Panel HONDA CIVIC 2003 7.G Service Manual

Hatch
Adjustment
1. Remove the support strut from each side (see page 20-91).
2. RemovetheC-pillartrimfromeachside(seepage20-5'l),andpull downtherearponionoftheheadliner(seepage 20-54). Take care not to bend the headliner excessively.
3. Remove the rear trim panel (see page 20-52).
4, Slightly loosen each bolt and nut.
5. Adjustthe hatch (A) alignment in the following sequence.
. Adjustthe hatch hinges (B) right and left, as well as forward and rearward, using th e elongated holes.'Turnthehatchedgecushions(C),inoroutasnecessary,tomakethehatch(D).fitflushwiththebodyattheside
edges.. Adjust the fit between the hatch and hatch opening by moving the striker (D).
8 x 1.25 mm18 N.m 11.8 kgf.m, 13 lbf.ft)
\
8 x 1.25 mm22 N.m{2.2 kgf.m, 16 lbf.ft}
20-90

Exterior Trim
\
Rear License Trim Replacement
NOTE: Put on gloves to protect your hands.
1. Remove the hatch lower trim panel (see page 20-
2. On inside the hatch. remove the bolts securing the
rear license trim (A) and hatch lock cylinder (B).
Fastener Locations
> : Bolt,2
-)
6x1.0mm9.8 N.m (1.0 kgf.m,7.2lbf.ftl
20-98
3. From inside the hatch, release the clips (A, B)while
holding the rear license trim (C), then remove lhe
trim, Take care not to scratch the hatch.
Fastener Locations
A>:Clip,2 B>:Clip.2
\!-
cHl €:t+
Installthe trim in the reverse order of removal, and
note these rtems:
. Replace any damaged clips.. Push the clip portions into place securely.
4.

Openers
Hood Opener Cable Replacement
NOTE:. Put on gloves to protect your hands.. Take care not to scratch the body and related parts.
l. Remove these items:
. Front bumper (see page 20-85). Front inner fender, leftside(seepage20-102). Kick panel, left side (see page 20-50)
2. Disconnect the hood openercable (A) from the hood latch {B) (see
remove the hood release handle (D)from the body.
Fastener Locations
C >:Bolt,2 E >:Clip,3
page 20-108), and remove the bolts (C), then
6x1.0mm9,8 N.m11.0 kgl.m, 7.2 lbl.ft)
@m
4.
Using a clip remover, detach the clips (E), and remove the grommet (F)from the body, then remove the hood
opener cable from the vehicle. Take care not to bend the cable.
Installthe cable in the reverse order of removal, and replace any damaged clips.
l,.t'.
W:"
20-106

2.
5.
Fuel Fill Door Opener Cable Replacement
SRS components are located in this area. Review the SRS component locations (see page 23-13) and the precautions
and procedures (see page 23-14) in the SRS section before performing repairs or service.
NOTE;. Put on gloves to protect your hands.. Take care notto scratch the body and related parts.
1. Remove these items from the left side of the vehicle:
. Door silltrim {see page 20-50). Rear side trim panel (see page 20-51)
Pullthe carpet back as necessary (see page 20-55).
Disconnect the fuel fill door opener cable (A) from the opener (B) (see step 3 on page 20-109).
Fastener Locations
C >:Cushiontape, 1 D >: Clip, 1E > : Clip, 2
4. KCmodel: Removethe left middle floor cross-member gusset (see page 20-113).
5. Remove the cushion tape {C), and release the cable from the clips (D, E).
6. Removethefuel fill doorlatch (F)fromthe bodybyturning it90'.
7. Remove the fuel fill door opener cable from the vehicle. Take care not to bend the cable
8. Install theopenercableinthereverseorderofremoval,replacethecushiontape,andreplacetheclipifitis
oamageo.
20-107

Openers
Hatch Handle Replacement
NOTE: Put on gloves to protect your hands.
1. Remove these items:
. Hatch lower trim panel (see page 20-53). Rear license trim panel (see page 20-98)
2. Remove the rear window wiper motor (see page
22-1461.
3. Disconnect the hatch
hatch handle (B), and
Locations
opener cable 1A)from the
remove the nuts.
6x1.0mm9.8 N.mFastener
a : Nut,
()rI
4. Pull outthe hatch handle (A), then remove it.
Installthe handle in the reverse order of removal.
and note these items:
lMake sure the hatch opener cable is connected
securely.
Make sure the hatch opens properly.
(1.0 kg{.m,7 2 tbt.{t\
a
,t.
20-110
Hatch Latch Replacement
NOTE: Put on gloves to protect your hands.
'1. Remove the hatch lowertrim panel (see page 20-
53).
2. Disconnect the hatch opener cable (A), cylinder rod(B). hatch actuator connector (C). and hatch latch
switch connector {D). and detach the hatch actuator
connector and hatch latch switch connector from
the hatch.
Faslener Locations
) : Bolt, 3
ttb
L- i-'-3;li9#-
11,0 kgt m,7.2lbf ftl
Remove the bolts, then pullthe hatch latch (E) out,
then remove it.
Installthe latch in the reverse order of removal, and
note these items:
. Make sure each connector is plugged in properly,
and the rod and cable are connected properly.. l\4ake sure the cable actuates the latch before you
close the hatch.. Make sure the hatch opens properly and locks
securely.

Hatch Lock Cylinder Replacement
NOTE; Put on gloves to protect your hands.
'1. Remove these items:
. Hatch lower trim panel (see page 20-53).. Rear license trim (see page 20-98).
2. Disconnect the cylinder rod (A)
-..
From outside the hatch, remove the bolt securing
the lock cylinder {A}. From inside the hatch, pull the
lock cylinder out by releasing the hook (B).
Fastener Location
> : Bolt, 1
rS'l-.u-ar
6x 1.0 mm9.8Nm(1.0 kgf m,7.2lbt.ftl
*/t
4. Install the lock cylinder in the reverse order of
removal, and note these items:
. Make sure the rod is connected properly.
. Make sure the hatch opens properly and locks
securely.
20-111

Frame Stiffener, Brace, and Gusset Replacement
Frame Stiffener, Brace, and Gusset Torque
NOTE: When installing the middle floor cross member brace or gussets, torque the mounting hardware in the
following sequence to avoid damage to the quarter panel.
MIDDLE FLOORCROSS-MEMgERBRACE/GUSSET
SIDE FRAME STIFFENER
8 x 1.25 mm29 N.m(3.0 kgf m,22 lbf ft)
U.S. model:
10 x 1.25 mm38 N.m(3.9 kgf.m.28lbf.ftl
To body.
Canada model:
MIDDLE FLOORCROSS.MEMBERGUSSET
MIODLE FLOORCROSS-MEMBERBRACE
.. __!:::-- | -
10 x 1.25 mm38 N m (3.9 kgt.m, 28 lbf.ftl
10 x 1.25 mm38Nm(3.9 kgf.m,28 lbl.ftl
I
20-113

21-2
z t-'5
z t-o
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21-8
21-9
21-10
21-11
21-14
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HVAC (Heating, Ventilation, and Air Gonditioningl
Heating and Air Conditioning
SpecialTools
Comoonent Location lndex ........
A/C Service Tios and
Precautions
A,/C Refrigerant Oil
ReDlacement
General Troubleshooting
lnformation
DTC Troubleshooting Index .......
Symptom Troubleshooting
1ndex..............
System Description .....................
Circuit Diagram
DTC Troubleshooting ..................
Recirculation Control Motor
CircuitTroubleshooting .......... 21-25
Heater Control Power and Ground
Circuits Troubleshooting ........ 21-27
Condenser Fan Circuit
Troubleshooting ...................... 21-28
Radiator and Condenser Fans
Common Circuit
Troubfeshooting ...................... 21-29
Compressor Clutch Circuit
Troubleshooting ...................... 21-30
A,/C Pressure Switch Circuit
Troubleshooting ...................... 21-32
Air Mix Control Motor
Test and Reolacement ............. 21-34
Mode Control Motor
Test and Replacement ............. 21-35
Recirculation Control Motor
Test and Reolacement ............. 21-36
Evaporator Temperature Sensor
Reolacement and Test ............. 21-31
Power Transistor Test ................. 21 -38
Heater Control Panel and
Push Switch Assemblv
Removal and Installation ........ 21-38
Dust and Pollen Filter
Reolacement ..21-39
Blower Unit Removal and
lnstallation ...... 21-39
Blower Unit Comoonents
ReDlacement ............................ 21-41
Evaporator Core
Reolacement ..21-42*Heater Unit/Core
ReDlacement ..21-43
Heater Valve Cable
Adjustment .....21-46
CompressorReplacement .......... 21-47
Comoressor Clutch Check .......... 21-48
Comoressor Clutch Overhaul ..... 21-49
Compressor Thermal Protector
Reo1acement ............................ 21-51
Comoressor Relief Valve
Reolacement ............................ 21-51
Condenser Reolacement ............ 21-52
Refrigerant Recovery .................. 21-53
System Evacuation ...................... 21-54
System CharginS ......................... 21-55
Refrigerant LeakTest .................. 21-56
A,/C Svstem Tests ........................ 21-57

HEATER UNIT/COREBeplacement, page 21-43
BLOWEN UNITRemoval and Installation, page 21-39
HEATER VALVE CABLEAdjustment, page 21-46
BLOWER UNIT COMPONENTSReplacement, page 21-41
DUSTAND POLLENFILTERReplacement, page 21'39
RECIRCULATION CONTROL MOTORTest, page 21-36Replacement, page 21-36
MODE CONTROL MOTORTest, page 21-35Replacement, page 21-35
AIR MIX CONTROL MOTORTest, page 21'34Replacement, page 21'34
POWER TRANSISTORTest, page 21-38
HEATER CONTROL PANELRemovaland Installation, page 21 38
PUSH SWITCH ASSEMBLYRemoval and Installation, page 21'38EVAPORATOR TEMPERATURESENSORReplacement, page 21-37Test, page 21-37
21-5

Heating and Air Conditioning
General Troubleshooting Information
How to Retrieve a DTC
The heater control panel has a self-diagnosis function. To run the self-diagnosis function, do the following:
1. Turn the fan switch OFF.
2. Pressand holdthe recirculation control switch andthe rear window defoooer switch down.
3. Turn the ignition switch oN {lli.
4. Release both switches. The recirculation indicator and the rear window defogger indicator come on. The
recirculation indicator goes off 3 seconds later and the Ay'C indicator comes on. then the self-diagnosis will begin.
About 10 seconds later, the self-diagnosis will finish and the A,/C indicator goes off.
.lfanytroubleisfound.therecirculationindicatorblinksthediagnostictroublecode(DTC)toindicateafaulty
circuil or comDonent.. lf the system is OK, the recirculation indicator stays off.
atc
@r
RECIRCULATIONCONTROL SWITCH
BECIRCULATIONINDICATOB
/A\
-:@
INOICATOR
REAR WINDOWOEFOGGER INDICATOR
REAR WINDOWDEFOGGER SWITCH
Examole of DTC indication Pattern IDTC 7)
DTC 7
Reseiting the Selt-diagnosis Function
Turn the ignition switch OFF to cancel the self-diagnosis function. After completing repair work, run the self-diagnosis
function aoain to make sure thatthere are no other malfunctions.
Recirculation +indicatot
Recirculation +indicalorgo6s oft----->
21-8