Engine parts HONDA CIVIC 2003 7.G User Guide

Cooling System
Radiator and Fans Replacement
1. Drain the engine coolant (see page 10-6).
2. Remove the front bumper {see page 20,85).
3. Remove the bulkhead.
4. Remove the upper radiator hose and lower radiator hose.
DRAIN PLUG
UPPER BADIATOR HOSE
BAOIATOA FANASSEMBLY
{
O.RINGRADIATOR CAP
BADIATOB
LOWERCUSHION
\-
RADIATOR FANswtTcH24Nm{2.1t kgl m. 17lbl hl
LOWER FADIATORHOSE
RESERVETANK
A/C CONDENSERFAN ASSEMBLY
9.8 N m {1.0 kgf m,7.2 lbf ft)CONNECTORSRADIATOB FAN SWITCHCONNECTOB
5. Disconnect the fan motor connectors and radiator fan switch connector, then pull the radiator up and out.
6. Remove the fan shroud assemblies and other parts from the radiator.
7. Installthe radiator in the reverse order of removal. Make sure the upper and lower cushions are set securelV.
8. Install the bulkhead in the reverse order of removal. Apply body paint to the bulkhead mounting bolts.
9. Fill the radiator with engine coolant and bleed the air (see page 10-6).
10-10
\.

PCV System
DTC Troubleshooting
DTC P1505: PCV Air Leakage
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
3. Let the engine idle tor al least 40 seconds with the
throttle fully closed.
4. Check for a DTC P1505 with the scan tool
ls DTC P1505 indicated?
YES-Check these parts for vacuum leaks l
. PCV valve. PCV hose. EVAP canister purge valve
. Throttle body. Brake booster hose
NO - Intermittent failure, system is OK at this
time.l
11-168

28.
29.
ls thete continuity?
YES-Go to step 28.
NO-Replace the EVAP canister vent shut valve (A)
and o-ring (B).1
Disconnect ECM connector E (31P).
Check for continuity between EVAP canister vent
solenoid valve 2P connector terminal No. 2 and
body ground.
EVAP CANISTER VENT SHUTVALVE 2P CONNECTOR
Wire side o{ female terminals
ls there continuity?
YES-Repair short in the wire between the EVAP
canister vent shut valve and the ECM (E21).1
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/indication
goes away with a known-good ECM, replace the
original ECM.I
30.
Vacuum Hoses and Connections Test
Do the fuel tank vapor control valve test (see page
1 1-187).
ls the fuel tank vapot control valve OK?
YES-Go to step 31.
NO Replace the fueltank vapor control valve.l
Tighten the fuel cap 3 "clicks", then monitorthe
FTP sensor readings with the Honda PGM Tester.
Start the engine. and let it idle for 5 minutes.
Check the FTP sensor readings.
ls the reading above 0.5 kpa (4 mm Hg, 0.16 in.
Hg) pressure, or about 3 V?
YES Update the ECM if it does not have the latest
software, or substitute a known-good ECM, then
recheck {see page 1 1-6). lf the symptom/indication
goes away with a known-good ECfvl, replace the
original ECM.t
NO Check the following parts for leaks:l
. Fueltank (A)
. Fuel fill cap (B)
. Fuel fill pipe (C)
. Fueltank vapor control valve(D). Fueltank vapor recirculation valve (E)
. Fueltank vapor recirculation tube (F)
. Fueltank vapor signaltube (G)
. Fueltank vapor control venttube(H). FTP sensor (J)
- Repair or replace any leaking parts.
5t.
11-179

Steering
Steering Column Removal
lnstallation
1.
4.
Install the steering column, and make sure the
wires are not caught or pinched by any parts.
Insertthe upper end ofthe steering joint onto the
steering shaft {A) (line up the bolt hole (B) with the
flat portion (C) on the shaft).
8 x 1,25 mm28 N.m{2.9 kgf m,21 rbr.ft)
A
Slip the lower end of the steering joint onto the
pinion shaft {D) (line up the bolt hole with the
groove (E) around the shaft), and loosely lnstallthe
lower joint bolt. Be sure that the lower joint bolt is
securely in the groove in the pinion shaft.
Pull on the steering joint to make su re that the
steering joint is fully seated. Then installthe upper
joint bolt, and tighten it to the specified torque.
Tighten the lower joint bolt to the specified torque.
Finish the installation, and note these items:
. Make sure the wire harness is routed and
fastened properly.
. Make sure the connectors are properly connected.. Reinstallthe steering wheel (see page 17-8).
. Reconnect the battery.- Do the power window control unitreset
procedure {see page 22-128).- Enter the anti-theft code for the radio, then
enter the custmer's radio station presets.
- Set the clock.. Verify horn, turn signal switch, and cruise control
switch operation.. Check wheel alignment, if necessary (see page
18-4).. Do the engine control module (ECM) idle learn
procedu re {see page '11-139).
17-10
and Installation (cont'd){

EPS Components
(Motor RemovaUlnstallation (cont'dl
lnsiallation
7. Clean the mating surface of the motor (A) and
gearbox.
Apply a thin coat of silicone grease (P/N 08733-
8070E)to the new O-ring (B), and carefully fit it on
the motor.
Apply grease {Nippon Grease WR-S or equivalent
steering gear grease) into the motor shaft (C).
qE
8 x '1.25 mm20 N.m12.0 kgt.m,7 .2lbl ftl
L==-c].E@
9.
17-50
r0.Install the motor on the gearbox by engaging the
motor shaft and worm shaft (D). Note the motor
installation position {direction of motor wires).
Before tightening the bolts, turn the motor two or
three times right and left about 45 degrees. lvlake
sure the motor is evenly seated on the steering
gearbox and that the O-ring is not pinched betlveen
the mating surfaces.
Installthe removed Darts in the reverse order of
removal. and note these items:
lvlake sure the motor 2P connector is properly
connected.
lvlake sure the motor and EPS wires are not
caught or pinched by any parts.
Reconnect the negative cable to the battery.
Do the engine control module (ECM) idle learn
procedure (see page 11-139).
Enter the anti-theft code for the radio station
Dresets. Reset the clock,
Do the oower window control unit reset
procedure (see page 22-1241.
After installation, start the engine, and let it idle.
Turn the steering wheel from lock-to-lock several
times. Check that the EPS indicator does not come
on.
11.
12.
13.

Master Cylinder Replacement
NOTE: Do not spill brake fluid on the vehicle; it may
damage the paint; if brake fluid does contact the paint,
wash it off immediately with water,
1, Remove the air cleaner assembly (A).
2, Disconnect the brake fluid level sensor connector
(A).
15 N.m{1.5 kgt.m, 11 lbt.ft)
3. Remove the clutch reservoir (B) andenginewire
harness clip (C)from the master cylinder mounting
base (D).
4. Remove the reservoir cap and brake fuid from the
reservoir.
5. Remove the reservoir (E) on the master cylinder
mountrng Dase.
6, Disconnect the brake lines (F)from the master
cylinder (G). To prevent spills, cover the hose joints
with rags or shop towels.
7. Remove the master cylinder mounting nuts {H) and
washers.
8. Remove the master cylinder from the brake booster.
Be careful not to bend or damage the brake lines
when removing the master cylinder.
9. Remove the rod seal (l) from the master cylinder.
10. Installthe master cylinder in the reverse order of
removal, and note these items:
. Replace all the rubber parts with new ones
whenever the master cylinder is removed.
. Check the pushrod clearance before installing the
master cylinder. and adjust it if necessary (see
page 19-16).. Use a new rod seal on reassemblY. Coat the inner bore lip and outer circumference
of the new rod seal {A) with the recommended
seal grease in the master cylinder set.
. Installthe rod seal ontothe master cylinder with
its grooved side (B)toward the master cylinder.
. Check the brake pedal height and free play after
installing the master cylinder, and adjust it if
necessary (see page 19-6).
19-15

Conventional Brake Components
Master Cylinder Inspection
NOTE:. Before reassembling, check that al I parts are f ree ofdust and other foreign particles.. Do nottryto disassemblethe mastercylinder
assembly. Replace the master cylinder assembly witha new part if necessary.. Do not allow dirt or foreign matter to contaminate thebrake fluid.
RESERVOIB CAPI unecK Ior otocKageof vent holes.
RESERVOIR
,--l RESERvOIR SEALCheck lor damaoe
RESERVOIR HOSESInspect hoses fordamage, leaks, anddeterioration.
r',,.J\+
v
MASTER CYLINDERCheck for leaks, rust, and damage
and deterioration.
STRAINERRemove accumulatedseotment.
19-16
Brake Booster Pushrod Clearance
Adjustment
SpecialTools Required
Pushrod adjustment gauge 07JAG-SD40100
NOTE: Brake booster pushrod-to-piston clearance mustbe checked and adjustments made, if necessarV, beforeinstalling the master cylinder.
1. Setthespecial tool (A) onthe mastercylinder bodv(B), push in the center shaft (C) until the top of itcontacts the end of the secondary piston {D) byturning the adjusting nut (E).
Without disturbing the center shaft's position,
installthe specialtool (A) backwards on the booster.
Install the master cylinder nuts (B), and tighten
them to the specified torque.
Connecl the booster in line with a vacuum gauge
{C) 0-101 kPa {0'-760 mmHg, 30 in.Hg) to thebooster's engine vacuum supply, and maintain anengine speed that will deliver 66 kPa (500 mmHg,20 in.Hg) vacuum.
15 N m {r.511 tbf.ftl

Heater Unit/Core Replacement
SRS components are located in this area. Review the
SRS component locations (see page 23'13), and
precautions and procedures (see page 23-14) in the SRS
section before performing repairs or service.
1. Make sure you have the anti-theft code forthe radio,
then write down the freouencies for the radio's
Dreset buttons.
4.
Disconnect the negative cable from the battery,
Disconnect the suction and receiver lines from the
evaporator core (see page 21-42).
From under the hood, open the cable clamp (A),
then disconnect the heater valve cable (B) from the
heater valve arm (C). Turn the heater valve arm to
the fully opened position as shown
When the engine is cool, drain the engine coolant
from the radiator (see page 10-6).
6. Slide the hose clamps (A) back, the n d isconnect the
inlet heater hose (B) and the outlet heater hose (C)
from the heater core. Engine coolant will run out
when the hoses are disconnected; drain it into a
clean drip pan. Be sure not to let coolant spill on
the electrical parts or the painted surfaces. lf any
coolant spills, rinse it off immediately.
Remove the bolt and the heater valve, then remove
the mounting nut from the heater unit. Take care
not to damage or bend the fuel lines and the brake
lines, etc.
7.
8 x 1.25 mm12 N.m (1.2 kgf.m,8.7lbf.ft)
(cont'd)
21-43

Compressor Replacement
1. lf the compressor is marginally operable, run the
engine at idle speed, and let the air conditioning
work for a few minutes, then shut the engine off.
2. Make sure you have the anti-theft code for the radio,
then write down the frequencies for the radio's
preset buttons.
3. Disconnect the negative cable from the battery.
4. Recover the refrigerant with a recovery/recycling/
charging station (see page 21-53).
5. Remove the alternator (see page 4-29).
6. Remove the Ay'C condenser fan assembly (see page
10-10).
7. Disconnectthe compressor clutch connector (A),
remove the bolts, then disconnect the suction line(B) and the discharge line (C)from the compressor.
Plug or cap the lines immediately after
disconnecting them to avoid moisture and dust
contamination.
6 x '1.0 mm9.8 N.m11.0 kgt.m,7.2 tbl.ttl
u1/
(
o
8. Remove the mounting bolts and the compressor.
8 x 1.25 mm22 N.m 12.2 kgf.m.
9. Installthe compressor in the reverse order of
removal, and note these items:
. Before installing the new compressor, check for
metal or other contamination in the line. Replace
any contaminated parts.. lf you're installing a newcompressor, you must
calculate the amount of refrigerant oil to be
removed from it (see page 21-6).. Replace the O-rings with new ones at each fitting,
and apply a thin coat of refrigerant oil before
installing them. Be sure to use the correct O-rings
for HFC-134a {R-134a) to avoid leakage,. Use refrigerant oil (KElHlN SP-'10) for HFC-134a
KEIHIN spiral type compressor only.. To avoid contaminatlon, do not return the oilto
the container once dispensed, and never mix it
with other refrigerant oils.. lmmediately after using the oil, reinstallthe cap
on the container, and seal it to avoid moisture
absorption.. Do not spill the refrigerant oil on the vehicle; it
may damage the paint. lf the refrlgerant oil
contacts the paint, wash it off immediately.. Charge the system (see page 21-55).. Do the engine control module (ECM) idle learn
procedure (see page 11-'139).. Enter the antitheft code for the radio, then enter
the customer's radio station presets.
21-47

sRs
Precautions and Procedures
General Precautions
Please read the following precautions carefully beforeperforming airbag system service. Observe theinstructions described in this manual. or the airbags
could accidentally deploy and cause damage or injuries.
. Except when performing electrical inspections.
always turn the ignition switch OFF, disconnect the
negative cable from the battery, and wait at least 3minutes before beginning work.
NOTE: The memory is not erased even if the ignition
switch is turned OFF or the battery cables are
disconnected from the battery.. Use replacement pans which are manufactured to the
same standards and quality as the original parts. Do
not install used SRS parts from another vehicle. Useonly new pans when making SRS repairs.. Carefully inspect any SRS part before you install it.
Do not install any part that shows signs of being
dropped or improperly handled, such as dents, cracks,
or deformation.
. Before removing any SRS parts (including the
disconnection of connectors), always disconnect the
SRS connector.. Use only a digital multimeter to check the system. lf itis not a Honda multimeter, make sure its outout is 10mA (0.01A) or less when switched to the lowest value
in the ohmmeter range. A tester with a higher output
could cause accidental deployment and possible
injury.. Do not put objects on the front passenger's airbag.. The original radio has a coded theft protection circuit.
Be sure to get the customer's radio code and write
down the frequencies for the radio's preset stations
before disconnecting the battery cable.. Before returning the vehicle to the customer, enter
the radio code. then enter the customer's radio
station presets, and set the clock. Do the engine
control module (ECM) idle learn procedure (see page
11-139).
23-14
c
Steering-related Plecautions
Cable Reel Alignment
. Misalignment of the cable reel could cause an open in
the wiring, making the SRS system and the horns
inoperative. Center the cable reel whenever the
following is performed (see step 6 on page 23-121).
- Installation of the steering wheel- Installation of the cable reel- Installation ofthe steering column- Other steering-related adjustment or installation
. Do not disassemble the cable reel.
. Do not apply grease to the cable reel.
. lf the cable reel shows any signs of damage or
contamination. replace it with a new one. For
example, it does not rotate smoothly.