Harness HONDA CIVIC 2003 7.G User Guide

Engine Assembly
Engine Installation {cont'dl
Install the select cable (A) and shift cable (B) using
the plastic washers (C), washers (D), and new cotter
pins (E).
6x1.0mm9.8 N.m (1.0 kgf.m,7.2 tbl.ftl
Install the clutch slave cylinder (A) and clutch line
bracket mounting bolt (B).
6x1.0mm9.8 N.m{1.0 kgf.m,7.2 tbt.ft)
"-.----->)
"------'6
8 x '1.25 mm24 N.m (2.4 kgl.m,
5-14
37. Installthe battery cables (A) on the under-hood
fuse/relay box, then install the harness clamp (B).
Installthe ground cable (C).
Installthe intake air duct.
6x1.0mm12Nm{1.2kgf.m,8.7 tbf.ft)
39.
\"
\-
a
6x1.0mm12Nm{1.2kgt.m,8.7 rbf.ft)

Gylinder Head Removal
NOTE:. Use fender covers to avoid damaging painted
surfaces.
To avoid damage, unplug the wiring connectors
carefully whlle holding the connector portion.
To avoid damaging the cylinder head, wait until the
engine coolant temperature drops below 100'F (38"C)
betore loosening the cylinder head bolts.
Mark all wiring and hoses to avoid misconnection.
Also, be sure that they do not contact other wiring or
hoses, or interfere with other parts.
'1.
2.
3.
Drain the engine coolant (see page 10-6).
Remove the drive belt (see page 4-26).
Remove the intake manifold {see page 9-3).
Remove the air cleaner housing (see step 7 on page
5-2t.
5. Remove the water bypass hose (A).
Remove the exhaust manifold (see page 9-7
Remove the cam chain (see page 6-12).
6.
7.
).
8. Remove the engine wire harness connectors and
wire harness clamps from the cylinder head.
. Engine coolant temperature (ECT) sensor
conneclor. Camshaft position (Cl\4P) (top dead center (TDC))
sensor B connector. Camshaft posilion (CMP) sensor A connector
9. Remove the upper radiator hose (A) and heater
hose (B).
'10. Remove the harness holder (A)from the bracket,
then remove the connecting pipe mounting boh {B)
and brake booster vacuum line mounting bolts {C).
(cont'd)
1 1. Remove the water bvpass hose (D).
6-23

Cylinder Head
8.
Cylinder Head lnstallation (cont'd)
7.Apply engine oil to the bolt threads and under thebolt heads of all the cylinder head bolts.
Tighten the cylinder head bolts in sequence to 39N.m {4.0 kgf.m, 29 lbf.ft). Use a beam-type torquewrench. When using a preset-type torque wrench,be sure to tighten slowly and do not overtighten. lf
a bolt makes any noise while you are torquing it,
loosen the bolt and retighten it from the first step.
9.After torquing, tighten all cylinder head bolts in twosteps (90" per step). lf you are using a new cylinderhead bolt, tighten the bolt an extra 90..
FIRST STEP
SECOND STEP
6-40
v
{\
10. Installthe rocker arm assembly {see page 6-38).
1't .Install the water bypass hose (A).
---l.-.
B6x1.0mm'r2 N.m(1.2 kgl.m,8.7 lbf.ftl
12.
't3.
c6xl.0mm'12 N,m (1.2 kgt.m,8.7 lbf.ft)
Tighten the connecting pipe mounting bolt (B) andbrake booster vacuum line mounting bolts (C), theninstallthe harness holder (D) on the bracket.
Installthe upper radiator hose {A) and heater hose(B).

Intake Manifold and Exhaust System
Intake Manifold Removal and Installation (cont'dl
5. Be prepared to catch and clean up spilled coolant.
Remove the water bypass hoses, then plug the
water bypass hoses.
6. Relievefuel pressure (see page 11-'144).
7. Remove the fuel line (seepagell-149).
8. Remove the positive crankcase ventilation (PCV)
hose (A), harness holder mounting bolt (B) and
harness clamp mounting bolt (C).
9-4
\-
(
9.Remove the engine wire harness connectors and
wire harness clamps from the intake manifold.
. Four injector connectors. ldle air control (lAC) valve connector. Throttle position (TP) sensor connector. fvlanifold absolute pressure {lvlAP) sensor
connector. Evaporative emission (EVAP)canister purge
valve connector
Remove the bolt securing the intake manifold and
bracket.
'1 0.
11.Remove allthe intake manifold mounting bolts/
nuts.
Remove the two stud bolts (A), then remove the
intake manifold (B).
1'>

1. Install the intake manifold (A)with a new gasket (B),
then install and tighten the two stud bolts (C).
8 x 1.25 mm22 N.m|.2.2k91.m.16 tbt.ft)
8 x 1.25 mm22 N.rn(2.2 kgf m. 16 lbf.ttl
Tighten all intake manifold mountlng bolts/nuts in a
crisscross pattern in two or three steps, beginning
with the inner bolt.
Tighten the bolt securing the intake manifold and
bracket.
8 x 1.25 mm22 N.m (2.2 ksf m, 16lbf.ft)
*&
\
2.
?
w
4.
7.
5.
6.
Install the PCV hose {A), harness holder mounting
bolt (B), and harness clamp mounting bolt (C).
e-li*h,r
6x1.0mm12 N.m (1.2 kgf.m,8.7 lbf.ft)
Installthe fuel line (see page 11-150).
Installthe water bypass hoses.
Install the th rottle cable (see page 1 1-164), then
adjust the cable (see page 11-163).
Install the cruise control cable (see page 4-44). then
adjust the cable (see page 4-45).
8.
(cont'd)
9-5

Fuel and Emissions Systems
Symptom Troubleshooting Index
When the vehicle has one of these symptoms, check the diagnostic trouble code (DTC) with the scan tool. lf there is no
DTC, do the diagnostic procedure for the symptom, in the sequence listed, until you find the cause.
SvmotomDiaqnostic procedureAlso check lor
Engine will not sta rt
(MlL works OK, no DTCS set)
1. Test the battery {see page 22-50).
2. Test the starter (see page 4-8).
3. Troubleshoot the fuel pump circult (see page 11
141).
Low compressron
No ignition spark
lntake air leaks
Locked up engine
Broken timing chain
Contaminated fuel
Engine will not start (MlL
comes on and stays on, or
never comes on at all, no
DTCS set)
Troubleshoot the l\4lL circuit (see page 1 '1-97).
Engine will not start
(immobilizer indicator stays
on or flashs)
Troubleshoot the immobilizer system (see page 22-165).
Hard starting(MlL works OK, no DTCS set)
1. Testthe battery (see page 22-50).
2. Checkthe fuel pressure (see page 11-145).
Low compression
Intake air leaks
Contaminated fuel
Cold fast idle too low(MlL works OK. no DTCS set)
1. Do the ECM idle learn procedure (see page 11-139).
2. Checkthe idle sDeed (see paqe 11-138).
Cold fast idle too high
(MlL works OK, no DTCS set)
Do the ECI\4 idle learn procedure (see page 1 1- 139).
Checkthe idle speed {see page 11-138).
Inspect/adjust the throttle cable (see page 1 '1-'163).
Inspect and test the throttle body {see page 1 1-160}.
']
2.
3.
ldle speed fluctuates
(MlL works OK, no DTCS set)
1. Dothe ECM idle learn procedure (see page 11-'139).
2. Check the idle speed (see page 11-138).
3, Inspecvadjust th e throttle cable (see page 11''163).
4. Insoect and test the throttle bodv (see paqe 11- 160)
Intake air leaks
After warming up, idle speed
is below specifications with
no load
{MlL works OK, no DTCS set)
1. Do the ECIVI idle learn procedure (see page 1 1- 139).
2. Troubleshootthe alternator FR signal circuit (see
page 11-'134).
3. InsDect and test the throttle bodv {see paqe 1 1-160).
Vacuum hose clogged/
cracked/poor
connectron
After warming up, idle speed
is above specifications with
no toao(MlL works OK. no DTCS set)
1. Do the ECM idle learn procedure {see page 1'j-139).
2. Troubleshoot the alternator FR signal circuit(see
page 11-134).
Low power
(MlL works OK, no DTCS set)
1. Check the fuel pressure(seepagell-145).
2. Inspect and test the th roftle body (see page 11-160).
3. Inspecvadjust the throttle cable (see page 11-'163).
Low compressron
Camshaft timing
problem
Engine oil levelprootem
Engine stalls(MlL works OK. no DTCS set)
1. Do the ECM idle learn procedure (see page 1'l'139).
2. Check the fuel pressure{seepagell-145).
3. Check the idle speed (see page I 1-138).
4. Troubleshootthe brake pedal position switch signal
circuit (see paqe 11-137).
lntake air leaks
Faulty harness and
sensor connections
\
\-
11-10
\-

11. At the wire harness side, check for continuity
between TP sensor 3P connector terminal No, 2
and body ground.
TP SENSOR 3P CONNECTOR
1 1213
'PS
REO
Wire side ot Iemale terminals
ls thete continuity?
YES-Repair short in the wire between the ECM
{A15) and the TP sensor.ll
NO-Go to step 12.
Connect ECM connector terminal A15 to body
ground with a jumper wire.
ECM CONNECTOR A 131P)
1121345679
1011112tc68 19 t2021
2312428129130
,tf$,rr*, ] ;uueen wrne
Wire side oJ .female terminals
/BLKI
12.
13. At the wire harness side, check for continuity
between TP sensor 3P connector terminal No. 2
and body ground.
TP SENSOR 3P CONNECTOR
(RED/BLX}
Wire side of female terminals
ls there continuity?
YES-Update the ECM if it does not have the latest
software, or substitute a known-good ECM, then
recheck (see page 11-6). lf the symptom/indication
goes away with a known-good ECM, replace the
original ECM.I
NO- Repair open in the wire between the ECM
(A15) and the TP sensor.l
14. lvleasure voltage between ECM connector
terminals 410 and A20.
ECM CONNECTOB A 131P}
vcc2(YEL/8LU)
Wire side of female terminals
ls there about 5 V?
YES Repair open in the wire betlveen the ECM
(A20) and the TP sensor.I
NO Update the ECM if it does nor have the latest
software, or substilute a known-good ECM, then
recheck (see page 1 1-6). lf the symplom indication
goes away with a known-good ECM. replace lhe
original ECM.I
123
TPS
11-61

PGM-FI System
(
(
DTC Troubleshooting (cont'd)
DTC P0123: TP Sensor Circuit High Voltage
1. Turn the ignition switch oN (ll)
2. Check the throttle position with the scan tool.
ls there about 10% or 0.5 V when the throttle is
fully closed and about 90% or 4.5 V when the
throttle is f ully opened?
YES lntermittent failure. system is OK at this time.
Check for poor connections or loose terminals at
the TP sensor and at the ECM, I
NO Go to step 3.
3. Turn the ignition switch OFF.
4. Disconnect the TP sensor 3P connector.
5. Turn the ignition switch ON (ll).
6. At the wire harness side, measure voltage between
the TP sensor 3P connector terminals No. 1 and
No.3.
TP SENSOR 3P CONNECTOR
W;re side of female terminals
ls thete about 5 V?
YES-Replace the throttle body (the TP sensor is
not available separately). I
NO Go to step 7.
11-62
7. Measure voltage between ECM connector
terminals A10 and A20.
ECM CONNECTOR A 131PI
Wire side of female terminals
Is there about 5 V?
YES- Repair open in the wire between the ECM(A10) and the TP sensor. t
NO Update the ECM if it does not have the latest
soflware, or substitute a known-good ECM, then
recheck (see page 11-6). lf the symptom/indicationgoes away with a known-good ECM, replace the
original ECM.I

DTG P0325: Malfunction in Knock Sensor
Circu it
1. Reset the ECM (see page 11-4).
2. Start the engine. Hold the engine at 3,000 rpm with
no load (in neutral) until the radiator fan comes on,
then let it idle.
3. Hold the engine at 3,000-4,000 rpm for at least
60 seconds.
ls DTC P0325 indicated?
YES-Go to step 4.
NO Intermittent failure, system is OK at this time.
Check for poor connections or loose terminals at
the knock sensor and at the ECM.I
4. Turn the ignition switch OFF.
5. Disconnect the starter subharness 6P connector.
6. Check for continuity between ECM connector
terminal Ag and body ground.
ECM CONNECTOR A 131P)
Wire side of lemale terminals
ls there continuity?
YES-Repair short in the wire between the ECM(A9) and the starter subharness 6P connector.l
NO Go to step 7.
7. Connect staner subharness 6P connector terminal
No. 5 to body ground with a jumper wire.
8.
STARTER SUAHARNESS6P CONNECTOR
l1l213ll,/l5l6l._
KS IJUMPER|RED/BLU) IW|REI
Wire side of female terminals
Check for continuity between body ground and
ECM connector terminal A9.
9.
ECM CONNECTOR A {31PI
Wire side of female terminals
ls there continuity?
YES-Go to step 9.
NO Repair open in the wire between the ECM (A9)
and the starter subharness 6P connector.l
Check the starter subharness between the 6P
connector and the knock sensor for an open or
short. lf it's OK, substitute a known-good knock
sensor and recheck.
ls DTC P0325 indicated?
YES Update the ECM if it does not have the latest
software. or substitute a known-good ECM, then
recheck {see page '11-6). lf the sym ptomlindication
goes away with a known good ECM, replace the
original ECM.I
NO Replace the original knock sensor and/or
sta rte r subharness.l
11-77

ECM ldle Learn Procedure
The idle learn procedure must be done so the ECM can
learn the engine idle characteristics.
Do the idle learn procedure whenever you do any of
these actions:. Disconnect the battery.
Replace the ECM or disconnect its connector.
Reset the ECM.
NOTE: Erasing DTCS with the Honda PGM Tester
does not require you to do the idle learn procedure.
Remove the No.6 ECU {ECM) ( 15A) fuse from the
under-hood fuse/relay box.
Remove the No.19 baftery (80A) fuse from the under-
hood fuse/relay box.
Remove PGM-FI main relay 1.
Remove any of the wires from the under-hood fuse/
retay Dox.
Disconnect any of the connectors from the under
hood fuse/relay box.
Disconnect the connector between the engine
compartment wire harness and ECM wire harness.
Disconnect the G2 terminal from the transmission
ho u srng.
Disconnectthe G'l terminal from the body.
Disconnectthe G101 terminal from the cylinder head
cover.
Procedure:
To complete the idle learn procedure, do this:
1. Make sure all electrical items (Ay'C, audio, rear
defogger, l:ghts, etc.,) are off.
2. Start the engine, and hold it at 3,000 rpm with no
load {in neutral) until the radiator fan comes on, or
until the engine coolanttemperature reaches 194"F(90'c).
3. Let the engine idle for about 5 minutes with the
throttle fully closed.
NOTE: lf the radiator fan comes on, do not include its
running time in the 5 minutes.
11-139