Index HONDA CIVIC 2003 7.G Workshop Manual

INTRODUCTION
Safety
Your safety, and the satety of others, is very important. To helpyou make informed decisions, we have provided safetymessages, and other safety information throughout this manual.Of course, it is not practical or possible to warn you about all thehazards associated with servicing this vehicle. You must useyour own good judgment.
You will find impoftant safety information in a variety of formsincluding:. Satety Labels - on the vehicle.. Satetv Messages preceded by a salety alert symbol A andone of three signal words, DANGEF, WARNING, or CAUTION.These signal words mean:
tmEnEEril y;,: H,ll i": 5* i5"?;r s E R I o u s LY H u Br ir
E$EEEE ys,: f#,ff ,:hl:3,:JjERrousLY HURT ir
tlGtltT]llilll You cAN b€ HUBT if vou don't follow
. lnstructions - how to service this vehicle correctlv and safelv.
All information contained in this manual is based on the latestproduct information available at the time of printing. We reservethe right to make changes at any time without notice. No part ofthis Oublication maV be reDrodLrced, or stored in a retrievalsystem, or transmitted, in any form by any means, electronic,mechanical, photocopying, recording, or otherwise, without theprior written permission o{ the publisher. This includes text,figures, and tables-
As vou read this manual, vou will tind information that ispreceded by a @ symbol. The purpose of this message isto help prevent damage to your vehicle, other property, or theenvironment,
*Bodyz-tl!^t l
First Edition 8/2002 1,168 pages HONDA MOTOR CO.. LTD.All Rights Reserved Service Publication OfficeSpecifications apply to U.S.A. and Canada
As seclion3 with *inclode SRS comoonentsispecial precautionsare required when servicing.
How to Use This Manual -
This manual is divided into 23 sections. The first page of eachseclion is marked with a black tab that lines up with itscorresponding thumb index tab on this page and the back cover.You can quickly find the first page of each section withoutlooking through a full table of contents. The symbols printed atthe top corner of each page can also be used as a quickre{erence system.
Each section includes:1. A table of contents, or an exploded view index showingl. Parts disassembly sequence.. Bolt torques and thread sizes.. Page references to descriptions in text.Disassembly/assembly procedures and tools.Inspefiron.Testing/troubleshootin g.Repair.Adjustments.
2.3.4.5.6.
Specifications1)ll:{l+'
Maintenance
Emissions
*Restraints

Lubricants and Fluids
For details of lubrication points and type of lubricants to be applied, refer to the illustrated index and various work
ures {such as Assemoverhaul. lnstallation. etc.) contained in each section.
NO.LUBBICATION POINTSLUBBICANT
1E ng ineHonda Motor Oil (P/N 08798-9023). The oil container
must disolav the API Cenification seal shown below.
Make sure it says "For Gasoline Engines." SAE
Viscositv: See chart below.
2TransmissionHonda MTF*' (P/N 08798-9016)
3Brake svstem (includes ABS line)Honda DOT 3 Brake Fluid*' (P/N 08798-9008)
4Clutch line
5
6
Release fork (manual transmissionl
Throftle cable end (throttle Iink)
Super High Temp Urea Grease {P/N 08798-9002)
7
I
Shift and select cable ends (manual
transmission)
Throttle cable end (dashboard lower panel hole)
Silicone grease
9
10
111'
14
16
17
Brake booster clevis
CIutch booster clevis
Shift lever pivot
Pedal linkage
Battery terminals
Fuel f ill door
Hood hinges and hood latch
Hatch hinges
Door hinoes, uoDer and lower
Multi-purpose grease
18Caliper piston boot, caliper pins and bootsHonda CaliDer Grease (P/N 08C30-80234lvl)
19Air conditioning compressorCompressoroil: SP-10 (P/N 38897-P13-A01AH or
38899-P'13-A01)
For refriqerant; HFC'134 a (R-134 a)
I
Recommond6d Engine OilEngine oilviscosily for amb enttemperalure fanges
-30 -20 -10 0 t0 20
*1:
"2:
Always use Honda Manual Transmission Fluid (MTF). Using motor oii can cause stiffer shifting because it does
not contain the Drooer additives.
Always use Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of
the system.
3-2

\.
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

\-
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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STARTER CUT RELAYTest, page 22-51
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4-3

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

Gharging System
Component Location Index
CHARGING SYSTEM INDICATOR(ln the gauge assembly)
q*o
DRIVE BELTInspection, page 4 26Replacement, page 4 26
BATTERYTest, page 22-50
ALTEBNATORTroubleshooting, page 4-22Replacement, page 4-29Overhaul, page 4-30
4-20

Gruise Control
Component Location Index
CLUTCH PEDAL POSITIONswtTcHTest, page 4-45Clutch Pedal Adjustment,page 12-4
t.- _,- _
CRUISE CONTROLACTUATORTest, page 4'43Replacement, page 4-44
CRUISE CONTROL UNITlnput Test, page 4-40
BRAKE PEDAL POSITION SWITCHTest, page 22-84Pedal Height Adjustment, page '19-6
CRUISE CONTROL INDICATOR(Built into gaug6 assembly)
ACTUATOR CABLEAdjustment, page 4-45
-ll
4-36
\-a

Cruise Control
Symptom Troubleshooting Index
NOTE:' The numbers in the table showthetroubleshooting sequence.. Before troubleshooting.- check the No, 10 (7.5A) and No. 4 (10A) fuses in the under-dash fuse/relay box. and the No. 7 (15A) fuse in theunder-hood fuse/relay box,- check that the horn sounds.- check the tachometer to see if it works properly.- check the speedometer lo see if it works properly.
SymptomDiagnostic procedureAlso check forCruise control cannot be
set
1. Check main switch (see page 4-42)
2. Check SET/RESUME/CANCEL switch (see page 4-42)
3. Test brake pedal position switch (see page 22-84) and checkits adjustment {see page 19,6)
4. Test clutch pedal position switch (see page 4-45) and check
its adjustment (see page 12-41
5. Check cruise control unit {see page 4-40}
6. Check vehicle speed sensor (VSS) (see page 22-65)
. Poor ground:
G501. Open circuit,
loose or
disconnected
term inals:
LT GRN,
BLI(ORN.
GRY/RED, BLU.
LT BLU,
BLUAA/HTCruise control can be set
but indicator light does
not go on
1. Check cruise control indicator bulb in gauge assembly {seepage 22-631
2. Check cruise control unit (see page 4-40)
. Poor ground:
G501. Open circuit,
loose or
disconnected
termrnats:
YEL, BLUA/ELar, 'i.a c^aa.l ic
noticeably higher or
lower than what was set
1. Check vehicle speed sensor (VSS) {see page 22-65)
Check cruise control actuator {see page 4-43)
2. Check cruise control unit (see page 4-40)
Excessive overshooting
or undershooting when
trying to set speed
1. Check cruise control actuator (see page 4-43)
2. Check vehicle speed sensor (VSS) (see page 22-65)
Check cruise control unit (see page 4-40)
3.
Speed fluctuation on a
flat road with cruise
control set
1. Check vehicle speed sensor (VSS) (see page 22-65)
Check cruise control actuator (see page 4-43)
2. Check cruise control unit (see page 4-40)
Vehicle does not
decelerate or accelerate
accordingly when SET/
RESUME/CANCEL button
is pushed
1. Check SET/RESU ME/CANCEL switch (see page 4-42)2. Check cruise control unit {see page 4-40)
Open circuit, loose
or disconnected
terminals:
GRY/RED,
LT GRN/BLKSet speed does not
cancel (engine rpm stays
high) when clutch pedal
is pushed
1. Testclutch pedal position switch (see page 4-45) and checkits adjustment (see page 12-4)
2. Check cruise control unit (see page 4-40)
Short to ground in
the LT BLU wire
Set speed does not
cancel when brake pedal
is pushed
'1. Test brake pedal position switch (see page 22-84) and checkits adjustment (see page 19-6)
2. Check cruise control unit (see page 4-40)
Open circuit, loose
or disconnected
terminals:
WHT/BLK
4-38
g,

\
Engine Mechanical
Cylinder Head
Special Tools
Comoonent Location Index
Engine Compression Inspection
VTEC Rocker Arm Test ........... ............ 6-7
VTC Actuator Inspection .................... 6-8
Valve Clearance Adjustment ............. 6-9
Crankshaft Pulley Removal and Installation .............. 6-11
Cam Chain Removal ........................... 6-12
Cam Chain Installation ....................... 6-15
Auto-Tensioner Removal/1nsta11ation ......................... 6-19
Chain Case Oil Seal Installation ........ 6-21
Cyf inder Head Cover Removal .......... 6-22
Cylinder Head Removal ..................... 6-23
WC Actuator. Exhaust Camshaft Sorocket
Repf acement .........6-24
Cylinder Head Inspection for Warpage ...................... 6-25
Rocker Arm Assembly Removal ................................. 6-26
Rocker Arms and Shafts
Disassembly/Reassembly .............. 6-27
Rocker Arms and Shafts Inspection ............................ 6-28
Camshaft Inspection .......................... 6-29
Valves, Springs, and Valve Seals Removal ................ 6-31
Valve Insoection ...................... ........... 6-32
Valve Stem-to-Guide Clearance Insoection ............... 6-32
Valve Guide Reolacement ................. 6-33
Valve Seat Reconditioning ................ 6-35
Valves, Springs, and Valve Seals Installation ............ 6-37
Rocker Arm Assemblv Installation .... 6-38
Cvlinder Head Installation ........................................... 6-39
Cylinder Head Cover Installation ...... 6-41
6-2
6-3
b-t'

Cylinder Head
Component Location Index (cont'd)
CAMSHAFT POSITIONICMP} SENSOR
TOP DEAD CENTER(TDC) SENSOR
CAMSHAFTHOLDER
f\
fr
T
F]
Fg
Y
R
LI
CAM CHAINGUIDE B
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EXHAUST CAMSHAFTSPROCKETRemoval, page 6 24Installation, page 6-25
EXHAUST CAMSHAFT
ROCKER ARMASSEMBLYOverhaul, page 6 27Inspection, page 6-28
6-4