20-54 HONDA CIVIC 2003 7.G Workshop Manual

Body
DoorsComponent Location Index ...........Door Panel Removal/lnstallation .....,..........Door Outer Handle ReplacementDoor Latch ReplacementDoor Glass and RegulatorReplacementDoor Sash Trim Replacement .......................
Door Glass Outer WeatherstripReplacement
Door Weatherstrip Beplacement
Door Glass Adjustment .................................Door Position Adjustment .............................Door Striker Adiustment ................................MirrorsComponent Location Index ...........................Power Mirror Replacement ...........................Mirror Holder Replacement ...........................Rearview Mirror Rep1acement ......................
GlassComponent Location Index ...........................Windshield Replacement
Bear Window Rep1acement ...........................
Ouarter Glass Replacement ..........................MoonroofComponent Location Index ...........................Symptom Troubleshooting Index
Glass Height Adjustment ...............................
Glass ReplacementWind Def lector 8ep1acement ........................Drain Channel Rep1acement ..........................Sunshade Replacement .................................Motor ReplacementFrame and Drain Tube Replacement ............Drain Channel Slider and Cable AssemblyReplacementLimit Switch Adjustment ...............................Closino Force and ODenina Draq Check ......lnterioi TrimComponent Location Index ...........................Trim Removal/lnstallation DoorArea ..........Trim Removal/lnstallation-Rear Side AreaTrim Removal/lnstallation-Cargo Floor AreaTrim Removal/lnstallation-Hatch Area .........Headliner Removal/lnstallation* Carpet Rep1acement .......................................ConsolesConsoles, Front and RearRemova l/lnsta llationFront Console Disassembly/Reassembly .....
20-220,420-620-7
20-920 t0
20- 10
20-1120-1120-1220 13
20-1420-1520-1520-16
20 1120-1920-2520-29
20,3520-3620-3720-3120-3820 3920-4020-4120,42
20 4420-4620,44
20-4920 50
20-51
DashboardInstrument Panel Removal/lnstallation ........Driver's Dashboard Lower CoverRemovat InstallationDriver's Dashboard Under CoverRemova t Insta llation
Oriver's Pocket Removal/lnstallation ............Shift Lever Trim Removal/lnstallation ..........Center Panel Removal/lnstallation ...............Passenger's Dashboard Lower CoverRemova l/lnsta llat ionx Glove Box Removal/lnstallationDashboard Side VentRemoval/lnstallation .................................. 20-64Beverage Holder Removal/lnstallation ........ 20-64Driver'sTray Removal/lnstallation ............... 20-65Passenger's Tray Removal/lnstallation ........ 20 65* Dashboard Removal/lnstallation .................. 20-66Steerinq Hanqer Beam Reolacement ........... 20-68Seats "
Component Location Index ........................... 20-10* Front Seat Removal/lnstallation ................... 20-11* Front Seat Disassembly/Reassembly-Driver's .................................. 20-73* Front Seat Disassembly/Reassembly-Passenger's ........................... 20-74* Front Seat Cover Replacement ..................... 2O-75Rear Seat Removal/1nsta11ation ..................... 20-80Rear Seat-back Latch Replacement .............. 20-81Rear Seat-backStriker Replacement ............ 20-81
20-59
20-59
Rear Seat-back Cover Replacement ............. 20-82Rear Seat Cushion Cover Replacement ....... 20.84BumpersFront Bumper Removal/lnstallation .............Rear Bumoer Removal/lnstallation ...............HoodAdjustmentHood Seal ReplacementHood Insulator Rep1acement .........................Hatch
20-6020,6020 6120-62
20-63
20-63
20,8520-86
20-4720,8820,89
20-5220-5320-5420-55
20-5720-58
Adjustment ................... 20-90Hatch Suppon Strut Replacement ................ 20-91Hatch WeatherstriD Reo1acement ................. 20-92
Fuel Fill DoorAdiustment ................... 20-93Exterior TrimFront Grille Replacement ..............Cowl Covers Replac"rn""t .. . .....................A pillar Corner Trim Replacement ................Roof lMolding Replacement ...........................Rear License Trim ReplacementHatch Spoiler 8ep1acement ...........................Emblem Rep1acement .........................
20-9420-9520-9620-9720,9820-9920-100

Windshield Replacement
NOTE:. Put on gloves to protect your hands,. Wear eye protection while cutting the glass adhesive
with piano wire.. Use seat covers to avoid damaging the seats.
1. Remove these items:
. Rearview mirror (see page 20-16). Windshield wiper arms (see page 22-145)
2. Pull up the side trim (A) to release the clips (B) from
the retainers (C), and pull the trim rearward to
release it from the cliD (D) then remove the trim
from each side of the windshield.
4.
Remove the cowl covers (see page 20-95).
Remove the molding (A) from the upper edge of the
windshield (B). lf necessary, cut the molding with a
utility knife.
lf the old windshield is to be reinstalled, make
alignment marks across the glass and body with a
grease pencil.
Pull down the front portion of the headliner (see
page 20-54). Take care not to bend the headliner
excessively, or you may crease or break it.
Apply protective tape along the edge of the
dashboard and body. Using an awl, make a hole
through the rubber dam, adhesive. and dashboard
seal from inside the vehicle at the corner ponion ot
the windshield. Push a piece of piano wire through
the hole, and wrap each end around a piece of
wood.
(cont'd)
7.
20-19

6. Remove the sunshade (A),
::lll' =r'"'---
----.-.. --.,
'l'i
?,
7.Remove both front sunshade base sliders (A) and
both rear sunshade base sliders (B)
t'-^'
'a{
8.
9.
Installthe sunshade in the reverse order of removal,
and check the glass height adjustment (see page
20-37 ).
Check for water leaks. Let the water run freely from
a hose without a nozzle. Do not use a high-pressure
spray.
1.
Motor Replacement
Remove the headliner (see page 20-54).
Put on gloves to protect your hands. Disconnecl the
connector (A), and remove the bolts, then remove
the motor (B).
Fastener Locations
>:Bolt,2 A
@@
..
{0.9 kgf.m.7 rbf.ftl
Installthe motor in the reverse order of removal,
and note these items:
. lvlake surethe connector is plugged in properly.
. Check the motor operation.
20-41

Moonroof
1.
Frame and Drain Tube Replacement
Remove these items:
. Headliner (see page 20-54). Moonroof glass (see page 20-37)
Put on gloves to protect you r hands. Disconnect the motor connector (A), open/close-tilt/close switch connector
{B), moonroof control unit connector {C), auto-stop switch connector (D), and the drain tubes (Ei, and remove the
moonroof relays (F).
Fastenor Locations
> : Bolt, 10
{um
/^
6x1.0mm9.8 N.m(1.0 kgf.m,7.2lbf ft)
4.
5.
2.
irl
@
Remove the interior harness (G) by detaching the harness clips (H).
With an assistant holding the frame (l). remove the bolts, starting at the rear, and release the rear hooks (J) by
moving the f rame forward, then remove the frame.
With the help of an assistant, carefully remove the frame through the passenger's door opening. Take care not to
scratch the interior trim and body, or tear the seat covers.
20-42

Moonroof
Limit Switch Adjustment
1. Remove the headliner (see page 20-54).
Fully closed position adiustment
2. With the moonroof wrench, close the glass (A) fully:
. Make sure both link lifters (B) are parallel, and in the position shown.. Check the g lass fit to the roof panel and the glass height (see page 20-37).
5x0.8mm5 N.m {0.5 kgf.m,4lbf.ft)
3. With an open-end wrench, loosen the limit switch mounting bolts (C).
4. Adjust the limit switch (D):
' Move the switch plate (E) a little at a time, then secure it atthe position where you hear a faint click when theswitch cam (F) pushes the position switch (open/close).. Check that the switch plate contacts the switch bracket (G).
20-46

Moonroof
\
Closing Force and Opening Drag Check
1. Remove the headliner (see page 20-54).
2. Closing force check:
. With a shop towel {A) on the leading edge of theglass (B), aftach a spring scale (C) as shown.. Have an assistant hold the switch to close theglass while you measure the force required to
stop it.. Read the force as soon as the glass stops moving,
then immediately release the switch and spring
scale.
Closing Force; 200 290 N (20 30 kgf,44 66 tbl)
lf the force in not within specification, remove themoonroof motor (see page 20-41), then check:
. The gear portion and the inner cable for breakageand damage. lf the gear portion is broken,
replace the motor. lf the inner cable is damaged,
remove the frame (see page 20-42), and replace
the cable assembly (see page 20-44).' The moonroof motor (see page 22-112). Ifthe
motor fails to run or doesn't tu rn smoothlv.
replace it (see page 20-41),. The opening drag. Go to step 4.
20-48
4. Opening drag check: Protect the leading edge of theglass with a shop towel (A). Measure the effortrequired to open the glass using a spring scale (B)
as shown.
5.lf the load is over 40 N (4 kgf, 9 lbf), check;
. The side clearance and glass height adjustment(see page 20'37),. For broken or damaged sliding parts. lf any
sliding parts are damaged, replace them.

Interior Trim
Headliner RemovaUlnstallation
NOTE:. When prying with a flat-tip screwdriver, wrap itwith
protective tape to prevent damage.. Take care not to bend and scratch the headliner.. Be careful not to damage the dashboard and other
interior trim.
1. Remove these items:
. A-pillar trim, both sides (see page 20-50). B-pillar uppertrim, both sides (see page 20-50). Hatch weatherstrip, as necessary {see page 20-
92\. C-pillar trim, both sides (see page 20-51). Moonroof switch (see page 22-'112). Spotlights (see page 22-961. Ceiling light (see page 22-96)
Remove the sunvisor {A) and holder {B) from both
srdes.
-1 Remove the caps {C).-2 Remove the screws.-3 Remove the sunvisor from the body and holder.-4 Using a flat-tip screwdriver, push the hook (D),
and turn the holder 90'. then pull it out.
Fastener Locations
> : Screw, 4
r(\'-r)*
5x0.8mm5 N.m{0.5 kst m.4lbf ft}
20-54
3. From both rear passenger's, remove the caps (A),
and remove the screws, then remove the grab
handles (B).
Fastener Locations
> : Screw, 4
t , t;---iJ
)e
5x0.8mm4 N.m{0.4 kgf.m, 3 lbf.ft}

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

Roof Antenna Replacement
1. Remove the rear part of headliner (see page 20-54).
2, Disconnect the antenna lead connector (A) and 1P
connector (B) from the roof antenna (C).
3. Remove the mounting nut and the antenna.
22-103

Moonroof
Moonroof Control Unit Input Test
Remove the headliner (see page 20-54).
Disconnect the 5P connector (A) from the control unit (B).
Wire side offemale terminals
Inspect the connector and socket terminals to be sure they are all making good contact.
. lf the terminals are bent, loose or corroded, repairthem asnecessary. and recheckthe system.. lf the terminals look OK, go to step 4.
IJ
1.
2.
bJ
GRN/WHT LT GRN
12345
RED/YEL BLK
22-110
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