seats HONDA CIVIC 2003 7.G Workshop Manual

Starting System
Starter Overhaul (cont'dl
Planetary Gear Inspection
16. Check the planetary gears (A) and ring gear {B).Replace them if they are worn or damaged.
Overrunning Cluich Inspection
17. Slide the overrunning clutch along the shaft.
Replace it if it does not slide smoothly.
18. Rotate the overrunning clutch (A) both ways.
Does it lock in one direction and rotate smoothly inreverse? lf it does not lock in either direction or it
locks in both directions, replace it.
lf the starter drive gear (B) is worn or damaged,
replace the overrunning clutch assembly; the gear
is not available separately.
Check the condition of the flywheel ring gear.
Replace it if the starter drive gear teeth are
oamageo.
19.
4-14
i.-
Starter Reassembly
20, Pry back each brush spring with a screwdriver, thenposition the brush about halfway out of its holder,
and release the spring to hold it there.
NOTE: To seatthe new brushes. slip a strip of #5OO
or # 600 sandpaper. with the grit side out, be&veen
the commutator and each brush, and smoothly
rotate the armature. The contact surface of the
brushes will be sanded to the same contour as the
commutator.
21lnstallthe armature in the housing, and installthe
brush holder. Next, pry back each brush spring
again, and push the brush down until it seats
against the commutator, then release the spring
against the end of the brush.
s
Install the starter end cover to retain the brush
holder.

Cylinder Head
Engine Compression Inspection
1. Warm up the engine to normal operating
temperature (cooling fan comes on).
2. Turn the ignition switch OFF.
3. Remove the intake manifold cover (see step 1 onpage 6-22).
4, Disconnect all four injector connectors.
5. Start the engine, and let it run until it stalls.
6. Remove the iour ignition coils (see page 4-18).
7. Remove the four spark plugs.
8. Attach the compression gauge to the spark plug
note.
6-6
V,
\
9.
10.
Open the throttle fully, then crank the engine with
the starter motor and measure the compression.
Compression Pressure
Above 930 kpa (9.5 kgf/cm', 135 psi)
Measure the compression on the remaining
cylinders,
Maximum vadation
Within 200 kPa (2.0 kgf/cm', 28 psi)
lf the compression is not within specifications,
check these items, then remeasure the
compressron.
. Damaged orworn valves and seats. Damaged cylinder head gasket. Damaged or worn piston rings. Damaged orworn piston and cylinder bore
11.
\-

Valve Guide Replacement
Special Tools Required. Valve guide driver, 5.5 mm 07742-0010100. Valve guide reamer, 5.5 mm 07HAH-PJ7o108
1.Inspect valve stem-to-guide clearance (see page 6-
32t.
As illustrated below, use a commercially available
air-impact valve guide driver (A) modified to fit the
diameter of the valve guides. In most cases, the
same procedure can be done using the special tool
and a conventional hammer.
10.8 mm{0.,|2 in.)
3. Select the proper replacement guides, and chill
lhem in the freezer section of a refriqerator for
about an hour.
4. Use a hot plate or oven to evenly heat the cylinder
head to 300'F (150"C). Monitor the temperature
with a cooking thermometer. Do not getthe head
hotterthan 300'F (150"C); excessive heat may
loosen the valve seats.
-_|Jfillr-.-4fi'11., -
tT
7.
Working from the camshaft side. use the driver and
an aar hammerto drive the guide about 2 mm (0.1
in.)towards the combustion chamber. This will
knock off some of the carbon and make removal
easier. Hold the air hammer directly in line with the
valve guide to prevent damaging the driver.
Turn lhe head over, and drive the guide out toward
the camshaft side of the head.
lf a valve guide won't move, drill it out with a I mm
(5/16 inch) bit. then try again. Drill guides only in
extreme cases;you could damage the cylinder
head if the guide breaks.
Remove the new guide(s) from the freezer, one at a
time, as vou need them.
(cont'd)
6-33

Valve Seat Reconditioning
1. Inspect valve stem-to-guide clearance (see page 6-
32). lf the valve guides are worn, replace them (see
page 6-33) before cutting the valve seats.
2. Renew the valve seats in the cylinder head using a
valve seat cutter.
Carefully cut a 45'seat, removing only enough
material to ensure a smooth and concentric seat.
Bevel the upper and lower edges at the angles
shown in the illustration.
Check the width of the seat and adjust accordingly.
INTAKE:35"EXHAUST:30'
3,
4.
- 45'
, { 67.5'
5. Make one more very light pass with the 45" cutter
to remove any possible burrs caused by the other
cutters.
Valve Seat Width:
Standard (New): 1.25 1.55 mm {0.049 0.061 in.)
Service Limit: 2.00 mm (0.079 in.)
6. After resurfacing the seat, inspect for even valve
seating: Apply Prussian Blue compound (A) to the
valve face. Insert the valve in its original location in
the head, then lift it and snap it closed against the
seat several trmes.
1.The actual valve seating surface (B), as shown by
the blue compound, should be centered on the seat.
. lf it is too high (closer to the valve stem), you
must make a second cut with the 67.5' cutter to
move it down, then one more cut with the 45"
cutter to restore seat width.. lf it is too low (close to the valve edge), you must
make a second cut with the 35'cutter (intake
sidel or the 30" cutter (exhaust side) to move it up,
then make one more cut with the 45" cutter to
restore seat width.
NOTE: The final cut should always be made with
the 45'cutter.
(cont'd)
6-35

Valves, Springs, and Valve Seals Installation
Special Tools Required
Valve spring compressor attachment 07VAE-00101 0A
1. Coat the valve stems with engine oil. lnstall the
valves in the valve guides.
2. Check that the valves move up and down smoothly.
Installthe spring seats on the cylinder head.
Install the new valve seals (A) using the valve guide
seal installer (B).
NOTE: The exhaust valve seal (C) has a black spring(D), and the intake valve seal (E) has a white spring(F). They are not interchangeable.
6.
lnstallthe valve spring. Place the end ofthe valve
spring with closely wound coils toward the cylinder
n eao.
Install the valve retainer.
Installthe valve spring compressor, Compress the
spring, and install the valve keepers. Remove the
valve spring compressor.
Lightly tap the end of each valve stem two or three
times with a plastic mallet (A) to ensure proper
seating of the valve and valve keepers. Tap the
valve stem only along its axis so you do not bend
the stem.
7.
6-37

Engine Lubrication
Engine Oil Filter Replacement
Special Tool Fequired
Oil filter wrench 07HAA-PJ70100
Engine Oil Filter (3/4-turn type)
1. Remove the oil filterwiththesDecial tool.
2. Inspect the threads {A) and rubber seal (B) on the
new filter. Wipe off the seat on the engine block,
then apply a light coat of oil to the filter rubber seal.
Use only filters with a built-in bypass system.
Installthe oilfilter by hand.
After the rubber seal seats, tighten the oil filter
clockwise with the special tool.
Tighten: 3/4 turn clockwise.
Tightening torque: 12 N.m (r.2 kgf.m,8.7 lbf.ft)
07HAA-PJ70100
8-6
\,
5. lf 4 numbers or marks (1 to 4 or V to VVVV) are
printed around the outside of the filter, use the
following procedure to tighten the filter.
. Spin the filter on until its seal lightly seats against
the block, and note which number or mark is at
the bottom.. Tighten the filter by turning it clockwise 3
numbers or marks from the one you noted. For
example, if number 2 is at the bottom when the
seal is seated, tighten the filter until the number 1
comes around the bottom.
Number when rubberseal is seated.Number after tightening.
(\..
6. After installation, fill the enginewith oil uptothe
specified level, run the engine for more than 3
minutes, then check for oil leakage.
Number or
Mark when
rubber seal is
1
or
V
2
or
VV
3
or
VVV
4
or
VVVV
Number or
Mark after
tightening
41
or or
vvvv. v
2
or
VV
3
or
VVV

Manual Transmission
Transmission Reassembly (cont'dl
9. Install the 14 x 20 mm dowel pins (A).
34 N.m(3.5 kgf.m,25 rbf.ft)
Set the tapered cone ring (B) as shown. Place the
transmission housing over the clutch housing,
being careful to line up the shafts.
10.
13-48
11. Lower the transmission housing the rest of the wayas you expand the 72 mm snap ring {C). Release
the snap ring so it seats in the groove of the
countershaft bearing.
12. Check that the 52 mm snap ring is securely seatedin the groove of the countershaft bearing.
Dimension O as instalted: 3.3 6.0 mm
{0.13 0.24 in.l
Apply liquid gasket (P/N 08718-0001) to the threads
of the 32 mm sealing cap {D), and install it on thetransmission housing,
Install the transmission hangers A. and B, and the
8 mm flange bolts finger-tight.
13.
't4.
15.
8 x 1.25 mm27 N.m(2.8 kgf.m.20 rbf.ft)
(t
\A
e././
Tighten the 8 mm flange bolts in a crisscross
Pattern In several steDs.
(

Front Suspension
Ball Joint Boot Replacement
Special Tools Required
Front hub dis/assembly tool 07965-5450500
1. Remove the boot.
2. Pack the interior and lip (A) of a new boot with fresh
grease. Keep the grease off of the boot-to-knuckle
mating surfaces (B).


-6r
rffi
€l
--B
Wipe the grease off the tapered section of the pin
(C), and pack fresh grease onto the base (D).
tI
18-16
Inst€ll the boot onto the ball joint pin, then squeeze
it gently to force out any air. Do not let dlrt or other
foreign materials get into the boot.
Press the boot with the special tool until the bottom
seats on the knuckle (A) evenly around.
pross
07965-SA50500
6.After installing a boot, wipe any grease off the
exposed portion of the ball joint pin.
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

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