HONDA CIVIC 2003 7.G Workshop Manual

12. Glue the side upper fasteners (A) andsidelower
fasteners (B) with adhesive tape (3M 5312, or
equivalent)to the hatch as shown.
Fastoner Locations
A>: Fastener, 2 B >: Fastener, 2
T-8.
cl
ar\
itf,
t5.Set the rear window in the opening, and center it.
Align the clips (A) of the rear window with the holes
in the opening flange. Make alignment marks (B)
across the rear window, hatch, and body with a
grease pencil at the four points shown. Be careful
not to touch the rear window where adhesive will
be applied.
14. Remove the rear window.
15. With a sponge, apply a light coat of glass primer
along the edge of the rear window (A), upper
rubber dams (B), and lower rubber dam (C) as
shown, then lightly wipe it off with gauze or
cheesecloth:
. With the printed dots (D) on the rear window as a
guide, apply the glass primer to both side
portions of the rear window.. Do not apply body primer to the rear window,
and do not get hatch and glass primer sponges
mixed up.. Never touch the primed surfaces with your hands.
lf you do, the adhesive may not bond to the rear
window properly. causing a leak after the rear
window is installed.. Keep water, dust, and abrasive materials away
from the primed surface.
.. : Apply glass piimer here.
(cont'd)
20-27

Glass
16.
Rear Window Replacement (cont'd)
With a sponge, apply a light coat of body primer to
the original adhesive remaining around the rear
window opening flange. Let the body primer dry for
at least 10 minutes;
. Do not apply glass primer to the body, and be
careful not to mix up glass and body primer
sponges.. Never touch the primed surfaces with your hands.
',,,,,' : Apply body primer he.e.
20 mm10.79 in.l
2mm{0.08 in.)
17.Before filling a cartridge, cut a "V" in the end ofthe
nozzle {A} as shown.
20-28
7 mm (0.27 in.)
I
18. Pack adhesive into the cartridge without air pockets
to ensure continuous delivery. Put the cartridge in a
caulking gun, and run a bead of adhesive (A)
around the edge of the rear window (B) as shown.
With the glass primer (C) you applied in step 15 as
a guide, apply the adhesive to both side portions of
the rear window.
Apply the adhesive within 30 minutes after
applying the glass primer. fMake a slightly thicker
bead at each corner.
12 mm r,10.47 in.) ,\
ii'-A (0.28 in.l
\
aru'.1{-----"

19. Use suction cups to hold the rear window over the
opening. align it with the alignment marks you
made in step '13, and set it down on the adhesive.
Lightly push on the rear window until its edges are
fully seated on the adhesive all the way around. Do
not open or close the doors until the adhesive is dry.
20. Scrape or wipe the excess adhesive off with a putty
knife or towel. To remove adhesive from a painted
surface or the rear window, use a soft shop towel
dampened with alcohol.
21. Let the adhesive dry for at least 'l hour,thenspray
water over the rear window and check for leaks.
Mark the leaking areas, let the rear window dry,
then seal with sealant. Let the vehicle stand for at
least 4 hours after rear window installation, lf the
vehicle has to be used within the first 4 hours, it
must be driven slowly.
22. Reinstallall remaining removed parts.
NOTE: Advise the customer not to do the following
things for 2 to 3 days:
. Slam the doors with all the windows rolled up.. Twist the body excessively (such as when going
in and out of driveways at an angle or driving
over rough, uneven roads).
Ouarter Glass Replacement
NOTE:. Put on gloves to protect your hands.. Wear eye protection while cufting the glass adhesive
with piano wire,. Use seat covers to avoid damaging any surfaces.
1. Remove the C-pillar trim (see page 20-51).
lf necessary, remove the rear side trim panel (see
page 20-51 ) and B-pillar upper trim (see page 20-
50).
2. Remove the front seal {A) from the front edge of the
glass (B). lf necessary, cut the seal with a utility
knife.
(cont'd)
20-29

Glass
3.
Ouarter Glass Replacement (cont'dl
Apply protective tape to along the inside and
outside edges of the body. Using an awl, make a
hole through the adhesive from inside the vehicle.
Push a piece of piano wire through the hole, and
wrap each end around a piece of wood.
With a helper on the outside, pull the piano wire (A)
back and forth in a sawing motion. Hold the piano
wire as close to the quarter glass (B) as possible to
prevent damage to the body, and carefully cut
through the adhesive (C) around the entire quarter
grass.
Cutting positions:
5. Carefully remove the quarter glass.
20-30
6.With a putty knife, scrape the old adhesive smooth
to a thickness of about 2 mm (0.08 in.) on the
bonding surface around the entire quaner glass
opening flange:
. Do not scrape down to the painted surface of the
body; damaged paint will interfere with proper
bonding. Remove the clips from the body.
Clean the body bonding surface with a sponge
dampened in alcohol. After cleaning. keep oil,
grease and water from getting on the surface.
lf the old quarter glass is to be reinstalled, use a
putty knife to scrape off all of the old adhesive and
the rubber dam from the glass. Clean the inside
face and the edge of the glass with alcohol where
new adhesive is to be applied. Make sure the
bonding su rface is kept free of water, oil, and
grease.
7.

9. Set the quarter glass (A) in the opening, and center
it. From inside the vehicle, make an alignment mark(B) to the quarter glass where the rear clip will be
installed with a grease pencil. Be careful not to
louch the glass where adhesive will be applied.
10. Remove the quarter glass.
1 1. Align the upper clip {A) and lower clip (B) with the
edge of the quarter glass (C), then anach them with
adhesive tape (NITTO 571, or equivalent) to the
inside face of the quarter glass, and align the center
of the rear clip (D) with the alignment mark (E) you
made in step 9, and attach it with adhesive tape (3
M 4215, or equivalent) to the inside face of the
quarter glass as shown. Be careful not to touch the
glass where the adhesive tape will be applied.
25.5 mm{1.0 in.)
(cont'd)
20-31

Glass
Ouarter Glass Replacement (cont'dl
First glue the front seal (A) with adhesive tape {31\4
4213, or equivalent). and glue the rubber dam (B)
with adhesive tape (NITTO 501M, or equivalent) to
the inslde face of the quarter glass (C) as shown.
Before installing the front seal and rubber dam,
apply primer (3M N-200, or equivalent)to the inside
tace of the glass. then glue the seal on:
. Be sure the front seal lines upwiththe bottom
and front edges of the glass.. Be careful not to touch the glass where adhesive
will be aoolied.
.,1.,,/:/ | Apply prlJner hete.
-"-c
i--l
'100 mm{3.9i1in.)
45 mm{1.77 in.}
3.5 mm{0.r4 in.l
30 mm11.18 in.l
50 mm I{1.97in.1 /

6 mm (0.24 in.)
nLv--
20-32
'13. With a sponge, apply a light coat of glass primer
along the edge of the rubber dam (A) and front seal(B) as shown, then lightly wipe it off with gauze or
cheesecloth:
With the printed dots (C) on the quarter glass (D)
as a guide, apply the glass primer to the upper
and lower corner ponions of the quarter glass.
Do not apply body primer to the quaner glass,
and do not get body and glass primer sponges
mrxed up.
Never touch the primed surfaces with your hands.
lf you do, the adhesive may not bond to the
quarter glass properly, causing a leak after the
quarter glass is inslalled.
Keep water, dust, and abrasive materials away
from the primed surface.
11 mmlo.i(} in.)

14, With a sponge. apply a light coat of body primer to
the original adhesive remaining around the quarter
glass opening flange. Let the body primer dry for at
least 10 minutes:
. Do not apply glass primer to the body, and be
careful not to mix up glass and body primer
sponges.. Never touch the primed surfaces with your hands.
)'/ii ,/ii. I Apply bodv prime. here,
mm(0.08 in.l
20 mm(0.79 in.)
2mm{0.08 in.)
Before filling a cartridge, cut a "V" in the end ofthe
nozzle (A) as shown.
'10 mm (0.39 in.)
20 mm{0.79 in.)
t5.
7 mm 10.27 in.)
20-33
16. Pack adhesive into the cartridge without air pockets
to ensure continuous delivery. Put the cartridge in a
caulking gun, and run a bead of adhesive (A)
around the edge of the rubber dam (B) as shown.
With the glass primer (C)you applied in step 13 on
the quarter glass (D) as a guide. apply the adhesive
to the upper and lower corner portions of the
quarter glass. Apply the adhesive within 30
minutes after applying the glass primer. lvlake a
slightly thicker bead at each corner.
l.:J611, ;\
7mm{0.28 in.)
3mm{0.'12 in.}
I
IA
(conl'd )

Glass
Ouarter Glass Replacement (cont'd)
17. Use suction cups (A)to hold the quarter glass over
the opening. align it with the clips (B) and set it
down on the adhesive. Lightly push on the quarter
glass until its edges are fully seated on the
adhesive all the way around. Do not open or close
the doors untilthe adhesive is drv.
18. Scrape or wipe the excess adhesive off with a putty
knife or towel. To remove adhesive from a painted
surface or the quarter glass, use a soft shop towel
dampened with alcohol.
19. Let the adhesive dry for at least t hour,thenspray
water over the quarter glass and check for leaks,
Mark the leaking areas, let the quarter glass dry,
then seal with sealant. Let the vehicle stand for at
least 4 hours after quarter glass installation. lf the
vehicle has to be used within the first 4 hours. it
must be driven slowlv.
20. Reinstall all remaining removed parts.
NOTE: Advise the customer not to do the following
things for 2 to 3 days:
. Slam the doors with all the windows rolled up.. Twist the body excessively (such as when going
in and out of driveways at an angle or driving
over rough, uneven roads).
20-34

Moonroof
Component Location Index
WIND DEFLECTORReplacement, page 20-38
GLASSHeight Adjustment, page 20 37Replacement, paqe 20-37Closino Force and Ooenino DraoCheck; page 20-48 "
DRAIN CHANNELReplacement, page 20-39
,5
?a<&,
@
..t'- ?.@-@c
_a
@
/,BR^CKEI
COVER
LIMIT SWITCH(AUTO.STOP SWITCH)Adjustment, page 20-46ER
I
CABLE TUBEREAR BRACKETE@
E STOP
.a'
MOONROOFCONTROL UNIT
FRAMEReplacement, page 20-42
CABLE ASSEMBLYBeplacement, page 20-44
*\
)REAR DRAIN VAI-VE
_-""-\q
Replacement, page 20'41
gJ -.- REAR DRA'N TUBE
20-35

Moonroof
Symptom Troubleshooting Index
SymptomDiagnostic procedureAlso check for
Water leaks'1. Check for a clogged drain tube.
2. Check for a gap between the glass weatherstrip and the roof
panel.
3. Check for a defective or an improperly installed glass
weatherstrip or drain channel.
4. Check for a gap between the drain seal and the roof panel.
G lass height
adJustment
Wind nolse1. Check for excessive clearance between the glass weatherstrip
and the root panel.
Glass height
adjustment
Deflector noise1. Check for a imDrooer clearance between deflector seal and
roof panel.
2, Check for a insufficient deflector extension.
3. Check for a deformed deflector.
Motor noise1. Check for a loose motor.
2. Check for a worn gear or bearing.
3. Check for a deformed cable assembly.
Check closing force
Glass does not move,
but motor turns
1. Check for a defective gear or inner cable.
2. Check for foreign matter stuck between the guide rail and the
slide r.
3. Check for a loose inner cable.
4. l\,4ake sure the cable assembly is attached properly.
Glass does not move
and motor does nol
turn (glass can be
moved with
moonroof wrench)
1. Check for a blown fuse.
2. Check for a faulty moonroof switch.
3. Check the limit switch.
4. Check for a run down battery.
5. Check for a defective motor.
6. Check for a faulty relay.
20-36