dashboard HONDA CIVIC 2003 7.G Workshop Manual

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

Cruise Control
1.
Main Switch Test/Replacement
Remove the driver's dashboard lower cover (see
page 20-59).
Release the clips of the main switch and push the
main switch 1A) out of the panel, then disconnect
the 5P connector (B) from the main switch.
Check for continuity between the terminals in each
switch position according to the table. lf the
continuity is not as specified, replace illumination
bulbs (C) or the switch.
\-------11v1
Position14
OFF(9@
ONo@o\Jo
4-42
r\--
Set/Resume/Cancel Switch Test/
Replacement
1. Remove the two screws. then remove the switch.
Check for continuity between the terminals in each
switch position according to the table.
. lfthere is continuity, and it matches the table, but
switch failure occurred on the cruise control unit
input test, check and repair the switch circult.. lf there is no continuity in one or both positions,
replace the switch.
Terminal
;"itl* '\2
sET (ONtCF--o
RESUME ION)o--o
CANCEL {ON}o

General Troubleshooting Information
Intermittent Failures
The term "intermittent failure" means a svstem mav
have had a failure. but it checks OK now. lf the
Malfunction Indicator Lamp (MlL) on the dash does not
come on, check for Door connections or loose terminals
at all connectors related to the circuit that Vou are
troubleshooting.
Opens and Shorts
"Ooen" and "Short" are common electrical terms. An
open is a break in a wire or at a connection. A short is
an accidental connection of a wire to ground or to
another wire. In simple electronics, this usually means
something won't work at all. With complex electronics(such as ECMs)this can sometimes mean something
works, but not the way it's supposed to.
How to Use the PGM Tester or a Scan Tool
lf the MIL {Malfunction Indicator Lamp} has come on
'1. Start the engine and check the MIL {A).
NOTE: lf the ignition switch is turned ON (ll), and
the engine is not started, the MIL will stay on for
15 20 seconds (see page 11-46).
K-> ;"PN/.- -::: - -d V-: !
w:ix&K#
2. lf the MIL stays on, connect the Honda PGM Tester(A) or an OBD ll scan tool to the Data Link
Connector {DLC) (B) located under the driver's side
of the dashboard.
3.
5.
Turn the ignition switch ON (ll).
Check the Diagnostic Trouble Code (DTC) and note
it. Also check the freeze data. Refer to the DTC
Troubleshooting Index, and begin the appropriate
troubleshooting procedure.
lf you do not find any DTCS, go to MIL circuit
troubleshooting (see page 11-97).
NOTE:. Freeze data indicates the engine conditions when the
first malfunction, misfire, or fuel trim malfunction
was detected.. The scan tool and the Honda PGM Tester can read the
DTC, freeze data, current data, and other Engine
Control l\4odule {EClvl) data.. For specific operations, refer to the user's manual
that came with the scan tool or Honda PG l\4 Tester.
lf the MIL did not stay
lf the MIL did not come on but there is a driveability
problem, refer to the Symptom Troubleshooting Index
in this section.
lf you can't duplicate the DTC
Some of the troubleshooting in this section requires
you to reset the ECM and try to duplicate the DTC. lf rhe
problem is intermittent and you can't duplicate the code,
do not continue through the procedure. To do so will
only result in confusion and, possibly, a needlessly
replaced ECM.
(cont'd)
11-3

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
\- ta
J
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

Fuel and Emissions Systems
General Troubleshooting Information (cont'd)
ECM Updating and Substitution for Testing
Special Tools Bequired
Honda Interface Module (HlM) EOS05435570
Use this procedure when you have to substitute a
known-good ECM in a troubleshooting procedure.
U pdate the ECM only if the ECN4 does not already have
the latest software loaded,
NOTE;. lMake sure the battery is fully charged before you
update the ECN4.. To prevent ECM damage during the update, do not
turn the ignition switch OFF, and do not use any of
the vehicle's electrical devices (light, horn, radio, etc. ).
How to Update the ECM
1. Turn the ignition switch ON (ll). Do not startthe
eng Ine.
2. Connect the Honda lnterface Module (HlM) to the
Data Link Connector {DLC) (A) located under the
driver's side of dashboard.
EOS05A35570
Do the ECM update procedure as described on the
HlN4 label and in the ECM update system.
11-6
\-
How to Substitute the ECM
'1. Remove the ECM f rom the vehicle.
2. Install a known-good ECM in the vehicle.
3. Rewrite the immobilizer code with the ECM
replacement procedure from the Honda PGM
Tester. lt allows you to start the engine.
4. After completing your tests, reinstall the original
ECM and rewrite the immobilizer code with the
ECM replacement procedure on the Honda PGM
Tester again.
L
(
I

ldle Control System
ldle Speed lnspection
NOTE:' Leave the idle air control (lAC) valve connecled.. Before checking the idle speed, check these items:- The malfunction indicator lamp (MlL) has not been
reported on.- lgnition timing- Spark plugs- Air cleaner- PCV system. Pullthe parking brake lever up. Start the engine, and
make sure the headlights are off.
1. Disconnect the evaporative emission (EVAP)
canister purge valve 2P connector.
2. Connect a tachometer (A)to the test tachometer
connector (B), or connect the Honda PGM Tester (C)
or an OBD ll scan tool to the data link connector(DLC) (D) located under the driver's side of the
dashboard.
11-138
4.
3.
5.
6.
Start the 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 with no-load conditions;
headlights, blower fan, radiator fan, and air
conditioner off.
ldle speed should be: 750 t 50 rpm
Let the engine idle for 1 minute with the heater fan
switch on Hl and air conditioner on, then check the
idle speed.
ldle speed should be: 750 t 50 rpm
NOTE: lf the idle speed is not wilhin specification,
go to the Symptom Troubleshooting Index,
Reconnect the EVAP canister purge valve 2P
connector.

T
\
Steering Column Removal and Installation
SRS components are located in this area. Review the SRS component locations (see page 23-13) and precautions andprocedures (see page 23-14) in the SRS section before performing repairs or service.
Removal
1, Record the radio station presets, and disconnect the battery.
2. Removethedriver'sairbagassembly(seepage23-113) and the steering wheel (see page 17-6).
3. Removethe driver's dashboard lowercover(see page 20-59) and undercover(see page 20-60).
4. Remove the column covers (A:
I x 1.25 mm16 N.m (1.6 kgf.m,12 lbl.fr)b
5.
6.
Disconnect the wire harness connectors from the combination switch assembly {B).
Remove the combination switch assembly from the steering column shaft by removing the screw (C) on the top of
the combination switch.
7. Disconnect the connectors from the ignition switch, and release the wire harness clips from the steering column.
8. Disconnect the steering joint (D), and remove it from the column shaft.
9. Remove the steering column {E) by removingthe attaching nuts and bolts.
(cont'd)
17-9

Steering Gearbox Removal
Special Tool Required
Ball ioint remover,2S mm 0TlvlAC-S100200
1. Raise the front of vehicle, and make sure it is
securely supponed.
2. Remove the front wheels.
Remove the driver's airbag (seepage23-113).
Remove the steering wheel (see page 17-6).
Remove the motor on the steering gearbox (see
page l T-49).
Remove the driver's dashboard lower cover (see
page 20-59) and under cover {see page20-60).
Remove the steering joint bolts (A), and disconnect
the steering joint by moving the steering joint (B)
toward the column.
4.
5.
6.
7.
'il
_t\
l- '/
,a.: --L -
8. Remove the cotter pin (A)from the tie-rod balljoint
nut {B), and loosen the nut.
r0 mm HEX NUT07MAC-S100200
Separate the tie-rod balljoint and damper steering
arm using the special tool (see page 18-10). Repeat
on the other side of the vehicle.
Grasp the right side tie-rod, and pull the rack all the
way to the passenger's side,
Remove the heat shield (A) mounting bolts from
the body stiffener, and let the heat shield lay
against the exhaust.
11.
9.
10.
(cont'd)
17-51

EPS Components
4
17.
18.
Steering Gearbox Installation (cont'dl
Install the motor on the steering gearbox (see page
17-49).
lnstall the steering joint (A). and reconnect the
steering shaft (B) and pinion shaft (C). Make sure
the steering joint is connected as follows:
. Insertthe upperend of thesteering jointontothe
steering shaft (line up the bolt hole (D) with the
flat portion (E) on the shaft).. Slip the lower end of the steering joint onto thepinion shaft (line up the bolt hole with the groove
(F) around the shaft), and loosely installthe lowerjoint bolt. Be sure that the lower joint bolt is
securely in the groove in the pinion shaft.. Pull on the steering joint to make sure that the
steering joint is fully seated. Then install the
upper joint bolt, and tighten it to the specified
torque. Tighten the lower joint bolt to the
specified torque.
8 x '1.25 mm28 N.m{2.9 kgf.m,21 tbt.ft)
19.
20.
Installthe driver's dashboard lower cover (see
page 20-59) and under cover (see page 20-60).
lf the steering wheel was turned, center the cable
reel by first rotating it clockwise until it stops. Then
rotate it counterclockwise (about two and half
turns) untilthe arrow mark on the label points
straight up. Reinstall the steering wheel (see page
17 -8).
Install the front wheels.)1
17-66
22. After installation, perform the following checks.
. Perform the front toe inspection.. Check the steering wheel spokeangle. lfsteering
spoke angles to the right and left are not equal(steering wheel and rack are not centered),
correct the engagement of the joinvpinion shaft
serrations, then adjust the front toe by turning
the tie-rods, if necessarv.
\

ABS Components
General Troubleshooting Information (cont'd)
How to Troubleshoot ABS DTCs
The troubleshooting flowchart procedures assume that
the cause of the oroblem is still Dresent and the ABS
indicator is still on. Following the flowchart when the
ABS indicator does not come on can result in incorrect
diagnosis.
The connector illustrations show the female terminal
connectors with a single outline and the male terminal
connectors with a double outline.
1. Ouestion the customer about the conditions when
the problem occured, and try to reproduce the
same conditions for troubleshooting. Find out
when the ABS indicator came on, such as during
ABS control, after ABS control, when the vehicle
was at a certain speed, etc.
2. When the ABS indicator does not come on during
the test-drive, but troubleshooting is done based on
the DTC, check for loose connectors. poor terminal
contact, etc., before you start troubleshooting.
3. After troubleshooting, clear the DTC,disconnect the
Honda PGM Tester. and test-drive the vehicle.
Make sure the ABS indicator does not come on.
How to Retrieve ABS DTCs
Honda PGM Tester Method:
1, Wjth the ignition switch OFF, connect the Honda
PGM Tester (A) to the 16P data link connector (DLC)
(B) under the driver's side of the dashboard.
19-32
2. Turn the ignition switch ON (ll), and follow the
prompts on the PGM Tester to display the DTC{S)
on the screen. After determining the DTC, refer to
the DTC Troubleshooting Index.
NOTE: See the Honda PGM Tester user's manual
for specific instructions.
Service Check Signal (SCS) Circuit Method:
1. With the ignition switch OFF, connect the Honda
PGM Tester (A) to the 16P data link connector (DLC)
(BI under the driver's side of the dashboard.
2. Short the SCS circuit to body ground using the
Honda PGM Tester.
3. Turn the ignition switch ON (ll).