Wire harness HONDA CIVIC 2003 7.G Owner's Manual

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.
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ry T,-.lt'^ \
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13.
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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

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
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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)

12. lnstallthe EPS wire harness bracket (A) on the
gearbox housing, and connect the 6P connector (B)
propefly.
9.8 N.m{1.0 kgt m,7.2 lbt.ftl
13. Installthe heat shield (A).
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14.
15.
Center the steering rack within its stroke.
Wipe off any grease contamination from lhe ball
joint tapered section and threads. Then reconnect
the tie-rod ends 1A)to the damper steering arms.
lnstall the ball joint nut (B) and tighten them.
Install the new cotter pins (C), and bend them as
shown.
(cont'd)
B10 x 1.25 mmi€ N.m{4.4 kgf.m.32 tbt.ftl
to.
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:1)
17-65

Master Cylinder Replacement
NOTE: Do not spill brake fluid on the vehicle; it may
damage the paint; if brake fluid does contact the paint,
wash it off immediately with water,
1, Remove the air cleaner assembly (A).
2, Disconnect the brake fluid level sensor connector
(A).
15 N.m{1.5 kgt.m, 11 lbt.ft)
3. Remove the clutch reservoir (B) andenginewire
harness clip (C)from the master cylinder mounting
base (D).
4. Remove the reservoir cap and brake fuid from the
reservoir.
5. Remove the reservoir (E) on the master cylinder
mountrng Dase.
6, Disconnect the brake lines (F)from the master
cylinder (G). To prevent spills, cover the hose joints
with rags or shop towels.
7. Remove the master cylinder mounting nuts {H) and
washers.
8. Remove the master cylinder from the brake booster.
Be careful not to bend or damage the brake lines
when removing the master cylinder.
9. Remove the rod seal (l) from the master cylinder.
10. Installthe master cylinder in the reverse order of
removal, and note these items:
. Replace all the rubber parts with new ones
whenever the master cylinder is removed.
. Check the pushrod clearance before installing the
master cylinder. and adjust it if necessary (see
page 19-16).. Use a new rod seal on reassemblY. Coat the inner bore lip and outer circumference
of the new rod seal {A) with the recommended
seal grease in the master cylinder set.
. Installthe rod seal ontothe master cylinder with
its grooved side (B)toward the master cylinder.
. Check the brake pedal height and free play after
installing the master cylinder, and adjust it if
necessary (see page 19-6).
19-15

\
DTC Troubleshooting
DTC 11, 13, 15, 17: Wheel Sensor
(Open/Short to Body Ground/Short to Power)
1. Disconnect the ABS control unit 31P connector.
2. Sta rt the engine.
3. Measure the voltage between the appropriate
wheel sensor (*)circuitterminal of theABS
control unit 31P connector and body ground (see
table).
DTCADpropriate Terminal
11 (Rioht-front)No.5: FRS (t)
13 (Left-front)No, 7: FLS (*)
15 {Riqht-rear}No. 2: RRS (*)
17 (Left-rear)No.9 RtS (f )
ABS CONTROL UNIT 31P CONNECTOR
FRS {+IIGNR/BLK} FLS I+I (BLU
RRS {+)(GNR/YEL)
Wire side of female terminals
ls thete battery voltage?
YES Repair short to power in the (+) circuit wire
between the ABS modulator-control unit and the
appropriate wheel sensor. I
NO Go to step 4.
4. Turn the ignition switch OFF.
5. Check for continuity between the appropriate
wheel sensor (+ ) circuit terminal and body ground
{see table).
DTCAppropriate Terminal
11 (Riqht-front)No. 5: FRS (+)
13 (Left-front)No. 7: FLS (*)
15 (Rioht-rear)No.2: RRS (*)
17 (Left-rear)No.9 RLS (+l
ABS CONTROL UNIT 31P CONNECTOR
Wire side
ls there continuity?
YES Go to step 6.
NO-Go to step 7.
Disconnect the harness 2P connector from the
appropriate wheel sensor, then check for continuity
between the 1+)and ( )terminals ofthe harness
and body ground.
ls there continuity?
YES-Repair shortto body ground in the (+)or { )
circuit wire between the ABS modulator-control
unit and the wheel sensor.l
NO Repiace the wheel sensor.l
(cont'd)
Wire side of female terminals
19-45

ABS Components
DTC Troubleshooting (cont'dl
7. Check the resistance between the appropriate
wheel sensor (+) and ( ) circuit terminals {seeta ble).
DTCAppropriate Terminal
l+) Side*lSide
11 {Riqht-front)No.5: FRS (*)No.4:FRS 1-)'13 {Left-front)No. 7: FLS {+iNo.6: FLS (-
15 (Rioht-rear)No. 2: RBS {+)No. 1:RBS (-)
17 (Left-rear)No.9: RLS 1-No.8: BLS (-
ABS CONTROL UNIT 31P CONNECTOR
Wire side of female terminals
Is the rcsistance between 450 2,000 A ?
YES Check for a loose ABS control unit3lP
connector. lf necessary. substitute a known-good
ABS modulator-control unit, and recheck.l
NO Go to step 8.
Disconnect the harness 2P connector from theappropriate wheel sensor, and check the resistance
between the (+) and { )terminalsof thewheel
sensor.
ls the resistance between 450- 2,000 Q ?
YES-Repair open in the (+) or (-) circuit wire, orshort between the (+) circuit wire and the { )circuit wire between the ABS modulator-control
unit and the wheel sensor.l
NO Replace the wheel sensor.l
19-46
DTC12,14, 16, 18: Wheel Sensor Putse
Signal
NOTE: lf the ABS indicator comes on for the reasonsdescribed below, the indicator goes off when you test-drive the vehicle at 31 mph (50 km/nl.
. Only the drive wheel rotated. The vehicle spun. Electrical noise
1. Visually check for appropriate wheel sensorandpulser installation and condition (see table).
DTCAppropriate Wheel Sensor
12Riqht-front
14Left-front
Riqht-rear
18Left-rear
Ate they installed correctly and not damaged?
YES-Go to step 2,
NO Reinstall or replace the appropriate wheelsensor or pulser,I
Disconnect the ABS control unit 31P connector.
Measure the resistance between the appropriate
wheel sensor ( f) and ( ) circuit terminals (see
table).
ls therc less than 450 Q ?
YES Go to step 1.
NO-Go to step 4.
\\|D
2.
3.
DTCAppropriate Terminal
l*) Side) Side
12 {Rioht-front)No.5:FBS (*No.4:FBS
14 (Left-front)No.7;FLS l*No,6:FLS
16 (Riqht.rear)No.2: RRS (*No. 1:BRS
18 (Left-readNo.9: BLS 1-No.8:RLS

4. Check for continuity between the appropriate
wheel sensor (+) circuittermlnal and otherwheel
sensor (+) circuit terminals (see table).
DTCAppropiate
Terminal
Other Terminal
12No.5:
FRW (*i
No.7No.2No.9
'14No.7:
FLW IT.)
No.5No.2No.9
toNo.2;
RRW (T-)
No.5No.7No.9
18No.9:
RLW (*)No.5No. 7No.2
ls there continuity?
YES Repair short in the wires between the
appropriate wheel sensor and the other wheel
sensor harnesses.l
NO Clear the DTC, disconnect the Honda PGM
Tester, and test-drive the vehicle. lf the ABS
indicator comes on and the same DTC is indicated,
replace the ABS modulator-control unit.l
Disconnect the harness 2P connector from the
appropriate wheel sensor and check the resistance
between the (+) side and the (-) side ofthe wheel
sensor.
ls there less than 450 Q ?
YES Replace the wheel sensor.
NO- Repair short to wire between the appropriate
wheel sensor (+) and (-)circuits.l
DTC 21: Continuous Operation (Chipped
pulser)
1. Clear the DTC, then disconnect the Honda PGM
tesler.
2. Test-drive the vehicle at 19 mph (30 km/h) or more.
Doesthe ABS indicator come on and is DTC 21
ind icated?
YES Go to step 3.
NO The system is OK at this time.l
3. Check the pulser gear for a chipped tooth.
ls the pulser OK?
YES Check for a loose ABS control unit 31P
connector. lf necessary, substitute a known-good
ABS modulator-control unit, and recheck.l
NO Replace the driveshaft or hub unit (chipped
pulser gear).1
1g-47

Power Mirror Replacement
1.
2.
5.
Lower the door glass fully.
Carefully pry out the mirror mount cover (A) by
hand in the sequence shown. Disconnect the
tweeter connector (B), and release the wire harness
(C) from the hook (D).
Fastener Location
) : Clip, 1
3. Remove the door panel (seepage20-4).
4. Disconnectthe connector (A), and detach the
harness clip (B). While holding the mirror {C),
remove the nuts, then remove the mirror. Take care
not to scratch the door.
Fastener Locrtions
O: Nut.3
lnstall the mirror in the reverse order of removal,
and note these items:
. Make sure the connector is plugged in properly.
. Attach the harness clip.
Mirror Holder Replacement
1. Carefully pulloutthe bottom edge ofthe mirror
holder (A) by hand. Take care not to scratch the
mrrror.
5.
Separate the mirror holder from the actuator (B) by
slowly pulling them apart while detaching the clips
(C). lf equipped, disconnect the mirror defogger
connectors{D) from the heater pad terminals.
lf equipped, reconnect the mirror defogger
connectors.
Reattach the clips of the mirror holder to the
actuator, then position the mirror holder on the
actuator. Carefully push on the clip portions of the
mirror holder untilthe mirror holder locks into
prace.
Check the operation of the actuator
20-15

Interior Trim
Carpet Replacement (cont'dl
Using a utility knife, cut the carpet (A) under the
heater areas (B), and cut out the parking brake lever
area (C) as shown, then pull back the carpet.
AB
Remove the clip (A), and release the fasteners (B).
Pull the carpet out from both rear side trim panels
(D), then remove the carpet (C).
Fastener Location
A >: Clip. 1
4.
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20-56
5. Installthe carpet in the reverse order of removal,
and note these items:
. Take care notto damage, wrinkle, ortwistthe
carpeL. Make sure the seat harnesses are routed
correctly.. Slip the carpet under the rear side trim panel on
each side properly.. Replace the clip if it's damaged.. Reattach the cut areas under the heater around
the parking brake lever with a wire tie.. When installing new carpet, cut the carpet (A)
under the heater areas (B), and around the
parking brake lever (C). After installing the new
carpet, slip the carpet from the driver's and
passenger's side through the space between the
heater unit and body, and reattach the cut area
{C) around the parking brake lever with wire ties.
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