ima HONDA CIVIC 2003 7.G Workshop Manual

L
vlo
2-3
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nder H
ItemMeasur6mentOualificationStandard or NewService Limit
HeadWarpage0.05 mm {0.002 in.)
Height'103.95 104.05 mm
(4.093 4.096 in.)
CamshaftEnd play0.05 0.20 mm (0.002 0.008 in.)0.4 mm (0.02 in.)
Camshaft to holder oil clearanceNo.l journal0.030 0.069 mm
{0.001 0.003 in.)
0.15 mm {0.006 in.)
No.2,3, 4,5
journals
0.060 0.099 mm
(0.002- 0.004 in.)
0.15 mm (0.006 in.)
Total runout0.03 mrn (0.001 in.) max.0.04 mm {0.002 in.)
Cam lobe heightIntake, primary33.925 mm (1.3356 in.)
Intake,29.638 mm (l.1668 in.)
Exhaust34.092 mm (1.3422 in.)
clearance (cold)lntake0.21 0.2s mm 10.008 0.010 in.)
Exhaust0.28 0.32 mm (0.011 0.013 in.)
Stem O.D-lnlaKe5.475 5.485 mm 10.2156 0.2159 in.)5.445 mm (0.214 in.)
Exhaust5.450 5.460 mm (0.2146 0.2150 in )5.42 mm (0.213 in.)
Stem-to-gLride clearancelntake0.030 0.055 mm (0.0012 0.0022in.|0.08 mm (0.003 in.)
Exhaust0.055 0.080 mm (0.0022 0.0031 in )0.11 mm (0.004 in.)
lntake1.25 1.55 mm (0.049 0.061 in.)2.00 mm {0.079 in.)
Exhaust1.25 1.55 mm (0.049 0.061 in.)2.00 mm {0.079 in.)
stem installed heightlntake40.8- 41.0 mm (1.606 1.614in.)
Exhaust54.6 54.8 mm (2.150 2.157 in.)
Valve springsFree lengthlntake47.61 mm (1.874 in.)
Exhaust49.64 mm (1.954 in.)
Valve guidesLD.Intake5.515 5.530 mm
|.0.2171 0.2117 4n.1
5.55 mm (0.219 in.)
Exhaust5.515 5.530 mm
\0.2111 0.2177 in.l
5.55 mm {0.219 in.)
Installed heightlntaKe15.2 "16.2 mm (0.598 0.638in.)
Exhaust15.5 16.5 mm (0.610 0.650 in.)
Rocker armsArm-to-shaft clearancelntaKe0.025 0.052 mm
(0.00'10 0.0020 in.)
0.08 mm (0.003 in.)
Exhaust0.018 0.056 mm
(0.0007 0.0022 in.)
0.08 mm (0.003 in.)

L
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2-11
Design Specifications
O
o
o
|temMeasurementOualificationSpecilication
DIMENSIONSOveralllength4,210 mm {165.8 in.)
Overallwidth1,695 mm 166.7 in.)
Overallheight1,440 mm (56.7 in.)
2,570 mm (101.2 in.)
Trackrront1,470 mm (57.9 in.)
Rear'1,470 mm (57.9 in.i
Ground clearance152 mm (5.98 in.)
Seating capacityfour {4)
wEtGt-iT {u.s.A.)Gross Vehicle Weight Rating
(GVWR)
3,660 rbs
WEIGHT
(CANADA)
Gross Vehicle Weight Rating
{GVWR)
1,660 kg
ENGIN ETvpeWater cooled. 4 stroke DOHC V-EC engin(
Cylinder arrangementInline 4'cylinder, transverse
Bore and stroke86 x 86 mm (3.39 x 3.39 in.)
Displacement1,998 cm'(122 cu in.)
Compression ratio9.8
Valve trainChain drive. DOHC VTEC 4 valves per cylinder
Lubrication systemForced, wet sump, with trochoid pumP
Oil pump displacementAt 6,000 engine
rpm
54.3 0 (57.4 US qo/minute
Water pump displacementAt 3,400 engine82 0 (87 US qt)/minute
F!el requiredUNLEADED gasoline with 86 pump octane number or higher
STARTERTvpeGear reduction
Normaloutput
Nominalvoltage12V
Hour rating30 seconds
Direction of rotationClockwise as viewecl from gear end
CLUTCHClutch tvpeSinqle plate dry, diaphragm spring
Clutch friction material surface area174 cm'{26.97 sq in.)
I\,1AN UAL
TRANSMISSION
TvpeSvnchronized, s-speed forward, 1 reverse
Primarv reductionDirect 1:1
Gear ratiolst3.062
2nd1.769
3rd1.212
4th0.921
5th0.738
Reverse3.583
FinalreductionTypeSinole helicalgear
Gear ratio4.164

WEC Rocker Arms Test
Special Tools Required. Air pressure regulator 07AAJ-PNAA100. VTEC air adaoter 07ZAJ-PNAA100. WEC air stoDoer 07ZAJ-PNAA200. Air joint adapter 07ZAJ-PNAA300
1. Remove the cylinder head cover (see page 6-22).
2. Set the No. 1 piston at top dead center (TDC) (see
step 1 on page 6-12).
3. Verify that the intake primary rocker arm (A) moves
independently of the intake secondary rocker arm
(B).
. lf the intake primary rockerarm does not move,
remove the primary and secondary rocker arms
as an assembly and check that the pistons in the
secondary and primary rocker arms move
smoothly. lf any rocker arm needs replacing,
replace the primary and secondary rocker arms
as an assemblv, and test.. lfthe intake primary rocker arm moves freely, go
to step 4.
6.
Repeat step 3 on the remaining intake primary
rocker arms with each piston at TDC. When all the
primary rocker arms pass the test, go to step 5.
Check that the air pressure on the shop air
compressor gauge indicates over 400 kPa
(4 kgflcm', 57 psi).
Inspect the valve clearance (see page 6-9).
Remove the sealing bolt (A)from the relief hole,
and install the VTEC air stopper (B).7.
OTAAJ.PNAAlOODOTZAJ-PNAA3OO
Remove the No. 2 and No. 3 camshaft holder bolts,
and installthe VTEC air adapters (C) finger-tight.
Connect the air joint adapter (D), and air pressure
regulator with a 0-100 psi gauge (E).
(cont'd)
OTZAJ.PNAAlOO
6-7

Cylinder Head
WEC Rocker Arms Test (cont'dl
'10. Loosen the valve on the regulator, and apply thespecified air pressure.
Specified air pressure:
290 kPa 13.0 kgt/cm', 42 psi)
NOTE: lf the synchronizing piston does not moveafter applying air pressure; move the primary orsecondary rocker arm up and down manually byrotating the crankshaft clockwise.
11. With the specified air pressure applied, move theintake primary rocker arm (A)forthe No, 1 cylinder.The primary rocker arm and secondary rocker arm(B) should move together.
lf the intake secondary rocker arm does not move,
remove the primary and secondary rocker arms asan assembly, and check that the pistons in theprimary and secondary rocker arms move
smoothly. lf any rocker arm needs replacing,
replace the primary and secondary rocker arms asan assembly, and test.
Remove the special tools.
Tighten the camshaft holder mounting bolts lo22N m 12.2 kgf.m, 16 lbf.ft).
Tighten the sealing boltto 20 N.m (2.0 kgf.m,
14 tbf.ft).
Installthe cylinder head cover (see page 6-41).
12.
13.
14.
t5.
6-8
VTG Actuator Inspection
'11. Remove the cylinder head cover (see page 6-22lr.
2. Remove the auto-tensioner (see page 6-19).
3. Loosen the rocker arm adjusting screws lsee step 2on page 6-26).
4. Remove the camshaft holder (see step 3 on page 6-
26t.
5. Remove the intake camshaft.
6, Check that the variable valve timing control (VTC)
actuator is locked by turning the VTC actuator
clockwise and counterclockwise. lf the VTC actuatoris not locked, replace the VTC actuator.
7. Seal the advance holes (A)and retard holes (B) in
the No. 1 camshaft journal with tape.
Punch a hole through the tape over one of theadvance holes.

Cylinder Head
1.
2.
Rocker Arms and Shafts Inspection
Remove the rocker arm assembly (see page 6-26).
Measure the diameter of the shaft at the first rocker
location.
3. Zero the gauge (A) to the shaft diameter.
6-28
\
4. Measure the inside diameter ofthe rocker arm, and
check it for an out-of-round condition.
Rocker Arm-to-Shaflt Clearance:
Standard lNew):
lntake: 0.025 0.052 mm(0.0010 0.0020 in.)
Exhaust: 0.018 0.056 mm
(0.0007 0.0022 in.)
Service Limit: 0.08 mm (0.003 in.)
5. Repeat for all rockerarms and both shafts. lfthe
clearance is over the Ilmit. replace the rocker shaft
and all overtolerance rocker arms. lf any VTEC
rocker arm needs replacement, replace the rocker
arms (primary and secondary) as a set.
6. Inspect the rocker arm pistons {A}. Push each
piston manually.
lf it does not move smoothly, replace the rocker
arm set.
NOTE: Apply oil to the pistons when reassembling.
,,,@@
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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
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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.)

Fuel and Emissions Systems
System Descriptions
Electronic Control System
The functions of the fuel and emlssion control systems are managed by the engine control module (ECM).
Fail-safe Function
When an abnormality occurs in the signal from a sensor, the ECI\4 ignores that signal and assumes a pre-programmed
value for that sensor that allows the enqine to continue to run.
Back-up Function
When an abnormality occurs in the ECM, the injectors are controlled by a back-up circuit independent of the system to
permit minimal driving.
Self-diagnosis
When an abnormality occurs in the signal from a sensor, the ECM supplies ground for the malfunction indicator lamp
{MlL) and stores the diagnostic trouble code {DTC) in erasable memory. When the ignition is first turned on, the EClvl
supplies ground to the l\4lL for 15 to 20 seconds to check the M lL bulb condition.
Two Driving Cycle Detection Method
To prevent false indications, the "two driving cycle detection method" is used for some self-diagnostic functions.
When an abnormality occurs, the ECM stores it in its memory. When the same abnormality recurs afterthe ignition
switch is turned OFF and ON (ll) again, the ECM turns on the MlL.
\
11-12
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ECM Data
You can retrieve data from the ECI\4 by connecting the OBD ll scan tool or the Honda PGM Tester to the data link
connector (DLC). The items listed in the table below conform to SAE recommended practice. The Honda PGM Tester
also reads data beyond that recommended by SAE to help you find the causes of intermittent problems.
The "operating values" listed are approximate and may vary depending on the environment and the individual
vehicle.
Unless noted otherwise, "at idle speed" means idling with the engine completely warmed up in the neutral position,
and the A,/C and all
Diagnostic
Trouble Code(DTC}
lf the ECM delects a problem, it will store it as a code
consisting of one letter and four numbers. Depending on
the problem, an SAE-defined code (Poxxx) or a Honda,
defined code {P1xxx) will be output to the tester.
The ECI\4 computes engine speed from the signals sent
from the crankshaft position (CKP) sensor. This data is
used for determining the time and amount of injected fuel.
detected, there is no
ourpul.
lf no problem is YES
Nearly the same as
tachometer indication
At idle speed;
The ECM converts pulse signals from the vehicle speed
sensor (VSS).Nearly the same as
speedometer
indication
Manifold
Absolute
Pressure(MAP)
The absolute pressure caused in the intake manifold by
engine load and speed.
With engine stopped: YES
Nearly the same as
almospnenc pressure.
At idle speed: about
20 4'1 kPa(150 310 mmHg,
6- 12 in.Hq).0.7 1.3 V
The ECT sensor converts coolant temperature into voltage
and signals the ECM. The sensor is a thermistor whose
internal resistance changes with coolant tempetature. The
ECM uses the voltage signals from the ECT sensor to
determine the amount of injected fuel.
With cold engine:
Same as ambient
temperature and IAT
With engine warmed
up; about 116 2'12"F
100'c).0.5-0.8 v
Air Fuel Ratio The A,/F sensor detects the oxygen content in the exha ust 0.0 - 1 .25 V(Ay'F) Sensor. gas and sends voltage signals to the Eclvl, Basedonthese 8.0 11.0mA(PGM(Sensor 1) signals, the ECM controls the airlfuel ratio. When the I Tester)
oxygen content is high (that is, when the ratio is leaner At idle speed:
than the stoichiometric ratio), the voltage signal is Iower. about 0.1 0.9 V
When the oxygen content is low (that is, when the ralio is
richer than the stoichiometric ratio). the voltage signal is
higher. The A'lF sensor signals are electrical current that
are indicated as voltaqe on the
The HO2S detects the oxygen content in the exhaust gas
and sends voltage signals to the ECM. Based on these
signals, the ECM controls the airlfuel ratio. When the
oxygen content is high (that is, when the ratio is leaner
than the stoichiometric ratio), the voltage signal is lower.
When the oxygen content is low (that is, when the ratio is
richer than the stoichiometric ratio), the voltage signal is
Secondary
Heated
Oxygen
Sensor(Secondary
H02S,
Sensor2)
0.0 1.25 V NO
At idle speed:
about 0.1 0.9 V
(cont'd)
11-13

Fuel and Emissions Systems
System Descriptions (cont'd)
ECM Data (cont'd)
w
DataDescriptionOpera'ting ValueFreeze Data
Fuel System
Status
Fuel system status is indicated as "open" or "closed".
Closed: Based on the A,/F Sensor output, the ECM
determines the airlfuel ratio and controls the amount of
injected fuel.
Open: lgnoring Ay'F Sensor output, the ECM refers to
signals from the throttle position {TP), manifold absolute
pressure (MAP), intake air temperature (lAT), barometric
pressure (BARO), and engine coolant temperature (ECT))
sensors to control the amount of iniected fuel.
At idle speed: closedYES
Short Term
FuelTrim
The airlfuel ratio correction coefficient for correcting the
amount of injected fuel when the fuel system status
is "closed." When the ratio is leaner than the
sloichiometric ratio, the ECM increases short term fuel
trim gradually, and the amount of iniected fuel increases.
The airlfuel ratio gradually gets richer, causing a lower
oxygen content in the exhaust gas. Consequently, the
short term fuel trim is lowered, and the ECM reduces the
amount of injected fuel.
This cvcle keeps the airlfuel ratio close to the
stoichiometric ratio when in closed loop status.
o.7 1.5YES
Long Term
Fuel Trim
Long term fuel trim is computed from short term fuel trim
and indicates changes occurring in the fuel supply system
over a long period.
lf long term fuel trlm is higher than 1.00, the amounl of
injected fuel must be increased. lf it is lower than 1.00, the
amount of injected fuel must be reduced.
0.8 1.2YES
Intake Air
Temperature
{IAT)
The IAT sensor converts intake air temperature into
voltage and signals the ECM. When intake air
temperature is low, the internal resistance ofthe sensor
increases, and the voltage signal is higher.
With cold engine:
Same as ambient
temperature and ECT
YES
Throttle
Position
Based on the accelerator pedal position, the opening
anole of the throttle valve is indicated.
At idle speed:
about 10 %
YES
lgnition
Timing
lgnition timing is the ignition advance angle set by the
ECM. The ECM matches ignition timing to driving
conditions.
At idle speed: 8" t 5"
|' tuL wnen rne >L)
service signal line is
jumped with the Honda
PGM Tester
NO
Calculated
Load Value
(cLV)
cLV is the enoine load calculated from IMAP data.At idle speed:
12 34%
At 2.500 rpm with no
toao:'t4- 34%
YES
11-14
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Fuel and Emissions Systems
System Descriptions (cont'dl
ldle Control System Diagram
The idle speed of the engine is controlled by the ldle Air Control (lAC) varve:
'Aftertheenginestarts,theIACvalveopensforacertainamountoftime.Theamountofairisincreasedtoraisethe
idle sDeed.. When the engine coolant temperature is low, the IAC valve is opened to obtain the proper fast idle speed. Theamount of bypassed air is controlled in relation to engine coolant temperature.
INTAKE MANIFOLDIAC VALVEAKE AIR DUCT
CLEANER
\
BLK/REO
YEL/BLK ---< FromPGM.FIMAINRELAY
THROTTLE AODY
Intake Air System Diagram
This system supplies air for engine needs. A resonator in the intake air
drawn into the svstem.
VARIOUSSENSOnS
pipe provides additional silencing as air is
THROTTLE AODYVARIOUSSENSORS
BLK
BLK
I
11-36
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