ENGINE HONDA CIVIC 2003 7.G Workshop Manual

General Information
Chassis and Paint Codes - 2OO2 Model
Vehicle ldentffi cation Number
SHHEP3 35'2 U 300001
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a. Manufacturer, Make and Type of Vehicle
SHH; HONDAOFTHE U.K. MFG., LTD. U.K.
HONDA Passenger vehicle
b. Line, Body and Engine Type
EP3: CIVIC/K20A3
c. Body Type and Transmission Type
3: 2-door HatchbacUs-speed Manual
d. Vehicle Grade lSeries)
5: Si {U.S.}
5; SiR (Canada)
6: Si with side airbag system (U,S.)
6: SiR with side airbag system (Canada)
e. Check Digit
l. ModelYear
2i 2002
g. Factory Code
U: Honda of U.K. Manufacturing in Swindon,
E ng land
h. Serial Number
U.S,: 300001 -
1-
V€hicle ldentif ication Numbo.and Federal Motor VehicleSaf ety Standard Certif ication/Color Label.
1-2
I
1700001K2OA3
a
a. Engine Type
K20A3: 2.0 0 DOHC VTEC Sequential Multiport
Fuel-injected engine
b. Serial Number
Engine Number
Transmission Number
Paint Code
CodeColoru.s.Canada
B-92PNiqhthawk Black Pearl
NH-578Taffeta White
NH-623MSatin Silver lvletallic
R-81Milano Red
Y-62PEuro Yeliow Pearl
NBH3
I
a
Transmission Type
NRH3; s-sDeed Manual
1000001
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Chassis and Paint Codes - 2003 Model
Vehicle ldentif ication Number
SHHEP3 35*3 U 400001
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G.
d.
Manufacturer, Make and Type of Vehicle
SHH: HONDAOFTHE U.K. MFG., LTD. U.K.
HONDA Passenger vehicle
Line. Body and Engine Type
EP3: CIVIC/K20A3
Body Type and Transmission Type
3: 2-door HatchbacldS-speed Manual
Vehicle Grade (Series)
5: Si (U.S.)
5: SiR (Canada)
6: Si with side airbag system (U.S.)
6: SiR with side airbag system (Canada)
Check Digir
Model Year
3: 2003
Factory Code
U: Honda of U.K. Manufacturing in Swindon,
England
Serial Number
U.S.: 400001
f.
:700001
Vehicle ldentification Numberand Federal Motor VehicleSaletv Standard Certif ication/Color Label.
)_.
2700001K2OA3
I
a
a. Engine Type
K20A3: 2.0 0 DOHC VTEC Sequential Multiport
Fuel-injected engine
b. Serial Number
Engine Number
Transmission Number
NRH3
I
a
Transmission Type
NRH3: 5-speed Manual
Serial Number
- 2000001
Paint Code
CodeColorU,S.Canada
B-92PNiohthawk Black Pearl
B-520PVivid Blue Pearl
NH-578Taffeta White
NH-623MSatin Silver N4etallic
R-81Milano Red
Y-62PEuro Yellow Pearl
1-3

General Information
ldentification Number Locations
Vehicle ldentif icationNumber {vlN}Vehicle ldentificalionNumbe.lvlN)
1-4
(
I0
Engine Number
t)

General Information
Warning/Caution Label Locations (cont'dl
SRS WARNINGLABEL
SERVICE INFORMATION LABEL(Undor-hood Emission ControlInformation lab€l) and ENGINECOOLANT INFORMATION
RADIATORCAP CAUTION
BATTERYCAUTION
1-6
t
TIRE INFORMATION
c

Under-hood Emission Control Label
Emission Group ldentif ication
Example: 2002 model
THIS VEHICLE CONFORMS TO U.S. EPA TIER 2 BIN 5
AND NLEV LEV REGULATIONS APPLICABLE TO 2002
MODEL YEAR NEW PASSENGER CARS AND
CALIFORNIA REGULATIONS APPLICABLE TO 2OO2
MODEL YEAR NEW LEV Ii LEV PASSENGER CARS.
Example: 2003 model
THIS VEHICLE CONFORMS TO U.S. EPA TIER 2 BIN 5
AND NLEV LEV REGULATIONS APPLICABLE TO 2O03
MODEL YEAR NEW PASSENGER CARS AND
CALIFORNIA REGULATIONS APPLICABLE TO 2OO3
MODEL YEAR NEW LEV II LEV PASSENGER CARS,
rH/ @
Engine and Evaporative Families:
Engine Family:
Model Year
2:2002
3: 2003
Manulacturer Subcode
HNX: HONDA
Family Type
V: LDV
Displacement
Sequence Characters
VBP: 2002
XKC: 2003
Evaporative Family:
2 HNX R OO99 AAH
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ab cd
Model Year
2t 2002
3: 2003
Manufacturer Subcode
HNX: HONDA
Family Type
R: EVAP/ORVR
Canister Work Capacity
Sequence Charactets
AAH: 2002
AAA: 2003
2 HNX V O2.O VBP
rr-tt--[ttl
ab cd e
c.
d.
e.
c.
d.
e.
1-7

General Information
Parts Marking
To deter vehicle theft, certain major components are marked with the vehicle identification number (VlN). Originalparts have self-adhesive labels. Replacement body parts have generic self-adhesive labels. The original engrne ortransmission VIN plate is transferred lo a replacement engine or transmission and attached with break-off bolts.
NOTE: Be careful not to damage the parts marking labels during body repair. Mask the labels before repairing the part.
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1-10

ne
ItemMeasurementOualificationStandard or New Service Limitlgnition coilRated voltage
Firing order12V
1 3-4 2
NGK: tZFB6K11
DENSO: SKJ20DR-M11
1.0 1.1mm(0.039 0.043 in.) 1.3mm(O.OS1 in.)
Spark plugType
Gap
lgnition timingAt idle (check rhein neutral: 8t2' ETDC at 650150 rpm
AlternatorOutputAt 13.5 V and
normalengine
temperature
80A
2.2 3.0 ACoil lrotor) resistanceAt 68.F (20'C)
5|lp flng u.u.14.4 mm {0_57 in.) 14.0 mm (0.55 in.)Brush length10.5 mm (0.41 in.l 1.5 mm {0.06 in.)Brush spring tension2.9 3.5 N (0.30 0.36 kgf,0.7-0.8 tbs)StarterOutput
Commutator mica depth0.50 0.80 mm (0.020-0.031 in.) 0.20 mm 1O.OO8 in.)Commutator tunouto:BlalqryL4i) max o.o5 mm (0.002 in.)Commutator O.D.28.0 mm (1.10 in.) 27.0 mm (1.06 in.)Brush length14.0 14.5 mm {0.55 0.57 in.) 9.0 mm {0.35 in.)
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I
Standards and Service Limits
Enqine Electrical
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ItemMeasurementOualificationStandard or NewService LimitCompressionPressure check at 250 rpm with wide
open throftle. (See Design Specs for
rato,
Minimum930 kPa (9.5 kgflcmr, 135 psi)
Maximum
vanatton
200 kPa {2.0 kgf/cm',28 psi)
2-2

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2-5
oi
Lubrication
a
a
nqlne
|temMeasurementOualificalionStanderd or New Service Limil
Engine oilCapacity5.3 0 (5.6 US qt)for engine overhaul
4.2 0 (4.4 US qt) for oil change, including filter
4.0 0 (4.2 US qt)for oil change, without filter
Oilpumplnner-to outer rotor clearance0.02 0.16 mm {0.001 0.006 in.)0.20 mm (0.008 in.)
Pump housing to outer rotor
clearance
0-15 0.21 mm {0.006-0.008 in.)0.23 mm (0.009 in.)
Pump housing-to-rotor axial
clearance
0.02 0.07 mm (0.001 0.003 in.)0.12 mm (0.005 in.)
Balancer shafts, journal diameterNo. 1 journal, front
shaft
19.938 19.950 mm 10.7850 0.7854 in.)19.92 mm (0.784 in.)
No 1 journal, rear shaft23.938 23.950 mm (0.9424 0.9429 in.)23.92 mm (0.942 in.)
No. 2 journal, front and
rear shaft
32.949 32.961 mm 11.2912 1.2911 in.l32.93 mm (1.296 in.)
Ealancer shafts, journal taper0.005 rnm (0.0002 in.) max.
Balancer shafts, end playFront0.070 0.135 mm (0.0028 0.0053 in.)0.15 mm (0.006 in.)
Rear0.070 0.135 mm (0.0028 0.0053 in.)0.15 mm (0.006 in.)
Balancer shatts, shaft-to'bear;ng
clearance
No. 1 iournal, front
shaft
0.050 0.082 mm (0.0020 0.0032 in.)0.10 mm (0.004 in.)
No. 1 Journal, rear shaft0.050 0.082 mm (0.0020 0.0032 in.) 0.10 mm (0.004 in.i
No. 2 journal, front and
rear shafl
0.060 -0.120 mm (0.0024 0.0047 in.) 0.15 mm (0.006 in.)
Balancer shaft bearings, LD.No. 1 journal, front
shaft
No. 1 iournal, rear shaft
20.000 20.020 mm (0.1814 0.7442 in.l
Z+.OOO ZI.OZO m- tOSa+e- OSa57 ir'.)
20.03 mm (0.789 in.)
24.03 mm (0.946 in.)
No. 2 journal, front and
rear shaft
33.021 33.069 mm (1.3000 1.3019 in.)33.09 mm {1.303 in.)
Reliefvalve, oil pressure with oil
temperature at 176'F (80"C)
At idle70 kPa (0.7 kq?cm , 10 psr) min.
At 3,000 rpm300 kPa {3.1 ksf/cm',44 psi)min.
Standard or New Service Limit
6.7 L (7.1 USCoolant capacity {includes engine,
heater, hoses, and reservoir)
0.53 L (0.56 US
93 123 kPa (0.95 1.25 kqtcm , 14 18 psi)'t69 176'F (76 80'C)Thermostat OPeningtemPerature
8.0 mm {0.31 in.) min.
Turns OFF Subtract 5 15'F (3 8"C)from actual ON

ItemMeasulementOualificationStandard or New Service LimitFuel pressure
regulator
Pressure with fuel pressure gauge
connected
320-370 kPa 13.3-'3.8 kgtcm', 47 52psi)
FueltankCapacity50 4 (13.2 US galiEngine idleldle speed with headlights and radiator
fan off
Neutral750 50 rpm
Fast idleNeutral1,600150 rpm
Standards and Service Limits
Fuel and Emissionsf
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Clutch
ItemMea3urem€nlOualificationSlandard or NewService LimitClutch pedalHeight from the floor193 mm (7.60 in.)Stroke130 140 mm 15.1 5.5in.)
10 16 mm (0.39 0.63 in.)Disengagement height from the floor1'15 mm (4.53 in.) min.Bunout on clutch mating surface0.05 mm 10.002 in.) max.0.15 mm (0.006 in.)Clutch discBivet head depth1.65 2.25 mm (0.065 0.089 in.)0.7 mm {0.03 in.)Ihickness8.3 8.9 mm (0.33 0.35 in.)6.0 mm (0.24 in.)Pressure plateWarpage0.03 mm (0.001 in.)max.0.15 mm (0.001 in.)Height of diaphragm spring fingersMeasured with
specialtool and
feeler gauge
0.6 mm (0.02 in.) max.0.8 mm (0-03 in.)
2-6
\

L
v
2-11
Design Specifications
O
o
o
|temMeasurementOualificationSpecilication
DIMENSIONSOveralllength4,210 mm {165.8 in.)
Overallwidth1,695 mm 166.7 in.)
Overallheight1,440 mm (56.7 in.)
2,570 mm (101.2 in.)
Trackrront1,470 mm (57.9 in.)
Rear'1,470 mm (57.9 in.i
Ground clearance152 mm (5.98 in.)
Seating capacityfour {4)
wEtGt-iT {u.s.A.)Gross Vehicle Weight Rating
(GVWR)
3,660 rbs
WEIGHT
(CANADA)
Gross Vehicle Weight Rating
{GVWR)
1,660 kg
ENGIN ETvpeWater cooled. 4 stroke DOHC V-EC engin(
Cylinder arrangementInline 4'cylinder, transverse
Bore and stroke86 x 86 mm (3.39 x 3.39 in.)
Displacement1,998 cm'(122 cu in.)
Compression ratio9.8
Valve trainChain drive. DOHC VTEC 4 valves per cylinder
Lubrication systemForced, wet sump, with trochoid pumP
Oil pump displacementAt 6,000 engine
rpm
54.3 0 (57.4 US qo/minute
Water pump displacementAt 3,400 engine82 0 (87 US qt)/minute
F!el requiredUNLEADED gasoline with 86 pump octane number or higher
STARTERTvpeGear reduction
Normaloutput
Nominalvoltage12V
Hour rating30 seconds
Direction of rotationClockwise as viewecl from gear end
CLUTCHClutch tvpeSinqle plate dry, diaphragm spring
Clutch friction material surface area174 cm'{26.97 sq in.)
I\,1AN UAL
TRANSMISSION
TvpeSvnchronized, s-speed forward, 1 reverse
Primarv reductionDirect 1:1
Gear ratiolst3.062
2nd1.769
3rd1.212
4th0.921
5th0.738
Reverse3.583
FinalreductionTypeSinole helicalgear
Gear ratio4.164