head HONDA CIVIC 2002 7.G Manual PDF

Rack Guide Adjustment
Special Tool Required
Locknut wrench, 43 mm 07MAA-S100200
1. Set the wheels in the straight ahead position.
2. Remove the heat shield (A).
3.
9.8 N.m (r.0 kgf.m,7.2lbtft)
Remove the transmission mount bracket (see step
32 on page 13-8).
Loosen the rack guide screw locknut (A)with the
special tool, then remove the rack guide screw (B).
Remove the old sealant from rack guide screw, and
apply new sealant to the middle of the threads (A).
Loosely installthe rack guide screw on the steering
gearDox.
'-.i. '' '
07MAA-S100200
6. Tighten the rack guide screw (A)ro 25 N.m (2.5
kgf.m, 18lbf.ft). then loosen it.
5" Max.
j i-rrrr-,
I 4il N.m{a.5 kgf.m,33lbt.ft)
Retighten the rack guide screw to 6 N.m (0.6 kgf m,
4 lbf.ft), then back it off to the specified angle.
Specified Return Angle: 5' Max.
Hold the rack guide screw stationary with a wrench,
and tighten the locknut by hand until it's fully
seated.
Installthe special tool on the locknut (B), and hold
the rack guide screw (A) stationary with a wrench,
Tighten the locknut an additional 30" with the
specialtool.
Reinstall the transmission mount bracket and heat
sh ie ld,
Check for unusual steering effort through the
complete turning travel.
Check the steering wheel rotation play (see page
17-4) and the power assist (see page 17-4).
11.
7.
9.
10.
12.
17-13

EPS Components
General Troubleshooting Information (cont'dl
5. The blinking frequency indicates the DTC. DTCS are
indicated by a series of long and short blinks. One
long blink equals 10 short blinks. Add the long and
short blinks together to determine the DTC. After
determining the DTC, refer to the DTC
Troubleshooting Index.
The system will not indicate the DTC unless these
conditions are met:. Set the front wheels in the straight ahead drivingposition.. The ignition switch is turned ON (ll).. The engine is stopped.. The SCS circuit is shorted to body ground before
the ignition switch is turned ON (ll).
Example of DTC 23
Long blinks Short blinks(two times) (three timesl
6.
7.
Turn the ignition switch OFF.
Disconnect the Honda PGM Tester from the DLC.
17-20
How to Clear EPS DTCs
Honda PGM Tesler Method:
1. With the ignition switch OFF, connect the Honda
PGM Tester (A) to the 16P data link connector (DLC)
(B) located under the dash on the driver's side of
the vehicle.
Turn the ignition switch ON (ll), and clear the
DTC{s) by following the screen prompts on the
PGM Tester.
NOTE: See the Honda PGM Tester user's manual
for specific instructions.

Service Check Signal Circuit Method:
NOTE: Use this procedure when the PGM Tester
software does not match the yearlmodel vehicle you
are working on.
1. With the ignition switch OFF, connect the Honda
PGM Tester (A) to the 16P data link connector {DLC)(B) located under the dash on the driver's side of
the vehicle.
With the vehicle on the ground, set the front wheels
in the straight ahead driving position.
Short the SCS circuit to body ground using the
Honda PGM Tester.
Turn the ignition switch ON (ll). The EPS indicator
comes on for about 6 seconds. Within 4 seconds of
turning the switch ON, while the EPS indicator is on,
turn the steering wheel 45 degrees to the left from
the straight ahead driving position, and hold the
steering wheel in that position until the EPS
indicator goes off.
Within 4 seconds afterthe EPS indicator goes off,
return the steering wheel to the straight ahead
driving position and release the steering wheel.
The EPS indicator comes on again 4 seconds after
releasing the steering wheel,
Within 4 seconds after the EPS indicator comes on,
turn the steering wheel 45 degrees to the left again
and hold it in that position.
The EPS indicator goes off after 4 seconds.
4.
1.Within 4 seconds after the EPS indicator goes off,
return the steering wheel to the straight ahead
driving position again and release the steering
wheel. The EPS indicator blinks twice 4 seconds
after releasing the steering wheel, indicating that
the DTC was erased.
NOTE: If the EPS indicator does not blink twice, an
error was made in the procedure and the DTC was
not erased. Turn the ignition switch OFF, and
repeat the operation from step 3.
Turn the ignition switch OFF afterthe EPS indicator
blinks twice.
9. Disconnect the Honda PGM Tester from the DLC.
10. Perform the DTC code output operation, and be
sure that the code has been erased.
17-21

EPS Components
Steering Gearbox Removal (cont'd)
Disconnect the EPS wire harness 6P connector (A),
and remove the EPS wire harness (B) and mountino
bracket (C).
12.
Remove the ground cable terminal (A) from the
steering gearbox housing.
..(
.,/ a
b-H\
ry T,-.lt'^ \
'" \--
13.
_-1..1.-'
-a--zii F--_1
17-52
14. Remove the engine wire harness clamps {A)fromthe three mounting brackets.
Remove the heater hose {B) from the bracket.
Open the heater valve cable clamp (A), and
disconnect the heater valve cable (B). Remove theheater valve (C) from the bulkhead, and move jt
aside.
t5.
16.
I

30, Retighten the 12 mm flange bolts (A) to the
soecified toroue value.
After tightening the 12 mm flange bolts, install a
new stop plate (B) over one of the bolt heads. Be
sure the tabs (C) of the stop plate are aligned with
the flat surfaces of the bolt head.
Clean off any grease or contamination from the
boot installation grooves on the housing.
Expand the boot (A) by removing the vinyltape,
and fit the boot ends (B) in the installation grooves
on the cylinder housing.
5t.
32,
74 N.m (7.5 kgf.m,5ir lbf.ft)
34. Close the ear portion (A) ofthe bands (B)with
commerciallv available pincers, Oetiker 1098 or
equivalent (C).
35. Installthe new lock washer (A) with its radiused
side facing (B) the tie-rod (C), and screw the tie-rod
on the bracket (D). Repeat this step for the other
side of the tie-rod. Hold the bracket with one
wrench, and tighten the tie-rods to the specified
torque with another wrench.
,,";=-...,.,
(cont'd)
*=,,',
17-61

Steering Gearbox Installation
2.
'1.Before installing the steering gearbox, slide the
rack all the way to the passenger's side (right
direction).
Pass the right side of the steering gearbox together
with the tie-rods through the wheelwell opening on
the passenger's side. Continue moving the steering
gearbox toward the passenger's side untilthe
driver's side tie-rod end and gearbox clears the
master cylinder and under-hood fuse Ielay box.
Lower the steering gearbox. and move it toward
the driver's side untilthe steering gearbox is ln
Dosition.
Be careful not to damage the hoses, lines
and wire harnesses.
3. Installthe pinion shaft grommet (A).
4. Insert the pinion shaft up through the bulkhead,
then slip the right side of the steering gearbox
housing (A) over the mounting stud (C) on the
gearbox mounting bracket.
\- --' '.'', i
10 x '1.25 mm61 N.m{6 2 kgl m, 45 lb{ ftl
Install the steering stiffener B, and lightly tighten
the steering gearbox mounting nuts.
Install the steering stiffener A with the gearbox
mounting bolts. Then tighten allthe steering
gearbox mounting hardware to the specified torque.
10 x 1.25 mm6l N.m(6.2 kgt.m, 45 lbt.ft)
: --.-{..
(cont'd )
:-1....
17-63

EPS Components
Steering Gearbox Installation (cont'd)
7. Installthe body stiffener (A), and torque the
mounting bolts to the specified torque.
8 x 1.25 mm29 N.m {3.0 kgf.m,22lbf.ftl
LInstall the heater valve (A) on the bulkhead, and
connect the heater valve cable end (B) to the heater
valve arm (C). Readjust the heater valve cable {seepage 21-46).
9.8 N.m(1.0 kgf m,7.2 tbf.ftl
L-t ,:.i.t'
17-64
9. Reinstall the heater hose (A) on the hose bracket.
Install the engine wire harness clamps (B) to the
three harness brackets.
Under the steering gearbox, install the ground
cable terminal (A) on the steering gearbox housing.
10.
'I t.
9.8 N.m{1.0 kgf.m, 7.2lbf.ft)

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.

Removal
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 flange bolt {A) from the bottom of the
damper.
Remove the rear bulkhead cover (see page 20-51).
Remove the flange nuts (A) from the top of the
damper in the trunk.
3.
5. Remove the damper assembly from the body.
i
(cont d)
18-35

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