Oil pan HONDA CIVIC 2003 7.G Owner's Manual

Rear Brake Caliper Overhaul
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
' Avoid breathing dust particles.
. Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner'
Remove, disassemble, inspect, reassemble, and installthe caliper, and note these items:
. Donotspill brake fluid on the vehicle; it may damage the paint; if brake f luid gets on the paint, wash it off
immediately with water.. To prevent dripping. cover disconnected hose joints with rags or shop towels.
. Cleanall partsinbrakefluidandairdry;blowoutall passageswith compressed air'
. Before reassembling, check that all parts are free of dust and other foreign particles
. Replace pans with new ones as specified in the illustration.. Make sure no dirt or other foreign matter contaminates the brake fluid.
. When reusing pads, always reinstallthem in their original positions to prevent loss of b ra king efficie ncy.
. Do not reuse drained brake fluid.
. Use only clean Honda DOT 3 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the
system.. Do not mix different brands ot brake fluid as they may not be compatible.
. Coatthe piston, piston seal groove, and caliper bore with clean brake fluid.
. Make sure no grease or oil gets on the brake discs or pads.
. Replaceall rubber parts with new ones whenever disassembled.
. After installing the caliper, check the brake hose and line for leaks, interference. and twisting.
oG , nonau."rip6r qreas€ lP/N 08c30-aoa4Ml34 N.m (3.5 kgf m,25lbtft)BOLT
WASHERS
BRAKE HOSE
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olT-J,.o"c.O.RING CUPBeplace. Beplace.
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ADJUSTING BOLT
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--t)(*ff l^7k ''"'t!1'ry#'
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: 10 MM FLANGE BOLTS.:r=,9!q!q}l 55 N m (5.6 lgf-m, 4r lbt ft)
19-23

Body
DoorsComponent Location Index ...........Door Panel Removal/lnstallation .....,..........Door Outer Handle ReplacementDoor Latch ReplacementDoor Glass and RegulatorReplacementDoor Sash Trim Replacement .......................
Door Glass Outer WeatherstripReplacement
Door Weatherstrip Beplacement
Door Glass Adjustment .................................Door Position Adjustment .............................Door Striker Adiustment ................................MirrorsComponent Location Index ...........................Power Mirror Replacement ...........................Mirror Holder Replacement ...........................Rearview Mirror Rep1acement ......................
GlassComponent Location Index ...........................Windshield Replacement
Bear Window Rep1acement ...........................
Ouarter Glass Replacement ..........................MoonroofComponent Location Index ...........................Symptom Troubleshooting Index
Glass Height Adjustment ...............................
Glass ReplacementWind Def lector 8ep1acement ........................Drain Channel Rep1acement ..........................Sunshade Replacement .................................Motor ReplacementFrame and Drain Tube Replacement ............Drain Channel Slider and Cable AssemblyReplacementLimit Switch Adjustment ...............................Closino Force and ODenina Draq Check ......lnterioi TrimComponent Location Index ...........................Trim Removal/lnstallation DoorArea ..........Trim Removal/lnstallation-Rear Side AreaTrim Removal/lnstallation-Cargo Floor AreaTrim Removal/lnstallation-Hatch Area .........Headliner Removal/lnstallation* Carpet Rep1acement .......................................ConsolesConsoles, Front and RearRemova l/lnsta llationFront Console Disassembly/Reassembly .....
20-220,420-620-7
20-920 t0
20- 10
20-1120-1120-1220 13
20-1420-1520-1520-16
20 1120-1920-2520-29
20,3520-3620-3720-3120-3820 3920-4020-4120,42
20 4420-4620,44
20-4920 50
20-51
DashboardInstrument Panel Removal/lnstallation ........Driver's Dashboard Lower CoverRemovat InstallationDriver's Dashboard Under CoverRemova t Insta llation
Oriver's Pocket Removal/lnstallation ............Shift Lever Trim Removal/lnstallation ..........Center Panel Removal/lnstallation ...............Passenger's Dashboard Lower CoverRemova l/lnsta llat ionx Glove Box Removal/lnstallationDashboard Side VentRemoval/lnstallation .................................. 20-64Beverage Holder Removal/lnstallation ........ 20-64Driver'sTray Removal/lnstallation ............... 20-65Passenger's Tray Removal/lnstallation ........ 20 65* Dashboard Removal/lnstallation .................. 20-66Steerinq Hanqer Beam Reolacement ........... 20-68Seats "
Component Location Index ........................... 20-10* Front Seat Removal/lnstallation ................... 20-11* Front Seat Disassembly/Reassembly-Driver's .................................. 20-73* Front Seat Disassembly/Reassembly-Passenger's ........................... 20-74* Front Seat Cover Replacement ..................... 2O-75Rear Seat Removal/1nsta11ation ..................... 20-80Rear Seat-back Latch Replacement .............. 20-81Rear Seat-backStriker Replacement ............ 20-81
20-59
20-59
Rear Seat-back Cover Replacement ............. 20-82Rear Seat Cushion Cover Replacement ....... 20.84BumpersFront Bumper Removal/lnstallation .............Rear Bumoer Removal/lnstallation ...............HoodAdjustmentHood Seal ReplacementHood Insulator Rep1acement .........................Hatch
20-6020,6020 6120-62
20-63
20-63
20,8520-86
20-4720,8820,89
20-5220-5320-5420-55
20-5720-58
Adjustment ................... 20-90Hatch Suppon Strut Replacement ................ 20-91Hatch WeatherstriD Reo1acement ................. 20-92
Fuel Fill DoorAdiustment ................... 20-93Exterior TrimFront Grille Replacement ..............Cowl Covers Replac"rn""t .. . .....................A pillar Corner Trim Replacement ................Roof lMolding Replacement ...........................Rear License Trim ReplacementHatch Spoiler 8ep1acement ...........................Emblem Rep1acement .........................
20-9420-9520-9620-9720,9820-9920-100

Rear Window Replacement
NOTE:. Put on gloves to protect your hands.. Wear eye protection while cutting the glass adhesive
with piano wire.. Use seat covers to avoid damaging any surfaces.. Do not damage the rear window defogger grid lines
and terminals.
1.Remove these items:
. Hatch lower trim panel (see page 20-53). Hatch spoiler (see page 20-99)
Remove these items:
. High mount brake light {see page 22-821. Rear window wiper motor {see page 22-1461
Disconnect the rear window defogger connectors
(A).
4.lf the old rear window is to be reinstalled, make
alignment marks across the glass and body with a
grease pencrl,
Apply protective tape along the inside and outside
edges of the hatch. Using an awl, make a hole
through the adhesive from inside the vehicle at the
corner portion of the rearwindow. Push the piano
wire through the hole, and wrap each end around a
piece of wood,
6. With a helper on the outside, pull the piano wire (A)
back and Jorth in a sawing motion. Hold the piano
wire as close to the rear window (B) as possible to
prevent damage to the hatch, and carefully cut
through the adhesive {C} around the entire rear
Cutting positions:
7. Carefully remove the rear window.
(cont'd)
20-25

21-2
z t-'5
z t-o
z t-o
21-8
21-9
21-10
21-11
21-14
z t- to
HVAC (Heating, Ventilation, and Air Gonditioningl
Heating and Air Conditioning
SpecialTools
Comoonent Location lndex ........
A/C Service Tios and
Precautions
A,/C Refrigerant Oil
ReDlacement
General Troubleshooting
lnformation
DTC Troubleshooting Index .......
Symptom Troubleshooting
1ndex..............
System Description .....................
Circuit Diagram
DTC Troubleshooting ..................
Recirculation Control Motor
CircuitTroubleshooting .......... 21-25
Heater Control Power and Ground
Circuits Troubleshooting ........ 21-27
Condenser Fan Circuit
Troubleshooting ...................... 21-28
Radiator and Condenser Fans
Common Circuit
Troubfeshooting ...................... 21-29
Compressor Clutch Circuit
Troubleshooting ...................... 21-30
A,/C Pressure Switch Circuit
Troubleshooting ...................... 21-32
Air Mix Control Motor
Test and Reolacement ............. 21-34
Mode Control Motor
Test and Replacement ............. 21-35
Recirculation Control Motor
Test and Reolacement ............. 21-36
Evaporator Temperature Sensor
Reolacement and Test ............. 21-31
Power Transistor Test ................. 21 -38
Heater Control Panel and
Push Switch Assemblv
Removal and Installation ........ 21-38
Dust and Pollen Filter
Reolacement ..21-39
Blower Unit Removal and
lnstallation ...... 21-39
Blower Unit Comoonents
ReDlacement ............................ 21-41
Evaporator Core
Reolacement ..21-42*Heater Unit/Core
ReDlacement ..21-43
Heater Valve Cable
Adjustment .....21-46
CompressorReplacement .......... 21-47
Comoressor Clutch Check .......... 21-48
Comoressor Clutch Overhaul ..... 21-49
Compressor Thermal Protector
Reo1acement ............................ 21-51
Comoressor Relief Valve
Reolacement ............................ 21-51
Condenser Reolacement ............ 21-52
Refrigerant Recovery .................. 21-53
System Evacuation ...................... 21-54
System CharginS ......................... 21-55
Refrigerant LeakTest .................. 21-56
A,/C Svstem Tests ........................ 21-57

Heating and Air Gonditioning
System Description (cont'dl
The air conditioning system removes heat from the passenger compartment by circulating refrigerant through the
system as shown below.
/
BLOWER FAN
\
\,u
EXPANSION VALVE(Meters the requiredamount of refrigerantinto the evaporator)
A/C PRESSURE SWITCHWhen the refriqerant is below196 kPa (2.0 kgi/cm',28 psi)or above 3,140 kPa (32 kgf/cm'455 psi), the Py'c pressureswitch opens the circuit tothe Py'C switch and stops theair conditioning to protect thecompressor-
RECEIVER/DRYER(Traps debris, andremoves morsturel
APOBATOR TEMPERATURESENSOR
THERMAL PROTECTOR(Opens the compressor clutch circuitwhen the compressot temperaturebecomes too high)
RELIEF VALVE(Relieves pressure at the compressorwhen the pressure is too high)
A/C COMPRESSOR(Suction and comoression)\-^
I HrcH PRESSURE vAPoR
[ '.... -:--l Low PREsSUBE LrourD
tffi Low PREssURE vAPoR
This vehicle uses HFC-134a (R-'134a) refrigerant which does not contain ch lorofluorocarbons. Pay attention to the
following service items:
. Do not mix refrigerants CFC-12 (R-12) and HFC-134a (R-134a). They are notcompatible.. Use onlythe recommended polyalkyleneglycol (PAG ) refrigera nt oil (KElHlN SP '!0) designedfortheR-134a
compressor. Intermixing the recommended (PAG) refrigerant oil with any other retrigerant oil will result in
compressor failu re.. AllAy'C system parts (compressor, discharge line, suction line, evaporator, condenser, receiver/dryer. expansion
valve, O-rings for joints) have to be designed for refrigerant R 134a. Do not exchange with R-'12 parts.
. Use a halogen gas leak detector designed for refrigerant R-134a.. R-12 and R-134a refrigerant servicing equipment are not interchangeable. Use only a recovery/recycling/charging
station that is U.L.-listed and is certified to meet the requirements of SAE J2210 to service R-134a air conditioning
system.. Always recover the refrigerant R-134a with an approved recovery/recycling/charging station before disconnecting
any Ay'C fifting.
/-
CONDENSER(Radiation of heat)
21-12

Heating and Air Conditioning
DTC Troubleshooting
DTC 7: An Open in the Air Mix Control Motor
Circuit
1. Test the air mix control motor {see page 2'l-341.
ls the air mix control motor OK?
YES-Go to step 2.
NO-Replace the air mix control motor.l
2. Disconnect the air mix control motor 5P connector.
3. Disconnect heater control panel connectors A {14P)
and B (22P).
4. Check for continuity between the following
terminals of heater control panel connectors A
(14P) and B (22P) and the air mix control motor 5P
connector,
14P: 5P:
No. 1 No.5
No.2 No.4
No.3 No.2
No.9 No. 1
22P: 5P:
No.6 No.3
Wire side ol lem.letehi.6ls
ls there continuity?
YES-Check for loose wires or poor connections at
heater control oanel connectors A (14P) and B (22P)
and at the air mix control motor 5P connector. lf the
connections are good. substitute a known-good air
mix control motor, and recheck, lf the symptom/
indication goes away, replace the original air mix
control motor. lf the symptom/indication continues,
substitute a known-good heater control panel, and
recheck. lf the symptom/indication goes away,
replace the original heater control panel.l
NO Repair any open inthewire(s) ketweenthe
heater control panel and the air mix control
motor.l
21-16
DTC 8: A Short in the Air Mix Control Motor
Circuit
1. Test the air mix control motor(see page 21-341.
ls the ait mix control motor OK?
YES-Go to step 2.
NO-Replace the air mix contorol motor.I
2. Disconnect the air mix control motor 5P connector.
3. Disconnect heater control panel connectors A (14P)
and B (22P).
4. Check for continuity between body ground and
heater control panel connector A (14P) terminals
No. 1, 2, 3, and 9 individually, and between body
ground and heater control panel connector B (22P)
terminal No. 6.
HEATERCONTROL PANEL CONNECTOR A {I4PI
HEATER CONTFOL PANELCONNECTOR B I22P1
ls therc continuity?
YES-Repair any shortto body ground ln the
wire(s) between the heater control panel and the air
mix control motor.l
NO-Go to step 5.
Wire side of female terminals
Wire side oilema e lerminals

Heating and Air Conditioning
Compressor Clutch Circuit
Troubleshooting (cont'dl
16. Check for continuity between the No. lterminal of
the compressor clutch relav 4P socket and the No. l
terminal of the compressor clutch 1P conneclor.
COMPRESSON CLUTCH RELAY 4P SOCKET
COMPRESSOR CLUTCH 1P CONNECTORTerminal side of male terminals
ls therc continuity?
YES-Check the compressor clutch clearance, the
thermal protector, and the compressor clutch field
coil (see page 21-48).I
NO-Repair open in the wire between the
compressor clutch relay and the compressor
clutch.l
21-32
A/C Pressure Switch Circuit
Troubleshooting
'1. Turn the ignition switch ON {ll).
2. Turn the blower switch on, and check for blower
motor operatron.
Does the blower motor run on all speeds?
YES Go to step 3.
NO Troubleshoot the blower motor circuit (see
page 21-20).
3. Turn the ignition switch OFF.
4. Disconnect heater control panel connectorA ('14P).
5. Turn the ignition switch ON (ll).
6. Measure the voltage between the No, 4 terminal of
heater control panel connector A {14P) and body
grou nd.
HEATER CONTROL PANEL CONNECTOR A (I4P}
1.
ls there battety voltage?
YES Go to step 7.
NO-Go to step 9.
Stan the engine.
Wire side of female termina's

Heating and Air Gonditioning
a
1.
Evaporator Core Replacement
Recover the refrigerant with a recovery/recycling/
charging station (see page 21-53).
Remove the bolt, then disconnect the suction line
(A) and the receiver line (B)from the evaporator
core.
6x10mm9.8 N.m (1.0 kgt.m, 7.2lbf.ft)
Remove the blower unit (see page 21-39).
Remove the self-tapping screws and the expansion
valve cover.
21-42
5. Carefully pull out the evaporator core without
bending the pipes.
Installthe core in the reverse order of removal, and
note these items.
. lfyou're installing a new evaporator core, add
refrigerant oil (KElHlN SP-]0) (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.. lmmediatelyafter usingthe oil, reinstallthecap
on the container, and seal it to avoid moisture
absorotion.. Do not spill the refrigerant oil on the vehicle; it
may damage the paint. lf the refrigerant oil
contacts the paint, wash it off immediately.. Charge the system (see page 21-55).
6.

A/C System Tests
Pressure Test
Test resultssvmotom3DGaUSeDischarge (high)pressureabnormally high
After stopping compressor, pressure
drops quickly, and then continues toAir in systemRecover, evacuate (see page 21-54),and recharge with specified amount{see oaoe 21 55).
Beduced or no air flow throughcondenserClogged condenser or radiatorfinsCondenser or radiator fan not
CleanCheck fan voltage and rpm.Check fan direction.
Line to condenser is excessively hot.Restricted flow of refrigerant inReplace restricted lines.
Discharge pressureHigh and low pressures are balancedsoon after stopping compressor, Lowside is hioherthan normal.
. Faulty compressor dischargevalve. Faultv comoressor seal
Beplace the compressor.
Outlet of expansion valve is notfrosted, low pressure gauge indicatesFaulty expansion valveMoisture in system
. Replace the expansion valve.. Recover, evacuate for at least30 minutes, and recharge withsDecified amount.
Suction (low)pressureabnormally low
Expansion valve is not frosted, andlow-pressure line is not cold. Lowpressure gauge indicates vacuum,
' Frozen expansion valve(Moisture in system). Faulty expansion valve
Recover, evacuate for at least30 minutes, and recharge withspecified amount.Beplace the expansion valve.
Discharge temperature is low, and theair flow from vents is restricted.Frozen evaporatorRun the fan with compressor off, thencheck evaooratot temoerature sensor.
Exoansion valve is frosted.ean or reolace,
Receivetdryer outlet is cool, and inletis warm (should be warm duringooeralton),
Clogged receiver/dryerReplace receaver/dryer.
Suction pressureabnormally highLow pressure hose and check joint arecooler than the temperature aroundevaoorator,
Expansion valve open too longBepair or replace.
Suction pressure is lowered when..nrlenser is cooled bv water.Excessive refrigerant in systemRecover, evacuate, and recharge withqnp.ifie.lamo'rnr
High and low pressure are equalizedas soon asthecompressor is stopped,and both gauges fluctuate while
Faulty gasketFaulty high pressure valveForeign panicle stuck in high
Replace the compressor.
Suction anddaschargepressuresabnormallv hioh
Reduced air flow through condenser.. Clogged condenser or radiatorfins' Condenser or radiator fan notworkino orooerlv
CleanCheck voltage and fan rpm.Check fan direction.
Suction anddischarge pressureabnormally low
Low-pressure hose and metalendareas are coolerthan evaoorator,Clogged or kinked low-pressurehose oartsRepair or replace.
Temperature around expansion valveis too low compared with that aroundClogged high-pressure lineRepair or replace,
Fefrigerant leaks:omoressor clulch is dirtv.:omoressor shaft seal leakinqReolace the comDressor,
lomoressor bolt(s) are dirtv.no around bolt(s)Tiohten bolt{s) ot reolace comDressor,
;omDressor oasket is wet with oil.ietnoace the comoressor.
(cont'd)
21-57

Connectors and Harnesses
Engine Wire Harness
Camshaft position (CMP) sensorLllr sensorEC[,4 connector AECI/l connector BEngine coolant temperature (ECT)
sensorEngine oil pressure switchEVAP canister purge valveldle air control (lAC)valve
lgnition coil No. llgnition coil No. 2lgnition coil No. 3lgnition coil No. 4Iniector No. 1Inlector No.2Iniector No.3Iniector No. 4Intake air temperature {lAT) sensor
TDC sensorThrottle position (TP) sensorVehicle speed sensor (VSSI
VTC oil control solenoid valveVTEC oil pressure switchVTEC solenoid valvec 101
c102
233
242
Transmission housingLeft side of engineRight side ofengineUnder glove boxUnder glove boxLeft side of engine
Bight side oI engineLeft side of intake manifoldLeft side of intake manifoldMiddle of engine compartmentMiddle of engine compartmentMiddle of engine compartmentMiddle of engine compartmentMiddle of engine compartmentMiddle of engine compartmentMiddle of engine compartmentMiddle of engine companment
28
1845672524201912
811102729303
22
12333332222233
322220
Left side of intake manifoldLeft side of engineLeft side of intake manifoldTransmission housingRight side o{ engineRight side of engineRight side of engineUnder right side of dash
Front of engine companment
Front of engine compartment
ECM wire harness {see page22-321Starter subharness (see page22-15)Starter subharness (see page22 151
Connector to Harness Index (cont'dl
22-16