INTAKE HONDA CIVIC 2003 7.G Repair Manual

Clutch
Slave Cylinder Replacement (cont'd)
11. Bleed the clutch hydraulic system.
. Aftach a hose to the bleeder screw (A), and
suspend the hose in a container of brake fluid.. Make sure there is an adequate supply offluid in
the clutch master cylinder, then slowly pump the
clutch pedal until no more bubbles appear atthe
bleeder hose.. lt may be necessary to llmit the movement of the
release fork (B) with a block of wood to remove
all the air from the system.. Tighten the bleed screw to I N.m (0.8 kgf.m, 6 lbf
ft); do not ovenighten it,. Refill the clutch master cylinder with fluid when
done.. Always use only Honda DOT 3 brake fluid.
Install the intake air duct (see step 36 on page 5-14).
Installthe air cleaner housing (see step 37 on page
5-15).
Install the battery tray.
Install the battery, connect the positive (+) cable
first, then the negative (- ) cable.
Reset the frequencies for the radio station preset
buttons,
12.
13.
14.
t5.
16.
12-8
L

Manual Transmission
Transmission Removal
SpecialTools Required. Engine hanger adapter.2.0 to 2.4 liter VSB02C000015. Engine hanger VSB02C000018. Engine support hanger, A & Reds AAR'T 12566'. Subframe adaDter EOS02C000011 '
* Available through the Honda Tool and Equipment
Program 888-424-6857
NOTE: Use fender covers to avoid damaging painted
surfaces.
4.
1.
7.
Write down the frequencies for the radio's preset
buttons. Disconnect the negative ( ) cable first,
then the positive ( )cable from the battery.
Remove the battery.
Remove the intake manifold cover {see page g-3).
Remove the air cleaner housing (see page 1 1-162).
Remove the intake air duct {see step 8 on page 5-3).
Remove the battery tray (A).
Disconnect the transmission ground cable (B).
Disconnect the back-up light switch connector (A)
and vehicle speed sensor (VSS) connector (B).
13-4
8. Remove the cable bracket (A). then disconnect the
cables (B) from the top of the transmission housing.
Carefully remove both cables and the bracket
together so as not to bend the cables.
9. Remove the harness clip.
I
HA @
ilB

28. Connect the transmission ground cable (A).
8 x 1.25 mm
B
22 N.m (2.2 kgf.m, 16lbf.ft)
[---.-.---e
e
6x1,0mm9.8 N.m{1.0 kgl m. 7 lbf ftl
29.
30.
8x125mm22Nm12.2 kgt m, 16 lbf ft)
lnstall the battery tray (B).
Installthe intake air duct (see step 36 on page 5-14).
Installthe air cleaner housing (see step 39 on page
5-15).
Installthe intake manifold cover (see step 41 on
page 5-15).
Install the battery. Connectthe positive (+) cable
first, then the negative (-)cable to the battery.
Reflllthe transmission fluid (see page 13-3).
Test-drive the vehicle.
Check the clutch operation.
Check the front wheel alignment (see page 18-4).
Enter the anti-theft code for the radio, then enter
the customer's radio station presets.
Do the engine control module (ECM) idle learn
procedure (see page 11-139).
32.
33.
34.
35.
36.
31.
38.
39.
13-13

Heating and Air Conditioning
A/C System Tests (cont'd)
1.
Performance Test
Air conditioning refrigerant or lubricant vapor
can irritate your eyes, nose, or throar.
Be carefulwhen connecting service equipment.
Do not breathe refrigerant or vapor.
The performance test will help determine if the air
conditioner system is operating within specifications.
Use only service equipment that is U.L.-listed and is
cenified to meet the requirements of SAE J2210 toremove HFC-134a (R-134alfrom the air conditioning
system.
lf accidental system discharge occurs, ventilate the
work area before resuming service
R-134a service equipment or vehicle air conditioning
systems should not be pressure tested or leak testedwith compressed air.
Additional health and safety information may be
obtained from the refrigerant and lubricant
manufacturers.
Connect a R-134a refrigerant recover/recycling/
charging station to the high-pressure service port
and the low-pressure service port, following the
equipment manufacturer's instructions.
Determine the relative humidity and air
Iemperaru re.
' Compressed air mixed with R-134a forms a
combustible vapor.. The vapor can burn or explode causing serious
Injury.. Never use compressed air to pressure test
R-134a service equipment or vehicle air
conditioning systems.
21-58
4.
Open the glove box. Remove both glove box stops,
then let the glove box hang down (see page 20-63).
Insert a thermometer (A) in the center vent, andplace another thermometer {B) near the blower unit.
Test conditions:
. Avoid direct sunlight.. Open the hood.. Open the front doors.. Sel the temperature control dial on Max Cool, the
mode control dial on Vent, and the recirculation
control switch on Recirculate.. Turn the A,/C switch on and the fan switch on Max.. Run the engine at 750 rpm.. No driver or passengers in vehicle.
After running the air conditioning for I0 minutes
under the above test conditjons, read the delivery
temperature from the thermometer in the center
vent, the intake temperature near the blower unit,
and the high and low system pressure from the Ay'Cga uges.

7. To complete the charts:
. Markthe deliverytemperature along the vertical line.
. Mark the intake temperature (ambient air temperature) along the bottom line.
. Draw a line straight up from the air temperature to the humidity.
. Mark a point 10 % above and 10 % belowthe humidity level.
. From each point. drawa horizontal line across the delivery temperature.
. The delivervtemperature should fall between thetwo lines
. Complete the low-side pressure test and high-side pressure test in the same way.
. Anv measurements outside the line may indicate the need for further inspection.
kPa(ksl{cm')Lpsrl
2500 -
[25) _360l
1500 -
{1s},21o)
1000 -(101:1401
500 -
{5)171l
DELIVERYPRESSURE
80 yo
a0 0/"
HUMIDITYLEVEL
30 9o
30%
80%
{kgflcm')Lpsil
600{6ttssl
2000(2011280
fcl
100{11h4l
INTAKEPRESSURE
OELIVERYTEMPERATURE
.F
{'cl
I104{40)95(35)
I86t30)
I77t25l68t20l
INTAKE TEMPEBATURE
21-59

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

IJVSS Replacement
1. Remove the intake resonator.
2. Disconnect the 3P connector from the vehicle
speed sensor {VSS) (A).
4.
Remove the mounting bolt, then remove the VSS.
lnstallthe VSS in the reverse order of removal.
22-67

Service Manual Index
(cont'dl
Gauge A3semblyReplacement......................................... 22 64
Gaug€sComponent Location Index ..........-...... 22 54How-to lnformation ........................22-56Circuit Diagram22-54
Heater Valve CableAdjustment ...................... .................... ?1-46
High Mount Brake Light8ep|acement......................................... 22 82
Hood
lmmobilizer SystemComponent Location In dex .............. 22-162
\
G
Description
Genoral Information(See seclion 1)
Glove BoxRemoval/1nsta11ation .......................-.... 20-63
GrilleReplacement...........-............................. 20-94
Hood lnsulatorReplacement......................................... 20-89
Hood LatchRep1acement................... ..........20 108
Hood Opener CableComponentLocation Index ..............20 105Replacement ................ . . ........... .....20 106
Hood SealBeplacement.-...........................-........... 20-88
HornTesVReplacement . . ................ ...... 22-122
CircuitDiagram ...........................22-164Troubleshooting ............................ 22,165
Inner Fender, FronlRepf acemenl....................................... 20-102
Inside Rearview MirrorReplacement..........-.............................. 20 16
Instrument PanelRemoval/1nsta11ation................. ....... 20-59
Intake Air Bypass ControlThermal ValveTesr................................ ..... ..11-161
Intake Air SystemComponent Location Index ...-.-........ 11-159
Intake ManitoldRemoval/1nsta11ation ................................ I 2
lntermediate Shaft AssemblyRemova1 ................-.-...-......................... 16-19Disassemb|y................... ... ......-.... 16,20Resassemb|y ........................................ 16 22Installation .........-...-.............................. 16-24
Keyless Entry Transmitter
Adjuslment
H
Adiustment .......
Hatch Handle
Horn SwitchTest ............-........
HornsComponent Location IndexCirc!it Diagram
H02S. SecondaryReplacement
..............22-120Replacement
22-122
22 12120-110
20-'110Hatch LatchReplacement$
K
Hatch Latch Switch
.... 11 113
HubsReplacement. ... .................................. 1A 26Test
Test
Replacement
Hatch Support StrutsBeplacement.....
Hatch WeatherstrioReplacement....
Hazard Warning Switchtest
ldle ControlSystemComponentLocation Index .............. 11-129Inspection,.,.........-.......,.,.,,,,,,.,,,.,.,..... 1'l 138
lgnition CoillslBemoval/lnstallation ...............-.............. 4 18
22-161Test ...................................................... 22 161
Keyless Entry/Security Alarm SystemComponenl Location Index .............. 22 150Circuil Diagram ................. . .............. 22 151
Keyless Receiver Unitlnput Test ............................................ 22-153
Knock SensorReplacement......-................................ 1 1 115
KnucklesReplacementFront Suspensron ............................. 18-1 1Rear Suspension ........ .................-... 18-28
Repair ...............
H.tch Lock Actuator22-159
Hatch Lock CylinderRep|acement....................................... 20,111
Hatch SpoilerIAT {lntake Air Temperature} SensorReplacement.,.........-...'11 115
20-91
20-92
.................... 22_88lgnition Key LightTest,,.,,,,.,...,......-.
H6adlightAdjustmentlgnition Key Switch
....................... 22-91
....................... 22-91..22-78TestReQ\ace$entlgnition SwitchTest .,,,.,.,.,,,,.,.,.......22-53License Plate LightReplacement...........-... - ... .....22-83
License TrimReplacement..................-...-..........-....... 20-98
Lights, ExteriorComponent Localion Index.................22 68
Lights,InteriorComponent Location Index................. 22-94CircuitDiagram .. .. ...... .... 22-95
HcadlightsCircuit Diagram .............................. 22-71, 72
HeadlinerRemoval/lnstallalion ............................ 20-54
Heater ControlPanelRemoval/1nsta11ation ............................ 21-38
Heater Control Power and Ground CircuitsTroubfeshooting......... .......................21-27
lgnition SystemComponent Location Index ................... 4-15CircuitDia9ram .................................... 4'161nspection ............................................... 4-17
lmmobilizer Control Unit-Receiver
J
22-161