Intake manifold HONDA CIVIC 2003 7.G Workshop Manual

Starter Replacement
1. Make sure you have the anti-theft code for the radio.
then write down the frequencies for the radio's
preset buttons.
2. Disconnect the negative cable from the battery first,
then disconnect the positive cable.
3. Disconnect the knock sensor connector.
4. Remove the bolt (A) securing the harness bracket,
then remove the intake manifold bracket (B).
A6x1,0mm12 N.m {1.2 kgf.m,8.7 tbt.ft)
8 x 1.25 mm22 N,m 12.2 kgt.m,16 rbf.ftl
L't2.
4-9
5. Disconnect the starter cable (A)from the B terminal
on the solenoid, then disconnect the BLK,/WHT wire
{B) from the S terminal.
10 x 1.25 mm44 N.m {a.5 kgf.m,33lblft)
8 x 1.25 mm9Nm10.9 kgf.m,7 lbl ft)
7.
9.
'10.
11.
2
S'-12x12smm6ilNm{6.5 kgl m,47lbfft)
Remove the two bolts holding the starter, then
remove the starter.
lnstall the starter in the reverse order of removal.
Make sure the crimped side of the ring terminal (A)
is facing out.
Connect the positive cable and negative cable to
the batterY.
Start the engine to make sure the starter operates
propeny.
Enter the anti-theft code for the radio, then enter
the customer's radio station presets.
Set the clock.
Perform the engine control module (EcM) idle learn
procedure (see page 1 '1- 139 ).
I

Engine Assembly
I
Engine Removal
Special Tools Required
Front subframe adapter EOS02C00001 1
NOTE:. Use fender covers to avoid damaging painted
surfaces.. To avoid damage, unplug the wiring connectors
carefully while holding the connector portion.. Mark all wiring and hoses to avoid misconnection.
Also, be sure that they do not contact other wiring orhoses, or interfere with other parts.
1. Secure the hood in the wide open position (support
rod in the lower hole).
2. Make sure you have the anti-theft code for the radio,
then write down the frequencies for the radio'spreset buttons.
3. Disconnect the negative cable from the battery first,then disconnect the positive cable.
4. Remove the battery.
5. Remove the intake manifold cover.
II
5-2
\,
6. Disconnectthe intake airtemperature (lAT) sensorconnector (A), remove the breather hose (B) and
vacuum hose (C), then remove the air cleaner
housing cover/intake air duct assemblv (D).
AC
7. Remove the air cleaner housing.

40. Install the air cleaner housinq.
6x1.0mm12 N m (1.2 kgf.m,8.7 lbt.ft)
Install the air cleaner housing cover (A) and
connect the intake air temperature (lAT) sensor
connector (B),
42. Installthe breather hose (C) and vacuum hose 1D).
41.
43. Installthe intake manifold cover.
6x1.0mm12Nm11.2kgf.m.8.7 tbf.ft)
Installthe battery. Clean the battery posts and
cable terminals with sandpaper, then assemble
them and apply grease to prevent corrosion.
Check that the transmission shifts into gear
smoothly.
Inspect for fuel leaks. Turn the ignition switch ON(ll) {do not operate the starter) so that the fuel pump
runs for about 2 seconds and pressurizes the fuel
line. Repeat this operation two or three times, then
check for fuel leakage at any point in the fuel line.
Refillthe engine with engine oil (see page 8-5).
Refill the transmission with fluid (see page 13-3).
Refill the radiator with engine coolant, and bleed
air from the cooling system with the heater valve
open (see page 10-6).
Perform the engine control module (ECM) idle learnprocedure (see page 11-139).
Inspect the idle speed (see page 1 1-138).
Inspect the ignition timing (see page 4-17).
Check the wheel alignment {see page 18-4).
Enter the anti-theft code for the radio, then enter
the customer's radio station presets.
Set the clock.
YE
44.
41.
]tE
46.
48.
49.
52.
53.
54.
50.
51.
55.
5-15

Cylinder Head
Engine Compression Inspection
1. Warm up the engine to normal operating
temperature (cooling fan comes on).
2. Turn the ignition switch OFF.
3. Remove the intake manifold cover (see step 1 onpage 6-22).
4, Disconnect all four injector connectors.
5. Start the engine, and let it run until it stalls.
6. Remove the iour ignition coils (see page 4-18).
7. Remove the four spark plugs.
8. Attach the compression gauge to the spark plug
note.
6-6
V,
\
9.
10.
Open the throttle fully, then crank the engine with
the starter motor and measure the compression.
Compression Pressure
Above 930 kpa (9.5 kgf/cm', 135 psi)
Measure the compression on the remaining
cylinders,
Maximum vadation
Within 200 kPa (2.0 kgf/cm', 28 psi)
lf the compression is not within specifications,
check these items, then remeasure the
compressron.
. Damaged orworn valves and seats. Damaged cylinder head gasket. Damaged or worn piston rings. Damaged orworn piston and cylinder bore
11.
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Gylinder Head
Cylinder Head Cover Removal
1. Remove the intake manifold cover.
2. Remove the four ignition coils (see page 4-'18).
3. Remove the dipstick (A) and breather hose (B).
6-22
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\
4, Remove the cylinder head cover
V:t :;t 1
|
,'.i/
(
(

Gylinder Head Removal
NOTE:. Use fender covers to avoid damaging painted
surfaces.
To avoid damage, unplug the wiring connectors
carefully whlle holding the connector portion.
To avoid damaging the cylinder head, wait until the
engine coolant temperature drops below 100'F (38"C)
betore loosening the cylinder head bolts.
Mark all wiring and hoses to avoid misconnection.
Also, be sure that they do not contact other wiring or
hoses, or interfere with other parts.
'1.
2.
3.
Drain the engine coolant (see page 10-6).
Remove the drive belt (see page 4-26).
Remove the intake manifold {see page 9-3).
Remove the air cleaner housing (see step 7 on page
5-2t.
5. Remove the water bypass hose (A).
Remove the exhaust manifold (see page 9-7
Remove the cam chain (see page 6-12).
6.
7.
).
8. Remove the engine wire harness connectors and
wire harness clamps from the cylinder head.
. Engine coolant temperature (ECT) sensor
conneclor. Camshaft position (Cl\4P) (top dead center (TDC))
sensor B connector. Camshaft posilion (CMP) sensor A connector
9. Remove the upper radiator hose (A) and heater
hose (B).
'10. Remove the harness holder (A)from the bracket,
then remove the connecting pipe mounting boh {B)
and brake booster vacuum line mounting bolts {C).
(cont'd)
1 1. Remove the water bvpass hose (D).
6-23

14. Installthe water bvpass hose.
15. Installthe air cleaner housing (see step 37 on page
5-15).
16. Installthe intake manifold (see page 9-5).
17. Installthe exhaust manifold (see page 9-7).
'18. Installthe cam chain (see page 6-15).
19. Adjust the valve clearance (seepage6-9).
20. Installthe drive belt (see page 4-26).
21. Clean the battery posts and cable terminals with
sandpaper, then assemble them and apply grease
to prevent corrosion.
22. After installation, checkthatall tubes, hosesand
connectors are installed correctly.
23. Inspectforfuel leaks. Turn the ignition switch ON
{ll) {do not operate the starter) so that the fuel pump
runs for about 2 seconds and pressurizes the fuel
line. Repeat thls operation two or three times, then
check for fuel leakage at any point in the fuel line.
24. Refillthe radiator with engine coolant, and bleed
air from the cooling system with the heater valve
open (see page 10-6).
25. Inspect the idle speed (see page 11-'138).
26. Inspect the ignition timing (see page 4-17).
Gylinder Head Cover lnstallation
1. Thoroughly clean the head cover gasket and the
groove.
2. Installthe head cover gasket (A) in the groove of
the cylinder head cover (B).
Check that the mating surfaces are clean and dry.
Apply liquid gasket. P/N 08718-0009, on the chain
case and the No.5 rocker shaft holder mating areas.
NOTE: Do not install the parts if 5 minutes or more
have elapsed since applying liquid gasket. Instead,
reapply liquid gasket after removing old residue.
(cont'd)
6-41

9.
10.
Install the four ignition coils (see page 4-'18).
Check that all tubes, hoses, and connectors are
installed correctly.
lnstallthe intake manifold cover.11.
6x 1,0 mm'12 N.m {1.2 kgf m.8.7 tbf.ftl
12. After assemblv, wait at least 30 minutes before
filling the engine with oil.
6-43

Engine Mechanical
Intake Manifold and Exhaust System
lntake Manifold Removal and Installation ................. 9-2
Exhaust Manifold Removal and Installation .............. 9-7
Exhaust Pipe and Muffler Replacement ..................... 9-8
r
r-!i!1

Intake Manifold and Exhaust System
lntake Manifold Removal and Installation
Exploded View:
INTAKE MANIFOLD PLATEReplace if cracked orif mating surface isdamaged.
6x1.0mm12 N.m{1.2 kgf.m,8.7 lbf.ft)
\
I
GASKETReplace.
8 x 1.2522Nm12.2 ksf
\
\8x22
k'e)
t9
w)
k
('!
16
.25 mm'mkgf.m, 1
8 x 1.25 mm22 N.m(2.2 kgf m. 16 lbt.ft)
(
8 x 1,25 mm22 N.m {2.2 kgf.m, 16 lbf ft}
INTAKE MANIFOLDReplace if cracked orif mating surface is
9-2
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