ect HONDA CIVIC 2003 7.G Workshop Manual

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).
,.!,..''6f
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.
, -', ''l
:1)
17-65

EPS Components
4
17.
18.
Steering Gearbox Installation (cont'dl
Install the motor on the steering gearbox (see page
17-49).
lnstall the steering joint (A). and reconnect the
steering shaft (B) and pinion shaft (C). Make sure
the steering joint is connected as follows:
. Insertthe upperend of thesteering jointontothe
steering shaft (line up the bolt hole (D) with the
flat portion (E) on the shaft).. Slip the lower end of the steering joint onto thepinion shaft (line up the bolt hole with the groove
(F) around the shaft), and loosely installthe lowerjoint bolt. Be sure that the lower joint bolt is
securely in the groove in the pinion shaft.. Pull on the steering joint to make sure that the
steering joint is fully seated. Then install the
upper joint bolt, and tighten it to the specified
torque. Tighten the lower joint bolt to the
specified torque.
8 x '1.25 mm28 N.m{2.9 kgf.m,21 tbt.ft)
19.
20.
Installthe driver's dashboard lower cover (see
page 20-59) and under cover (see page 20-60).
lf the steering wheel was turned, center the cable
reel by first rotating it clockwise until it stops. Then
rotate it counterclockwise (about two and half
turns) untilthe arrow mark on the label points
straight up. Reinstall the steering wheel (see page
17 -8).
Install the front wheels.)1
17-66
22. After installation, perform the following checks.
. Perform the front toe inspection.. Check the steering wheel spokeangle. lfsteering
spoke angles to the right and left are not equal(steering wheel and rack are not centered),
correct the engagement of the joinvpinion shaft
serrations, then adjust the front toe by turning
the tie-rods, if necessarv.
\

EPS Control Unit Removal/
Installation
1. Remove the passenger's under panel.
2. Turn up the floor carpel, remove lhe EPS control
untr.
Disconnect the EPS control unit connectors.
lnstallthe EPS control unit in the reverse order of
removal.
After installation, start the engine, and let it idle.
Turn the steering wheelfrom lock-to-lock several
times. Check that the EPS indicator does not come
on.
3.
E
Tie-rod Ball Joint Boot Replacement
Special Tool Required
Attachment, 42 mm 07OAD-P0A0100
l. Remove the boot from the tie-rod end, and wipe the
old grease off the ball pin.
2. Pack the lower area of the ball pin(A)wilhfresh
mulr purpose grease.
3. Pack the interior of the new boot (B) and lip (C) with
fresh multipurpose grease.
Note these items when installing new grease;
. Keep grease offthe boot installation section (D)
and the tapered section (E) of the ball pin.
. Do not allow dust, dirt, or other foreign materials
to enter the boot.
4. Installthe new boot (A) using the specialtool. The
boot must not have a gap at the boot installation
sections (B). After installing the boot. check the ball
pin tapered section for grease contamination, and
wipe it if necessary.
07(lAD-P0A0100
*-4
r/ \-,d______i.l+_D
-6rA
17-67

Suspension
Front and Rear Suspension
SpecialTools ............. 18-2
Component Location Index ......................................... 18-3
Wheel Alignment ..................... ........... 18-4
Wheel Bearing End Play Inspection ............................ 18-8
Wheel Runout Inspection .................. 18-9
Ball Joint Removal ... 18-10
Front Suspension
Kn uckle/H u bAVheel Bearing Replacement
Ball Joint Boot Reolacement ..................
Stabilizer Bar Rep|acement ....................
Stabilizer Link Removal/lnstallation
LowerArm Removal/lnstallation ...............
Damper/Spring Replacement
Rear Suspension
Hub Bearing Unit Replacement .....................
Knuckle Reolacement
Stabilizer Bar Replacement ....................
Stabilizer Link Removal/lnstallation ..........................
Upper Arm Removal/lnstallation ...............
Trailing Arm Removal/lnstallation
Damper/Spring Replacement
18-1 1
18-16
18-17
18-18
18-19
18-20
18-26
18-28
18-30
18-31
18-32
18-33
18-34

Front and Rear Suspension
WheelAlignment
The suspension can be adjusted for front camber, front
toe, and rear toe. However, each of these adjustments
are interrelated to each other. For example, when you
adjust the toe, the camber changes. Therefore, you
must adjust the front wheel alignment whenever you
adjust the camber or toe.
Pre-Alignment Checks
For proper inspection and adjustment of the wheel
alignment, do these checks:
1. Release the parking brake to avoid an incorrect
measurement.
Make sure the suspension is not modified.
Check the tire size and tire pressure
Tire size:
Front/rear: 195/60R15
Tire pressure:
Front: 230 kPa {2.3 kgf/cm',33 psil
Rear: 210 kPa |'2.1 kgf/cm', 30 psi)
Check the runout of the wheels and tires.
Check the suspension ball joints. (Hold a wheel
with your hands, and move it up and down and
right and left to check for wobbling),
2.
3.
Bounce the vehicle up and down several times to
stabilize the suspension.
18-4
Front Caster lnspection
Use commerciallv available comDuterized four wheel
alignment equipment to measure wheel alignment
(caster, camber, toe, and turning angle). Follow the
eouioment manufacturer's instructions.
Check the caster angle. lf the caster angle is not within
the specification, check for bent or damaged
susoensron comoonents.
Front caster angle: 1'40't 1"
\

Front Camber Inspection
Use commercially available computerized four wheel
alignment equipment to measure wheel alignment(caster, camber, toe, and turning angle). Follow the
equipment manufacturer's instructions.
Check the camber angle. lf the camber angle is not
within the specification, adjust the camber.
Front camber angle: 0"30' t 45'
Front Camber Adjustment
The front camber can be adjusted by exchanging one or
both of the damDer Dinch bolts with the smaller
diameter adjusting bolt(s). The difference between the
adjusting bolt diameter and the pinch bolt hole
diameter allows a small range of adjustment.
DamDer Pinch Bolt:Adiusting Boh:
P/N 90188-55A-000
Raise the front of the vehicle, and support it with
safety stands in the proper location (see page 1-8).
Remove the front wheels.
Loosen the damper pinch nuts and bolts (A), and
adjust the camber by moving the bottom of the
damper within the range of the damper pinch bolt
free play.
1.
-++tA16 x 1.5 mm157 N.m(16.0 kgf.m,116 tbf.ftl
3.
4.
Tighten the bolts to the specified torque.
Reinstall the front wheels. Lower the front of the
veh icle to the ground, and bounce the vehicle
several times to stabilize the suspension.
Check the camber angle. lf it is within the
specification, check the front toe. lf it is not within
the specification, go to step 6.
(cont'dl
5.
18-5

Front and Rear Suspension
Wheel Alignment (cont'd)
7.
Raise the front of the vehicle, and support it with
safety stands in the proper location (see page 1-8).
Remove the front wheels.
Replace the damper pinch bolts with the adjusting
bolts (A), and adjust the camber angle.
NOTE: The camber angle can be adjusted up to t
15' (center of tolerance) by replacing one damper
pinch bolt with the adjusting bolt. The camber
angle can be adjusted up to a 30' by replacing both
upper and lower damper pinch bolts with the
adjusting bolts.
15 x 1.5 mm157 N.m{16.0 kgt.m,116 tbf.ft)
8.Tighten the bolts to the specified torque.
Reinstall the front wheels. Lower the front of the
vehicle to the ground, and bounce the vehicle
several times to stabilize the suspension.
Check the camber angle. lf it is within the
specification, check the front toe. and adjust it if
necessary. lf it is not within the specification,
readjust, and recheck. lJ the camber angle cannot
be adjusted to the specification, check for bent or
damaged suspension components.
10.
'rntr
i,iY. a
.:r,//
18-6
Rear Camber Inspection
Use commercially-available computerized four wheel
alignment equipment to measure wheel alignment(caster, camber, toe, and turning angle). Follow the
eouiDment manufacturer's instructions.
Check the camber angle. lf lhe camber angle is not
within the specification, check for bent or damaged
susDenston comoonenrs.
0"55't 45'
bolts on the trailing arm.
Rear camber angle: 0
NOn-dEl
Do not loosen the special
\

Front Toe Inspection/Adjustment
Use commercially-available computerized four wheel
alignment equipment to measure wheel alignment(caster, camber, toe, and turning angle). Follow the
equipment manufacturer's instructions,
1. Center the steering wheel spokes.
2. Checkthetoe. lf it is not with in the specif ication, go
to step 3.
Front toe-in: 0 t 3 mm {0 t 0.12 in.)
3. Loosen the locknut (A) while holding the tie-rod end(B ).
A14x 1.5 mm,14 N.m(a.5 kgt m,33 lbt.ftl
5.
Turn the tie-rod (C) untilthe toe is correct.
After adjusting, tighten the locknut while holding
the tie-rod end. Make sure the toe setting does not
change.
1,;
Rear Toe Inspection/Adiustment
Use commercially-available computerized four wheel
alignment equipment to measure wheel alignment(caster, camber, toe, and turning angle). Follow the
equipment manufacturer's instructions.
1, Release the parking brake.
2. Checkthe toe. lf it is not within the specification. go
to step 3.
Rear toe-in {inspection):
1 1 3 mm (0.04 a 0.12 in.)
3. Loosen the self-locking nut (A)while holding the
adjusting bolt (B).
Do not loosen lhe special bolts (C) on the
lower arm to adjust the alignment.
4. Replace the self-locking nut with a new one, and
lightly tighten.
NOTE: Always use a new self-locking nut whenever
it has been loosened.
Turn the adjusting bolt until the toe is correct.
Rear toe.in (adiustment):
2 ' , mm {0.08 "' ,. in.}
Tighten the self-locking nut to the specified torque
while holding the adjusting bolt.
(cont'd )
18-7

Front and Rear Suspension
Wheel Alignment (cont'dl
Turning Angle Inspection
Use commercially-available computerized four wheel
alignment equipment to measure wheel alignment(caster. camber, toe, and turning angle). Followthe
equiDment manufacturer's instructions.
1. Turn the steering wheel fullytotherightandleft
while applying the brake, and check the turning
angles of both front wheels, lf the turning angle is
not within the specification or the inward turning
angles differ between the right and left side, go to
steD 2.
Turning angle:
lnward: 34'00'+ 2'
Outward: 28'00' {reference)
Check the toe. lf it is correct, but the turning angle
is not within the specification, check ior bent or
damaged suspension components,
18-8
Wheel Bearing End Play Inspec'tion
1. Raise lhe vehicle, and support it with safety stands
in the proper location (see page 1-8). Remove the
wheels.
2. Install suita ble f lat washe rs (A) and wheel nuts, and
tighten the nuts to the specified torque to hold the
brake disc securely against the hub.
Front:
108 N.m(11.0 kgf.m,80 rbf.ft)
Rear:
108 N.m
3. Set up the dial gauge against the hub flange as
shown, and measure the bearing end play moving
the brake disc inward and outward.
Bearing end play:
Standard:
Front/rear: 0 0.05 mm {0 0.002 in.}
4. lf the bearing end play is more than the standard,
replace the wheel bearing.
\
(11.0 kgf.m,80 lbf.ft)

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