2003 HONDA CIVIC %27

NOTE:. The parking brake cables must not be bent or
distorted. This will lead to stiff operation and
premature failure.. Refer to the Exploded View as needed during this
proceoure.
1. Release the parking brake lever fully.
2. Remove the rear console (see page 20-57).
Remove the parking brake cable clip (A) from the
brake cable (B).4.
6.
Disconnectthe parking brake cable from the lever
{c).
Remove the parking brake cable mounting
hardware, then remove the cable.
7. lnstallthe new cable in the reverse order of
removal. and note these items:
. Be careful not to bend or distort the cable.. Make sure the parking brake cable clip is fully
seated on the cable housing.. Do the parking brake cable adjuslment (see page
19-7 ).
19-27

19. With a sponge, apply a light coat of body primer to
the original adhesive remaining around the
windshield opening flange, Let the body primer dry
for at least 10 minutes:
. Do not apply glass primer to the body, and be
careful not to mix up glass and body primer
sponges.. Never touch the primed surfaces with your hands.. l\4ask off the dashboard before paintingthe
flange.
20 mm(0.79 in.l
Before filling a cartridge, cut a "V" in the end of the
nozzle (A) as shown.
20.
12 mm (0.47 in.)
7 mm {0.27 in.)
21. Pack adhesive into the cartridge without air pockets
to ensure continuous delivery. Put the cartridge in a
caulking gun, and run a bead of adhesive (A)
around the edge of the windshield (B) between the
dams (C) and molding (D) as shown. Apply the
adhesive within 30 minutes after applying the glass
primer. Make a slightly thicker bead at each corner.
l'1fifr.,1:?mm n10.28 in.l ,..-A.. )t
$?I.",x1"u.80.".,trl
.,r []\"Inside
-'
A
Use suction cups to hold the windshield over the
opening, align it with the alignment marks made in
step 16, and set it down on the adhesive. Lightly
push on the windshield until its edges are fully
seated on the adhesive allthe way around. Do not
open or close the doors until the adhesive is dry.
c.. N\F12mm I nl{0.08 in.} I 'Z l
./"
(cont'd)
20-23

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.

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

Glass
16.
Rear Window Replacement (cont'd)
With a sponge, apply a light coat of body primer to
the original adhesive remaining around the rear
window opening flange. Let the body primer dry for
at least 10 minutes;
. Do not apply glass primer to the body, and be
careful not to mix up glass and body primer
sponges.. Never touch the primed surfaces with your hands.
',,,,,' : Apply body primer he.e.
20 mm10.79 in.l
2mm{0.08 in.)
17.Before filling a cartridge, cut a "V" in the end ofthe
nozzle {A} as shown.
20-28
7 mm (0.27 in.)
I
18. Pack adhesive into the cartridge without air pockets
to ensure continuous delivery. Put the cartridge in a
caulking gun, and run a bead of adhesive (A)
around the edge of the rear window (B) as shown.
With the glass primer (C) you applied in step 15 as
a guide, apply the adhesive to both side portions of
the rear window.
Apply the adhesive within 30 minutes after
applying the glass primer. fMake a slightly thicker
bead at each corner.
12 mm r,10.47 in.) ,\
ii'-A (0.28 in.l
\
aru'.1{-----"

14, With a sponge. apply a light coat of body primer to
the original adhesive remaining around the quarter
glass opening flange. Let the body primer dry for at
least 10 minutes:
. Do not apply glass primer to the body, and be
careful not to mix up glass and body primer
sponges.. Never touch the primed surfaces with your hands.
)'/ii ,/ii. I Apply bodv prime. here,
mm(0.08 in.l
20 mm(0.79 in.)
2mm{0.08 in.)
Before filling a cartridge, cut a "V" in the end ofthe
nozzle (A) as shown.
'10 mm (0.39 in.)
20 mm{0.79 in.)
t5.
7 mm 10.27 in.)
20-33
16. Pack adhesive into the cartridge without air pockets
to ensure continuous delivery. Put the cartridge in a
caulking gun, and run a bead of adhesive (A)
around the edge of the rubber dam (B) as shown.
With the glass primer (C)you applied in step 13 on
the quarter glass (D) as a guide. apply the adhesive
to the upper and lower corner portions of the
quarter glass. Apply the adhesive within 30
minutes after applying the glass primer. lvlake a
slightly thicker bead at each corner.
l.:J611, ;\
7mm{0.28 in.)
3mm{0.'12 in.}
I
IA
(conl'd )

21-2
z t-'5
z t-o
z t-o
21-8
21-9
21-10
21-11
21-14
z t- to
HVAC (Heating, Ventilation, and Air Gonditioningl
Heating and Air Conditioning
SpecialTools
Comoonent Location lndex ........
A/C Service Tios and
Precautions
A,/C Refrigerant Oil
ReDlacement
General Troubleshooting
lnformation
DTC Troubleshooting Index .......
Symptom Troubleshooting
1ndex..............
System Description .....................
Circuit Diagram
DTC Troubleshooting ..................
Recirculation Control Motor
CircuitTroubleshooting .......... 21-25
Heater Control Power and Ground
Circuits Troubleshooting ........ 21-27
Condenser Fan Circuit
Troubleshooting ...................... 21-28
Radiator and Condenser Fans
Common Circuit
Troubfeshooting ...................... 21-29
Compressor Clutch Circuit
Troubleshooting ...................... 21-30
A,/C Pressure Switch Circuit
Troubleshooting ...................... 21-32
Air Mix Control Motor
Test and Reolacement ............. 21-34
Mode Control Motor
Test and Replacement ............. 21-35
Recirculation Control Motor
Test and Reolacement ............. 21-36
Evaporator Temperature Sensor
Reolacement and Test ............. 21-31
Power Transistor Test ................. 21 -38
Heater Control Panel and
Push Switch Assemblv
Removal and Installation ........ 21-38
Dust and Pollen Filter
Reolacement ..21-39
Blower Unit Removal and
lnstallation ...... 21-39
Blower Unit Comoonents
ReDlacement ............................ 21-41
Evaporator Core
Reolacement ..21-42*Heater Unit/Core
ReDlacement ..21-43
Heater Valve Cable
Adjustment .....21-46
CompressorReplacement .......... 21-47
Comoressor Clutch Check .......... 21-48
Comoressor Clutch Overhaul ..... 21-49
Compressor Thermal Protector
Reo1acement ............................ 21-51
Comoressor Relief Valve
Reolacement ............................ 21-51
Condenser Reolacement ............ 21-52
Refrigerant Recovery .................. 21-53
System Evacuation ...................... 21-54
System CharginS ......................... 21-55
Refrigerant LeakTest .................. 21-56
A,/C Svstem Tests ........................ 21-57

Heating and Air Conditioning
{
a
a
SvmptomDiagnostic procedureAlso check for
Recirculation control doors do not
change between Fresh and Recirculate
Recirculation Control Motor
Circuit Troubleshooting (see page
21 251
Cleanliness and tightness of all
connectors
Both heater and Ay'C do not workHeater Control Power and Ground
Circuits Troubleshooting (see
page 21-27)
Blown fuse No. '14 (10A) in the
under-dash fuse/relay box
Poor ground at G501
Cleanliness and tightness of all
conneclors
Condenser fan does not run at all (but
radiator fan runs with the Ay'C on)
Condenser Fan Circuit
Troubleshooting {see page 21-28)
. Poor ground at G301. Cleanliness and tightness of all
connectors
Both fans do not run with the A,/C onRadiator and Condenser Fans
Common Circuit Troubleshooting
(see page 21-29)
Blown fuse No. 1 (20A) and No.4
(20A) in the under-hood fuse/relay
box
Poor ground at G30l
Cleanliness and tightness of all
connectors
Compressor clutch does not engage(both fans run with A,/C on)
Compressor Clutch Circuit
Troubleshootinq (see Daqe 21-30)
Cleanliness and tightness of all
connectors
A/C system does not come on (both
fans and compressor)
Ay'C Pressure Switch Circuit
Troubleshooting (see page 21-32)
Blown fuse No. 1 (20A) and No. 4
(20A) in the under-hood fuse/relay
box
Poor ground at G301
Cleanliness and tightness of all
connectors
\Symptom Troubleshooting Index
\
21-10
!