ERS HONDA CIVIC 2003 7.G Workshop Manual

INTRODUCTION
Safety
Your safety, and the satety of others, is very important. To helpyou make informed decisions, we have provided safetymessages, and other safety information throughout this manual.Of course, it is not practical or possible to warn you about all thehazards associated with servicing this vehicle. You must useyour own good judgment.
You will find impoftant safety information in a variety of formsincluding:. Satety Labels - on the vehicle.. Satetv Messages preceded by a salety alert symbol A andone of three signal words, DANGEF, WARNING, or CAUTION.These signal words mean:
tmEnEEril y;,: H,ll i": 5* i5"?;r s E R I o u s LY H u Br ir
E$EEEE ys,: f#,ff ,:hl:3,:JjERrousLY HURT ir
tlGtltT]llilll You cAN b€ HUBT if vou don't follow
. lnstructions - how to service this vehicle correctlv and safelv.
All information contained in this manual is based on the latestproduct information available at the time of printing. We reservethe right to make changes at any time without notice. No part ofthis Oublication maV be reDrodLrced, or stored in a retrievalsystem, or transmitted, in any form by any means, electronic,mechanical, photocopying, recording, or otherwise, without theprior written permission o{ the publisher. This includes text,figures, and tables-
As vou read this manual, vou will tind information that ispreceded by a @ symbol. The purpose of this message isto help prevent damage to your vehicle, other property, or theenvironment,
*Bodyz-tl!^t l
First Edition 8/2002 1,168 pages HONDA MOTOR CO.. LTD.All Rights Reserved Service Publication OfficeSpecifications apply to U.S.A. and Canada
As seclion3 with *inclode SRS comoonentsispecial precautionsare required when servicing.
How to Use This Manual -
This manual is divided into 23 sections. The first page of eachseclion is marked with a black tab that lines up with itscorresponding thumb index tab on this page and the back cover.You can quickly find the first page of each section withoutlooking through a full table of contents. The symbols printed atthe top corner of each page can also be used as a quickre{erence system.
Each section includes:1. A table of contents, or an exploded view index showingl. Parts disassembly sequence.. Bolt torques and thread sizes.. Page references to descriptions in text.Disassembly/assembly procedures and tools.Inspefiron.Testing/troubleshootin g.Repair.Adjustments.
2.3.4.5.6.
Specifications1)ll:{l+'
Maintenance
Emissions
*Restraints

Under-hood Emission Control Label
Emission Group ldentif ication
Example: 2002 model
THIS VEHICLE CONFORMS TO U.S. EPA TIER 2 BIN 5
AND NLEV LEV REGULATIONS APPLICABLE TO 2002
MODEL YEAR NEW PASSENGER CARS AND
CALIFORNIA REGULATIONS APPLICABLE TO 2OO2
MODEL YEAR NEW LEV Ii LEV PASSENGER CARS.
Example: 2003 model
THIS VEHICLE CONFORMS TO U.S. EPA TIER 2 BIN 5
AND NLEV LEV REGULATIONS APPLICABLE TO 2O03
MODEL YEAR NEW PASSENGER CARS AND
CALIFORNIA REGULATIONS APPLICABLE TO 2OO3
MODEL YEAR NEW LEV II LEV PASSENGER CARS,
rH/ @
Engine and Evaporative Families:
Engine Family:
Model Year
2:2002
3: 2003
Manulacturer Subcode
HNX: HONDA
Family Type
V: LDV
Displacement
Sequence Characters
VBP: 2002
XKC: 2003
Evaporative Family:
2 HNX R OO99 AAH
t[-l=[
ab cd
Model Year
2t 2002
3: 2003
Manufacturer Subcode
HNX: HONDA
Family Type
R: EVAP/ORVR
Canister Work Capacity
Sequence Charactets
AAH: 2002
AAA: 2003
2 HNX V O2.O VBP
rr-tt--[ttl
ab cd e
c.
d.
e.
c.
d.
e.
1-7

General Information
Lift and Support Points
NOTE: If you are going to remove heavy componentssuch as suspension or the fuel tank from the rear of thevehicle, first supportthe front ofthe vehicle with tallsafety stands. When substantialweight is removed
from the rear of the vehicle, the center of gravity canchange and cause the vehicle to tip forward on the hoist.
Frame Hoist
1. Position the hoist lift blocks (A), or safety stands,under the vehicle's front support points (B) and rearsupport points (C).
2. Raise the hoist a few inches, and rock the vehiclegently to be sure it is firmly supported.
3. Raise the hoistto full height, and inspectthe liftpoints for solid contact with the lift blocks.
Safety Stands
To support the vehicle on safety stands. use the samesuppon points (B and C) as for a frame hoist, Alwaysuse satety stands when working on or under anyvehicle that is supported only by a jack.
1-8
Floor Jack
1. Set the parking brake.
2. Block the wheels that are not being lifted.
3. When lifting the rear of the vehicle. put thegearshift Iever in reverse.
4. Position the floor jack under the front jacking
bracket (A) or rear jacking bracket (B), center thejacking bracket in the jack lift ptatform (C), and jack
up the vehicle high enough to fit the safety standsunder it.
c
Position the safety stands underthe support points
and adjust them so the vehicle will tevet.
Lower the vehicle onto the stands.
0
Jt

Towing
lf the vehicle needs to be towed, call a professional
towing service. Never tow the vehicle behind another
vehicle with just a rope or chain. lt is very dangerous.
Emergency Towing
There are three popular methods of towing a vehicle.
Flat-bed Equipment The operator loads the vehicle
on the back of a truck. This is the best way of
transporting the vehicle.
To accommodate flat-bed equipment. the vehicle is
equipped with towing hooks (A)and tie down hooks {B).
The towing hook can be used with a winch to pull the
vehicle onto the truck, and the tie down hooks slots can
be used to secure the vehicle to truck.
1-9
Wheel Lift Equipment The tow truck uses two
pivoting arms that go under the tires (front or rear) and
lifts them off the ground. The other two wheels remain
on the ground. This is an acceptable way of towing the
vehicle.
Sling-type Equipment The tow truck uses metal
cables with hooks on the ends. These hooks go around
parts of the frame or suspension and the cables lift that
end of the vehicle off the ground. The vehicle's
suspension and body can be seriously damaged if this
method of towing is attemPted.
lf the vehicle cannot be transported by flat-bed, it
should be towed with the front wheels off the ground lf
due to damage, the vehicle must be towed with the
front wheels on the ground, do the following:
. Release the parking brake.. shift the transmission in Neutral.
It is best to tow the vehicle no farther than 50 miles (80
km), and keep the speed below 35 mph (55 km/h).
. lmproper towing preparation will damage the
transmission. Follow the above procedure exactly. lf
you cannot shift the transmission, the vehicle must
be transDorted on a flat-bed.. Trying to lift or tow the vehicle by the bumpers will
cause serious damage, The bumpers are not
designed to support the vehicle's weight.

ItemMeasulementOualificationStandard or New Service LimitFuel pressure
regulator
Pressure with fuel pressure gauge
connected
320-370 kPa 13.3-'3.8 kgtcm', 47 52psi)
FueltankCapacity50 4 (13.2 US galiEngine idleldle speed with headlights and radiator
fan off
Neutral750 50 rpm
Fast idleNeutral1,600150 rpm
Standards and Service Limits
Fuel and Emissionsf
.\
ra
Clutch
ItemMea3urem€nlOualificationSlandard or NewService LimitClutch pedalHeight from the floor193 mm (7.60 in.)Stroke130 140 mm 15.1 5.5in.)
10 16 mm (0.39 0.63 in.)Disengagement height from the floor1'15 mm (4.53 in.) min.Bunout on clutch mating surface0.05 mm 10.002 in.) max.0.15 mm (0.006 in.)Clutch discBivet head depth1.65 2.25 mm (0.065 0.089 in.)0.7 mm {0.03 in.)Ihickness8.3 8.9 mm (0.33 0.35 in.)6.0 mm (0.24 in.)Pressure plateWarpage0.03 mm (0.001 in.)max.0.15 mm (0.001 in.)Height of diaphragm spring fingersMeasured with
specialtool and
feeler gauge
0.6 mm (0.02 in.) max.0.8 mm (0-03 in.)
2-6
\

L
v
2-7
OE
a
o
nual Transmission and M/T Differential
ItemM€asurementOualificationStandard or NewSe.vice Limit
Transmission
fluid
CapacityFor fluid change: 1.5 0 (1.6 US qt)
For overhaul: 1.7 011.8 US qt)
MainshaftEnd plav0.1 'l -0.17 mm (0.004 0.007in.)Adiust
Diameter of bushing surface20.80 20.85 mm {0.819 0.821 in.)20.75 mm 10.817 in.)
Diameter of distance collar31.984-32.000 mm (1.2594 1.2598 in.)3'1.93 mm (1.257 in.)
Diameter of ball bearing contact area
(clutch housing side)
27.977 27s90 mm \1.1015 - 1.1020 in.)27.92 mm (1.099 in.)
Diameter of needle bearing contact
area
38.984 39.000 mm (1.5348 '1.5354 in.)38.93 mm (1.533 4n.)
Diameter of ball bearing contact area
(transmission housing side)
27.987 28.000 mm (1.10'19 1.1024 in.)27.93 mm {1.100 in.)
Runout0.02 mm (0.001 in.) max.0.05 mm (0.002 in.)
Mainshaft 3rd,
4th and sth
gears
t.D.44.009 44.025 mm 11.7326 1.7333 in.)44.08 mm (1.735 in.)
End play0.06 0.16 mm {0.002 0.006;n.)0.25 mm (0.010 in.)
Thickness23.92 23.97 mm (0.94'1 0.944 in.)23.80 mm (0.937 in.)
CountershaftDiameter of needle bearing contact
area (clutch housing side)
35.000-35.015 mm (1.3780 '1.3785 in.)34.95 mm (1.376 in.)
Diameter of distance collar contact
alea
39.937 39 950 mm (1.5723 1.512ain.|39.88 mm (1.570 in.)
Diameter of ball bearing contact area
(transmission housing side)
30.020-30.033 mm (1.1819- 1.1824 in.)29.97 mm (1.180 in.)
Runout0.02 mm {0.001 in.) max.0.05 mm (0.002 in.)
35 mm shim-to'bearing inner race
clearance
0.04 0.10 mm (0.0016 0.0039 in.)Adjust
CountershaftLD.52.010 52.029 mm (2.0476-2.0484 in.i52.08 mm (2.050 in.)
End play0.06 0.16 mm (0.002 0.006 in.)0.25 mm 10.010 in.)
Thickness22.92 22.91 $m 10.902 -0.904 in.)22.87 mm (0.900 in.)
Countershaft
2nd gear
t.D.52.010 52.029 mm (2.0476 2.0484 in.)52.08 mm {2.050 in.}
End play0.06 0.16 mm (0.002 0.006 in.)0.25 mm 10.010 4n.)
Thickness21.92 27.91 mtn \1.099 1.101 in.)27.87 mm 11.097 in.)
Countershaft'l st gear
distance collar
LD.39.95 39.96 mm (1.572a 1.5132 in.)39.97 mm (1.574 in.)
o.D.46.989- 47.000 mm (1.8499- 1.8504 in.)46.94 mm (l.848 in.)
Length23.03 23.08 mm (0.907-0.909 in.i
Countersha{l
2nd gear
distance coliar
l.D.39.95 39.96 mm {1.5728'- 1.5732 in.l39.97 mm (1.574 in.)
o.o.46.989 47.000 mm (1.8499 1.8504 in.)46.94 mm (1.848 in.)
Length28.03 28.08 mm (l.104 1.106in.)

anuat I ransmcont'
ItemMeasutemenlOualificationStandard or NewServicc LimitNlainshaft 4th
and 5th gears
distance collar
LD.32.00-32.01 mm (1.2598 1.2602 in.)32.02 mm (1.261 in.)o.D.38.989 39.000 mm (1.5350 1.5354 in.)38.94 mm (1.533 in.)Length51.95 52.05 mm (2.045 2.049 in.)
B24.03 24.08 mm (0.946-0.947 in.)
MBS distanceLD.28.00 28.01mm (1.102 1.103 in.)28.02 mm (1.103 in.)Len9th23.95 24.05 mm (0.943 0.947 in.)Reverse idler
gear
t.D.20.016 20.043 mm (0.7880 0.7891 in.)20.90 mm (0.832 in.)Gear lo reverse gear shafi clearance0.036 0.08a mm (0.0014 0.0033 in.)0.16 mm {0.006 in.)Synchro ringBing to'gear clearanceRing pushed
against gear
0.70 1.49 mm (0.028 0 059 in )0.4 mm (0.016 4n.)
Triple coneOuter synchro ring-to synchro cone
clearance
Ring pushed
against qear
0.70 - '1.19 mm {0.028 0.047 in.)0.3 mm (0.012 in.)
Synchro cone-to-gear clearanceRing pushed
against gear
0.50 1.04 mm (0.020 0.041 in.)0.3 mm (0.012 in.)
Outer synchro ring-to-gear cone
clearance
Ring pushed
against gear
0.95 1.68 mm (0.037 0.066 in.)0.6 mm (0.024 in.)
Shift forkFinger thickness7.4 7.6 mm 10.29 0.30 in.)Fork to-synchro sleeve clearance0.35 0.65 mm (0.014 0.026 in.i1.0 mm (0.039 in.)Reverse shift
fork
Finger thinkness13.4 13.7 mm (0.527 0.539 in.)Fork-to-reverse idler gear clearance0.20 0.59 mm (0.007 0.024 in.)1.3 mm (0.051 in.)Shift armt.D.13.973 '14.000 mm (0.5501 0.5512 in.)Shift fork diameter at conlact area16.9 '17.0 mm (0.665 0.669 in.)Shift arm'to-shift lever clearance0.2 0.5 mm (0.008 0.020 in.)0.62 mm (0.024 in.)Select leverFinger width14.85 '14.95 mm (0.585 0.589 in.)Shift leverShaft -to-select lever clearance0.05 0.25 mm (0.002 0.010 in.)0.50 mm (0.020 in.)Groove {to select lever)15.00 15.10 mm {0.591 0.594 in.)
Shaft to shift arm clearance0.013 0.07 mm (0.0005 0.003 in.)0.1 mm {0.004 in.)Mfi
differential
carrier
Pinion shaft contact area l.D.18.010 18.028 mm (0.7091 0.7098 in.)Carrier-to-pinion shaft clearance0.027 0.057 mm (0.0011 0.0022 in.)0.1 mm (0.004 in.lDriveshaft contact area LD.28.025 28.045 mm (1.1033 1.1041 in.)Mfi
differential
pinion qear
Backlash0.05 0.15 mm {0.002 0.006 in.)
t.D.18.042 18.066 mm (0.7103 0.7113in.)Pinion gearto pinion shaft clearance0.059 0.095 mm (0.0023 0.0037 in.)0.15 mm (0.006 in.)80 mm shim80 mm shim to-bearing outer race
clearance in transmission housing
0 0.10 mm (0 0.0039 in.)Adjust
Standards and Service Limits
Manual Transmission and Differential?
LO
2-8
-

L
v
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

cont'
ItemMeasuremeniOualificationSpecilicationSTEERINGTypeElectric, Power assisted rack and pinion
Overall ratio15.1Turns,lock to-lock
Steering wheel diameter360 mm (14.2 in)SUSPENSIONTypeIndependent srrul with stabiliTer. coil springRearDouble wishboneShock absorberFrontTelescopic, hydraulic. nitrogen gas-frlled
RearTelescopic, hydraulic, nitrogen gas,filledWHEEL
ALIGNMENT
CamberFront0"00'
Bear0.45'
CasterFront1'33'TotaltoeFront0 mm (0 in.)
RearIn 2 mm (1/16 in.)BRAKESType of service brakeFrontPowerassisted self-adjusling ventilated disc
BearPower-assisted self-adjusting solid discType of parking brakeMechanical actuating, rear wheelsPad friction surface areaFront45 cm'(7.0 sq in.)x2
Rear28 cm'(4.3 sq in.) x 2TIRESSize offront and reartiresPl95/60 815 88VSize o{ spare tireT125r0 D15 95MAIR
CONDITIONING
CompressorTypeScroll
Number of
cylinders
Capacity85.7 m015.23 cu in.)/rev.
Maximum speed12,000 rpm
Lubricant capacity130 m0 {4 1/3 floz)
LubricanttypeSP-10 (P/N 38897'P13-A01AH or38899-P13 A01)CondenserTypeCorrugated finEvaporatorTvpeCorrugated fin
BlowerTypeSirocco fan
Motor type220 Wl12 V
Speed control4 Speeo
Maximum capacity480 m" 116.900 cu ft)/hTemperature controlAirmixtype
Compressor clutchTvpeDry, single plate, poly-V belt drive
Electricalpower
cons!mptron at
68"F (20.C)
42 W maximum at 12 V
RefrigerantTypeHFC 134a (R-134a)
Capacity500 550 g (17.6 19.4 oz)
Design Specifications
C
aL
2-12
../ a

Maintenance Schedule
Listed by Distance/Time for Normal Conditions
This two page l/lanitenance Schedule outlines the minimun required maintenance. Service at the indicated distance or time, whichever comesfirst. use the lvlaintenance Schedule for Severe conditions if the vehicle meets any of the qualifiers in the Severe Conditions schedule or if thevehicle is normally driven in Canada.
Inspect valve clearance. (cold) (see page 6-321r Intake: 0.21-0.25 mm (0.008 0.010 in.) Exhaust: 0.28 0.32 mm (0.011 0.013 in.)Replace spark plugs. Use IZFR6K'11 (NGK) or SKJ20DR-M11 (DENSO).1.0 1.1 mm
! Do items in A,B, alqq.,
120,000 mi/ 192,000 km/ 6 yearsI Replace transmission fluid.Use Honda MTF (see page 13-3).
/ / Y vcdrs120,000 mil 192,000Beplace coolant (see page 10 6). Capacity: 5.0 0 (5.3 US qt). Use Honda All Season Antifreeze/Coolant Type 2.
According to state and lederal regulations, tailure to do the maintenance items marked with an asterisk {*) will not void the customer'semissions warranties, However, Honda recommends that all maintenance services be done at the recommended interval to ensure long-termreliability.
I
3-4