roof HONDA CIVIC 2003 7.G Workshop Manual

Fuel Supply System
Fuel Line/Ouick-Connect Fittings Precaution
The fuel tube/quick-connect fittings connect the fuel rail(A)to fuel feed hose (B), the fuel feed hose (B) to the
fuel line (C), and the fueltube (D) to the fuel pump
assembly (E). When removing or installing the fuelfeed
hose, fuel pump assembly, or fuel tank, it is necessary
to disconnect or connect the quick-connect fittings.
Pay attention to the following:
. The fuel feed hose (B), fuel tube (D), and quick-
connect fittings (F) are not heat-resistanU be careful
not to damage them during welding or other heat-
generalrng proceoures.
. The fuelfeed hose (B), fueltube (D) andquick-
connect fittings (F) are not acid-proof; do not touch
them with a shop towel which was used for wiping
battery electrolyte. Replace them if they came into
contact with electrolyte or something similar.
. When connecting or disconnecting the fuel feed hose(B), fuel tube (D), and quick'connect fittings (F). be
careful not to bend or twist them excessivelv. ReDlace
them it they are damaged.
11-148
A disconnected quick-connect fitting can be
reconnected, but the retainer on the mating line cannot
be reused once it has been removed from the line.
Replace the retainer when
. replacing the fuel rail.. replacing the fuel line.. replacing the fuel pump.
. replacing the fuel filter,. replacing the fuel gauge sending unit.. it has been removed from the line.. it is damaged.
PARTI\4ANUFACTUREBRETAINER
COLOR
E NG INE
COI\4PARTMENT(FUEL FEED
HOSE; FU EL
LINE SIDE)
TOKAIGREEN
EN G INE
COIVIPARTMENT(FUEL FEED
HOSE: FUEL
RAIL SIDE)
TOKAIBLU
FUEL TANK
UNIT
SANOHWHITE
I

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

Doors
Door Glass Adiustment {cont'd)
6. Raise the glass fully, and check for gaps. Check that
the glass (A) contacts the glass run channel (B)
evenrv.
7.Check for water leaks. Run water over the roof and
on the sealing area as shown, and note these items:
. Use a 12 mm (1/2 in.) diameter hose (A).. Adjust the rate of water flow as shown {B).. Do not use a nozzle.. Hold the hose about 300 mm (12 in.) awayfrom
the door (C).
12mm1112in,l !
\e
Attach the plastic cover, and installthe door panel(see page 20-4).
9. Test-drive and check for wind noise.
300 mm {12 in.l
20-12
Door Position Adiustment\
NOTE; Check for equal gaps between the front, rear,
and bottom door edges and the body. Check that the
door and body edges are parallel.
1. Place the vehicle on a firm, level surface when
adjusting the door.
2. Adjust at the hinges {A):
. Remove the front inner fender (see page 20-102)
and front fender fairing (see page 20-103).
Loosen the hinge mounting bolts (B) slightly, and
move the door backward or forward, uD or down
as necessary to equalize the gaps.. Place a shop towel (C) on the jack (D) to prevent
damage to the door when adjusting the door.
t, 8x1.25mm29 N.m (3.0 kgf.m,22 tbt.trl
\

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

Glass Height Adjustment
The roof panel (A) should be even with the glass
weatherstrip (B). to within 2*0.5/ 1 mm (0.08+0.02l
0.04 in.) all the way around. lf not, make the following
adjustment:
B
2 + 0.5/ 1mm{0.08 + 0.02/-0.0i1 in.}
2.
1,
\o
Remove the bracket cover from each side.
Loosen the nuts {A), and installthe shims (B)
between the glass frame (C) and glass bracket (D)
on each side.
Shim ihickness: Front and rear max. 2 mm 10.08 in.l
Forward
A6x1.0mmI N.m (0.9 kgf.m,7 lbt.ft)
3. lf necessary, repeat on the opposite side.
B
\
Glass Replacement
'LClose the glass fully.
Slide the sunshade allthe way back.
Remove the screws (A), then remove both bracket
covers (B). Remove the nuts (C) and shims {D) from
both glass brackets (E).
Fastengr Locations
cO,
6x1.0mm9 N.m {0.9 kgf.m, 7 lbf.ft}
4. Remove the glass {A) by lifting it up. Do not
damage the roof panel.
5. Install the glass in the reverse order of the removal,
and adjust the glass height alignment.
6. Check for water leaks. Use free-flowing water from
a hose without a nozzle. Do not use high-pressure
water.
Nut. il
@
A}:Screw, 2
E
20-37

Moonroof
Wind Deflector Replacement
2.
1.Open the glass fully.
Remove the screws (A, B), and release the hooks
(C), then remove the wind deflector (D).
Fastener Locations
A>:Screw,2 B>:Screw, 2
20-38
3. Installthe deflector (A) in the reverse order of
removal, and check that lhe deflector arm base (B)
and deflector link pivot base (C) line up with the
same alignment lines (D). lf necessary, adjust them
forward or backward so the edge of the deflector
seal (E) touches the roof panel (F) evenly. Each
base must be moved the same amount for
adjustment. lf the deflector seal and roof panel
make a rubbing sound, move the deflector
backward as necessary to position it properly.
4il mm(1.7 in.)_-l
'a- -' -
\

1.
2.
Drain Channel Replacement
Remove the moonroof glass (see page 20-37).
With the moonroof wrench, move both glass
brackets (A) to the position where the moonroof
normally pivots down, and remove the screws
securing the drain channel (B).
Fastener Locations
) : Screw, 2
@
Release the drain channel (A) from both hooks {B)
of the drain channel slider by pulling the drain
channel forward,
4. Remove the drain channel (A).
Installthe channel in the reverse order of removal,
and note these items:
Push the drain channel onto the hooks until a
faint click is heard.
Check the glass height adjustment (see page 20-
31).
Check for water leaks. Let the water run freely from
a hose without a nozzle. Do not use a high-pressure
spray.
20-39

Moonroof
Sunshade Replacement
1.Remove the drain channel.
Slide the sunshade (A) until you can see both
sunshade slider spacers (B).
Fastener Locations
> : Screw, 4
tF
3. Remove the screws, then remove both spacers.
20-40
4. While lifting the front portion ofthe sunshade (A),
move the sunshade forward until you can see both
sunshade rear hooks (B). Do not damage the
sunshade and hooks.
Fastener Locations
) : Screw, 4
(F
5. Remove the screws, then remove both hooks.
\

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