Circuit HONDA CIVIC 2003 7.G Workshop Manual

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Engine Electrical
Engine Electrical
SpecialTools
Starting System
Comoonent Location Index ...............
Circuit Diagram
Starter Circu it Troubleshooting
Clutch Interlock Switch Test
Starter Solenoid Test ..............
Sta rter Performance Test
Starter Reolacement ...............
Starter Overhaul .......................
lgnition System
Component Location Index ...............
Circuit Diagram
lgnition Timing Inspection
lgnition Coil Removal/1nsta11ation .......................
Spark Plug Inspection
Charging System
Component Location Index .................................. 4-2O
Circuit Diagram ........................... 4-21
Charging Circuit Troubleshooting ....................... 4-22
Drive Belt Inspection ................... 4-26
Drive Beft Replacement .............. 4-26
Drive BeftAuto-tensioner Inspection .................. 4-27
Drive Beft Auto-tensioner Replacement .............. 4-28
Alternator Reolacement ............. 4-29
Alternator Overhaul ................ .... 4-30
Cruise Control
Component Location Index .................................. 4-36
Circuit Diagram ........................... 4-37
Symptom Troubleshooting Index ....................... 4-38
Cruise Control Unit lnDut Test ............................. 4-40
Main Switch TesVReolacement ........................... 4-42
SeVResume/Cancel Switch TesVReplacement .. 4-42
Cruise Control Actuator Test ...... 4-43
Cruise Control Actuator/Cable Replacement ...... 4-44
Actuator Cable Adjustment .................................. 4-45
Clutch Pedal Position Switch Test ....................... 4-45
4-2
4-J
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-15
4-16
4-17
4-18
4- 19
-+
ENGINE

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Starting System
Component Location Index
UNDER-DASHFUSE/RELAY BOX
CLUTCH INTERLOCK SWITCHTest, page 4-6
STARTERStaner Circuit Troubleshoot,ng, page 4 5Solenoid Test, page 4-7Performance Test, page 4-8Replacement, page 4-9Overhaul, page 4 '10
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4-3

Starting System
Circuit Diagram
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Starter Circuit Troubleshooting
NOTE:. Airtemperature must be between 59'and 100'F (15'
and 38'C) during this procedure.
. After this test, or any subsequent repair, reset the
engine controle module (ECM) to clear any diagnostlc
trouble codes (DTCS) {see page 11-4).. The battery must be in good condition and fully
charged.. lf you disconnect the baftery, do the ECM idle learn
procedure (see page 11-139).
Recommended Procedure:. Use a starter system tester.. Connect and operate the equipment in accordance
with the manuf acturer's instructions.
Alternate Procedure
1. Hook up the following equipment:. Ammeter, 0 400 A. Voltmeter, 0 20 V (accurate within 0.1 volt). Tachometer,0 1200 rpm
2.Remove the No. 17 (15A) fuse from the under-dash
fuse/relay box.
With the clutch pedal pressed, turn the ignition
switch to start (lll).
Did the starter crank the engine normally?
YES-The starting system is OK.I
NO-Go to step 4.
3.
L
4-5
4. Check the battery condition. Check electrical
connections at the battery, the negative baftery
cable to body, the engine ground cables and the
starter for looseness and corrosion. Then try
starting the engine again.
Did the statter crank the engine?
YES Repairing the loose connection fixed the
problem. The starting system is now OK.!
NO lf starterwill notcranktheengine atall, goto
step 5. lf it cranks the engine erratically or too
slowly, go to step 7. lf it won't disengage from the
flywheel ring gear when you release the key, check
for the following until you find the cause.
. Solenoid plunger and switch malfunction. Dirty drive gear or damaged overrunning clutch
5. Make sure the transmission is in neutral, then
disconnect the starter subharness 1P connector (A)
from the engine wire harness 'lP connector (B).
Connect a jumper wire from the battery positive
terminal to the starter subharness 'l P connector.
Did the starter crank the engine?
YES-Go to step 6.
NO Check the BLK,ANHT wire between the starter
subharness 1P connector and the starter. lf wire is
OK, remove the starter, and repair or replace as
necessary.
(cont'd)

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

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,

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Circuit Diagram
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4-21

Gharging System
Charging Circuit Troubleshooting
lf the charging system indicator does not come on or
does not go off, or the battery is dead or low, test these
items in the order listed below:
Battery (see page 22-50)
Charging system indicator
Alternator and regulator circuit
Alternator control system
Charging System Indicator Test
1. Turn the ignition switch ON {ll).
Does the chatging system indicator come on?
YES Go to step 2.
NO Go to step 3.
2. Start the engine.
Does the charging system indicator go off?
YES-Charging system indicator circuit is OK. Go
to the Alternator and Regulator circuit Test. t
NO-Go to step 3.
3. Turn the ignition switch OFF.
4. Troubleshoot the multiplex control system (see
page 22 172).
ls the multiplex control system OK?
YES Go to step 5.
NO Check the multiplex control system as
indicated by the diagnostic trouble code (DTC) (see
step 8 on page 22-172).1
5. Disconnect the engine wire harness 6P connector
from the starter sub harness 6P connector.
4-22
\"4
6. Measure the voltage at the No. 3 terminal of the
engine wire harness 6P connector with the ignition
switch ON { ll).
ENGINE WIRE HARNESS 6P CONNECTOR
IBLK/YEL}
Wire side of female terminals
ls there battery voltage?
YES-Go to step 7.
NO-Check for a blown No.4 {10A) fuse in the
under-dash fuse/relay box. lf the fuse is OK, repair
open in the wire between the alternator and the
under-dash fuse/relay box. I
Turn the ignition switch OFF.
Disconnect engine control module (ECM) connector
B (24P).
Check continuity between the ECM connector
terminal B'10 and engine wire harness 6P connector
terminal No. 6.
?
7.
8.
9.
ACGL {WHT/BLU)
ENGINE WIBEHARNESS6PL (WHT/BLUI
Wire side of femaletermina s
ls there continuity?
YES Go to step 10.
NO-Repair open in the wire between the
alternator and the ECN4.I
ECM CONNECTOB A (24P)

'10. Check continuity between the ECM connector
terminal 810 and body ground.
ECM CONNECTOR S I24PI
23 t4 t567
8I10,/1,/315
118,Nnt,/2123
ACGL (WHT/BLUI
t1'
Wire side ol female terminals
ls there continuity?
YES- Repair short to ground in the wire between
the ECM and the engine wire harness 6P connector.
t
NO-Go to alternator and regulator test.
Alternator and Regulator Circuit Test
1. Be sure the battery is sufficiently charged and in
good condition {see page 22-50), and the
connections at the fuse box and alternator are
clean and tight.
2. Raise the hoist to full height.
3. Hook up the ammeter, 0 400 A, to the starter
sub harness.
Lower the hoist.
Hook up the voltmeter, 0 20 V (accurate within
0.1V),toT101.
(cont'd)
4-23

Gharging System
Charging Circuit Troubleshooting (cont'd)
6. Start the engine. Hold the engine at 3,000 rpm with
no load (in Neutral) until the radiator fan comes on,
then let it idle.
7. Raise the engine speed to 2,000 rpm, and hold it
there.
8. Turn the headlights (high beam) on, and measure
voltage at the under-hood fuse/relay box terminal.
ls the voltage between 13.9 and 15.1 v?
YES-Go to step 9.
NO Repair or replace the alternator components
(see page 4-30).1
9. Read the amperage at '13.5 V.
NOTE: Adjust the voltage by turning the blower
motor, rear window defogger, brake lights. etc. ON.
ls the amperage 604 ot morc?
YES-Alternator/regulator operation is OK. I
NO Repair or replace the alternator components(see page 4-30).1
4-24
\,
Alternator Control System Test
NOTE: After troubleshooting, perform the engine
control module (ECM) idle learn procedure (see page
11-139).
1 . Check for proper operation of the electrical load
detector (ELD) by checking the malfunction
indicator lamp (MlL) (see page 1 l-3). lf a DTC is
present, diagnose and repair the cause before
continuing with this test.
2. Disconnect the engine wire harness 6P connector
from the starter sub harness 6P connector.
3. Start the engine, and turn the headlights (high
beam) ON,
4. Measure voltage between the engine wire harness
6P connector terminal No. 2 and the positive
terminal of lhe battery.
C {WHT/GRN)
ENGINE WIRE HARNESS 6P CONNECTOR
Wire side of female terminals
ls there 1 V or less?
YES Go to step 8.
NO-Go to step 5.
Turn the headlights and ignition switch OFF.
Disconnect ECM connector B (24P).
5.
6.
BATTERY