heater removal HONDA CIVIC 2003 7.G Workshop Manual

Engine Assembly
Engine Removal (cont'd)
32. Lower the hoist.
33. Remove the upper hose (A)and heater hoses (B).
34. Bemove the radiator (see page 10-10).
35. Attach the chain hoist to the engine as shown.
5-6
36. Remove the transmission mount bracket support
bolt and nuts.
37. Remove the upper bracket mounting bolt and nut.
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Gylinder Head Removal
NOTE:. Use fender covers to avoid damaging painted
surfaces.
To avoid damage, unplug the wiring connectors
carefully whlle holding the connector portion.
To avoid damaging the cylinder head, wait until the
engine coolant temperature drops below 100'F (38"C)
betore loosening the cylinder head bolts.
Mark all wiring and hoses to avoid misconnection.
Also, be sure that they do not contact other wiring or
hoses, or interfere with other parts.
'1.
2.
3.
Drain the engine coolant (see page 10-6).
Remove the drive belt (see page 4-26).
Remove the intake manifold {see page 9-3).
Remove the air cleaner housing (see step 7 on page
5-2t.
5. Remove the water bypass hose (A).
Remove the exhaust manifold (see page 9-7
Remove the cam chain (see page 6-12).
6.
7.
).
8. Remove the engine wire harness connectors and
wire harness clamps from the cylinder head.
. Engine coolant temperature (ECT) sensor
conneclor. Camshaft position (Cl\4P) (top dead center (TDC))
sensor B connector. Camshaft posilion (CMP) sensor A connector
9. Remove the upper radiator hose (A) and heater
hose (B).
'10. Remove the harness holder (A)from the bracket,
then remove the connecting pipe mounting boh {B)
and brake booster vacuum line mounting bolts {C).
(cont'd)
1 1. Remove the water bvpass hose (D).
6-23

lntake Manifold and Exhaust System
Intake Manifold Removal and Installation (cont'd)
9. lnstallthe air cleaner housing cover (A), and
connect the IAT sensor connector (B).
BC
Installthe breather hose (C).
lnstallthe EVAP canister hose (A), brake booster
vacuum hose (B), and vacuum hoses {C).
10.
11.
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12. Installthe intake manifold cover.
6x1.0mm12 N.ml.1.2k91.m,8.7 tbf.ftl
Clean up any spilled engine coolant.
After installation, check that all tubes, hoses, and
connectors are installed correctly.
Inspect for fuel leaks. Turn the ignition switch ON
(ll) (do not operate the starter) so that the fuel pump
runs for about 2 seconds and pressurizes the fuel
line. Repeat this operation two or three times, then
check for fuel leakage at any point in the fuel line.
Refill the radiator with engine coolant, and bleed
air from the cooling system with the heater valve
open (see page 10-6).
to.
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1.
2.
Water Pump Inspection
Remove the drive belt (see page 4-26),
Turn the water pump pulley counterclockwise.
Check that it turns freely.
Check for signs of seal leakage. A small amount of"weeping" from the bleed holes (A) is normal.
Water Pump Replacement
1. Remove the drive belt (see page 4-26).
2. Drain the engine coolant {see page 10-6).
3. Remove the crankshaft pulley (see page 6-11).
4. Remove the six bolts securing the water pump,
then remove the water pump (A).
6x1.0mm12 N m {1.2 kgt m,8.7 rbf.ft)
Inspect and clean the O-ring groove and mating
surface with the water passage.
Installthe water pump with new O rings in the
reverse order of removal.
7. Clean up any spilled engine coolant.
8. Installthe crankshaft pulley (see page 6-12).
L Refill the radiator with engine coolant, and bleed
air from the cooling system with the heater valve
open {see page 10-6}.
10-5

EPS Components
Steering Gearbox Removal (cont'd)
Disconnect the EPS wire harness 6P connector (A),
and remove the EPS wire harness (B) and mountino
bracket (C).
12.
Remove the ground cable terminal (A) from the
steering gearbox housing.
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13.
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17-52
14. Remove the engine wire harness clamps {A)fromthe three mounting brackets.
Remove the heater hose {B) from the bracket.
Open the heater valve cable clamp (A), and
disconnect the heater valve cable (B). Remove theheater valve (C) from the bulkhead, and move jt
aside.
t5.
16.
I

Power Mirror Replacement
1.
2.
5.
Lower the door glass fully.
Carefully pry out the mirror mount cover (A) by
hand in the sequence shown. Disconnect the
tweeter connector (B), and release the wire harness
(C) from the hook (D).
Fastener Location
) : Clip, 1
3. Remove the door panel (seepage20-4).
4. Disconnectthe connector (A), and detach the
harness clip (B). While holding the mirror {C),
remove the nuts, then remove the mirror. Take care
not to scratch the door.
Fastener Locrtions
O: Nut.3
lnstall the mirror in the reverse order of removal,
and note these items:
. Make sure the connector is plugged in properly.
. Attach the harness clip.
Mirror Holder Replacement
1. Carefully pulloutthe bottom edge ofthe mirror
holder (A) by hand. Take care not to scratch the
mrrror.
5.
Separate the mirror holder from the actuator (B) by
slowly pulling them apart while detaching the clips
(C). lf equipped, disconnect the mirror defogger
connectors{D) from the heater pad terminals.
lf equipped, reconnect the mirror defogger
connectors.
Reattach the clips of the mirror holder to the
actuator, then position the mirror holder on the
actuator. Carefully push on the clip portions of the
mirror holder untilthe mirror holder locks into
prace.
Check the operation of the actuator
20-15

Interior Trim
Carpet Replacement (cont'dl
Using a utility knife, cut the carpet (A) under the
heater areas (B), and cut out the parking brake lever
area (C) as shown, then pull back the carpet.
AB
Remove the clip (A), and release the fasteners (B).
Pull the carpet out from both rear side trim panels
(D), then remove the carpet (C).
Fastener Location
A >: Clip. 1
4.
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20-56
5. Installthe carpet in the reverse order of removal,
and note these items:
. Take care notto damage, wrinkle, ortwistthe
carpeL. Make sure the seat harnesses are routed
correctly.. Slip the carpet under the rear side trim panel on
each side properly.. Replace the clip if it's damaged.. Reattach the cut areas under the heater around
the parking brake lever with a wire tie.. When installing new carpet, cut the carpet (A)
under the heater areas (B), and around the
parking brake lever (C). After installing the new
carpet, slip the carpet from the driver's and
passenger's side through the space between the
heater unit and body, and reattach the cut area
{C) around the parking brake lever with wire ties.
t

Dashboard
Dashboard Center Panel Removal/lnstallation
NOTE:. Put on gloves to protect your hands.. When prying with a flat-tip screwdriver, wrap it with
protective tape, and apply protective tape around the
related parts, to prevent damage.. Take care not to scratch the dashboard and related
parts.
1. Make sure you have the anti-theft code for the radio,
the write down the frequencies for the preset
buttons.
Remove these items:
. Driver's dashboard lower cover (see page 20-59)
. Passenger's dashboard lower cover (see page
20-63).. Glove box (see page 20-63).. Shift lever trim {see page 20-61).
From the glove box and driver's dashboard Iower
cover openings, loosen the bolts (A) securing the
center panel (B).
2.
Fastener Locations
A): Bolt, 2x 0.8 mm5Nm
;.'
20-62
4. Pull out the center panel (A) to release the clips (B)
and hooks (C), and remove the harness holder (D)
from the bracket (E). Disconnect the audio unit
connector (F), antenna lead (G), heater switch
connector (H) and heater control unit connectors (l).
Fastener Locations
B ): Clip, 8
Installthe panel in the reverse order of removal,
and note these items:
Make sure each connector is plugged in properly,
and antenna lead is connected properly.
Push the clip portions into place securely.
Reconnect the negative cable to the battery.
Do the ECN4/PCt\4 idle learn procedure {see page
1l-139).
Enter the anti-theft code for the radio. then enter
the customer's radio station presets.
Reset the clock.
*4
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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
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