Locks HONDA CIVIC 2003 7.G Workshop Manual

General Information
Lift and Support Points
NOTE: If you are going to remove heavy componentssuch as suspension or the fuel tank from the rear of thevehicle, first supportthe front ofthe vehicle with tallsafety stands. When substantialweight is removed
from the rear of the vehicle, the center of gravity canchange and cause the vehicle to tip forward on the hoist.
Frame Hoist
1. Position the hoist lift blocks (A), or safety stands,under the vehicle's front support points (B) and rearsupport points (C).
2. Raise the hoist a few inches, and rock the vehiclegently to be sure it is firmly supported.
3. Raise the hoistto full height, and inspectthe liftpoints for solid contact with the lift blocks.
Safety Stands
To support the vehicle on safety stands. use the samesuppon points (B and C) as for a frame hoist, Alwaysuse satety stands when working on or under anyvehicle that is supported only by a jack.
1-8
Floor Jack
1. Set the parking brake.
2. Block the wheels that are not being lifted.
3. When lifting the rear of the vehicle. put thegearshift Iever in reverse.
4. Position the floor jack under the front jacking
bracket (A) or rear jacking bracket (B), center thejacking bracket in the jack lift ptatform (C), and jack
up the vehicle high enough to fit the safety standsunder it.
c
Position the safety stands underthe support points
and adjust them so the vehicle will tevet.
Lower the vehicle onto the stands.
0
Jt

L
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.
L
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

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

Starting System
Circuit Diagram
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UiIOEN H@D fUSE/REI.IY BOX
UNDEi OASTIFUST/ifLAY80x
Y.
ST HOT in STA8T illl
cLuTot [{Tr8LocKswtlcH
4-4
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Starting System
Starter Overhaul (cont'dl
Planetary Gear Inspection
16. Check the planetary gears (A) and ring gear {B).Replace them if they are worn or damaged.
Overrunning Cluich Inspection
17. Slide the overrunning clutch along the shaft.
Replace it if it does not slide smoothly.
18. Rotate the overrunning clutch (A) both ways.
Does it lock in one direction and rotate smoothly inreverse? lf it does not lock in either direction or it
locks in both directions, replace it.
lf the starter drive gear (B) is worn or damaged,
replace the overrunning clutch assembly; the gear
is not available separately.
Check the condition of the flywheel ring gear.
Replace it if the starter drive gear teeth are
oamageo.
19.
4-14
i.-
Starter Reassembly
20, Pry back each brush spring with a screwdriver, thenposition the brush about halfway out of its holder,
and release the spring to hold it there.
NOTE: To seatthe new brushes. slip a strip of #5OO
or # 600 sandpaper. with the grit side out, be&veen
the commutator and each brush, and smoothly
rotate the armature. The contact surface of the
brushes will be sanded to the same contour as the
commutator.
21lnstallthe armature in the housing, and installthe
brush holder. Next, pry back each brush spring
again, and push the brush down until it seats
against the commutator, then release the spring
against the end of the brush.
s
Install the starter end cover to retain the brush
holder.

Cylinder Head
Camshaft Inspection (cont'dl
1.
9.
Unscrew the camshaft holder bolts two turns at a
time, in a crisscross pattern. Then remove the
camshaft holders from the cylinder head.
Lift the camshafts out of the cylinder head, wipe
them clean. then inspect the lift ramps. Replace the
camshaft if any lobes are pitted, scored, or
excessively worn,
Clean the camshaft journal surfaces in the cylinder
head, then set the camshafts back in place. Place a
plastigage strip across each journal.
Install the camshaft holders, then tighten the bolts
to the specified torque as shown in step 2.
Remove the camshaft holders. Measure the widest
portion of plastigage on each journal.
. lf the camshaft-to-holder clearance is within
limits, go to step 1 1.. lf the camshaft-to-holder clearance is beyond the
service limit and the camshaft has been replaced,
replace the cylinder head.. lf the camshaft-to-holder clearance is beyond the
service limit and the camshaft has not been
replaced, go to step 10.
Camshaft-to-Holder Oil Clearance:
Standard (New):
No. 1 Journal:
No.2,3,4,5 Journals:
Service Limit:
0.030 0.069 mm
{0.001 0.003 in-)
0.060*0.099 mm
{0.002 0.004 in.)
0.15 mm {0.006 in.)
6-30
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{\
10. Check the total runout with the camshaft supported
on V-blocks,
.lfthetotal runout of the camshaft is within the
service limit, replace the cylinder head.. lf the total runout is beyond the service limit,
replace the camshaft and recheck the camshaft-
to-holder oil clearance. lf the oil clearance is still
beyond the service limit, replace the cylinder
neao.
Camshaft Total Runout:
Standard (New): 0.03 mm (0.001 in.) max.
Service Limit: 0.04 mm {0.002 in.)
11. Measure cam lobe height.
Cam
PRI: Primary
C/C: Cam Chain
SEC: Secondary
I\,
Lobe Heioht Standard (New
INTAKEEXHAUST
PRI33.925 mm(1.3356 in.)
34.092 mm
\1 .3422 in.l
SEC29.638 mm(1.1668 in.)

Fuel and Emissions Systems
aSystem Descriptions (cont'dl
ECM Electrical Connections
\
No. INJECTOR
No,2INJECTOR
No.3 INJEC]OB
No./tINJECTOF
MAPSENSON
TPSENSOR
IATSENSOR
ECTSENSOB
\'
CMP SENSOR B(TDC SENSOSJ
CKPSENSOR
11-16
F€VERSE LOCKSOLENOIDVAIVE
\-

Wire side o{ female terminals
NOTE: Standard baftery voltage is 12 V.
Terminalnumo€tWire color[erminal nameDescriptionSignal
BLUAvHTVTC+ lVTC OIL CONTBOLSOLENOID VALVE +SIDE)Drives VTC oilcontrolWith ignition switch ON (ll): 0 V
2lNJa {No. 4INJECTOR)Driveso. 4 iniectorAt idle: duty controlled
3BLJo.3INJECTORIDriveso.3 iniector4R1)TOR)Driveso.2 iniector
5BRNlNJl 1No. I INJECTOR)Drives No. 1 iniector
6GRNFANC (RAOIATOR FANCONTROL)Drives radiator fan relayWith radiator fan running: about 0 VWith radiator fan stopped: batterv voltaoe
7GRN/vVHTRVS (REVERSE LOCKSOLENOID VALVE)Drives reverse lock solenoidWith vehicle speed below 9.4 mph (15 km/h):battery voltageWith vehicle speed above 12.5 mph (20 km/h): 0 V
8REDAVHTECT (ENGINE COOLANTTFMPFRATURE SENSOR)Detects ECT sensor signalWith the ignition switch ON (ll): about 0.1 4.8 Videoendino on enoine coolant temDerature)
9BLU/BLKVTPSW (VTEC OILPRFSSTIRF SWITCH)Detects VTEc oil pressureswitch sionalWith engine at low engine speed: about 0 .Wirh enoine at hioh enoine soeed: batterv voltaqe
10WHT/BLUALTL (ALTEBNATOR LSIGNAI IDetects alternator L signalWith ignition swit'ch ON (ll): about 0 VWhh enoine runnino: batterv voltaqe
WHT/REDALTF (ALTERNATOR FRSIG NALIDetecls alternator FB signalWith engine running: about 0 V- 5 V{deoendinq on electrical load)
GRN/YELVTS {VTEC SOLENOIDDrives VIEC solenoid valveAt idle: about 0 V
'17REDI/ELIAT (INTAKE AIRTEMPERATURE SENSOR)Detects IAT sensor signalWith ignition switch ON {ll): about 0.1 V 4.8 vl.lcnen.iino on intake air temoerature)
18WHT/GRNALTC (ALTERNATOR
CONTROL)Sends alternator controlWith engine running: about 0 V 5 V(.lcocn.lino on electrical ioad)
21YEUBLUPCS {EVAPORATIVEEMISSION CANISTERPURGE VALVE)
Drives EVAPcanister purgevalveWith engine running, engine coolant below 149'F
165'C): battery voltageWith engine running, engine coolant above 149'F165"C): dutv controlled
23BLK/Vr'HTVTC (VTC OIL CONTROLSOI FNOID VALVE SIDE)Drives VTC oilcontrolWith the ignition switch ON (ll): 0 V
(confd)
11-21

'10. Measure the thickness ofthe MBS distance collar.
. lf the thickness of MBS distance collar is less
than the standard, replace the MBS distance
collar with a new one.
Standard:23.95 24.05 mm
{0.9(3 0.947 in.)
E-f
Mainshaft Disassembly
1.Remove the angular ball bearing (A) and the
tapered cone ring using a commercially available
bearing separator {B) and a commercially available
bearing puller {C). Be sure the bearing separator is
under the tapered cone ring.
Support 5th gear (A) on steel blocks, and press the
mainshaft out of the sth synchro hub (B). Use of ajaw-type puller can damage the gear teeth.
(cont'd)
13-25

Manual Transmission
Mainshaft Disassembly (cont'dl
3. Supportthe 3rd gear (A) on steel blocks, and press
the mainshaft out of the 3rd/4th synchro hub (B).
Use of a jaw-type puller can damage the gear teeth.
13-26
Mainshaft Inspection
1. Inspect the gear surface and bearing surface for
wear and damage, then measure the mainshaft at
points A, B, C, D, and E. lf any part of the mainshaft
is less than the service limit, reDlace it with a new
o ne.
Standard:
A Ball bearing surface (transmission housing side):
27.987 28.000 mm (1.1019 1.1024in.)
B Distance collar surtace:
31.984 32.000 mm {1.2594 1.2598in.)
C Needle bearing surlace:
38.984-39.000 mm (1.53/t8 1.5354 in.)
D Ball bearing surface (clutch housing side):
27 .977 -27 .990 mm (1.1015 1.1020in.)
E Bushing surface:
20.80 20.85 mm (0.819 0.821 in.)
Service Limit;
A: 27.93 mm 11.100 in.l
B: 31.93 mm |.1.257 in.l
C: 38.93 mm 11.533 in.l
Di 27.92 mm {1.099 in.l
E: 20.75 mm 10.817 in.l
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