2002 HONDA CIVIC light

3.
Trailing Arm Removal/lnstallation
1.Raise the rear of the vehicle, and suppon it with
safety stands in the proper location (see page 1,8).
Remove the rear wheels.
Remove the knuckle (see page 18-28).
Place the floor jack under the trailing arm (A) to
support it.
B10 x 1.25 mm38Nm(3.9 kgl.m,28 tbf.ftl
12 x 1.25 mm61 N m (6.2 kgt m.
A 4s tbf,ft)
Remove the flange nut (B), and disconnect the
stabilizer link (C) from the trailing arm.
Remove the flange bolt {D), and disconnect the
damper (E) from the trailing arm.
Remove the trailing arm front mounting bolts (A).
A12 x 1.25 Jnm108 N.m {11.0 kgt.m,80 tbf.ft)
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7. Remove the trailing arm rear mounting bolt (A).
Do not loosen the special bolts (B) on the
trailing arm.
A12 x 1.25 mm59 N.m
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Lower the jack, and remove the trailing arm.
Install the trailing arm in the reverse order of
removal, and note these items:
. First install allthe suspension components and
lightly tlghten the bolts and nuts, then place ajack under the trailing arm, and raise the
suspension to load it with the vehicle's weight
before fully tightening the bolts and nuts to the
specified torque values.. Tighten allthe mounting hardware to the
specif ied torque values.. Before installing the wheel, clean the mating
surface of the brake disc and the inside of the
wneei.. Check the wheel alignment, and adjust it if
necessary (see page'18-4).
8.
9.
18-33

Gonventional Brake Components
ComponentProcedureAlso check for:
l\4aster CylinderLook for damage or signs of fluid leakage at;. Reservoir or reservoir grommets
. Line joints
. Between master cvlinder and booster
Brake HosesLook for damage or signs of fluid leakage at:. Line joints and banjo bolt connections. Hoses and lines. also inspect for twisting or
damaqe
Bulging, twisted or bent lines.
CaliperLook for damage or signs of fluid leakage at:. Piston seal. Banjo bolt connections. Bleeder screw
Seized or sticking caliper pins.
ABS l\ilodulatorLook for damage or signs of fluid leakage at:. Line joints
. Modulator
Brake System Inspection and Tests
Brake System Test
Brake pedal sinks/fades when braking
1. Start the engine, and let it warm up to operating temperature.
2. Attach a 2-inch pieceof masking tape along the bottom of the steering wheel, and draw a horizontal reference
mark across it.
With the transmission in Neutral, press and hold the brake pedal lightly, then release the parking brake.
While still holding the brake pedal, hook the end of the tape measure behind it. Then pull the tape up to the
steering wheel, noting where the tape measure lines up with the reference mark you made on the masking tape.
Apply steady pressure to the brake pedal for 3 minutes.
Watch the tape measure.
. if it moves less than 10 mm, the master cylinder is OK.
. if it moves more than 10 mm replace the master cylinder.
t-
3.
5.
6.
19-4

Conventional Brake Components
Brake Pedaland Brake PedalPosition Switch Adjustment
Pedal Height
1.Disconnect the brake pedal position switch
connector, turn the brake pedal position switch (A)
counterclockwise, and pull it back until it is no
longer touching the brake pedal.
Lift up the carpet and the insulator cutout (B).
l\4easure the pedal height (C) from the middle of
the left side of the pedal pad (D).
Standard Pedal Height (with carpet removed):
184 mm (7 4/16 in.)
Loosen the pushrod locknut (A), and screw the
pushrod in or out with pliers until the standard
pedal height from the floor is reached. After
adjustment, tighten the locknut firmly. Do not
adjust the pedal height with the pushrod pressed.
15 N.m(1.5 kgl m. 11 lbl ft)
19-6
7. Check the brake pedal free play as described below.
Pedal Free Play
4. With the engine off, inspect the play (A) on the
pedal pad (B) by pushing the pedal by hand.
Free Play: 0.4- 3.0 mm {0.016 0.'l18in.)
lf the pedal free play is out of specification, adjust
the brake pedal position switch (C). lf the pedal free
play is insufficient, it may result in brake drag.
Push in the brake oedal oosition switch until its
plunger is fully pressed (threaded end (A)touching
the pad (B) on the pedal arm). Then, turn the switch
45" clockwise to lock it. The gap between the brake
pedal position switch and the pad is automatically
adjusted to 0.4 to 3.0 mm (0.016 0.118 in.) by
locking the switch. Make sure the brake lights go
otf when the pedal is released.
t
6.

Parking Brake Check and Adiustment
Check
1. Pull the parking brake lever {A) with 196 N (20 kgf,
44 lbf) of force to fully apply the parking brake. The
parking brake lever should be locked within the
specified number of clicks (B).
Lever locked clicks: 7-8
- l2okqf, a4lbl)
2. Adjust the parking brake if the lever clicks are not
within the specification.
Adjustment
1. Release the parking brake lever fully.
Loosen the parking brake adjusting nut, start the
engine, and press the brake pedal several times to
set the self-adjusting brake before adjusting the
parking brake.
Block the front wheels, then raise the rear of the
vehicle, and support it with safety stands in the
proper location (see page 1-8).
Make sure the parking brake arm (A) on the rear
brake caliper contacts the brake caliper pin (B),
NOTE: The parking brake arm will only contact the
brake caliper pin when the parking brake adjusting
nut is loosened.
Remove the rear console {see page 20-57).
Pull the parking brake lever up one click,
7, Tighten the adjusting nut {A} until the parking
brakes drag slightly when the rear wheels are
tu rned.
A/
Release the parking brake lever fully, and check
that the parking brakes do not drag when the rear
wheels are turned. Readjust if necessary.
Make sure the parking brakes are fully applied
when the parking brake lever is pulled up fully.
Reinstall the rear console.
8.
9.
10.
19-7

Gonventional Brake Components
IBrake Booster Test
Functional Test
1. With the engine stopped, press the brake pedal
several times to deplete the vacuum reservoir, thenpress the pedal hard, and hold itfor 15 seconds. lfthe pedal sinks, either the master cylinder is
bypassing internally, or the brake system (master
cylinder, lines. modulator, or calipers) is leaking.
2. Start the engine with the brake pedal pressed. lf thepedal sinks slightly, the vacuum booster is workingproperly. lf the pedal height does not vary, thebooster or check valve is faulty.
3. With the engine running, press the brake pedal
lightly. lfthe brake pedal sinks more than 1O mm
{3/8 in, ) in 3 minutes, the master cylinder is faulty.A slight change in pedal height when the Ay'C
compressor cycles on and off is normal. (The A,/C
compressor load changes the vacuum available tothe booster.)
Leak Test
1. Press the brake pedal with the engine running, thenstop the engine. lf the pedal height does not vary
while pressed for 30 seconds, the vacuum boosteris OK. lf the pedal rises, the booster is faulty.
2. With the engine stopped, press the brake pedal
several times using normal pressure. When thepedal is first pressed, it should oe row.
On consecutive applications, the pedal height
should gradually rise. lfthe pedal position does notvarv, check the booster check valve.
19-18
3. Disconnect the brake booster vacuum hose (check
valve built-in) (A) at the booster side.
5.
4.Start the engine, and let it idle. There should bevacuum available. lf no vacuum is available, thecheck valve is not working properly. Repiace thebrake booster vacuum hose and check valve, andrelesI.
Reconnect the brake booster vacuum nose.
Start the engine, and then pinch the brake boostervacuum hose between the check valve and thebooster,
Turn the ignition switch OFF, and wait 30 seconds,Press the brake pedal several times using normalpressu re,
When the pedal is first pressed, it should be low.On consecutive applications, the pedal height
should gradually rise.
. lf the pedal position does notvary, replacethe
brake booster.. lf the pedal position varies, replace the brake
booster vacuum hose/check valve assembly.

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
\

3. Check that the door and body edges are parallel. lf
necessary, adjust the door cushions (A) to make the
rear of the door flush with the bodv.
Apply body paint to the hinge mounting bolts and
around the hinges.
Check for water leaks (see step 7 on page 20-12).
Test-drive and check for wind noise.
5.
Door Striker Adjustment
Make sure the door latches securely without slamming
it. lf necessary, adjust the striker (A): The striker nuts
are fixed, but the striker can be adjusted slightly up or
down, and in or out.
1. Loosen the screws (B), rhen insert a shop towel (C)
between the body and striker.
Lightly tlghten the screws.
Wrap the striker with a shop towel, then adjust the
striker by tapping it with a plastic hammer (D). Do
not tap the striker too hard.
Loosen the screws, and remove the shop towel.
Lightly tighten the screws.
Hold the outer handle out, and push the door
against the body to be sure the striker allows a
flush fit, lf the door latches properly, tighten the
screws and recheck.
5.
6.
8 x 1.25 mm18 N.m 11.8 kgf m, 13 lbf.ft)
20-13

Glass
to.
Windshield Replacement (cont'dl
Set the windshield in the opening, and center it.
Make alignment marks (A) across the windshield
and body with a grease pencil at the four points
shown. Be careful not to touch the windshield
where adhesive will be applied.
17. Remove the windshield.
20-22
18. With a sponge, apply a light coat of glass primer
around the edge of the windshield (A) between the
dams (B) and molding {C) as shown, then lightly
wipe it off with gauze or cheesecloth:
. Apply glass primer to the molding.. Do not apply body primer to the windshield, and
do not get body and glass primer sponges mixed
up.. Never touch the primed surfaces with your hands.
lf you do, the adhesive may not bond to the
windshield properly. causing a leak afterthe
windshield is installed.. Keep water. dust, and abrasive materials away
from the primed surface.
'l',,1r- r Apply glass primer here.
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