HONDA CIVIC 2003 7.G Service Manual

Starting System
Starter Circuit Troubleshooting
(cont'dl
6. Check the following items in the order listed untilyou find the open circuit.
. Check the BLIVWHT wire and connectors
between the under-dash fuse/relay box and theignition switch, and between the under-dash
fuse/relay box and the starter.. Check the ignition switch {see page 22-53).. Check the clutch interlock switch and connector.. Check the starter cut relay (see page 22-51).. Check LT GRN wire between the starter cut relayl
under-dash fuse/relay box and the clutch
interlock switch.. Check the BLK wire between the clutch interlock
switch and G501.
7, Check the cranking voltage and current draw.
ls ctanking voltage greatet than or equal to 8.7 V
and current draw less than or equal to 230 A?
YES-Go to step 8.
NO Replace the starter. or remove and
disassemble it, and check these items until you find
the cause.
. Starter armature dragging. Shorted armatu re winding. Excessive drag in engine
8. Check the engine speed while cranking the engine.
ls the engine speed above 100 tpm?
YES Go to step 9.
NO-Replace the starter, or remove and
disassemble it, and check for the following untilyou find the cause.
. Excessively worn starter brushes. Open circuit in commutator brushes. Open circuit in starter armature commutator
segments. Dirty or damaged helical splines or drive gear. Faulty drive gear clutch
9. Remove the starter, and inspect its drive gear andthe flywheel ring gear for damage. Replace anydamaged pans.I
4-6
Clutch Interlock Switch Test
1. Disconnect the clutch interlock switch 2P connector.
2. Remove the clutch interlock switch (A).
Check for continuity between the terminals
according to the table.
. lf the continuity is not as specified, replace the
clutch interlock switch.. lf OK, install clutch interlock switch and adjust
the pedal height (see page 12-4l..
Terminal
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RELEASED

et
Starter Solenoid Test
1. Disconnect the S and lvl connectors from the starter
solenoid.
2. Check the hold-in coil for continuity between the S
terminal and the armature housing (ground). There
should be continuity.
. lf there is continuity, goto step 3.. lf there is no continuity, replace the solenoid,
3. Check the pull-in coil for continuity betwee n the S
terminal and M terminal. There should be
continuity,
. lf there is continuity, the solenoid is OK.
. lf there is no continuity, replace the solenoid,
4-7

Starting System
Starter Performance Test
1,Disconnect the wires from the S terminal and the M
termrnal.
Make a connection as described below using as
heavy a wire as possible (preterably equivalent to
the wire used for the vehicle). To avoid damaging
the starter, never leave the battery connected for
more than 10 seconds,
Connect the battery as shown. Be sure to
disconnect the starter motor wire from the solenoid.
lf the starter pinion moves out, it is workingpropefly.
Disconnect the battery from the M terminal. lf thepinion does not retract, the hold-in coil of the
solenoid is working properly.
4-8
L
5. Disconnect the battery from the starter body. lfthepinion retracts immediately, it is working properly.
Clamp the starter firmly in a vise.
Connect the starter to the battery as described in
the diagram below, and confirm that the motor
sta rts and keeps rotating.
6.
7.
lf the eiectric cu rrent and motor speed meet the
specifications when the battery voltage is at 1 1.5 V,
the staner is working properly,
Specifications:
1.1 kw 90 A or less (Electric current),
ot more

Starter Replacement
1. Make sure you have the anti-theft code for the radio.
then write down the frequencies for the radio's
preset buttons.
2. Disconnect the negative cable from the battery first,
then disconnect the positive cable.
3. Disconnect the knock sensor connector.
4. Remove the bolt (A) securing the harness bracket,
then remove the intake manifold bracket (B).
A6x1,0mm12 N.m {1.2 kgf.m,8.7 tbt.ft)
8 x 1.25 mm22 N,m 12.2 kgt.m,16 rbf.ftl
L't2.
4-9
5. Disconnect the starter cable (A)from the B terminal
on the solenoid, then disconnect the BLK,/WHT wire
{B) from the S terminal.
10 x 1.25 mm44 N.m {a.5 kgf.m,33lblft)
8 x 1.25 mm9Nm10.9 kgf.m,7 lbl ft)
7.
9.
'10.
11.
2
S'-12x12smm6ilNm{6.5 kgl m,47lbfft)
Remove the two bolts holding the starter, then
remove the starter.
lnstall the starter in the reverse order of removal.
Make sure the crimped side of the ring terminal (A)
is facing out.
Connect the positive cable and negative cable to
the batterY.
Start the engine to make sure the starter operates
propeny.
Enter the anti-theft code for the radio, then enter
the customer's radio station presets.
Set the clock.
Perform the engine control module (EcM) idle learn
procedure (see page 1 '1- 139 ).
I

Starting System
Starter Overhaul
Disassembly/Reassembly
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STARTER SOLENOID
4-10
BRUSH HOLDER

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?.-
Armature Inspection and Test
1. Remove the starter (see page 4-9).
2. Disassemble the starter as shown atthe beginning
of this procedure.
3. Inspect the armature for wear or damage from
contact with the permanent magnet. lf there is wear
or damage, replace the armature.
Check the commutator (A) surface. lf the surface is
dirty or burnt, resurface with emery cloth or a lathe
within the specifications in step 5, or recondition
with # 500 or # 600 sandpaper (B).
6.
5. Check the commutator diameter. lf the diameter is
below the service limit, replace the armature.
Commutator Diameter
Standard (Newl: 28.0 mm (1.10 in.l
Service Limit: 27.0 mm (1.06 in.)
Measure the commutator (A) runout.
. lf the commutator runout is within the service
limit, check the commutator for carbon dust or
brass chips between the segments.. lf the commutator runout is not within the service
limit, reolace the armature.
Commutator Runout
Standard lNew): 0.02 mm 10.001 in.) max.
Service Limit: 0.05 mm (0.002 in.)
(cont'd)
4-11

Starting System
Starter Overhaul (cont'dl
7. Check the mica depth (A). lf the mica is too high {B),undercut the mica with a hacksaw blade to theproper depth. Cut away allthe mica (C) between
the commutator segments. The undercut should
not be too shallow, too narrow, or V-shaped (D).
Commutator Mica Depth
Standard (New): 0.50-0.80 mm {0.020-0.031 in.)
Service Limit: 0.20 mm (0.008 in.)
Check for continuity between the segments of the
commutator. lf an open circuit exists between any
segments, replace the armature.
M
4-12
\
9. Place the armature (A) on an armature tester (B).
Hold a hacksaw blade (C) on the armature core. lf
the blade is attracted to the core or vibrates while
the core is turned, the armature is shoned. Replace
the armature.
Check with an ohmmeter that no continuity exists
between the commutator (A) and armature coll
core (B), and between the commutator and
armature shaft (C). lf continuity exists, replace the
armature.
10,

Starter Brush Inspection
11. lvleasure the brush length. lf it is not within the
service limit, replace the brush holder assembly.
Brush Length
Standard {New): 14.0-14.5 mm (0.55-0.57 in.)
Service Limit: 9.0 mm {0.35 in.)
Starter Field Winding Test
12. Check for continuity between the brushes (A). lf
there is no continuity. replace the armature
housing (B).
Check for continuity between each brush (A) and
the armature housing (B). li there is continuity,
replace the armature housing.
13.
Starter Brush Holder Test
14, Check that there is no continuity between the (+ )
brush holder {A) and ( ) brush holder (B}. lfthere
is continuity, replace the brush holder assembly.
Brush Spring Inspection
15. Insen the brush (A) into the brush holder, and bring
the brush into contact with the commutator, then
attach a spring scale (B) to the spring (C). Measure
the spring tension at the moment the spring lifts off
the brush. lf the spring tension is not within
specification, replace the spring.
Spring Tension: 13.7-17.7 N {1.40-1.80 kgf,
3.09 3.97 lbf)
(cont'd)
4-13

Starting System
Starter Overhaul (cont'dl
Planetary Gear Inspection
16. Check the planetary gears (A) and ring gear {B).Replace them if they are worn or damaged.
Overrunning Cluich Inspection
17. Slide the overrunning clutch along the shaft.
Replace it if it does not slide smoothly.
18. Rotate the overrunning clutch (A) both ways.
Does it lock in one direction and rotate smoothly inreverse? lf it does not lock in either direction or it
locks in both directions, replace it.
lf the starter drive gear (B) is worn or damaged,
replace the overrunning clutch assembly; the gear
is not available separately.
Check the condition of the flywheel ring gear.
Replace it if the starter drive gear teeth are
oamageo.
19.
4-14
i.-
Starter Reassembly
20, Pry back each brush spring with a screwdriver, thenposition the brush about halfway out of its holder,
and release the spring to hold it there.
NOTE: To seatthe new brushes. slip a strip of #5OO
or # 600 sandpaper. with the grit side out, be&veen
the commutator and each brush, and smoothly
rotate the armature. The contact surface of the
brushes will be sanded to the same contour as the
commutator.
21lnstallthe armature in the housing, and installthe
brush holder. Next, pry back each brush spring
again, and push the brush down until it seats
against the commutator, then release the spring
against the end of the brush.
s
Install the starter end cover to retain the brush
holder.

lgnition System
Component Location Index
SPARK PLUGInspection, page 4-'19IGNITION COILlgnition Timing Inspection, page 4-17Removal/lnstallation, page 4-18
4-15