Front seat HONDA CIVIC 1999 6.G Workshop Manual

Warnin g/Gaution Label Locations
(cont'dl
to
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v7777m7na
ro
* Except CANADA CX
E: SBS INFORMATION: U.S. model ('96. '97 model)
CAUTIONTO AVOID SERIOUS INJURY:. FOR MAXIMUM SAFEW PROTECTION IN ALL TYPES OFCBASHES, YOU MUST ALWAYS WEAR YOUR SAFETYBELT.. DO NOT INSTALL REARWARD-FACING CHILD SEATS lNANY FRONT PASSENGER SEAT POSITION.. DO NOT SIT OR LEAN UNNECESSARILY CLOSE TO THEAIRBAG.. DO NOT PLACE ANY OBJECTS OVER THE AIRBAG ORBETWEEN THE AIRSAG AND YOURSELF.o SEE THE OWNER,S MANUAL FOB FURTHERINFORMATION AND EXPLANATIONS.. THE SRS MUST BE INSPECTED TEN YEASS AFTER IT ISINSTALLED,. THE DATE OF INSTALI-ATION IS SHOWN OF THEDRIVER'S DOORJAMB.
U.S. model ('00 modelI
WARNINGDEATH OR SERIOUS INJURY CAN OCCUR,. CHILDREN 12 AND UNDER CAN BE KILLED BY THEAIRBAG.. THE BACK SEAT IS THE SAFEST PLACE FOR CHILOREN.. NEVER PUT A REAR-FACING CHILD SEAT lN THEFRONT.o SIT AS FAR BACK AS POSSIBLE FROM THE AIRBAG.o ALWAYS USE SEAT BELTS AND CHILD RESTRAINTS.
D: DRIVER INFORMATION: CANADA mod6l l'96 - gtt modell
ALWAYS WEAR YOUR SEAT BELT. THIS CAR IS EOUIPPED WITH A DRIVER AIRBAG AND AFRONT SEAT PASSENGER AIRBAG' AS A SUPPLEMEN-TAL RESTRAINT SYSTEM ISRSI.. IT IS OESIGNED TO SUPPLEMENT THE SEAT BELT,
U.S. model l'98, 39 model)
WARNINGOEATH OR SERIOUS INJURY CAN OCCUR.. CHILDREN 12 AND UNOER CAN BE KILLED BY THEAIREAG.. THE BACK SEAT IS THE SAFEST PLACE FOR CHILDREN.o NEVER PUT A BEAR.FACING CHILD SEAT IN THEFRONT.. SIT AS FAR BACK AS POSSIBLE FROM THE AIRBAG.. ALWAYS USE SEAT BELTS AND CHILD RESTRAINTS.. THE SRS MUST BE INSPECTED TEN YEARS AFTER IT ISINSTALLED,. THE DATE OF INSTALLATION IS SHOWN ON THEDRIVER'S DOORJAMB.
1-34
ro

Llo
CANADA model ('00 model)
CAUTIONTO AVOID SERIOUS INJURYT. FOR MAXIMUM SAFETY PROTECTION lN ALL TYPES OF
CRASHES, YOU MUST ALWAYS WEAR YOUR SAFETY
BELT.. DO NOT INSTALL REARWARD-FACING CHILD SEATS lN
ANY FRONI PASSENGER SEAT POSITION.
. DO NOT PLACE ANY OBJECTS OVER THE AIRBAG OR
BETWEEN THE AIRBAG AND YOURSELF.. SEE THE OWNER'S MANUAL FOR FURTHER
INFORMATION AND EXPLANATIONS.
Except Cx tor passenger side
F: ASSISTANT INFoRMATION: US MODEL ('96. '97 mod€l)
AIRBAG SEE OTHER SIDE,
U.S. model l'98 - 00 modell
AIRBAG WARNINGFLIP VISOR OVER
Llo
G: STEERING COLUMN NOTICE
NOTICETO PBEVENT SRS DAMAGE, REMOVE STEERING WHEEL
BEFORE REMOVING STEERING SHAFT CONNECTING
BOLT.
ll: MONITOR CAUTION
NOTICE. NO SERVICEABIf PABTS lNSlDE.. REFER TO SERVICE MANUAL FOR DETAILED INSTRUC'
TtoNs.
DANGEREXPLOSIVE/FLAMMABLECONTACT WITH ACID, WATER OR HEAVY METALS SUCH
AS COPPER, LEAD OR MERCURY MAY PRODUCE HARM.
FUL AND IRRITATING GASES OR EXPLOSIVE COM-
POUNDS, STORAGE TEMPERATURES MUST NOT EXCEED
2OO'F I1OO"C}. FOR PROPER HANOLING, STORAGE AND
DISPOSAL PNOCEDURES REFER TO SERVICE MANUAL'
SRS SUPPLEMENT.POISONCONTAINS POISONOUS SODIUM AZIDE AND POTASSIUM
NITRATE.FIRST AIDIF CONTENTS ARE SWALLOWEO, INDUCE VOMITING. FOR
EYE CONTACT, FLUSH EYES WITH WATEB FOR 15 MIN-
UTES. IF GASES IFROM ACID OB WATER CONTACT) ABE
INHALED. SEEK FRESH AIR. IN EVERY CASE, GET PROMPT
MEDICAL ATTENTION.KEEP OUT OF REACH OF CHILDREN,
WARNINGTHE AIRBAG INFLATOR IS EXPLOSIVE AND, IF ACCIDEN-
TALLY OEPLOYED, CAN SERIOUSLY HUBT OR KILL YOU.
. DO NOT USE ELECTRICAL TEST EOUIPMENT OR
PROBING DEVICES.TH€Y CAN CAUSE ACCIDENTAL DEPLOYMENT'
. NO SERVICEABLE PABTS lNSlDE. oO NoT
DISASSEMBLE.. PLACE AIRBAG UPRIGHT WHEN REMOVED. FOLTOW SERVICE MANUAL INSTRUCTIONS CAREFULLY
I: FRONT SEAT PASSENGER MOOULE DANGER
Jr SRS WARNING IHOOD)
' Exceot CANADA CX
K: PASSENGER AIRBAG CAUTION
u.S. model l'98 - 00 model)
WARNINGCHILDREN CAN 8E KILLED OR INJUREO BY PASSENGER
AIRBAG,THE BACK SEAT IS THE SAFEST PLACE FOR CHILDREN 12
AND UNDER. MAKE SURE ALLCHILDREN USE SEAT BELTS
OR CHILD SEATS.
(cont'd)
1-35
SUPPLEMENTAL RESTRAINT SYSTEM ISRS}
THIS VEHICLE IS EOUIPPED WITH DBIVER AND FRONT
SEAT PASSENGER AIRBAGS'.ALL SRS ELECTRICAL WIRING AND CONNECTORS ABE
COLORED YELLOW.TAMPERING WITH, DISCONNECTING OR USING
ELECTRICAL TEST EOUIPMENT ON THE SRS WIRING CAN
MAKE THE SYSTEM INOPERATIVE OR CAUSE ACCIDENTAL
FIRING OF THE INFLATOR.
WARNINGTHE AIRBAG INFLATOR IS EXPLOSIVE AND, IF ACCIDEN.
TALLY DEPLOYED, CAN SERIOUSLY HURT YOU. FOLLOW
SERVICE MANUAL INSTRUCTIONS CAFEFULLY'

Shift Cable
Adjustment
@ Make sure lifts are ptaced properly (see
section 1).
1. Remove the front console (see section Z0l.
2. Shift to @ position. then remove the lock pin fromthe adiuster.
7 N.m (0.75 tbtftlkgtm.
14-190
3. Check that the hole in the adjuster is perfectlyaligned with the hole in the shift cable. There aretwo holes in the adjuster. They are positioned 90.apart to allow cable adjustment in 1/4 turn incre-ments.
ExactAlignment
4. lf the hole is not perfectly aligned, loosen the lock-nut on the adjuster and adjust as required.
5. Tighten the tocknut to 7 N.m (0.7 kgf.m, 5 tbf.ft).
6. Install the lock pin on the adjuster. lf you feel thelock pin binding as you reinstall it, the cable is stillout of adjustment and must be readjusted.
7. Make sure the lock pin is seated in the adjustersecuretv.
8. Move the shift lever to each gear, and verify that theshift position indicator follows the automatic trans-axle gear position switch.
9. Start the engine, and check the shift lever in allgears. lf any gear does not work properly, refer totroubleshooting (see page 14-109 thru 1'4-'112).
10. Insert the ignition key into the key cylinder on theAy'T gear position indicator panel, and verify that theshift lock lever is released.
CableToo ShortCableToo Long

t
Adjustment
!@ Make sure lifts, jacks and safety stands are
placed properly (see section 1).
l. Remove the front console (see section 20).
2. Shift to I posirion, then remove the lock pin from
the adjuster.
SHIFT CAELE
l,
,l
{0.7 kgf.m, 5lbf'ltl
3. Check that the hole in the adiuster is perfectly aligned
with the hole in the shift cable. There are two holes in
the adjuster. They are positioned 90" apart to allow
cable adjustment in 1/4 turn increments.
lf the hole is not perfectly aligned, loosen the lock-
nut on the adjuster and adjust as required.
Tighten rhe locknut to 7 N.m (0.7 kgim,5 lbf'ft).
Install the lock pin on the adjuster' lf you feel the
lock pin binding as you reinstall it. the cable is still
out of adjustment and must be readjusted
Make sure the lock pin is seated in the adiuster
securery.
lMove the shift lever to each position, and verify that
the shift position indicator follows the automatlc
transaxle gear position switch.
Start the engine, and check the shift lever in all
positions. lf any gear does not work properly, refer
to troubleshooting (see page 14-294 and 14-295).
Insert the ignition key into the key cylinder on the
Aff gear position indicator panel, and verify that the
shift lock lever is released.
7.
10.
14-355

Driveshafts
Removal (cont'd)
8. Remove the cotter pin from the lawer arm ball joint
castle nut. and remove the nut.
Install a 12 mm hex nut on 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 special tool.
Use the special tool as shown in section 18, to sepa-
rate the ball joint and lower arm. Be careful not to
damage the ball joint boot.
NOTE: lf necessary, apply penetrating type lubri,
cant to loosen the ball joint.
Pry the driveshaft assembly with a screwdriver, as
shown, to force the set ring at the driveshaft endpast the groove.
10.
11.
3.5 mm
07MAC - SL00200
SCREWDRIVER
16-4
12. Pull the inboard joint, and remove the driveshaft
from the differential case as an assembly. Do notpull on the driveshaft; the inboard joint may come
apart. Use care when prying out the assembly, andpull it straight to avoid damaging the differential oil
seat.
13. Pull the knuckle outward, and remove the driveshaft
outboard joint from the front wheel hub using aplastic hammer.
SCREWDRIVER
DRIVESHAFT

3. lnsert the inboard end of the driveshaft into the dif-
terential or intermediate shaft until the set ring
locks in the groove
NOTE: Clean the areas where the driveshaft contact
the transmission (differential) thoroughly with solvent
or carburetor cleaner, and dry with compressed air'
INBOARD JOINT
INBOARD JOINTReplace.
GROOVE
an
DIFFERENTIAL
lnstall the knuckie on the lower arm. then trghten
the castle nut and install a new cotter pin
NOTE: wipe off the grease before tightening the
nut at the ball ioint.
CAUTION:
. Be careful not to damago the ball ioint boot'
. Torque the castle nut to the lower torque sp€ci-
fication, thsn tighten it only far enough to align
the slot with th€ pin hol6. Do not align the nut
by loosening.
CASTLE NUT12 x 1 .25 mm
COTTER PINReplace.On reassemblY,bend the cotter pinJi$ - 59 N.m 15.0 - 6.0 kgl m,35 - 43 lbf ftl
16-19
5. lnstall the damper tork over the driveshaft and onto
the lower arm. Install the damper in the damper
fork so the aligning tab is aligned with the slot in
the damPer fork.
FLANGE BOLTl0 r 1.25 mmrit N.m t4.a kgf.m, 32 lbf.ft) AIIGN|NG TAB
1.
SELF-LOGKING NUT12 x 1.25 mm6,1N.m 16.5 kgi.m, a7 lbfftl
Replace.
Loosely install the flange bolts and the new self-
locking nut.
Apply oil to the seating surface of the new spindle
nut.
181 N m 118.5 kgt'm, 13il lbt'ftl
NOTE: Aftortightening, use a drift to
stake the spindle nut shoulder against the drivoshaft'
8. Install a new spindle nut, then tighten the nut'
9. Clean the mating surfaces ot the brake disc and the
wheel. then install the front wheel with the wheel
nuts.
10. Tighten the flange bolts and the new self-locking
nut with the vehicle's weight on the damper.
11. Refill the transmission with recommended fluid (see
section 13 or 14).'t2. Check the front wheel alignment and adjust if nec-
essary (see section 18),
FRONT WHEEL
SPINDLE NUT 22 x 1.5 mm
WHEEL NUT 12 x 1.5 mm108 N.m (11.0 kgl'm, g) lbl ftl

Steering Gearbox
l.r
Rack Guide Adjustment
NOTE: Perform the rack guide adjustment with the
wheels in the straight ahead position.
1. Loosen the rack guide screw locknut with the spe-
cial tool, then loosen the rack guide screw.
LOCKNUT WRENCH, 40 mm07916 - SA5000r
Tighten the rack guide screw until it compresses the
spring and seats against the rack guide, then loosen
rt.
Retighten the rack guide screw to 4 N'm (0.4 kgf m,
2.9 lbf.ft), then back it off to specified angle.
Specilied Return Angle: 30' max.
Tighten the locknut while holding the rack guide
Check for tight or loose steering through the com-
plete turning travel.
Recheck steering effort (see page 17-4).
4.
RACK GUIDE SCREW
l,z
Removal
NOTE: Using solvent and a brush, to wash any oil and
dirt off the gearbox. Blow dry with compressed air.
1. Raise the front of vehicle, and support it on satety
stands in the proper locations (see section I ).
2. Remove the front wheels.
3. Remove the steering wheel (see page 17-35).
4. Remove the steering loint cover
Remove the steering joint lower bolt, and discon-
nect the steering joint by moving the joint toward
the column.
(cont'd)
17-5
STEERING JOINT COVER
LOWER BOLT
STEERING JOINT

Front Suspension
Knuckle/Hub Replacement
CAUTION:
. Replaco tho salf-locking nuts after romoval.
. The vehiclo should be on tho ground bsfore any bohs or nuls connected to rubber mounb or bushings are tightened.. Torqu€ th€ castle nut to the lowor torque specification, ihen tighton it only far enough to align th€ slot whh the pin
hole. Do not align the nut by loosening.
NOTE:
. Use only genuine Honda wheel weights for aluminum wheels. Non-genuine wheel weights may corrode and damagethe aluminum wheels.
. On the aluminum wheels, remove the center cap from the inside of the wheel after removing the wheel,. Before installing the brake disc, clean the mating surfaces of the front hub and brake disc,. Before installing the wheel, clean the mating surfaces of the brake disc and wheel.o Wipe off the grease before tightening the nut at the ball joint.
CALIPER MOUNTING BOLT12 x 1.25 mm108 N.m {11.0 kgl.m, 80lbf.ft)
LOWER BALL JOINTInspect for faultymovement and wear.
CASTLE NUT10 r 1.25 mm39 - ia7 N.m (4.0 - 4.8 kgf.m, 29 - 35 lbf,ftl
COTTER PINReplace.
WHEEL BEARINGReplace.Replacement, page 18-14
CIRCLIP
SCREW5x0.8mm5 N.m {0.5 ksl.m, 4 lbf.ftlReplacement, page 18-16
SET RING
BALL JOINT BOOT
FRONT HUBCheck for damage andcracks.Replacement,page 18-10Check for deteriorationand damage.
CASTLE NUT12 x 1.25 mm49 - 59 N.m l5.O - 6.0 kg{.m. 36 - /(} lbf,ftl
SPINDI.T ]{UT22 r 1.5 mmlEl N.m {18.5 kgf.rn, 13{ lbl.ttlReplace.NOTE:. Before instelling the spindle nut. apply6n9ine oilto th6 seating surface ofthe nut.. Atter tightening, uso a drift to stake thespindle nut should6r against the driveshaft.
BRAKE DISCCheck for wear andrust.Replacement, page 18-11lnspection, section 19.
WHEEL NUT12 x 1.5 mm'108 N.m1r1.0 kgf.m, 8lt lbf.ft)
6 mm BRAKE DISC RETAINING SCREW9.8 N.m 11.0 kgf.m, 7 lbtft)
18-10

)
1.Loosen the wheel nuts slightlY.
Raise the front of the vehicle, and support it with safe-
ty stands in the proper locations (see section 1).
Remove the wheel nuts and wheel.3.
l)
WHEEL NUT'108 N.m
18'l N.m 118.5 kgf m, 134lblfti
Replace.NOTEI Before installing the spandle nut, apply
engine oil to the seating surface of the nut After
tightening, use a drift to stake the spindle nut
shoulder againsl the driveshaft
Raise the locking tab on the spindle nut, then remove
the nut.
Remove the brake hose mounting bolts.
BRAKE HOSE MOUNTING BOLT
I x 1.25 mm12 N.m (1,2 kgtm,8,7 lbf'ftl
6. Remove the caliper mounting bolts and hang the
caliper assembiy to one side
CAUTTON: To prevent accidental damage to the
caliper assembly or brake hoso' use a short piece of
wire to hang the caliPer tlom lhe undelcarriage.
{11 kgf m, 80 lbl.ft)
CALIPER MOUNTING BOLTS12 x 1.25 mm108 N.m {'11.0 kgtm, 80 lbt.ft)
7. Remove the 6 mm brake disc retaining screws.
8.
I x 1.25 mm BOLTS
Screw two 8 x 1.25 mm bolts into the disc to push it
away from the hub,
NOTE: Turn each bolt two turns at a tame to prevent
cocking the disc excessivelY.
Remove the brake disc from the knuckle.
Check the front hub for damage and cracks.
Remove the wheel sensor from the knuckle (for
vehicles with ABS).
NOTE: Do not disconnect the wheel sensor connec-
tor.
N.m
6 mm BRAKE OISCRETAINING SCREWS9.8 N.m t1.0 kgf.m, 7 lbf'ft)
{'1.0 kgf m,
7 tbf.ft)
10.
11.
MOUNTING
WHEEL
BOLTS9.8 N.m11.0 kgf,m, 7 lbf'ft)(cont'd)

l}
e\
Body ('96 modell
Doors
Front Door Index (4D) ...20-2
Rear Door Index {4Dl .....20-8
Door fndex lzDl3Dl .......20-14
Emblems
f nstallation 20-118
Exterior
Component Location Index ............... 20-93
*Frame Repair Chart .......... 20-120
* Interior
Component Location Index ............... 20-58
Mirrors
Mirror Rep|acement .................. ......... 20-24
Mirror Holder/Gover Replacement ... 20-25
Rearview Mirror Reolacement .......... 20-25
Moonroof
lndex .......... .....................20-50
Opener Cable/Opener and Latch/
Wiper and Washer
Component Location Index .......... ...,. 20-107
Seats and Seat Belts
Gomponent Location Index .......... ..... 20-73
Sub-frame ....20-119
Windshield, Rear Window and Ouarter Glass
Index .......... .....................20-26
Body {'97 modell
Body ('98 modell
Body ('99 modell
Body ('00 model)
20-123
20-131
20-135
20-141
It