Tdc HONDA CIVIC 2003 7.G Workshop Manual

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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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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

lgnition Timing Inspection
1.
4.
5.
Connect the Honda PGM Tester to the data link
connector (DTC), and check for DTC'S. lf a DTC is
present, diagnose and repair the cause before
inspecting the ignition timing.
Startthe engine. Hold the engine at 3,000 rpm with
no load (in Neutral) until the radiator fan comes on,
then let it idle.
Check the idle speed (see page 11-138).
Follow the tester's prompts in the "SCS" menu
{see the tester operator's manual),
Connect the timing light to the service loop.
o
6. Point the light toward the pointer (A) on the cam
chain case. Check the ignition timing under no load
conditions: headlights, blower fan. rear window
defogger, and air conditioner are not operaling. lf
the ignition timing differs from the specification,
and there are no engine control module {ECM)DTcs,
replace the ECM (see page 11-4)
lgnition Timing:
8"+2" BTDC {RED mark {B)) during idling in neutral
A
7. Turn the ignition switch OFF.
Disconnectthe Honda PGM Tester and thetiming
light.
4-17

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
/EEI
g----- -"-oowetew
EXHAUST CAMSHAFTSPROCKETRemoval, page 6 24Installation, page 6-25
EXHAUST CAMSHAFT
ROCKER ARMASSEMBLYOverhaul, page 6 27Inspection, page 6-28
6-4

WEC Rocker Arms Test
Special Tools Required. Air pressure regulator 07AAJ-PNAA100. VTEC air adaoter 07ZAJ-PNAA100. WEC air stoDoer 07ZAJ-PNAA200. Air joint adapter 07ZAJ-PNAA300
1. Remove the cylinder head cover (see page 6-22).
2. Set the No. 1 piston at top dead center (TDC) (see
step 1 on page 6-12).
3. Verify that the intake primary rocker arm (A) moves
independently of the intake secondary rocker arm
(B).
. lf the intake primary rockerarm does not move,
remove the primary and secondary rocker arms
as an assembly and check that the pistons in the
secondary and primary rocker arms move
smoothly. lf any rocker arm needs replacing,
replace the primary and secondary rocker arms
as an assemblv, and test.. lfthe intake primary rocker arm moves freely, go
to step 4.
6.
Repeat step 3 on the remaining intake primary
rocker arms with each piston at TDC. When all the
primary rocker arms pass the test, go to step 5.
Check that the air pressure on the shop air
compressor gauge indicates over 400 kPa
(4 kgflcm', 57 psi).
Inspect the valve clearance (see page 6-9).
Remove the sealing bolt (A)from the relief hole,
and install the VTEC air stopper (B).7.
OTAAJ.PNAAlOODOTZAJ-PNAA3OO
Remove the No. 2 and No. 3 camshaft holder bolts,
and installthe VTEC air adapters (C) finger-tight.
Connect the air joint adapter (D), and air pressure
regulator with a 0-100 psi gauge (E).
(cont'd)
OTZAJ.PNAAlOO
6-7

9. Apply air to the advance hole to release the lock.
Check that the VTC actuator moves smoothly. lf the
VTC actuator does not move smoothly, replace the
VTC acluator.
10.
Valve Glearance Adiustment
NOTE: Adjust the valves only when the cylinder head
temperature is less than 100'F (38'C).
1. Remove the cylinder head cover (see page 6-22).
2. Set the No. 1 piston at top dead center (TDC). The
punch mark (A) on the variable valve timing control
(VTC) actuator and the punch mark (B) on the
exhaust camshaft sprocket should be at the top.
Align the TDC marks (C) on the VTC actuator and
exhaust camshaft sprocket.
{cont'd)
6-9

Cylinder Head
Crankshaft Pulley Removal and
Installation (cont'dl
Installation
1. Clean the crankshaft pulley (A), crankshaft (B), bolt(C). and washer (D). Lubricate as shown below.
. .: Clean
O; Lubricate
Installthe crankshaft pulley, and hold the pulley
with holder handle (A) and holder attachment {B).
B07NAB-0010iroA
A07JAB-001020A
Tighten the bolt to 245 N.m (25.0 kgf.m, 181 tbf.ft)with a torque wrench and 19 mm socket (C). Do notuse an impact wrench.
Install the splash shield (see step 20 on page 5-12).
Insta ll front tires/wh eels.
ll
ll
t[] rL-'....-----=a
(-, ,
5U-1JItt-
5.
6-12
\-
Cam Chain Removal
NOTE: Keep the cam chain away from magnetic fields.
1. Turn the crankshaft pulley so ils top dead center(TDC) mark (A) lines up with the poinrer (B).
Remove the front tires/wheels.
Remove the splash shield.
a
2.
3.
-,,--.=.-----__--_
4. Remove the drive belt (see page 4-26).
5. Remove the cylinder head cover (see page 6-22).
6. Remove the crankshaft pulley (see page 6-11).
\

t
18. Remove the cam chain guide A (A) and tensioner
arm (B).
g"'-
19. Remove the cam chain.
,ot./6. | \{n$1J;
Cam Chain Installation
NOTE: Keep the cam chain away from magnetic fields.
1. Set the crankshaft to top dead center (TDC). Align
the TDC mark {A) on the crankshaft sprocket with
the pointer (B) on the cylinder block.
Setthe camshafts to TDC. The punch mark (A) on
the variable valve timing control {VTC) actuator and
the punch mark (B) on the exhaust camshaft
sprocket should be at the top. Align the TDC marks
(C) on the VTC actuator and exhaust camshaft
sprocKet.
(cont'd )
6-15

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

Cylinder Head Installation
Install the cylinder head in the reverse order of
removat:
1. Clean the cylinder head and block surface.
2. Install the new cylinder head gasket (A) anddowel
pins (B) on the cylinder block. Always use a new
cylinder head gasket.
Set the crankshaft to top dead center {TDC). Align
the TDC mark (A) on the crankshaft sprocket with
the pointer (B) on the cylinder block.
4. Install the cylinder head on the block.
5. Measure the diameter of each cylinder head bolt at
ooint A and Doint B.
a 50 mm (2.0 in.l
f.f )>-
A '15 mm {'1.8 in.)"<>.
lf either diameter is less than 10.6 mm {0.42 in.),
replace the cvlinder head bolt.
(cont d)
6-39

Oil Pump Removal
1. Setthe No. 1 piston attop dead center {TDC) {see
step 1 on page 6-12).
2. Remove the oil pan(seepageT-11).
3. Remove and discard the oil pumpchaintensioner.
4. To hold the rear balancer shaft, insert a 6 mm pin
driver (A) into the maintenance hole in the lower
balancer shaft holder and through the rear balancer
shaft.
5. Loosen the oil pump sprocket mounting bolt.
6. Remove the oil pump sprocket (A), then remove the
oil pump (B).
(cont'd)
8-9