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Honda 2002 Civic Hatchback, Service Manual

The Honda 2002 Civic Hatchback Service Manual is available for download for free on manualshive.com. This comprehensive manual provides detailed instructions on maintenance, repair, and troubleshooting for your vehicle. Get your hands on this essential manual today to ensure the optimal performance of your Civic.

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Summary of Contents for 2002 Civic Hatchback

Page 1: ...rd Instrument Panel Removal lnstallation Driver s Dashboard LowerCover Removat Installation Driver s Dashboard UnderCover Remova t Insta llation Oriver s Pocket Removal lnstallation ShiftLever TrimRem...

Page 2: ...nt Fuel FillDoorOpener Cable Replacement HoodLatch Rep1acement Fuel FillDoorOpener Replacement Hatch Handle Replacement Hatch Latch Replacement Hatch Lock Cylinder Replacement Frame Subf rameReplaceme...

Page 3: ...a DOORSASHTRIM Replacement page20 10 DOOR GLASS OUTER WEATHERSTRIP Replacement page20 10 DOOR Position Adiustment page 20 12 t POWER DOOR LOCKSWITCH Driver s DOOR OUTER TRIM K p IJ A A dq W2 Ya J ait...

Page 4: ...ge 20 9 CYLINDER ROO PROTECTOR GLASS Replacement page20 9 Adjustment page20 11 6X W STRIKER Adjustment page20 13 LATCH Replacement page20 7 RETAINER CLIP POWERDOOR LOCKACTUATOR OUTER HANDLE PROTECTOR...

Page 5: ...e B Pushthe door grip cover C out to release the hook D andtab E andpulloutthe coverto releasethe tabs F and hook G by hand then removethe cover 20 4 3 Removethe armrestcover A Takecarenotto scratchth...

Page 6: ...r breakingit FastenerLocations 95mm 3 74 in l 12mm r q i 0 17in l r _ r Clip 9 ffi EtA l m m 0 04 in l 45mm 1 77 in l 7 Disconnect the innerhandlecable A from the innerhandle B anddisconnectthe powerd...

Page 7: ...ctor B 3 Pullthe protectordown to release the hook C from the door Fastener Location Screw 1 2 5 20 6 4 Disconnect the cylinderrod A and release the retainerclip B then removethe lockcylinder C Discon...

Page 8: ...nstallthe lockcylinder Besurethe clipisfullyseated inthesloton the lockcylinder Whenreinstalling thedoorpanel makesurethe plasticcoveris installedproperly and is sealed aroundthe coversDerimeter DoorL...

Page 9: ...ghthe holein the door Takecarenotto bend the outerhandlerod B cylinderrod C lockrod D andinnerhandle cable E Fastener Locations 8 Screw U 6 x 1 0 m m 5 N m 0 5kgf m 4 tbf ft 20 8 9 Installthelatchin t...

Page 10: ...0 m m 8 N m 0 8 kgf m 6 rbf ftl Remove thebolts C andloosen thebolts D then remove theregulator E through theholeinthe door Applymultipurpose grease to allthesliding surfaces oftheregulator A wheresho...

Page 11: ...im lnstallthetrim in the reverseorderof removal 3 20 10 DoorGlassOuterWeatherstrip Replacement NOTE Puton glovesto protectyour hands Takecarenotto scratchthe door 1 Remove thepowermirror seepage20 15...

Page 12: ...stallation Checkfor water leaks seestep7 on page20 121 Test drive andcheckfor wind noase 14 r o tL rrt DoorGlassAdjustment NOTE Checkthe weatherstrips and glassrun channelfor damageor deterioration an...

Page 13: ...nel seepage20 4 9 Test drive andcheckfor wind noise 300mm 12in l 20 12 DoorPositionAdiustment NOTE Checkfor equalgapsbetweenthe front rear and bottomdoor edgesandthe body Checkthatthe door and body ed...

Page 14: ...r A The strikernuts arefixed butthestriker canbe adjusted slightly up or down andin or out 1 Loosenthe screws B rhen inserta shoptowel C betweenthe body and striker Lightlytlghtenthe screws Wrapthe st...

Page 15: ...ndex POWER MIRROR Replacement page 20 15 a b r J 4 1 TWEETER TWEETER MIRROR MOUNTCOVER MIRROR HOLDER Replacement page20 15 __ Q MOUNT REARVIEW MIRROR Replacement page 20 16 POWER MIRROR ACTUATOR Repla...

Page 16: ...f removal and notetheseitems Makesurethe connectoris pluggedin properly Attachthe harnessclip Mirror HolderReplacement 1 Carefully pulloutthebottomedgeofthe mirror holder A by hand Takecarenotto scrat...

Page 17: ...iewmirror A down towardthe bottomof the windshield then detachit from the spring B in the mount C and removethe rearviewmirror Takecarenotto scratchthe mirror Dase 3 lf necessary removethe springfrom...

Page 18: ...STENER 2 Self adhesive type glassside SIDERUBBER DAM WINDSHIELD SIDETRIM m _ lny S RErA NER 6 f N tJ e N8 CLIP 4 Blue CLIP WINDSHIELD Beplacement page20 19 SPOILER FASTENER 2 Selt adhesive type LOWER...

Page 19: ...ont d OUARTER GLASS UPPER CLIP FRONT SEAL tsetladhesive typel n iT J n l l l Pl v I LowERcLrp _ Self adhesive type b I R ARCLIP Self adhesive type OUARTER GLASS Beplacement page 20 29 LEV EMBLEM 03mod...

Page 20: ...s seepage20 95 Removethe molding A from the upperedgeof the windshield B lf necessary cutthe moldingwith a utilityknife lf the old windshieldisto be reinstalled make alignmentmarksacrossthe glassand b...

Page 21: ...ntirewindshieldopening flange Do not scrapedown to the paintedsurfaceofthe body damagedpaintwill interferewith proper bonding Removethe rubberdam andfasteners from the oooy 11 Cleanthe body bondingsur...

Page 22: ...E Becarefulnotto touchthewindshieldwhere adhesive will beaoolied t 3 14 Gluethemolding A withadhesive tape B 3M4212 or equivalent to the upperedgeofthe windshield C Besurethealignment mark D of the mo...

Page 23: ...aroundthe edgeof the windshield A betweenthe dams B andmolding C asshown thenlightly wipe it off with gauzeor cheesecloth Applyglassprimerto the molding Do not apply body primerto the windshield and d...

Page 24: ...the cartridgewithout air pockets to ensurecontinuousdelivery Putthe cartridgein a caulkinggun and run a beadof adhesive A aroundthe edgeof the windshield B betweenthe dams C andmolding D asshown Apply...

Page 25: ...s seepage20 95 NOTE Thecowl coverclipsmay not setproperlyif the windshieldadhesiveistoo wet Installthe clips A B on bothsidetrim C lf the clip D is damaged replacethe sidetrim andclips as an assembly...

Page 26: ...tors A 4 lf the old rearwindow is to be reinstalled make alignmentmarksacrossthe glassand bodywith a grease pencrl Apply protective tapealongthe insideand outside edgesof thehatch Usingan awl makea ho...

Page 27: ...ngsurfaceis kept free of water oil and grease 10 20 26 11 Gluethesideupperfasteners A andsidelower fasteners B with adhesivetape 3M 5312 or equivalent Gluetheupperrubberdams C with adhesive tape NITTO...

Page 28: ...d 14 Remove the rearwindow 15 Witha sponge applya lightcoatof glassprimer alongthe edgeof the rearwindow A upper rubberdams B and lower rubberdam C as shown then lightlywipe it off with gauzeor cheese...

Page 29: ...20mm 10 79 in l 2 m m 0 08in 1 7 Beforefilling a cartridge cuta V in the end ofthe nozzle A asshown 20 28 7 mm 0 27in I 18 Packadhesiveintothe cartridgewithout air pockets to ensurecontinuousdelivery...

Page 30: ...e vehiclestandfor at least4 hoursafterrearwindow installation lf the vehiclehasto be usedwithin the first 4 hours it must be drivenslowly 22 Reinstallall remaining removed parts NOTE Advisethe custome...

Page 31: ...yremovethe quarterglass 20 30 6 With a putty knife scrapethe old adhesivesmooth to a thickness of about2 mm 0 08in on the bondingsurfacearoundthe entirequanerglass opening flange Do not scrapedown to...

Page 32: ...terglass 11 Alignthe upperclip A andlowerclip B withthe edgeof the quarterglass C then anachthem with adhesive tape NITTO571 or equivalent to the insidefaceof the quarterglass andalignthe center of th...

Page 33: ...mm 3 9i1in 45 mm 1 77 in 3 5mm 0 r4in l 30mm 11 18 in l 50mm I 1 97in 1 t 6 mm 0 24in n L v 20 32 13 With a sponge applya lightcoatof glassprimer alongthe edgeof the rubberdam A andfront seal B asshow...

Page 34: ...cartridge cut a V in the end ofthe nozzle A asshown 10mm 0 39in 20mm 0 79 in t 5 7 mm 10 27 in 20 33 16 Packadhesiveintothe cartridgewithout air pockets to ensurecontinuousdelivery Putthe cartridgein...

Page 35: ...erglass usea softshoptowel dampenedwith alcohol 19 Letthe adhesivedry for at leastt hour thenspray water overthe quarterglassandcheckfor leaks Markthe leakingareas letthe quarterglassdry then sealwith...

Page 36: ...andOoenino Drao Check page20 48 DRAINCHANNEL Replacement page20 39 5 a t c _ a BR CKEI COVER LIMITSWITCH AUTO STOP SWITCH Adjustment page 20 46 E R I CABLE TUBE REAR BRACKET E ESTOP a MOONROOF CONTRO...

Page 37: ...etweendeflectorsealand roof panel 2 Checkfor a insufficient deflectorextension 3 Checkfor a deformeddeflector Motor noise 1 Checkfor a loosemotor 2 Check for a worngearor bearing 3 Checkfor a deformed...

Page 38: ...d A 6 x 1 0 m m I N m 0 9 kgf m 7lbt ft 3 lf necessary repeaton the oppositeside B GlassReplacement L Close theglassfully Slidethesunshade alltheway back Removethe screws A then removeboth bracket cov...

Page 39: ...derof removal and checkthatlhe deflectorarm base B and deflectorlink pivotbase C line up with the samealignment lines D lf necessary adjust them forwardor backwardso the edgeof the deflector seal E to...

Page 40: ...cations Screw 2 Release the drainchannel A from both hooks B of thedrainchannel sliderby pulling thedrain channelforward 4 Remove thedrainchannel A Installthe channel inthe reverse orderof removal and...

Page 41: ...erspacers B Fastener Locations Screw 4 tF 3 Removethe screws then removebothspacers 20 40 4 While liftingthe front portionofthe sunshade A movethe sunshadeforwarduntilyou canseeboth sunshade rearhooks...

Page 42: ...Letthe water run freelyfrom a hosewithout a nozzle Do not usea high pressure spray 1 Motor Replacement Removethe headliner seepage20 54 Puton glovesto protectyour hands Disconnecl the connector A and...

Page 43: ...es Ei and removethe moonroof relays F FastenorLocations Bolt 10 um 6 x 1 0 m m 9 8N m 1 0 kgf m 7 2lbf ft 4 5 2 irl Removethe interiorharness G by detaching the harnessclips H With an assistantholding...

Page 44: ...the reverse order of removal and notetheseitems Before installing theframe clearthedraintubes and drainvalvesusingcompressed air Checkthe frame seal Clean thesurface ofthe frame When installingthe fra...

Page 45: ...bletube sidebracket F andthe cable tube mountingscrews G from bothsidesof the frame H Fastener Locations A rScrew 2 B Screw 2 r Position switch side 6 x 1 0 m m A c g aN m No switch sidel o E Bolt 2 S...

Page 46: ...sshouldbe replaced Apply multipurposegreaseto the glassbracket A andguiderailportionof theframe B indicatedby the arrows Beforereinstalling the motor makesureboth linklifters areparallel andinthefully...

Page 47: ...hown Checkthe glassfit to the roof panelandthe glassheight seepage20 37 5 x 0 8 m m 5 N m 0 5kgf m 4lbf ft 3 Withan open end wrench loosen the limitswitchmountingbolts C 4 Adjustthe limit switch D Mov...

Page 48: ...ereyouhearafaintclickwhenthe switchcam F pushesthe switch auto stop Checkthatthe switchplatecontactsthe switchbracket G Checkthe operationof the glassby operatingthe moonroofswitch Fromthe tilt upposi...

Page 49: ...eepage20 41 then check The gearportionandthe innercablefor breakage and damage lf the gearportionis broken replace themotor lf the innercableis damaged removethe frame seepage20 42 and replace the cab...

Page 50: ...SHELF page20 5l REARSIDETRIM PANEL page20 51 B PILLARUPPEBTRIM page20 50 DOOROPENING TRIM page20 50 A PILLAR TRIM page20 50 Removal lnstallation page2054 KICKPANEL page20 50 DOORSILLTRIM page20 50 Rep...

Page 51: ...epage20 51 2 Installthetrim in the reverseorderof removal and notetheseitems Replace anydamaged clips Apply liquidthreadlockto the anchorboltsbeforereinstallatior Beforeinstallingthe anchorbolts makes...

Page 52: ...tconnectoris pluggedin properly lfthethreadsontherearsidetrimpanel mounting self tapping ETscrewsareworn out useanoversized self tappingETscrew P N90137 S1A Eo1 1 madespecifically forthisapplication W...

Page 53: ...renotto bendor scratchthe trim and panels 1 To remove the reartrim panel remove thechildseattetheranchor seepage23 11 2 Removethe trim as shown 3 Installthe trim in the reverse orderof removal andrepl...

Page 54: ...Removethe trim in the sequenceshown Hatchuppertrim panel Lefthatchsidetrim Righthatchsidetrim Hatchlowertrim panel 2 Installthe trim in thereverse orderof removal andreplace anydamaged clips FastenerL...

Page 55: ...2 C pillar trim bothsides seepage20 51 Moonroofswitch seepage22 112 Spotlights seepage22 961 Ceilinglight seepage22 96 Removethe sunvisor A and holder B from both srdes 1 Removethe caps C 2 Removethe...

Page 56: ...ace anyclipsthatremaininthe roofduring removal Reinstallthe clipsbackinthe headliner beforeinstallation F C l i p 2 H C l i p 2 CarpetReplacement SRScomponentsare locatedin this area Reviewthe SRScomp...

Page 57: ...and notetheseitems Takecarenotto damage wrinkle ortwistthe carpeL Makesurethe seatharnesses are routed correctly Slipthecarpetundertherearsidetrim panelon eachsideproperly Replace theclipif it sdamage...

Page 58: ...earconsole up then removeit Fastener Locations B Screw 2 C Clip 2 2 Removethe front console A 1 Pulloutthedashboard centerlowercover B to detachthe clips C 2 Dlsconnect the accessory power socket conn...

Page 59: ...Consoles FrontConsoleDisassembly Reassembly NOTE Takecarenotto scratchthe consoleand relatedparts FastenerLocations Screw 8 C FRONTCONSOLE a BEVERAGE HOLDER ASSEMBLY CONSOLE BOX 20 58...

Page 60: ...he clips B andhooks C 2 Gentlypull out the upperportionto release the clips D andhooks E FastenerLocations B clip 2 DD Clip 2 4 Installthepanelin the reverseorderof removal and pushthe clipand hookpor...

Page 61: ...erin the reverseorderof removal and pushthe clip portioninto placesecurely 20 60 Driver sPocketRemoval lnstallation NOTE Puton glovesto protectyour hands Takecarenotto scratchthe dashboardand related...

Page 62: ...ift levertrim C from underthe trim to releasethe clips D and hooks E of the leftside Fastener D clip i F V Locations 2 E Hook 2 a7 r t1 u 4 Pulloutthe shift levertrim A by handto release the remaining...

Page 63: ...ver sdashboardIower coveropenings loosenthe bolts A securingthe centerpanel B 2 FastenerLocations A Bolt 2 x 0 8mm 5 N m 20 62 4 Pullout the centerpanel A to release the clips B and hooks C and remove...

Page 64: ...onionsinto place securety GloveBoxRemoval lnstallation SRScomponentsare locatedin this area Reviewthe SRScomponent locations seepage23 13 andthe precautions andprocedures seepage23 14 intheSRS section...

Page 65: ...fromthedashboard B Fastener Locations Screw 7 6hD t 4 Remove the screws lhen remove the slde vent A FastenerLocations Screw 4 5 lnstallthe sideventin thereverse orderof removal 20 64 Beverage HolderR...

Page 66: ...ons Screw 3 4 lnstallthe tray in the reverseorderof removal Passenger s TrayRemoval Installation NOTE Take carenotto scratch thedashboard Putongloves to protect yourhands 1 2 3 4 Removethe dashboard s...

Page 67: ...requencies for the preset buttons Disconnect the negativecablefrom the battery and wait at leastthreeminutesbeforebeginningwork Removetheseitems Driver sdashboardlowercover seepage20 59 Driver sdashbo...

Page 68: ...nginecompartmentwire harnessconnectors l from the under dash fuse relavbox J Middleportion 8 Disconnect the floor wire harnessconnectors A andcombination subharness connector B Passenger s side 9 From...

Page 69: ...rd mountingboltsof the middleportionbefore reinstallation Beforetighteningthe bolts makesureeachwire harnessandcontrolcablesare not pinched Makesurethe connectorsarepluggedin properly andthe antennale...

Page 70: ...E andcruisecontrolmain switchconnector F Separate thedashboard andsteering hangerbeam Faslener Locations A r B o l t 4 B S c r e w 9 5 N m 0 5kgf m 4lbf ftl 5 Installthe beamin thereverse orderof rem...

Page 71: ...ent page20 81 Seat back StrikerReplacement page20 81 Seat back CoverReplacement page 20 82 SeatCushionCoverReplacement page20 84 FRONTSEAT Removal lnstallation page20 i1 Disassembly Reassembly Driver...

Page 72: ...protective tapeto preventdamage Takecarenotto scratchthe body or tearthe seat covers Puton glovesto protectyour hands 1 Makesureyou havethe anti theft codefor the radio thenwrite down the frequencies...

Page 73: ...shown thedriver s seatis similarexceptit hasno OPDSunitconnector With the helpof an assistant carefullyremovethe front seatthroughthe front door opening Installthe seatinthe reverse orderof removal a...

Page 74: ...renotto tearthe seamsor damagethe seatcovers Puton glovesto protectyour hands Whenpryingwith a flat tipscrewdriver wrap it with protective tapeto preventdamage Apply multipurposegreasetothe moving por...

Page 75: ...ntdamage Apply multipurposegreaseto the moving portionof the seattrack To Drevent wrinklesin the seatcushioncover stretchthe materialevenlyoverthe pad lvlake surethe rearseataccess cableis connectedpr...

Page 76: ...yfrom oil Oil cancorrodethe sensorcausingit to fail Puton glovesto protectyour hands Seat back Cover Removethe front seatiseepage20 71 Withsideairbag Fromundertheseatcushion detachthe sideairbagconnec...

Page 77: ......

Page 78: ...iB andremovethe cover A installthecoverin the reverseorderof removal and notetheseitems Fitall the hooksof the headrest front trim intothe holesin theheadrest reartrim thenpushon the headrest trim un...

Page 79: ...ltbuckle seestep4 on page23 6 3 From undertheseatcushion detachthe side airbagconnectorclip and on the passenger s seat detachthe OPDSunitconnectorclip Release the hookspringsfrom the seatcushionframe...

Page 80: ...r r 8 Installthecover in the reverseorderof removal and notetheseitems To preventwrinkleswhen installlnga seat cushioncover makesurethe materialis stretchedevenlyoverthe pad beforesecuring theclipsan...

Page 81: ...i t h t h e c e n t e r s h o u l d e r b e l t m a k e s u r e t h e r e a r e n o twistsor kinksin the belt Makesurethe seat backs locksecurelv FastenerLocations A Bolt 2 B rBolt 1 C Bott 1 D Clip...

Page 82: ...pivot pin C of the latchlever D from the seat backf rame Fastener Locations lnstallthelatchin the reverseorderof removal and makesurethe seat back locksand unlocksproperly RearSeat back StrikerReplac...

Page 83: ...eedgeof the latchlevercover A to releasethe clips and release the coverfrom the pivotpins B ofthe latchlever C whilepulljng the latch lever FastenerLocations D Clip 2 i r rJ 20 82 5 On rightseat backi...

Page 84: ...ith centershoulder belt passthe centerbelt C throughthe holein the seat bacl cover lnstallthecoverin the reverseorderof removal and notetheseitems To preventwrinkleswhen installinga seat back cover ma...

Page 85: ...tcushioncoverall the way around and release the clips A then remove the seatcushioncover i w F 1 1 L t s i l 1 r l J l l 20 84 4 Installthecoverin the reverseorderof removal and notetheseitems To prev...

Page 86: ...Makesurebothfront sidemarkerlightconnectors are pluggedin properly Makesurethe front bumperengagesthe hooksof the sidespacersand upperbeamson bothsidessecurely Replace anydamaged clips Fastener Locat...

Page 87: ...reboth rearsidemarkerlightconnectorsare pluggedin properly M a k e s u r e t h e r e a r b u m p e r e n g a g e s t h e h o o k s o f t h e s i d e s p a c e r s s i d e b r a c k e t s a n d u p p e...

Page 88: ...he hoodhinge B Turnthe hoodedgecushions C as necessary to makethe hoodiit flushwith the body at the front and side edges 6 x 1 0 m m 9 8N m 1 0kgf m 7 2lbf ft Adjustthe hoodlatch D to obtainthe proper...

Page 89: ...ltipurposegreaseto eachlocationof the hoodlatchand hood hingeas indicatedby the arrows I 20 88 HoodSealReplacement 1 Usinga clip remover detachthe clips then remove the hoodseal A Takecarenotto scratc...

Page 90: ...Locations Clip 10 t 2V H Usinga clip remover detachthe clips Release the hooks B thenremove the hoodinsulator C Take carenot to scratchthe hood Installthe insulator inthe reverse orderof removal and n...

Page 91: ...l seepage20 52 4 Slightlylooseneachboltand nut 5 Adjustthehatch A alignment inthefollowing sequence Adjustthe hatchhinges B rightand left aswell asforwardand rearward usingthe elongatedholes T u r n t...

Page 92: ...9 1 0 HatchSupportStrut Replacement 1 With the helpof an assistant usea flat tip screwdriver A to pry the supportstrutclips B from eachend of the supportstrut C at the hatch and body then release the...

Page 93: ...Locate the painted alignment mark B onthehatch weatherstrip Allgn the paintedmarkwith the alignmenttab in the the centerof the hatchopening andinstall thehatchweatherstrip alltheway aroundin the dire...

Page 94: ...s necessary to a r r l i 7 a t h a n n c Tighten the hingemountingbolts Reinstallthe fuelfilldoorspring Checkthatthefuel fill door opensproperlyand lockssecurely and checkthatthe rearof the door is fl...

Page 95: ...ws C 2 Removethe clips D 3 Release the bottom hooks E ofthe grille 4 Pullout the boftomof the grilleto release the upperhooks F 5 Pulloutthegrilleto release the slits G from the ribs H then removethe...

Page 96: ...clips C by carefullypullingthe passenger s cowl cover D upward to release the hooks E and pull outthe coverforwardto release the hooks F then removethe cover Takecarenotto scratchthe body Detachthe c...

Page 97: ...he upperclip and detachthe clipby pryingon theA pillar cornertrim A Take carenot to scratchthe body and relatedparts Fastener Location Closethe door half way Pullthe A pillercornertrim A out to detach...

Page 98: ...bodv Pullup andslidethe roof moldingto release the front bracket D from the pin E Pullup the front portionof roof molding 4 Pullup and release the rearbracket A from the pin B then removethe roof mold...

Page 99: ...chlockcylinder B Fastener Locations Bolt 2 6 x 1 0 m m 9 8N m 1 0kgf m 7 2lbf ftl 20 98 3 Frominside thehatch release theclips A B while holding therearlicense trim C thenremove lhe trim Takecarenotto...

Page 100: ...ase theclips while pulling the hatchspoiler A away andrelease the fasteners B then removethe spoiler Takecare notto scratchthe body Fastener Locations Clip 2 t Installthe spoilerinthe reverse orderof...

Page 101: ...hereshown Wheninstalling thesidei VTEC emblemon the body alignthe application tapewiththeedgeof thewheelarch then pressthe emblem into place and removethe application tape 03model Wheninstalling the L...

Page 102: ...EM LEVEMBLEM Ontoinside face of the guarterglass REARSiREMBLEM ilg 1 93 t 50 CIVICEMBLEM Edgeofthe hatch SIDEi VTECEMBLEM 9 SIDE i WEC EMBLEM ADHESIVE TAPE Edge of the hatch RightSide 63 2 5 F l 6 l r...

Page 103: ...nd removethe clip E securingthe front air spoiler front bumper andfront innerfender 3 Fromthewheelarch remove theclips F G securing thefrontinnerfender andsplash shield onthebody 4 Release the hook H...

Page 104: ...heelarch removethe clip A and releasethe clip B then removethe front fender fairing C Fastener Locations A C l i p 1 B C l i p 1 J Installthe fenderfairing in the reverseorderof removal and notethesei...

Page 105: ...FastenerLocations Clip 4 4 Installthe protector inthe reverse orderof removal and notetheseitems Replace anydamaged clips Pushtheclipsintoplacesecurelv 20 104 RearAir OutletReplacement 1 Remove the re...

Page 106: ...l 1 HATCH HANDLE Replacement page 20 110 FUELFILLDOOROPENER Replacement page20 109 HATCHLATCH Replacement page20 110 FUELFILLDOOR LATCH page 20 107 FUELFILLDOOROPENEB CABLE Replacement page20 107 I O...

Page 107: ...hoodopenercable A from the hood latch B see removethe hood releasehandle D from the body Fastener Locations C B o l t 2 E C l i p 3 page20 108 and removethe bolts C then 6 x 1 0 m m 9 8N m 11 0 kgl m...

Page 108: ...necessary seepage20 55 Disconnect the fuelfill door openercable A from the opener B seestep3 on page20 109 Fastener Locations C Cushiontape 1 D Clip 1 E Clip 2 4 KCmodel Removethe leftmiddlefloorcros...

Page 109: ...latch Takecarenotto bendthe cable 6 x 1 0 m m 9 8N m 1 0kgf m 7 2lbf ft 20 108 Installthehood latchin the reverseorderof removal and notetheseitems Apply multipurposegreaseto eachlocationof the hoodla...

Page 110: ...filldooropener 6 x 1 0 m m 9 8N m 11 0 kgf m 7 2 lbf ft Removethe leftdoor silltrim seepage20 50i Remove theopener Alfromthe bolt B 2 3 4 Disconnect the fuelfill door openercable A then removethe open...

Page 111: ...properly 1 0kg m 7 2 tbt t a t 20 110 HatchLatchReplacement NOTE Puton glovesto protectyour hands 1 Removethe hatchlowertrim panel seepage20 53 2 Disconnect the hatchopenercable A cylinderrod B hatch...

Page 112: ...A Fromoutsidethe hatch removethe boltsecuring the lockcylinder A Frominsidethe hatch pull the lockcylinder out by releasing the hook B FastenerLocation Bolt 1 rS l u ar 6 x 1 0 m m 9 8 N m 1 0kgfm 7...

Page 113: ...em with new ones Reference holesalignment SUBFRAME REFERENCE HOLE Body Side INSTALLATION REFERENCE HOLE Subframe side INSTALLATION REFERENCE HOLE FRONTSUSPENSION SCREWDRIVER or TAPERED PUNCH INSTALLAT...

Page 114: ...the followingsequence to avoiddamageto the quarterpanel MIDDLE FLOOR CROSS MEMgER BRACE GUSSET SIDEFRAME STIFFENER 8 x 1 25 mm 29 N m 3 0kgf m 22 lbf ft U S model 10x 1 25 mm 38 N m 3 9kgf m 28lbf ftl...

Page 115: ...to13 0 51 Forengine mountrl3 0 51 Formanual transmission mouoto13 0 5 Formanual transmission mounto1310 5 Formanual t ansmission mo nt d13 0 51 o I g h Fordampermounts11 5 0 45 Fordampercentero78 3 07...

Page 116: ...981 Locatingholes20 0 79 Trailingarm center Reardampercenter Forupperarmo13 0 51 Fortrailingarmd13 0 511 Forupperarm bracketcenterrl5 0 59 Locating holes13 0 51 Foruppe armo13 0 511 Forrearlower arm...

Page 117: ...engine mount113 0 511 Formanual transmission mount013 0 51 Formanual trensmission mount613 0 51 Formanual trrnsmission mounro13 0 51 Fordampermounto11 5 0 45 Fordampercenterr78 3 07 Fordampermounto11...

Page 118: ...engine mount113 0 511 Formanual transmission mount013 0 51 Formanual trensmission mount613 0 51 Formanual trrnsmission mounro13 0 51 Fordampermounto11 5 0 45 Fordampercenterr78 3 07 Fordampermounto11...

Page 119: ...Locatingholer20 0 79 Trailingarm center Reardampercentel Forupperarmo13 0 51 11 t2 Fortrailingarms13 0 51 Forupperarm bracketcentero15 0 591 Locating holeo13 0 51 Forupperarmd13 0 51 Forrearlower arm...

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