FUEL AND EMISSION HONDA CIVIC 2003 7.G Workshop Manual

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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ra
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
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A
I
Do the items in parts A, B, C, D, E, F, and G as required for mileage/time interval listed.
Feplace engine oil(see pageS 5). Capacity withoutlilter change:4.0 q (4.2 US qt,3.5lmp qt)
Replace engjne oil filter (see page I 6). Capacity with filter change: 4.2 0 14.4 US qt, 3.7 lmp qt)Insoect front and rear brakes,. Check pads and discsforwearlthickness), damage, andcracks.. Check calipers for damage, leaks, and tightness of mount bolts.Lubricate door locks, latches and hinges with Honda white lithium grease.Rotate tires, if the vehicle has been driven the distance listed. Follow the pattern shown in the Owner's Manual-Check tire inflaron aoocondition,Inspecttie rod ends, steering gearbox, and boots (see page 17,5).. Check rack grease and steering linkage.. Check boots for damage and leaking grease.. Checklluid linefordamage and leaks.Inspect suspensron components. Check bolts for tightness.. Check condition of ball joint boots for deterioration and damage.Inspect driveshaft boots. Check boots for cracks and boot bands for tightness (see page 16-3).
Check parking brake adjustment. Should be fully applied within 7 to 9 clicks.Insp€ct brake hoses and lioes. (including ABS). Check the master cylinder, proportioning control valve, and ABS modulator for damageand leakage (see page 19-24).Check all fluid levels and condition ot lluids; check for leaks. lf necessary, add MTF (see page 13 3), engine coolant, brake fluid, andwindshield washer f luid.Inspect exhaust system*. Check catalytic converter heat shield, exhaust pipe and muffler for damage, leaks, and tightness (see page 9 8).Inspect fuel lines and connections*. Check for loose connections, cracks and deterioration; retighten loose connections and replacedamaged pans (seo page 11'146).Check alllights. Checkfunction otallinterior and exterior lights, andthe position ofthe headlights (see page 22-68).Inspect the v€hicle underbody. Check the paint for damage, scratches, stone chippin0, and dents.
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D
E
F
H
InsDect and adiust drive belt.. Look tor cracks and damage, and inspect auto tensioner {needs no adjustment).Reolace dust and oollen filter.
Replace air cleaner element every 15,000 miles 124,000 km) in dustv condition {independent ol timei otherwise use Normal Conditionsscredule (see page 11-162).
lReplaceaircleanerelementevery30,000miles(48,000km)(independento{timei(seepagell-162).
Replace brake fluid every 3 years (independent oJ mileagei.
Replacethe dust and pollen Iilter every 15,000 miles ifvehicle is driven mostlywhere air has high concentration olsootfrom industryanddiesel powered vehiclesj also replace the dust and pollen filter anytime aarflow is less than ussal (see pags 21-39).
According to state and federal regulations, failure to do the maintenance items marked with asterisk (*) will not void customer's emissionswarranties. However, Honda recommends that all maintenance services be done at the recommended interval to ensure long-term reliability,
3-7

Maintenance Schedule
Service atthe indicated distance ortime,whichever comes first.miles x 1,000t020304050708090 100110r20
km x 1,000163248648096112128144 160192
months12243486012
Replace engine oilooooaooaaoOa
Rotate tires{Check tire intlation and condition at least once per month)
Replace engine oil filterooaaaa
Inspect front and rear brakes
Check parking brake adjustment
Visually inspect the following items:. Tie-rod ends, steering gearbox and boots. Suspension components. Driveshaft boots. Brake hoses and lines (including ABSi. Allfluid levels and condition of{luids. Exhaust system*. Fuel lines and connections*
Inspect and adjust drive beltaaaa
Replace dust and pollen filter
Reolace transmission fluid
Servicethe following items at the recommended intervals
a
Replace air cleaner elementEvery 30,000 miles (48,000 km)
Replace spark plugsEvery 110,000 miles (176,000 Lm)
Inspect valve clearanceInspect every 110,000 miles {176,000 km), otherwise adiusl only if noisy.
Inspect idle speed*Every 160.000 mr es 1256,000 km) or 8 years
Replace engine coolantAt 120,000 miles (192,000 km) or 10 years, then every 60,000 miles (96,000 km) or 5
Replace brake fluidEvery 3 years
Listed by Maintenance ltem for Normal Conditions
Follow the Normal Schedule if the severe driving conditions specified in the lMaintenance Schedule for Severe Conditions on the next page do
not apply, and if only OCCASIONALLY driven in severe driving conditions.Follow the Severe Conditions schedule if the vehicle is driven MAINLY in Canada.
* : According to state and lederal regulations, failure to do the maintenance items marked with asterisk (*) will not void customer's emissions
warranties. However, Honda recommends that all maintenance service be done at the recommended interval to ensure long-term reliability-
c
3-8

Listed by Maintenance ltem for Severe Conditions
Use this schedule if the vehicle is driven MAINLY in Canada or in anv of the followina conditions.NOTE: it only OCCASIONALLY driven in theseconditions, use the Normal Conditions schedute.Sovere Driving Conditions. Driving less than 5 miles (8 km) per trip or, in lreezing temperatures, driving less than. Driving in extremely hot over 90 "F 132 'C)conditions.10 miles (16 km) per trip.
. Extensive idling, or long periods ot stop-and-go-driving, such as a taxi or a commercial delivery vehicle.. Trailer towing, driving with a cartop carrier, or driving in mountainous conditions.. Driving on muddy, dusty, or de iced roads.
Service at the indicated distance or time,whichever comes first.miles x 1,000102030405060708090100110120
km x 1,0001648648096112128144160176192
months122436486072
Replace engine oilReplace every 5,000 miies 18,000 km)or 6 months
Rotate tires{Checktire intlation and condition at leastonce per monthiaoaaoaaoaaao
Replace engine oil fiher
Inspect front and rear brakes
Lubricate all locks, hinges, and latches
Visually inspect the following items:. Tie rod ends, steering gearbox and boots. Suspension components' Driveshaft boots
Checl parking brale adjuslmentaaOaoa
Visually inspect the following items:. Brake hoses and lines {including ABSi. Allfluid levels and condition oflluids. Exhaust system*. Fuel lines and connections*. Lights and controls, vehicle underbody
Inspect and adjust drive behoaoa
Replace dust and pollen filter"o't'
Replace transmission lluidaa
Service the following items atthe recommended interuals
Replace air cleaner elementEvery 15,000 miies (24,000 km) in dusty conditions, otheMise use normal schedule.
Replace spark plugsEvery 110,000 miles (176,000 km)
Inspect valve clearanceInspect every 110,000 miles (176,000 km), otheMise adiust only if noisy.
Inspect idle speed'Every 160,000 miles (256,000 km)or8 vears
Replace engine coolantAt 120,000 miles (192,000 km) of 10 years,lhen every 60,000 miles (96,000 km)or 5
Replace brake fluidEvery 3 years
* : According to state and federal regulations, failure to do the maintenance items marked with asterisk 1*)will not void customer's emissionswarranties. However, Honda recommends that all maintenance service be done at the recommended interval to ensure long{erm reliabilitv.
NOTE 1: Replace the dust and pollen filter at 15,000 miles/24,000 km if the vehicle is driven mostly in urban areas that have high concentrationsof soot in the air from industrv and diesel-Dowered vehicles.
t,
3-9

8. Remove the intake air duct.
9. Remove the battery cables {A) fromthe under-hood
fuse/relay box. then remove the harness clamp (B)
and ground cable (C).
10. Fullv ooen the throttle link and cruise control link
by hand, then remove the throttle cable (A) and
cruise control cable (B)from the links. Loosen the
locknuts {C), and remove the cables from the
bracket.
11. Relievefuel pressure (see page 11-144).
12. Remove the fuel line(seepagell-149).
13. Remove the evaporative emission (EVAP) canister
hose {A) and brake booster vacuum hose (B).
(cont'd)
5-3

27. lnstallthe upper radiator hose {A) and heater hoses(B).
Push the engine control module (ECM) connectors
through the bulkhead, then installthe grommet (A).
29. Installthe harness clamps (B).
30. Connect the ECI\4 connectors (A) and main wire
harness connector (B).
Install the throttle cable (see page 11-164), then
adjustthe cable {see page 11-'163).
Installthe cruise control cable (see page 4-44), then
adjust the cable (see page 4-45),
Install the brake booster vacuum hose (A) and the
evaporative emission (EVAP) canister hose (B).
34. Installthe fuel line (see page 11-150).
31.
32.
33.
(cont'd)
5-13

Intake Manifold and Exhaust System
Intake Manifold Removal and Installation (cont'dl
5. Be prepared to catch and clean up spilled coolant.
Remove the water bypass hoses, then plug the
water bypass hoses.
6. Relievefuel pressure (see page 11-'144).
7. Remove the fuel line (seepagell-149).
8. Remove the positive crankcase ventilation (PCV)
hose (A), harness holder mounting bolt (B) and
harness clamp mounting bolt (C).
9-4
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9.Remove the engine wire harness connectors and
wire harness clamps from the intake manifold.
. Four injector connectors. ldle air control (lAC) valve connector. Throttle position (TP) sensor connector. fvlanifold absolute pressure {lvlAP) sensor
connector. Evaporative emission (EVAP)canister purge
valve connector
Remove the bolt securing the intake manifold and
bracket.
'1 0.
11.Remove allthe intake manifold mounting bolts/
nuts.
Remove the two stud bolts (A), then remove the
intake manifold (B).
1'>

Fuel and Emissions
Fuel and Emissions Systems
SpecialTools
General Troubleshooting
Information
DTC Troubleshooting lndex ....
Symptom Troubleshooting
1ndex...............
System Descriptions ................
Howto Set Readiness Codes ..
PGM-FlSystem
Component Location Index ....
DTC Troubleshooting ..............
MIL Circuit Troubleshooting ...
DLC Circuit Troubleshooting ..
Injector Replacement ...............
A,/F Sensor Replacement .........
Secondary HO2S
Replacement
ECT Sensor Reolacement .......
CMP Sensor B {TDC Sensor)
Replacement
IAT Sensor Replacement .........
Knock Sensor Replacement ....
CKP Sensor Reolacement .......
VTEC/VTC
Comoonent Location Index ....
DTC Troubleshooting ..............
VTC Oil Control Solenoid
Valve Removal/Test .............
CMP Sensor A Replacement ...
VTEC Solenoid Valve
Removal/lnsoection .............
ldle Control System
Component Location Index
DTC Troubleshooting ..............
A,/C Signal Circuit
TroubleshootinS ...................
Alternator FR Signal Circu it
TroubleshootinS ...................
EPS Signal Circuit
TroubleshootinS ...................
Brake Pedal Position Switch Signal
Circuit Troubleshooting .............
ldle Speed Inspection
ECM ldle learn Procedure .......
Fuel Supply System
Component Location Index
Fuel Pump Circuit Troubleshooting
1't-2
I I-J
11-7
1 1-10
11-12
11-46
11-49
11-52
11-97
11-109
11-111
11-113
11-113
11-114
11-114
11-115
11-115
11-116
11-117
1 1-1 18
11-127
11-128
11-128
11-129
1I-130
I t- t55
11-134
1 1- 135
1 1-137
1 1-138
1 1-139
1 1-140
11-141
11-144
Fuel PressureTest ................... 11-145
Fuel Lines Inspection ............... 11-146
Fuel Line/Ouick-Connect
Fittings Precautions ............. 1 1-148
Fuel Line/Ou ick-Con nect
Fittings Removal .................. 1 1-149
Fuel Line/Ou ick-Con nect
Fittings lnstallation ............... 11-150
Fuel Pressure Regu lator
Replacement ......................... 11-152
Fuel Fifter Replacement ........... 11-152
Fuel Pump/Fuel Gauge Sending
UnitReDlacement ................. 11-153
Fuel Pulsation Damoer
Rep1acement ......................... 11-154
Fuel Tank Reolacement ........... 11-155
Fuel GaugeSending UnitTest ....... 11-156
Low Fuel lndicatorTest ................. 1 1-158
Intake Air System
Comoonent Location Index .... 11-159
Throttle BodyTest ................... 11-160
Intake Air Bypass Control
Thermal Valve Test .............. 11-161
Air Cleaner Reolacement ........ 11-162
Air Cleaner Element
Reolacement ......................... 11-162
Throttle Cable Adjustment ...... 11-163
Th rottle Cable
Removal/lnstallation ............ 1 1-164
Th rottle Body Removal/
Installation .. 11-165
Th rottle Body Disassembly/
Reassemblv .......................... 11-166
Catalytic Converter System
DTC Troubleshooting .............. 1 1-167
PCV System
DTC Troubleshooting .............. 1 1-168
PCV Valve InsDection
and Test ...... 1 1- 169
PCV Valve Reolacement .......... 11-169
EVAP System
Component Location Index .... 11-170
DTCTroubleshooting .............. 11-171
EVAP Two Way Valve Test ...... 11-186
Fuel Tank Vaoor Control
Valve Test ... 11-187
EVAP Canister Replacement ... 11-189
Fuel Tank Vaoor Control
Valve Reolacement .............. 1 1-189Fuel Pressu re Relieving ...........

Fuel and Emissions Systems
Rel. No.Tool NumberDescriptionotv(L)
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@-2
O-3
@-4
@(iD
A973X-041-XXXXX
07JAZ-0010008
07sAz-001000A
07vAJ-0040100
07NAJ-P07010A
07xAA-001010A
07zAJ-S5AA200
07406-0020201
07406-0070300
OTMAJ-PY4O11A
07MAJ-PY40120
07406-004000A
07zAJ-S5A0100
Vacuum Pump/Gauge, 0 30 in.Hg
Vacuum/Pressure Gauge. 0 4 in.Hg
Backprobe Set
Fuel Pressure Gauge Adapter
Pressure Gauge Adapter
Fuel Sender Wrench
Hose, Oil Pressure
A,/T Pressure Hose
A,/T Low Pressure Gauge W/Panel
A,/T Pressure Hose ,2,210 mm
A,/T Pressure Hose Adapter
Fuel Pressure Gauge
Fuel Pressure Gauoe Set
1
1
2
1
1
1
SpecialTools
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11-2
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Fuel and Emissions Systems
General Troubleshooting Information (cont'dl
How to Reset the ECM
You can reset the ECM in either of two ways:
. Use the OBD ll scantool or Honda PGMTesterto
reset the ECM memory.
See the OBD ll scan tool or Honda PGI\4 Tester user's
manuals for specific instructions.' Turn the ignition switch OFF, and remove the No. 6
ECU {ECM} (15A) fuse (A)from the under-hood fuse/
relav box (Blfor 10 seconds.
How to End a Troubleshooting Session
(required after any troubleshootingl
1. Reset the ECM as described above.
2. Do the ECM idle learn procedure (see page 11-139)
3. Turn the ignition switch OFF.
4. Disconnectthe OBD ll scan tool or Honda PGM
Tester from the DLC.
NOTE: The ECM is part of the immobilizer system.
lf vou replace the ECM, it will have a different
immobilizer code. In order for the engine to start,
you must rewrite the immobilizer code with the
Honda PGM Tester.
11-4
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How to Remove the ECM for Testing
1. Remove the passenger's dashboard lower cover
{see page 20-63), the passenger's kick panel (see
page 20-63), and the glove box (see page 20-63).
2. Remove the ECM mounting bolts (B) and the ECM
(c),
9.8 N.m{1.0 kgf.m,7.2lbt.ft}
3. Remove the ECM (B).
4. Installthe ECM in the reverse order of removal.
L