ect HONDA CIVIC 2003 7.G Workshop Manual

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.

8. Remove the flange bolt {A) andwheel sensor(B)
from the knuckle. Do not disconnect the wheel
sensor conneclor.
Remove the flange nut (A) while holding the joint
pin (B) with a hex wrench (C), and disconnect the
stabilizer link {D) from the lower arm (E).
A5x1.0mm9.8 N.m(1.0 kgl.m,7.2 tbt.ftl
9.
10 x 1.25 mm39 N.m (,1.0 kgf.m,29lbf.ft)
10. Remove the lock pin (A)from the lower arm ball
joint, and remove the castle nut (B).
NOTE: During installation, insert the lock pin into
the balljoint pin from the lnside to the outside of
the vehicle. The closed end of the lock Din must be
in the range shown.
07 MAC-SL00200
€--....-"12 x 1.25 mm59 69N m
'R.
11.
12.
(6.0 7.0 kgl m,43 -51 lbf tt)
Disconnect the lower arm from the knuckle using
the special tool (see page l8-10).
Loosen the damper pinch bolts (A) while holding
the nuts (B), and remove the bolts and nuts.
'13. Remove the driveshaft outboard joint {C) fromthe
knuckle (D) by tapping the driveshaft end (E) with a
plastic hammer while drawing the knuckle outward,
then remove the knuckle.
NOTE: Do not Dull the driveshaft end outward. The
driveshaft joint may come off.
(cont'd)
18-13

Front Suspension
Ball Joint Boot Replacement
Special Tools Required
Front hub dis/assembly tool 07965-5450500
1. Remove the boot.
2. Pack the interior and lip (A) of a new boot with fresh
grease. Keep the grease off of the boot-to-knuckle
mating surfaces (B).


-6r
rffi
€l
--B
Wipe the grease off the tapered section of the pin
(C), and pack fresh grease onto the base (D).
tI
18-16
Inst€ll the boot onto the ball joint pin, then squeeze
it gently to force out any air. Do not let dlrt or other
foreign materials get into the boot.
Press the boot with the special tool until the bottom
seats on the knuckle (A) evenly around.
pross
07965-SA50500
6.After installing a boot, wipe any grease off the
exposed portion of the ball joint pin.
i

Stabilizer Bar Replacement
1.Raise the front of the vehicle, and support it with
safety stands in the proper location (see page 1-8).
Remove the front wheels.
Remove the self-locking nuts (A) while holding the
joint pin (B) with a hex wrench (C), and disconnect
the stabilizer links (D)from the stabilizer bar (E) on
the right and left.
D
10 x 1.25 mm39Nm(4.0 kgf m,29 tbl,ft)
Remove the flange bolts {A) and bushing holders
{B), then remove the bushings (C) and the stabilizer
bar (D).
FORWARD
A10 x 1.25 mm39Nm(4.0 ksf.m, 29lbl.ftl
,.'i i
''i]
. i.',.:-l I
\' ,r' ,' i :..r'j-- r-'1 _: i'
i-ii::;i
;4-llt,-'j--;
4. lnstallthe stabilizer bar in the reverse order of
removal. and note these itemsl
. Use new self-locking nuts on reassembly.. Note the right and left direction of the stabilizer
oar.. Align the ends ofthe paint marks (A) on the
stabilizer bar with each end of the bushings (8).
. Note the forelaft direction ofthe bushing holders.. Refer to stabilizer Link Replacement to connect
the stabilizer bar to the links (see page 18-18).
18-17

Front Suspension
Stabilizer Link Removal/lnstallation
1.Raise the front of the vehicle, and support it with
safety stands in the proper location (see page 1-8).
Remove the front wheels.
Remove the self-locking nut (A) and flange nut {B)while holding the respective joint pin (C) with a hex
wrench (D), and remove the stabilizer link (E).
3. lnstallthe stabilizer link (A) on the stabilizer bar {B)
and lower arm (C) with the joint pins (D) set at the
center of their range of movement.
18-18
4. Install the self-locking nut and flange nut, and
lightly tighten them.
NOTE: Use a new self-locking nut on reassembly.
5. Place the floor jack under the lower arm balljoint,
and raise the suspension to load it with the vehicle's
weaght.
mri-dEl
Do not place the jack against the lower arm
balljoint.
6. Tighten the self-locking nut (A) and flange nut (B) to
the specified torque values while holding the
respective joint pins (C) with a hex wrench (D).
A10 x 1.25 mm38 N.m(3.9 kgf m,28 lbf.ft)
\
..,
1.
B10 x 1.25 mm39 N.m{4.0 kgf.m, 29lbf.ft}
After 5 minutes of driving, re-tighten the self,
locking nut again to the specified torque.

Lower Arm Removal/lnstallation
SpecialTools Required
Ball joint remover,2S mm 07|MAC-S100200
1. Raise the front of the vehicle, and support it with
safety stands in the proper location (see page 1-8).
Remove the front wheels.
Remove the flange nut (A) while holding the joint
pin {B) with a hex wrench (C), and disconnect the
stabilizer link (D)from the lower arm (E).
10 x 1.25 mm39 N.m{4.0 kgf m, 29 lbt.ft)
3.Remove the lock pin (A) from the lower arm ball
joint, and remove the castle nut (B).
NOTE: During installation, insertthe lock pin into
the ball joint pin from the inside to the outside of
the vehicle. The closed end of the lock pin must be
in the range shown.
6--__ oTMAc-sloo2oo
@a12 x 1.25 mm59 69Nm16.0-7.0 kgt-m,43 51 lbf.ft)
4.Disconnect the lower arm from the knuckle using
the special tool (see page 18-10).
5. Remove the flange bolts (A), and remove the lower
arm {B}.
14 x 1.5 mm83 N.m (8.5 kgf.m,61 lbf.ft)
6. Installthe lower arm in the reverse order of
removal, and note these items:
. Be careful not to damage the ball joint boot when
connecting the lower arm to the knuckle.
' Tighten all mounting hardware to the specified
torque values,. Firstinstall all the components and lightlytighten
the bolts and nuts. then raise the suspension to
load it with the vehicle's weight before fully
tightening it to the specified torques.. Torque the castle nut to the lower torque
specification, then tighten it only far enough to
align the slot with the ball joint pin hole. Do not
allgn the castle nut by loosening it.
. Install a new lock pin on the castle nut after
torquing.. Before installing the wheel, clean the mating
surface of the brake disc and the inside of the
wneet.. Check the wheel alignment, and adjustitif
necessary (see page '18-4).
18-19

Special Tools Required
Ball joint remover,28 mm 07MAC-S100200
Removal
1. Raise the front of the vehicle, and support it with
safety stands in the proper location (see page 1-8).
Remove the front wheels.
Remove the cotter pin (A) from the tie-rod end ball
ioint, and remove the nut (B).
10 mm HEX NUT
07MAC-S1002000
Disconnectthe tie-rod end from the steering arm
on the damper using the specialtool (see page 18-
10 ).
Remove the bolts, and remove the wheel sensor
harness bracket {A) and brake hose bracket (B)
from the damper. Do not disconnect the wheel
4.
sensor connector.
A6x1.0mm
/.8
x 1.25 nm
q
5. Remove the damper pinch bolts (A)while holding
the nuts (B).
6. Remove the flange nuts (A)from the top ofthe
damper,
A10 x 'l.25 mm
7. Lower the lower arm, and remove the damper
assembly (B).
(cont'd)
18-21

Front Suspension
Damper/Spring Replacement (cont'd)
Disassembly/lnspection
1. Compress the damper spring with a commercially
available strut spring compressor (A) according to
the manufacturer's instructions. then remove the
self-locking nut (B)while holding the damper shaft(C) with a hex wrench (D). Do not compress the
spring more than necessary to remove the nut,
Release the pressure from the strut spring
compressor, then disassemble the damper as
shown in the Exploded View.
18-22
4.
Reassemble all the pans, except for the upper
spring seat and spring.
Compress the damper assembly by hand, and
check for smooth operation through a full stroke.
both compression and extension. The damper
should extend smoothly and constantly when
compression is released. lf it does not, the gas is
leaking and the damper should be replaced.
Check for oil leaks, abnormal noises, and binding
during these tests.
\

3. Position the damper on the knuckle, and installthe
new damper pinch bolts (A) and nuts (B), and
lightly tighten the nuts.
B16x 1,5 mm157 N.m(16.0 kgt m,116 tbt.ftl
4. Place the floor jack under the lower arm balljoint,
and raise the suspension to load it with the vehicle's
weight.
Do not place the jack against the lower arm
balljoint.
Tighten the flange nuts on the top of the damper to
the specified torque.
Tighten the damper pinch nuts to the specified
torque.
Install the brake hose bracket (A) and the wheel
sensor harness bracket (B) onto the damper, and
tighten the bolt to the specified torque.
5.
1.
9.8 N.m11.0 kgf.m, 7.2lbf.ftl22N|rl.12.2 kgI m,16 rbr,ftl
q
8. Connect the tie-rod end to the steering arm, and
tighten the nut (A) to the specified torque. Install
the cotter pin (B) after tightening, and bend lts end
as shown.
9. Clean the mating surface ofthe brake disc and the
inside of the wheel, then install the front wheels.
10. Check the wheel alignment, and adjustitif
necessary {see page 18-4).
18-25

Rear Suspension
Hub Bearing Unit Replacement
(cont'd)
9. Remove the hub bearing unit (A) from the spindle.
Install the hub bearing unit in the reverse order of
removal, and note these items:
. Tighten all mounting hardware to the specified
torque values,. Before installing the brake disc, clean the mating
surface ot the hub and the inside of the brake
disc.. Use a new spindle nut on reassembly.. After tightening, use a drift to stake the spindle
nut shoulder against the spindle.. Use a new hub cap on reassembly.. Before installing the wheel, clean the mating
surface of the brake disc and the inside of the
wneel.
10.
,=,,,
18-28
Raise the rear of the vehicle, and suppon it with
safety stands in the proper location (see page 1-8).
Remove the rear wheels.
Remove the brake disc and hub bearing unit (see
step 1 on page 18-27).
Remove the flange bolts (A) and splash guard (B)
from the knuckle.
11.0 kgf.m, 7.2 lbf ft)
4. Remove the wheel sensor(A), braKe nose
mounting bracket (B), and parking cable mounting
bracket (C) from the knuckle. Do not disconnect the
wheel sensor connector.
8 x 1.25 mm22 N.m{2.2 kgf m, 16 lbf ftl
Knuckle Replacement
1.
6x1.0mm9.8 N,m{I.0 kgt.m,7.2 lbf ft)
tt