Torque head HONDA CIVIC 2003 7.G Workshop Manual

Spark Plug Inspection
1.Inspect the electrodes and ceramic insulator.
Burned or worn electrodes may be caused by:. Advanced ignition timing. Loose spark plug
. Plug heat range too hot.Insufficientcooling
Fouled plug may be caused by:. Retarded ignition timing. Oil in combustion chamber. Incorrect spark plug gap
. Plug heat range too cold. Excessive idling/low speed running. Clogged air cleaner element. Deteriorated ignition coils
Worn or deformedelectrodes
Do not adjust the gap of iridium tip plugs (A);
replace the spark plug if the gap is out of
specification.
Electrode Gap:
Standard (New): 1.0 1.1 mm
{0.039-0.0€ in.)
Service Limit: 1.3 mm {0.051 in.l
f .lmproper gap
I J.Oil-toulingr- 1 . Cs6on deposits' I . Cracked center electrode insulator
L
3. Replace the plug at the specified interval, or if the
center electrode is rounded {A). Use onlV the spark
plugs listed below.
Spark Plugs: lZFR6Kl1 (NGK)
SKJ2ODR-M11 (DENSO)
Apply a small quantity of anti-seize compound to
the plug threads, and screw the plugs into the
cylinder head finger-tight. Then torque them to
18 N m (1.8 kgf.m, 13lbf ft).
4.
4-19

Cylinder Head
Crankshaft Pulley Removal and
Installation (cont'dl
Installation
1. Clean the crankshaft pulley (A), crankshaft (B), bolt(C). and washer (D). Lubricate as shown below.
. .: Clean
O; Lubricate
Installthe crankshaft pulley, and hold the pulley
with holder handle (A) and holder attachment {B).
B07NAB-0010iroA
A07JAB-001020A
Tighten the bolt to 245 N.m (25.0 kgf.m, 181 tbf.ft)with a torque wrench and 19 mm socket (C). Do notuse an impact wrench.
Install the splash shield (see step 20 on page 5-12).
Insta ll front tires/wh eels.
ll
ll
t[] rL-'....-----=a
(-, ,
5U-1JItt-
5.
6-12
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Cam Chain Removal
NOTE: Keep the cam chain away from magnetic fields.
1. Turn the crankshaft pulley so ils top dead center(TDC) mark (A) lines up with the poinrer (B).
Remove the front tires/wheels.
Remove the splash shield.
a
2.
3.
-,,--.=.-----__--_
4. Remove the drive belt (see page 4-26).
5. Remove the cylinder head cover (see page 6-22).
6. Remove the crankshaft pulley (see page 6-11).
\

Installation:
1. Install the VTC actuator and exhaust camshaft
sprocket.
2. Apply engine oil to the th reads of the VTC actuato r
mounting bolt and exhaust camshaft mounting bolt,
then install them.
3. Hold the camshaft with an open-end wrench, then
tighten the bolts.
Specified torque:
VTC actuator mounting bolt:
113 N.m (11.5 kgl.m,83 lbl.ft)
Exhaust camshaft sprocket mounting bolt:
72 N m (7.3 kgf.m, 53 lbf.ft)
4. Install the cam chain {see page 6-15).
1,
Cylinder Head Inspection for
Warpage
Remove the cylinder head {see page 6-23).
Inspect the camshaft (see page 6-29).
Check the cylinder head for warpage. Measure
along the edges, and three ways across the center.
. lf warpage is less than 0.05 mm (0.002 in.)
cylinder head resurfacing is not required.. lf warpage is between 0.05 mm (0.002 in.) and
0.2 mm (0.008 in.), resurface the cylinder head.. Maximum resurface limit is 0.2 mm (0.008 in,)
based on a height of 104 mm (4.09 in.).
Cylinder Head Height;
Standard {New}: 103.95 104.05 mm
{4.093 4.096 in.}
6-25

Gamshaft Inspection
NOTE: Do not rotate the camshaft during inspection.
1. Remove the rocker arm assembly (see page 6-26).
and disassemble it (see page 6-27).
2. Put the rocker shaft holders, camshaft, and
camshaft holders on the cylinder head, then tighten
the bolts to the specified torque.
Specified torque:
I mm bolis:
22 N.m {2.2 kgt m, 16lbf.ft}
6 mm bolts:
12 N.m {1.2 kgf.m,8.7 tbf.ftl
6 mm bolts: @, €0, @
I
I
3. Seat the camshaft by pushing it away from the
camshaft pulley end ofthe cylinder head.
4. Zero the dial indicator against the end of the
camshaft, then push the camshaft back and forth
and read the end play. lf the end play is beyond the
service limit, replace the camshaft head and
recheck. lf it is still beyond the service limit, replace
the cylinder.
Camshaft End Play:
Standard {New}: 0.05 0.20 mm(0.002 0.008 in.l
Service Limit: 0.4 mm (0.02 in.)
(cont'd)
6-29

Cylinder Head
Camshaft Inspection (cont'dl
1.
9.
Unscrew the camshaft holder bolts two turns at a
time, in a crisscross pattern. Then remove the
camshaft holders from the cylinder head.
Lift the camshafts out of the cylinder head, wipe
them clean. then inspect the lift ramps. Replace the
camshaft if any lobes are pitted, scored, or
excessively worn,
Clean the camshaft journal surfaces in the cylinder
head, then set the camshafts back in place. Place a
plastigage strip across each journal.
Install the camshaft holders, then tighten the bolts
to the specified torque as shown in step 2.
Remove the camshaft holders. Measure the widest
portion of plastigage on each journal.
. lf the camshaft-to-holder clearance is within
limits, go to step 1 1.. lf the camshaft-to-holder clearance is beyond the
service limit and the camshaft has been replaced,
replace the cylinder head.. lf the camshaft-to-holder clearance is beyond the
service limit and the camshaft has not been
replaced, go to step 10.
Camshaft-to-Holder Oil Clearance:
Standard (New):
No. 1 Journal:
No.2,3,4,5 Journals:
Service Limit:
0.030 0.069 mm
{0.001 0.003 in-)
0.060*0.099 mm
{0.002 0.004 in.)
0.15 mm {0.006 in.)
6-30
\-
{\
10. Check the total runout with the camshaft supported
on V-blocks,
.lfthetotal runout of the camshaft is within the
service limit, replace the cylinder head.. lf the total runout is beyond the service limit,
replace the camshaft and recheck the camshaft-
to-holder oil clearance. lf the oil clearance is still
beyond the service limit, replace the cylinder
neao.
Camshaft Total Runout:
Standard (New): 0.03 mm (0.001 in.) max.
Service Limit: 0.04 mm {0.002 in.)
11. Measure cam lobe height.
Cam
PRI: Primary
C/C: Cam Chain
SEC: Secondary
I\,
Lobe Heioht Standard (New
INTAKEEXHAUST
PRI33.925 mm(1.3356 in.)
34.092 mm
\1 .3422 in.l
SEC29.638 mm(1.1668 in.)

Cylinder Head
Rocker Arm Assembly Installation
:,ean and dry the No. 5 rocker shaft holder mating
surfaces.
eeassemble the rocker arm assembly (see page 6-
21 t.
Apply liquid gasket, P/N 08718-0009, evenly to the
:ylinder head mating surface ofthe No. 5 rocker
shaft holder.
\OTE: Do not lnstall the parts if 5 minutes or more
rave elapsed since applying liquid gasket. Instead,'eapply liquid gasket after removing old residue.
Insert the bolts (A) into the rocker shaft holder, then
install the rocker arm assembly (B) on the cylinder
head.
Apply liquid gasketalong the broken line.
6-38
l-
\
5.
6.
Remove the bolts from the rocker shaft holder.
Make sure the DUnch marks on the variable valve
timing control (VTC) actuator and exhaust camshaft
sprocket are facing up. then set the camshafts (A) in
the holder.
Set the camshaft holders (B) and cam chain guide B
(C) in place.
Tighten the bolts to the specified torque.
Specified torque:
8 mm bolts: 22 N.m (2.2 kgf.m, 16 lbl.ft)
6 mm bolts: 12 N.m {1.2 kgf.m,8.7 lbf.fil
6 mm bolts: @),@.@
lnstall the cam chain (see page 6-15). and adjust the
valve clearance (see page 6-9).
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flc
a\-
7.
{

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).

30, Retighten the 12 mm flange bolts (A) to the
soecified toroue value.
After tightening the 12 mm flange bolts, install a
new stop plate (B) over one of the bolt heads. Be
sure the tabs (C) of the stop plate are aligned with
the flat surfaces of the bolt head.
Clean off any grease or contamination from the
boot installation grooves on the housing.
Expand the boot (A) by removing the vinyltape,
and fit the boot ends (B) in the installation grooves
on the cylinder housing.
5t.
32,
74 N.m (7.5 kgf.m,5ir lbf.ft)
34. Close the ear portion (A) ofthe bands (B)with
commerciallv available pincers, Oetiker 1098 or
equivalent (C).
35. Installthe new lock washer (A) with its radiused
side facing (B) the tie-rod (C), and screw the tie-rod
on the bracket (D). Repeat this step for the other
side of the tie-rod. Hold the bracket with one
wrench, and tighten the tie-rods to the specified
torque with another wrench.
,,";=-...,.,
(cont'd)
*=,,',
17-61

Steering Gearbox Installation
2.
'1.Before installing the steering gearbox, slide the
rack all the way to the passenger's side (right
direction).
Pass the right side of the steering gearbox together
with the tie-rods through the wheelwell opening on
the passenger's side. Continue moving the steering
gearbox toward the passenger's side untilthe
driver's side tie-rod end and gearbox clears the
master cylinder and under-hood fuse Ielay box.
Lower the steering gearbox. and move it toward
the driver's side untilthe steering gearbox is ln
Dosition.
Be careful not to damage the hoses, lines
and wire harnesses.
3. Installthe pinion shaft grommet (A).
4. Insert the pinion shaft up through the bulkhead,
then slip the right side of the steering gearbox
housing (A) over the mounting stud (C) on the
gearbox mounting bracket.
\- --' '.'', i
10 x '1.25 mm61 N.m{6 2 kgl m, 45 lb{ ftl
Install the steering stiffener B, and lightly tighten
the steering gearbox mounting nuts.
Install the steering stiffener A with the gearbox
mounting bolts. Then tighten allthe steering
gearbox mounting hardware to the specified torque.
10 x 1.25 mm6l N.m(6.2 kgt.m, 45 lbt.ft)
: --.-{..
(cont'd )
:-1....
17-63

EPS Components
Steering Gearbox Installation (cont'd)
7. Installthe body stiffener (A), and torque the
mounting bolts to the specified torque.
8 x 1.25 mm29 N.m {3.0 kgf.m,22lbf.ftl
LInstall the heater valve (A) on the bulkhead, and
connect the heater valve cable end (B) to the heater
valve arm (C). Readjust the heater valve cable {seepage 21-46).
9.8 N.m(1.0 kgf m,7.2 tbf.ftl
L-t ,:.i.t'
17-64
9. Reinstall the heater hose (A) on the hose bracket.
Install the engine wire harness clamps (B) to the
three harness brackets.
Under the steering gearbox, install the ground
cable terminal (A) on the steering gearbox housing.
10.
'I t.
9.8 N.m{1.0 kgf.m, 7.2lbf.ft)