
Service limit: 1.6 mm (0.06 in.)
B -::--
lf the brake pad thickness is less than the servicelimit, replace allthe pads as a set.
3.
19-20
Replacement
1. Remove the bolt (A) and brake hose {B} from themounting bracket.
Remove the caliper bolts (C), and remove thecaliper (D) from the caliper bracket.
Remove the pad shims (A) and pads (B).3.
A
t{
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tIA
A
\
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\

Conventional Brake Components
Rear Brake Disc Inspection
Runout
1. Raise the rear of the vehicle, and support it with
safety stands in the proper location (see page 1-8).Remove the rear wheels,
2. Remove the brake pads (see page 19-20).
3. Inspect the disc surface for damage and cracks.
Clean the disc thoroughly, and remove all rust,
4. lnstall suita ble f lat washers (A) and wheel nuts, andtighten the nuts to the specified torque to hold thebrake disc securely against the hub.
108 N.m (11.0 kgf.m,80lbf.ft)
Set up the dial gauge against the brake disc as
shown. and measure the runout at 10 mm (0.4 in.)
from the outer edge of the disc.
Brake Disc Runout;
Service Limit: 0.10 mm {0.004 in.)
lf the disc is beyond the service limit, refinish thebrake disc.
Max. Refinish Limit: 9.0 mm (0.35 in.)
NOTE:. lf the brake disc is beyondtheservice limitfor
refinishing, replace it (see page 18-26).. A new disc should be refinished if its runout isgreater than 0.10 mm (0.004 in.).
19-22
Thickness and Parallelism
1. Raise the rear of the vehicle, and support with
safety stands in the proper location (see page l-g).Remove the rear wheels.
2. Remove the brake pads {see page 19 20).
3, Using a micrometer, measure disc thickness ateight points, approximately 45'apart and 10 mm
{0.4 in.) from the outer edge of the disc.
Brake Disc Thickness:
Standard: 9.9-10.1 mm (0.389 0.397 in.l
Max. Retinishing Limit: 9.0 mm (0.35 in.)
Brake Disc Parallelism: 0.016 mm 10.0006 in.)
max.
4.lf the smallest measurement is less than the max.
refinishing limit, replace the brake disc (see page
18-26).
lf the disc is beyond the service limit for parallelism,
refinish the brake disc with an on-car brake lathe.

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