plastic HONDA CIVIC 1997 6.G Owner's Manual

)
20, Remove the cotter pin from the lower arm ball joint
castle nut. and remove the nut.
COTTER.PINReplace.On reassembly,bend the cotter Pan
lr
CASTLE NUT12 x 1.25 mm49 - 59 N.m (5.0 - 6.0 kgl m,36-,13 lbf'ft|
BALL JOINT REMOVER, 28 mm
07MAC - SL00200
21. lnstall a 12 mm hex nut onto the ball joint. Be sure
that the hex nut is flush with the ball joint pin end'
or the threaded section of the ball joint pin might be
damaged by the ball joint remover.
22. Use the special tool as shown on page l8-12 to sep-
arate the ball ioint and lower arm.
NOTE; lf necessary, apply penetrating type lubri-
cant to loosen the ball joint.
lJ
18-13
25.
26.
Remove the cotter pin from the upper ball joint cas-
tle nut, and remove the nut.
12 mm HEX NUT 07MAC - SL00200
lnstall the 12 mm hex nut onto the ball joint
Be sure that the hex nut is flush with the ball joint
pin end, or the threaded section of the ball joint pin
mlght be damaged by the ball joint remover'
Use the special tool as shown on page l8-12 to sep-
arate the ball joint and knuckle.
NOTE: lf necessary, apply penetrating type lubri
cant to loosen the ball joint.
Putl the knuckte outward and remove the driveshaft
outboard joint from the knuckle by tapping the drive-
shaft end with a plastic hammer, then remove the
knuckle.KNUCKLE
'12 x 1.25 mm39 - 47 N.m
14.0 - 4.8 kgf m,29 - 35 tbf.ft)
Check for damage.

\:Outer Handle Replacement
NOTE: Raise the glass fully.
'1. Remove:
. Door panel
. Plastic cover (see page 2o-21
2. Pull out the retainer cliP.
6x1.omm Ii.e N.. tr.o rgf.-, I7.2 rbr.fi) ,2
C3.
CYLINDER PROTECTOR
LOCK CYLINDEB
RETAINERCLIP
Remove the bolts, then remove the cylinder protec-
tor, lock cylinder and outer handle.
>: Bolt locaiions,2
CYLINDER
LOCK CYLINDER
CYLINDER ROD
20-5
4. Pull out the outer handle. Pry the outer handle rod
out of its joint using diagonal cutters
NOTE:
a To ease reassembly, note location @ of the outer
handle rod on the joint before disconnecting it.
. Take care not to bend the outer handle rod.
o Use a shop towel to protect the opening in the
ooor.
OUTER HANDLEROD
DIAGONALCUTTERS
SHOPTOWEL
lnstallation is the reverse of the removal procedure
NOTE: Make sure the door locks and opens properly.
BUSHINGReplace.
\
,w.
5.
i4'

Doors
Latch Replacement
NOTE: Baise the glass fully.
1. Remove:
. Door panel (see page 20-4)
. Plastic cover (see page 20-2). Outer handle (see page 20-5)
Remove the bolt, then move the center lower channel
forwa rd.
Disconnect the connector, and detach the harness
clip from the door. Bemove the latch through the
hole in the door.
NOTE: Take care not to bend the inner handle rod,
outer handle rod, cylinder rod and lock rod.
>: Screw locations, 3
6 x 't.0 mm8 N.m (0.8 kgt m,6 tbf.ftl
4. Installation is the reverse of the removal procedure.
NOTE:
. Make sure the inner handle rod and connector
are connected properly.
. Make sure the door locks and opens properly.
LOCK ROO
20-6
'1.
Glass/Regulator Replacement
Removel
o Door panel (see page 20-4)
. Plastic cover (see page 20-2l,
Carefully move the glass until you can see the bolts,
then remove them. Carefully pull the glass out
through the window slot.
NOTE: Take care not to drop the glass inside the door.
>i Bolt loc.tions,2
fi s'r.o-. iClb9.8 N.m 11.0 kst m,l
_-l't!!t ,/
GLASS
REGULATOR

Doors
Rear Door Index
,[D:
OUTERWEATHERSTRIP
INNERWEATHERSTRIP
DOORAdjustment,page 20-23
INNER MOLDING
fu4 ffir",
M
R*
/-HINGEPOWER WTNDOW \a-sw[cH
\\€\
\;\
€ -*r'
*e€
(=__: \:-? \
/\
/\/ DooR
/ GRIP
DOOnGRIPCOVER
o(x)RPROTECTOR
t\
\
PLASTICCOVER
20-8

tOuter Handle Replacement
NOTE: Raise the glass fullY.
1. Remove:
. Door panel
. Plastic cover (see page 20-8)
2. Remove the screws.
>: Screw locations, 3
6x1.0mm6 N.m {0.6 kgf m,4 tbf.ftl
a\
3. Move the latch down, and remove the bolts.
>: Bolt locations,2
6x1.0mm9.8 N,m )11.O kst.n,7.2lbiftl //
4. Pull out the outer handle. Pry the outer handle rod
out of its joint using diagonal cutters.
NOTE:
. To ease reassembly, note location O of the outer
handle rod on the joint before disconnecting it.
. Take care not to bend the outer handle rod.
. Use a shop towel to protect the opening in the
door.
BUSHINGReplace.
OUTERHANDLEROD
5.
o
DIAGONAL \
:"'* ,w,
lnstallation is the reverse of the removal procedure
NOTE: N4ake sure the door locks and opens properly.
SHOP TOWEL
20-11

Doors
Latch Replacement
NOTE: Raise the glass futty.
1. Remove:
. Door panel (see page 20-10). Plastic cover (see page 20-8). Outer handle (see page 2O-1 ,l
2. Remove the lock crank and clip.
>: Screw location, I >: Clip location, I
qn@l # |
_ __) _-__)
LOCKROO
LATCH
Remove the rear channel collar.
NOTE: Take care not to bend the lock rod and innerhandle rod.
Disconnect theconnector.
6x1.0mm8 N.m (0.8 kgt m,
5.
6 tbtttl
Remove the latch through the hole in lne door.
lnstallation is the reverse of the removat proceoure.
NOTE: Make sure the door locks and opens properly.
20-12
,,< 8 N.m to.8 ksf.m, 6 tbt.ftt
IDF-IIID I
.)-__,/
2.
L
p o'r.o-,n I@ 9.8 N.m {t.o kof.m. I
.- :'zulnt -
/
3. Carefully lower the glass. Remove the bolts andscrew from the rear channel, then remove the glassfrom the rear channel.
NOTE: Take care not to drop the glass inside the door.
>: Bolt. screw locations
A, 1 , c, 1I
q)h:iT(--n,,". i m
- - illt) '/ -)
Glass/Regulator Replacement
Remove:
. Door panel {see page 20-10). Plastic cover (see page 20,8)
Carefully move the glass until you can see the bolts,then remove them.
NOTE: Take care notto drop the glass inside the door.
>: Eolt locations, 2
6x1.0mmB, 1

Doors
Door Index
2DI3D:
OU?ERWEATHERSIRIP
GLASS GUIDECLIP
I sAsH
€*/
.u\
\Y\I
et'
SPEAKER COVER
INNER HANDLE
ii MTRROR MOUNT<]<-- COVER PANEL
-it v
$=-!xtruce
re
(sqjR5f"'
@." \s-l
h-P
-Qa,
(l+,
@
TRIM(with power door locks)
eowen ooon

rocK swrrcH
\b
INNEF HANOLETRIM{without power
dD door locks)
DOORAdjustment,page 20-23
BRACKET
dl
h
W/
ARMRESTPOCKET
;ril;"i-"- 9
JE
powen____-.-@
wtNDow .*\L'l
swrrcH
t
-p
Q*-BsfL-,"ARMRESTPOCKETlwith power
PLASTICCOVER
,",
S
dnJ.*-{
r-1*{
,P
SPEAKER
20-14

bOuter Handle Replacement
NOTE: Raise the glass fully.
1. Remove:
. Door panel
. Plastic cover (see page 20-14)
2. Pull out the retainer clip.
3.e\
CYLINOER PROTECTOR
LOCK CYLINDER
RETAINERCLIP
Remove the bolts, then remove the cylinder protec-
tor, lock cylinder and outer handle.
>: Bolt locations,2
6x1.omm ]9.8 N.m {1.0 kgf.m,1.2tbl,ttl )_, _-_-,/
CYLINDERPROTECTOR
LOCK CYLINOER
CYLINOER ROD
20-17
4. Pull out the outer handle. Pry the outer handle rod
out of its joint using diagonal cutters.
NOTE:
. To ease reassembly, note location @ ot the outer
handle rod on the joint before disconnecting it.
. Take care not to bend the outer handle rod.
. Use a shop towel to protect the opening in the
door.
DIAGONALCUTTERS
SHOPTOWEL
5. Installation is the reverse of the removal procedure.
NOTE: Make sure the door locks and opens properly.
EUSHINGReplace.
\
,pr,

Doors
Latch Replacement
NOTE: Raise the glass fully.
1. Remove:
. Door panel (see page 20-16)
. Plastic cover (see page 20-14). Outer handle {see page 20-17}
2. Remove the rod protector.
LATCH
PROTECTOR
20-18
3. Remove the bolts and move the center lower channel.
NOTE: Take care not to bend the inner handle rod
and lock rods.
>: Screw locations
A>,38>,3
q)
CENTER LOWEBCHANNEICBANKHOLDER
Disconnectthe connector,
6x1.0mm8 N.m 10.8 kgt.m,6 tbtft)
Remove the inner handle, then remove the latch
through the hole in the door.
lnstallation is the reverse of the removal procedure.
NOTE: Make sure the door locks and opens properly.
5.
6x1.0mm l
ffu 6 N.m {0.6 kef.m,
_" 11111 )

LGlass/Regulator Replacement
2.
1.Remove:
. Door panel (see page 20-'16)
. Plastic cover (see page 20-14)
Carefully move the glass until you can see the bolts,
then loosen them. Slide the guide rearward, remove
the glass trom the guide, and carefully pull the
glass out through the window slot.
NOTE: Take care not to drop the glass inside the door.
>: Bolt localions,2
6x1.0mm
E 9.8 N.m {1.0 kgtm, Il* 7.2 tbrfil I\3 Loosen ,/
Jt
GUIDE
3. Disconnect the connector, and detach the harness
clip, then remove the regulator through the hole in
the door.
NOTE: Scribe a line around the rear roller guide bolt
to show the original adjustment.
>: Bolt locations
a >,4
6xL0mmI6x1.omm II N.m {0.8 kgt.m,6lbrft ]Loosen. ,/
B >,2
8 N.m (0.8 kgt m, i'-1
)
ROLLERREGULATOR
BOLTS
(cont'd)
20-19