2003 HONDA CIVIC ERS

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

Glass
Windshield Replacement (cont'd)
With a helper on the outside, pullthe piano wire {A)back and forth in a sawing motion. Hold the piano
wire as close to the windshield (B) as possible toprevent damage to the body and dashboard.
Carefully cut through the rubber dam and adhesive(C) around the entire windshield.
-A\, ,.-
,,t""""""""',-\i-.. -1:-, -
-=-.--
20-20
10. With a knife, scrape the old adhesive smooth to a
thickness of about 2 mm (0.08 in.) on the bonding
surface around the entire windshield opening
flange:
. Do not scrape down to the painted surface ofthe
body; damaged paint will interfere with proper
bonding.. Remove the rubber dam and fasteners from the
oooy.
1 1. Clean the body bonding surface with a sponge
dampened in alcohol. After cleaning, keep oil,grease and water from getting on the clean surface.
12. lf the old windshield is to be reinstalled, use a puttv
knife to scrape off all of the old adhesive, the
fasteners and the rubber dam from the windshield.
Clean the inside face and the edge of the
windshield with alcohol where new adhesive is to
be applied. Make sure the bonding surface is kept
free of water, oil, and grease.
\

t5.Glue the side rubber dams (A) and lower rubber
dam (B) with adhesive tape (NITTO 501M, or
equivalent). Glue the fasteners (C)with adhesive
tape (3M 4215, or equivalent) to the inside face of
the windshield {D) as shown:
. Be sure the rubber dams and fasteners line uD
with the alignment marks (E).
. Be careful not to touch the windshield where
adhesive will be aoolied.
t3.
14. Glue the molding (A)with adhesive tape {B)(3M 4212, or equivalent)to the upper edge ofthe
windshield (C);
. Be sure the alignment mark (D) of the molding
lines up with the alignment mark (E) of the
windshield.. Be careful not to touch the windshield where
adhesive will be applied.
Install the fasteners (A), retalners (B, C), and clips
(D) to lhe body.
Fastener Locations
A>:Fastener.2B>:Retainer,2
q\
C >: Retainer,6 O > : Clip,2
(cont'd)
20-21

Glass
23.
24.
Windshield Replacement (cont'd)
Scrape or wipe the excess adhesive off with a putty
knife or towel. To remove adhesive from a painted
surface or the windshield, wipe with a soft shop
towel dampensd with alcohol.
Let the adhesive dry for at least t hour, then spray
water over the windshield and check for leaks.
Mark Ieaking areas, and let the windshield dry, then
seal with sealant:
. Let the vehicle stand for at least 4 hours after
windshield installation. lf the vehicle has to be
used within the first 4 hours, it must be driven
slowly.. Keep the windshield dry for the first hour after
installation.
Reinstallthe cowl covers (see page 20-95).
NOTE:The cowl cover clips may not set properly if
the windshield adhesive is too wet.
Install the clips (A, B) on both side trim {C). lf the
clip (D) is damaged, replace the side trim and clips
as an assembly.
A: GreyB: Blue
20-24
27. On both sides ofthe windshield, install the side
trim (Alto the clip (B), then set the bottom edge of
the side trim over the cowl cover (C), and align the
clips (D)with the retainers (E), and push on the clipportions of the trim until the trim is fully seated on
the windshield.
Reinstall all remaining removed parts. Installthe
rearview mirror after the adhesive has dried
thoroughly.
NOTE: Advise the customer not to do the following
things for 2 to 3 days:
. Slam the doors with allthe windows rolled up.. Twist the body excessively (such as when going
in and out of driveways at an angle or driving
over rough, uneven roads).
28.

Rear Window 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 any surfaces.. Do not damage the rear window defogger grid lines
and terminals.
1.Remove these items:
. Hatch lower trim panel (see page 20-53). Hatch spoiler (see page 20-99)
Remove these items:
. High mount brake light {see page 22-821. Rear window wiper motor {see page 22-1461
Disconnect the rear window defogger connectors
(A).
4.lf the old rear window is to be reinstalled, make
alignment marks across the glass and body with a
grease pencrl,
Apply protective tape along the inside and outside
edges of the hatch. Using an awl, make a hole
through the adhesive from inside the vehicle at the
corner portion of the rearwindow. Push the piano
wire through the hole, and wrap each end around a
piece of wood,
6. With a helper on the outside, pull the piano wire (A)
back and Jorth in a sawing motion. Hold the piano
wire as close to the rear window (B) as possible to
prevent damage to the hatch, and carefully cut
through the adhesive {C} around the entire rear
Cutting positions:
7. Carefully remove the rear window.
(cont'd)
20-25

Glass
Rear Window Replacement (cont'd)
With a putty kniie. scrape the old adhesive smooth
to a thickness of about 2 mm (0.08 in.) on the
bonding surface around the entire rear window
opening flange:
. Do not scraDe down to the Dainted surface of the
body; damaged paint will interfere with proper
bonding. Remove the fasteners from the tailqate.
Clean the hatch bonding surface with a sponge
dampened in alcohol. After cleaning, keep oil,grease and water from getting on the surface,
lf the old rear window is to be reinstalled, use a
putty knife to scrape off all of the old adhesive, the
fasteners and the rubber dams from the rear
window. Clean the inside face and the edge oi the
rear window with alcohol where new adhesive is to
be applied. Make sure the bonding surface is kept
free of water, oil and grease.
10.
20-26
11. Glue the side upper fasteners (A) andsidelower
fasteners {B) with adhesive tape {3M 5312, or
equivalent). Glue the upper rubber dams (C)with
adhesive tape (NITTO 501fM, or equivalent) andglue the lower rubber dam (D) with adhesive tape(3M 4216, or equivalent) to the inside face of the
rear window (E) as shown. Before installing the
lower rubber dam, apply primer (3M N-200, or
equivalent) to the areas between the alignment
marks {F), then glue the rubber dam on. lf
necessary, glue the spoiler fasteners (G) with
adhesive tape (3M 5671, or equivalent) to the
outside face of the rear window:
. Be sure the side upper fasteners, and upper
rubber dams line up with alignment marks {H, l).. Be sure both ends of the lower rubber dam line
up with the edge of the glass,. Be sure the spoiler fasteners line up with
alignment marks {J).. Be careful not to touch the rear window where
adhesive will be aDolied.
1,1,.,1,' : Apply primer here.
E
"6'J1r-,
G

12. Glue the side upper fasteners (A) andsidelower
fasteners (B) with adhesive tape (3M 5312, or
equivalent)to the hatch as shown.
Fastoner Locations
A>: Fastener, 2 B >: Fastener, 2
T-8.
cl
ar\
itf,
t5.Set the rear window in the opening, and center it.
Align the clips (A) of the rear window with the holes
in the opening flange. Make alignment marks (B)
across the rear window, hatch, and body with a
grease pencil at the four points shown. Be careful
not to touch the rear window where adhesive will
be applied.
14. Remove the rear window.
15. With a sponge, apply a light coat of glass primer
along the edge of the rear window (A), upper
rubber dams (B), and lower rubber dam (C) as
shown, then lightly wipe it off with gauze or
cheesecloth:
. With the printed dots (D) on the rear window as a
guide, apply the glass primer to both side
portions of the rear window.. Do not apply body primer to the rear window,
and do not get hatch and glass primer sponges
mixed up.. Never touch the primed surfaces with your hands.
lf you do, the adhesive may not bond to the rear
window properly. causing a leak after the rear
window is installed.. Keep water, dust, and abrasive materials away
from the primed surface.
.. : Apply glass piimer here.
(cont'd)
20-27

19. Use suction cups to hold the rear window over the
opening. align it with the alignment marks you
made in step '13, and set it down on the adhesive.
Lightly push on the rear window until its edges are
fully seated on the adhesive all the way around. Do
not open or close the doors until the adhesive is dry.
20. Scrape or wipe the excess adhesive off with a putty
knife or towel. To remove adhesive from a painted
surface or the rear window, use a soft shop towel
dampened with alcohol.
21. Let the adhesive dry for at least 'l hour,thenspray
water over the rear window and check for leaks.
Mark the leaking areas, let the rear window dry,
then seal with sealant. Let the vehicle stand for at
least 4 hours after rear window installation, lf the
vehicle has to be used within the first 4 hours, it
must be driven slowly.
22. Reinstallall remaining removed parts.
NOTE: Advise the customer not to do the following
things for 2 to 3 days:
. Slam the doors with all the windows rolled up.. Twist the body excessively (such as when going
in and out of driveways at an angle or driving
over rough, uneven roads).
Ouarter Glass Replacement
NOTE:. Put on gloves to protect your hands.. Wear eye protection while cufting the glass adhesive
with piano wire,. Use seat covers to avoid damaging any surfaces.
1. Remove the C-pillar trim (see page 20-51).
lf necessary, remove the rear side trim panel (see
page 20-51 ) and B-pillar upper trim (see page 20-
50).
2. Remove the front seal {A) from the front edge of the
glass (B). lf necessary, cut the seal with a utility
knife.
(cont'd)
20-29