index HONDA CIVIC 2003 7.G User Guide

Engine Mechanical
Engine Block
Soecial Tools ............. 7 -2
Comoonent Location Index ......................................... 7-3
Connecting Rod and Crankshaft End Play
InsDection .............. 7-5
Crankshaft Main Bearing Replacement ...................... 7-6
Connecting Rod Bearing Replacement ...................... 7-8
Oil Pan Removal ....................... .......... 7-11
Crankshaft and Piston Removal ........ 7-12
Crankshaft Inspection ........................ 7-14
Block and Piston Insoection ........................................ 7-15
Cyfinder Honing ............ .".................... 7 -'17
Piston, Pin and Connecting Rod Replacement .......... 7-18
Piston Ring Replacement ................... 7 -21
Piston lnstallation .................... ........... 7-23
Connecting Rod Bolt Inspection .......' 7 -24
Crankshaft lnstallation .....................'. 7-24
Oil Pan lnstallation .................. ........... 7 -27
Transmission End Crankshaft Seal
lnstallation-ln Car ................... ........' 7 -28

Component Location Index
MAIN BEARINGSOilclearance, page 7-6Selection, page 7-6
CRANKSHAFTEnd play, page 7-5Runout, page 7-14Out-of-Round, page 7-14Removal, page 7-12lnstallation, page 7-24
fifr"8
-4
E
I
BAFFLE PLATE
LOWER BLOCK
FLYWHEEL
CRANKSHAFT OIL SEAL.TRANSMISSION ENDInstallation, step 21 on page 7-26
THRUST WASHERS
(cont'd)
7-3

Engine Block
Component Location Index (cont'd)
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Y1 l-"t Benlacement. Page 7-21
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PISTONRemoval, page 7-'12Measurement, page 7-15
PISTON PINRemoval, page 7-18Inspection, page 7-19Installation, page 7,20
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6
CONNECTING RODEnd play, page 7-5Small end measurement, page 7-19
CONNECTING ROD
ENGINE BLOCKCylinder bore inspection, page 7-'15Warpage inspection, page 7-15Cylinder bore honing, page 1-11Ridge removai, step 13 on page 7-13
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CONNECTING ROD BOLTlnspectaon, page 7 24
7-4

Component Location Index
OIL PUMPCHAIN TENSIONER
DRAIN BOLT
OIL PANRemoval, page 7 11Installataon, page 7-27
OIL PUMPOverhaLrl, page 8-8
HL]
BAFFLE PLATE
OIL FILTER FEED PIPEReplacement, page 8-7
OIL FILTERReplacement, page 8-6
OIL CONTROLORIFICE
WASHER
OIL PRESSURE SWITCHSwitch Test, page 8 4Oil Pressure test, page 8'4Replacement, page 8 16
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\OIL PUMPCHAIN GUIDE
8-3

Engine Cooling
Cooling System
Component Location Index ......................................... 10-2
Radiator Cap Test ..................... .......... 10-3
RadiatorTest ............. 10-3
Fan Motor Test .......... l0-4
Thermostat Test ...................... ........... 10-4
Water Pump Inspection ..................... 10-5
Water Pump Replacement ................. 10-5
Coolant Check .............. ....................... 10-6
Coolant Replacement ......................... 10-6
Thermostat Replacement .................. 10-8
Water Passage Installation ................ 10-9
Water Outlet Installation .................... 10-9
Radiator and Fan Replacement ................................... 10-10
Fan Controls
Component Location Index ......................................... 10-11
Symptom Troubleshooting Index ............................... 10-12
Circuit Diagram ......... 10-13
Radiator Fan CircuitTroubleshooting ........................ 10-14
Radiator Fan Switch Circuit Troubleshooting
(Open) ............ ........ 10-16
Radiator Fan Switch Circuit Troubleshooting
(Short) ............ ........ 10-16
Radiator Fan Switch Test ................... 10-17
Radiator Fan Switch Reolacement .............................. 10-17

Cooling System
Component Location Index
WATER PUMPInspection, page 10-5Replacement. page 10-5
RESERVETANK
RADIATORCAP
RAOIATOR FAN SWITCHTest, page 10-17Replacement, page 10'17
\
WATER OUTLET,Installation, page'10-g
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CONNECTING PIPE
WATER PASSAGEInstallation, page 10-9
THERMOSTATTest, page 10 4Replacement, page 10 8
RADIATORReplacement, page 10-'l0
RADIATOR FANASSEMgLYReplacement, page 10-10Fan MotorTest, page 10 4A/C CONDENSERFAN ASSEMBLYReplacement, page 10 10Fan Motor Test, page '10-4
10-2
\J

Fan Controls
Component Location Index
RADIATOR FAN RELAY
RADIATOB FAN SWITCHTest, page 10'17Replacement, page'10-17
UNDER.HOODFUSE/RELAY BOX
RADIATOR FAN ASSEMBLYMotor Test, page 10 4
CONDENSER FAN ASSEMBLYMotor Test, page 10-4
10-11

Fan Controls
Symptom Troubleshooting Index
Before performing any troubleshooting procedures check:. Fuses. Grounds. Cleanliness and tightness of all connectors
\{
\,4
SYMPTOMPROCEDURE
Radiator fan does not run at allRadiator Fan Circuil Troubleshooting (see page 1O-14).
Radiator fan does not run for engine cooling, but it runswith A,/C ON
Radiator Fan Switch Circuit Troubleshooting (Open)
(see page 10-16).
Radiator fan runs with ignition switch ON (ll), Ay'C OFF,
and engine temperature below 199"F (93"C)Radiator Fan Switch Circuit Troubleshooting (Short)
(see page 10-'16).
10-12
\-

Fuel and Emissions
Fuel and Emissions Systems
SpecialTools
General Troubleshooting
Information
DTC Troubleshooting lndex ....
Symptom Troubleshooting
1ndex...............
System Descriptions ................
Howto Set Readiness Codes ..
PGM-FlSystem
Component Location Index ....
DTC Troubleshooting ..............
MIL Circuit Troubleshooting ...
DLC Circuit Troubleshooting ..
Injector Replacement ...............
A,/F Sensor Replacement .........
Secondary HO2S
Replacement
ECT Sensor Reolacement .......
CMP Sensor B {TDC Sensor)
Replacement
IAT Sensor Replacement .........
Knock Sensor Replacement ....
CKP Sensor Reolacement .......
VTEC/VTC
Comoonent Location Index ....
DTC Troubleshooting ..............
VTC Oil Control Solenoid
Valve Removal/Test .............
CMP Sensor A Replacement ...
VTEC Solenoid Valve
Removal/lnsoection .............
ldle Control System
Component Location Index
DTC Troubleshooting ..............
A,/C Signal Circuit
TroubleshootinS ...................
Alternator FR Signal Circu it
TroubleshootinS ...................
EPS Signal Circuit
TroubleshootinS ...................
Brake Pedal Position Switch Signal
Circuit Troubleshooting .............
ldle Speed Inspection
ECM ldle learn Procedure .......
Fuel Supply System
Component Location Index
Fuel Pump Circuit Troubleshooting
1't-2
I I-J
11-7
1 1-10
11-12
11-46
11-49
11-52
11-97
11-109
11-111
11-113
11-113
11-114
11-114
11-115
11-115
11-116
11-117
1 1-1 18
11-127
11-128
11-128
11-129
1I-130
I t- t55
11-134
1 1- 135
1 1-137
1 1-138
1 1-139
1 1-140
11-141
11-144
Fuel PressureTest ................... 11-145
Fuel Lines Inspection ............... 11-146
Fuel Line/Ouick-Connect
Fittings Precautions ............. 1 1-148
Fuel Line/Ou ick-Con nect
Fittings Removal .................. 1 1-149
Fuel Line/Ou ick-Con nect
Fittings lnstallation ............... 11-150
Fuel Pressure Regu lator
Replacement ......................... 11-152
Fuel Fifter Replacement ........... 11-152
Fuel Pump/Fuel Gauge Sending
UnitReDlacement ................. 11-153
Fuel Pulsation Damoer
Rep1acement ......................... 11-154
Fuel Tank Reolacement ........... 11-155
Fuel GaugeSending UnitTest ....... 11-156
Low Fuel lndicatorTest ................. 1 1-158
Intake Air System
Comoonent Location Index .... 11-159
Throttle BodyTest ................... 11-160
Intake Air Bypass Control
Thermal Valve Test .............. 11-161
Air Cleaner Reolacement ........ 11-162
Air Cleaner Element
Reolacement ......................... 11-162
Throttle Cable Adjustment ...... 11-163
Th rottle Cable
Removal/lnstallation ............ 1 1-164
Th rottle Body Removal/
Installation .. 11-165
Th rottle Body Disassembly/
Reassemblv .......................... 11-166
Catalytic Converter System
DTC Troubleshooting .............. 1 1-167
PCV System
DTC Troubleshooting .............. 1 1-168
PCV Valve InsDection
and Test ...... 1 1- 169
PCV Valve Reolacement .......... 11-169
EVAP System
Component Location Index .... 11-170
DTCTroubleshooting .............. 11-171
EVAP Two Way Valve Test ...... 11-186
Fuel Tank Vaoor Control
Valve Test ... 11-187
EVAP Canister Replacement ... 11-189
Fuel Tank Vaoor Control
Valve Reolacement .............. 1 1-189Fuel Pressu re Relieving ...........

General Troubleshooting Information
Intermittent Failures
The term "intermittent failure" means a svstem mav
have had a failure. but it checks OK now. lf the
Malfunction Indicator Lamp (MlL) on the dash does not
come on, check for Door connections or loose terminals
at all connectors related to the circuit that Vou are
troubleshooting.
Opens and Shorts
"Ooen" and "Short" are common electrical terms. An
open is a break in a wire or at a connection. A short is
an accidental connection of a wire to ground or to
another wire. In simple electronics, this usually means
something won't work at all. With complex electronics(such as ECMs)this can sometimes mean something
works, but not the way it's supposed to.
How to Use the PGM Tester or a Scan Tool
lf the MIL {Malfunction Indicator Lamp} has come on
'1. Start the engine and check the MIL {A).
NOTE: lf the ignition switch is turned ON (ll), and
the engine is not started, the MIL will stay on for
15 20 seconds (see page 11-46).
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2. lf the MIL stays on, connect the Honda PGM Tester(A) or an OBD ll scan tool to the Data Link
Connector {DLC) (B) located under the driver's side
of the dashboard.
3.
5.
Turn the ignition switch ON (ll).
Check the Diagnostic Trouble Code (DTC) and note
it. Also check the freeze data. Refer to the DTC
Troubleshooting Index, and begin the appropriate
troubleshooting procedure.
lf you do not find any DTCS, go to MIL circuit
troubleshooting (see page 11-97).
NOTE:. Freeze data indicates the engine conditions when the
first malfunction, misfire, or fuel trim malfunction
was detected.. The scan tool and the Honda PGM Tester can read the
DTC, freeze data, current data, and other Engine
Control l\4odule {EClvl) data.. For specific operations, refer to the user's manual
that came with the scan tool or Honda PG l\4 Tester.
lf the MIL did not stay
lf the MIL did not come on but there is a driveability
problem, refer to the Symptom Troubleshooting Index
in this section.
lf you can't duplicate the DTC
Some of the troubleshooting in this section requires
you to reset the ECM and try to duplicate the DTC. lf rhe
problem is intermittent and you can't duplicate the code,
do not continue through the procedure. To do so will
only result in confusion and, possibly, a needlessly
replaced ECM.
(cont'd)
11-3