2003 HONDA CIVIC Oil bolt

Driveline/Axle
Intermediate Shaft Reassembly
(cont'd)
6. lnstallthe outer seal (A) intothebearingsupport(B)
using the special tool and a press.
7. Installthe set ring.
PRESS
I
Pack the interiorofthe outer seal.
16-24
Intermediate Shaft Installation
1. Use solvent or brake cleaner to thoroughly clean
the areas where the intermediate shaft {A) contacts
the transmission (differential), and dry with
compressed air. Insert the intermediate shaft
assembly into the differential. Hold the
intermediate shaft horizontal to prevent damage to
the differential oil seal (B).
2. Installthe llange bolt (A) and two dowel bolts (Bl.
A10 x 1.25 mm39Nm(4.0 kgf.m,29lbf.ft)
Bl0 x 1.25 mm39 N.m(4.0 kgf.m,29 tbf.ftl
(

5. Place the floor jack under the trailing arm {A), to
support it.
Do not place the jack against the plate
section of the lower arm, Be careful not to
damage any suspension components.
12 x 1.25 mm59 N.m{6.0 ksf.m.43lbf.ft)
1.
Remove the flange bolt (B), and disconnect the
upper arm {C) from the knuckle.
Mark the cam positions of the adjusting bolt (A) and
adjusting cam (B), the remove the self-locking nut
{C}, adjusting cam, and adjusting bolt. Discard the
self-locking nut.
12 x 1.25 mm59Nm(6.0kgf.m,43 tbI.ftl12 x 1.25 mm59 N.m {6.0 kgf m,43lbl.ft)
8. Remove the flange bolt (D), and remove the
knuckle {E).
9. Installthe knuckle in the reverse order of removal,
and note these items:
. First install all the suspension components, and
lightly tighten the bolts and nuls, then place a
floor jack under the lower a rm, and raise the
suspension to load it with the vehicle's weight
before fully tightening the bolts and nuts to the
specified torque values.. Align the cam positions of the adjusting bolt (A)
and adjusting cam (B) with the marked positions
when tightening.. Use a new self-locking nut on reassembly.. Tighten allthe mounting hardware to the
specified torque values.. Use a new spindle nut on reassembly.. Before installing the spindle nut, apply a small
amount of engine oil to the seating surface of the
nut. After tightening, use a drift to stake the
spindle nut shoulder against the driveshaft.. Before installing the brake disc, clean the mating
surface of the hub and the inside of the brake
drsc.. Use a new hub cap on reassembly.. Before installing the wheel, clean the mating
surface of the brake disc and the inside of the
wheel.. Check the wheel alignment, and adjust it if
necessary {see page 18-4).
18-29

Rear Brake Caliper Overhaul
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
' Avoid breathing dust particles.
. Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner'
Remove, disassemble, inspect, reassemble, and installthe caliper, and note these items:
. Donotspill brake fluid on the vehicle; it may damage the paint; if brake f luid gets on the paint, wash it off
immediately with water.. To prevent dripping. cover disconnected hose joints with rags or shop towels.
. Cleanall partsinbrakefluidandairdry;blowoutall passageswith compressed air'
. Before reassembling, check that all parts are free of dust and other foreign particles
. Replace pans with new ones as specified in the illustration.. Make sure no dirt or other foreign matter contaminates the brake fluid.
. When reusing pads, always reinstallthem in their original positions to prevent loss of b ra king efficie ncy.
. Do not reuse drained brake fluid.
. Use only clean Honda DOT 3 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the
system.. Do not mix different brands ot brake fluid as they may not be compatible.
. Coatthe piston, piston seal groove, and caliper bore with clean brake fluid.
. Make sure no grease or oil gets on the brake discs or pads.
. Replaceall rubber parts with new ones whenever disassembled.
. After installing the caliper, check the brake hose and line for leaks, interference. and twisting.
oG , nonau."rip6r qreas€ lP/N 08c30-aoa4Ml34 N.m (3.5 kgf m,25lbtft)BOLT
WASHERS
BRAKE HOSE
a
l,i,,'IltE" / !!;,ff
olT-J,.o"c.O.RING CUPBeplace. Beplace.
.ARKING NUr lii.'i rz.r rgr.. Gd ffi27Nm{2.8kgtm,
\-"o, V((rA ",1 ;[.,.JF /;;;;---
t H\a \l / t,i*t'*"
?,,.t/*"^.,,.:,"", /"V4#
ADJUSTING BOLT
,/
27Nm{2.8kgf.m,20 tbf.ftr PAD SPRING
A,n Na 7lfl,lif,loffi ',,0,n, ,,:,o" \
--t)(*ff l^7k ''"'t!1'ry#'
INNEBPA'SHIM
/ .r.:._U i*E'( ":;*" *dF ,.2>a>-
fr.x{_>@ fftt **-->**^'"
,,.-"iV ,/q &'"o.,"."""o"^.,
: 10 MM FLANGE BOLTS.:r=,9!q!q}l 55 N m (5.6 lgf-m, 4r lbt ft)
19-23

Bumpers
Front Bumper RemovaUlnstallation
NOTE:. Have an assistant help you when removing and installing the front bumper.. Take care not to scratch the front bumper and body.. Put on gloves to protect your hands.
'L Remove the front bumper as shown.
2. Installthe bumper in the reverse order of removal, and note these items:
. Make sure both front side marker light connectors are plugged in properly.
. Make sure the front bumper engages the hooks of the side spacers and upper beams on both sides securely.
. Replace any damaged clips.
Fastener Locations
A),Screw, 2
{D[]
>:Bolt.4 D>:Clip,7 E >:Clip,2
f'h-64k/- *S =$t
B >: Screw,2 C
ABSORBER
SIDE SPACER
UPPER BEAM
LEFT FRONT SIDE MARKERLIGHT CONNECTOR
BUMPER
FRONT INNERFENDER
FEONT BUMPER
AEClI
6x9.8
FRONT AIR SPOILER
AIR SPOILERPLATE1.0 mmN.m (1.0 kgt.m,7.2 lbf.ft)
'*D ;e3
e
ti-\
SPOILER
PLATE
20-85

Hatch Spoiler Replacement
NOTE: Put on gloves to protect your hands.
'l. Remove the hatch upper trim (see page 20-53).
2. Remove the high mount brake light (see page 22-
82).
3. From inside the hatch, remove the bolts {A} and
nuts (B).
Fastener Locaiions
A>: Bolt,2 Bar Nut,
fi'f$t-- /,fluLt* v_/
5x1.0mm9.8Nm(1.0 kgf.m.7.2 lbf.ft)
$.A
4. From inside the hatch, release the clips, whilepulling the hatch spoiler (A) away, and release the
fasteners (B), then remove the spoiler. Take care
not to scratch the body.
Fastener Locations
>: Clip. 2
t
Installthe spoiler in the reverse order of removal,
and note these items:
Replace any damaged clips.
Replace any damaged fasteners. Before
installing the fastener to the spoiler, clean the
spoiler bonding surface with a sponge
dampened in alcohol. Glue the fastener with
adhesive tape (3M 5671, or equivalent)to the
spoiler.
Push the clip and fastener portions into place
securely.
5.
20-99

Heating and Air Gonditioning
a
1.
Evaporator Core Replacement
Recover the refrigerant with a recovery/recycling/
charging station (see page 21-53).
Remove the bolt, then disconnect the suction line
(A) and the receiver line (B)from the evaporator
core.
6x10mm9.8 N.m (1.0 kgt.m, 7.2lbf.ft)
Remove the blower unit (see page 21-39).
Remove the self-tapping screws and the expansion
valve cover.
21-42
5. Carefully pull out the evaporator core without
bending the pipes.
Installthe core in the reverse order of removal, and
note these items.
. lfyou're installing a new evaporator core, add
refrigerant oil (KElHlN SP-]0) (see page 21-6).. Replace the O-rings with new ones at each fitting,
and apply a thin coat of refrigerant oil before
installing them. Be sure to use the correct O-rings
for HFC-134a (R-'134a) to avoid leakage.. lmmediatelyafter usingthe oil, reinstallthecap
on the container, and seal it to avoid moisture
absorotion.. Do not spill the refrigerant oil on the vehicle; it
may damage the paint. lf the refrigerant oil
contacts the paint, wash it off immediately.. Charge the system (see page 21-55).
6.

Compressor Replacement
1. lf the compressor is marginally operable, run the
engine at idle speed, and let the air conditioning
work for a few minutes, then shut the engine off.
2. Make sure you have the anti-theft code for the radio,
then write down the frequencies for the radio's
preset buttons.
3. Disconnect the negative cable from the battery.
4. Recover the refrigerant with a recovery/recycling/
charging station (see page 21-53).
5. Remove the alternator (see page 4-29).
6. Remove the Ay'C condenser fan assembly (see page
10-10).
7. Disconnectthe compressor clutch connector (A),
remove the bolts, then disconnect the suction line(B) and the discharge line (C)from the compressor.
Plug or cap the lines immediately after
disconnecting them to avoid moisture and dust
contamination.
6 x '1.0 mm9.8 N.m11.0 kgt.m,7.2 tbl.ttl
u1/
(
o
8. Remove the mounting bolts and the compressor.
8 x 1.25 mm22 N.m 12.2 kgf.m.
9. Installthe compressor in the reverse order of
removal, and note these items:
. Before installing the new compressor, check for
metal or other contamination in the line. Replace
any contaminated parts.. lf you're installing a newcompressor, you must
calculate the amount of refrigerant oil to be
removed from it (see page 21-6).. Replace the O-rings with new ones at each fitting,
and apply a thin coat of refrigerant oil before
installing them. Be sure to use the correct O-rings
for HFC-134a {R-134a) to avoid leakage,. Use refrigerant oil (KElHlN SP-'10) for HFC-134a
KEIHIN spiral type compressor only.. To avoid contaminatlon, do not return the oilto
the container once dispensed, and never mix it
with other refrigerant oils.. lmmediately after using the oil, reinstallthe cap
on the container, and seal it to avoid moisture
absorption.. Do not spill the refrigerant oil on the vehicle; it
may damage the paint. lf the refrlgerant oil
contacts the paint, wash it off immediately.. Charge the system (see page 21-55).. Do the engine control module (ECM) idle learn
procedure (see page 11-'139).. Enter the antitheft code for the radio, then enter
the customer's radio station presets.
21-47

Compressor Clutch Overhaul
Special Tool Required
A,/C clutch holder, Robinair 10204. Kent-Moore J37872,
or Honda Tool and Equipment KMT-J33939,
commercially available
1. Remove the center nut (A) while holding the
armature plate with a commercially available A,/C
clutch holder (B).
17.6 N.m{1.8 kgf.m,13 tbt.ft)
Remove the armature plate (A) and shim(s) (B),
taking care not to lose the shim(s). lf the clutch
needs adjustment, increase or decrease the
number and thickness of shims as necessary, then
reinstallthe armature Dlate, and recheck its
clearance (see page 21-481.
NOTE: The shims are available in four thicknesses:
0.1 mm,0.2 mm,0.4 mm, and 0.5 mm.
9-=-g
3. lf you are replacing the field coil, remove the snap
ring (A) with snap ring pliers, then remove the rotor
pulley (B). Be careful not to damage the rotor pulley
or tne compressor.
4. Remove the bolt and holder (A). then disconnect
the field coil connector (B). Loosen the clamp screw(C) to iree the field coil wire. Remove the snap ring
{D)with snap ring pliers, then remove the field coil(E). Be careful not to damage the field coil or the
comoressor.
\ot
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/@h"
.ffi
7.4 N.m(0.75 kgf m,5 tbf.ft)---------------- ")
(cont'd)
21-49