ect 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

General Information
Chassis and Paint Codes - 2OO2 Model
Vehicle ldentffi cation Number
SHHEP3 35'2 U 300001
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cdef gh
a. Manufacturer, Make and Type of Vehicle
SHH; HONDAOFTHE U.K. MFG., LTD. U.K.
HONDA Passenger vehicle
b. Line, Body and Engine Type
EP3: CIVIC/K20A3
c. Body Type and Transmission Type
3: 2-door HatchbacUs-speed Manual
d. Vehicle Grade lSeries)
5: Si {U.S.}
5; SiR (Canada)
6: Si with side airbag system (U,S.)
6: SiR with side airbag system (Canada)
e. Check Digit
l. ModelYear
2i 2002
g. Factory Code
U: Honda of U.K. Manufacturing in Swindon,
E ng land
h. Serial Number
U.S,: 300001 -
1-
V€hicle ldentif ication Numbo.and Federal Motor VehicleSaf ety Standard Certif ication/Color Label.
1-2
I
1700001K2OA3
a
a. Engine Type
K20A3: 2.0 0 DOHC VTEC Sequential Multiport
Fuel-injected engine
b. Serial Number
Engine Number
Transmission Number
Paint Code
CodeColoru.s.Canada
B-92PNiqhthawk Black Pearl
NH-578Taffeta White
NH-623MSatin Silver lvletallic
R-81Milano Red
Y-62PEuro Yeliow Pearl
NBH3
I
a
Transmission Type
NRH3; s-sDeed Manual
1000001
t0

Chassis and Paint Codes - 2003 Model
Vehicle ldentif ication Number
SHHEP3 35*3 U 400001
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cdef gh
G.
d.
Manufacturer, Make and Type of Vehicle
SHH: HONDAOFTHE U.K. MFG., LTD. U.K.
HONDA Passenger vehicle
Line. Body and Engine Type
EP3: CIVIC/K20A3
Body Type and Transmission Type
3: 2-door HatchbacldS-speed Manual
Vehicle Grade (Series)
5: Si (U.S.)
5: SiR (Canada)
6: Si with side airbag system (U.S.)
6: SiR with side airbag system (Canada)
Check Digir
Model Year
3: 2003
Factory Code
U: Honda of U.K. Manufacturing in Swindon,
England
Serial Number
U.S.: 400001
f.
:700001
Vehicle ldentification Numberand Federal Motor VehicleSaletv Standard Certif ication/Color Label.
)_.
2700001K2OA3
I
a
a. Engine Type
K20A3: 2.0 0 DOHC VTEC Sequential Multiport
Fuel-injected engine
b. Serial Number
Engine Number
Transmission Number
NRH3
I
a
Transmission Type
NRH3: 5-speed Manual
Serial Number
- 2000001
Paint Code
CodeColorU,S.Canada
B-92PNiohthawk Black Pearl
B-520PVivid Blue Pearl
NH-578Taffeta White
NH-623MSatin Silver N4etallic
R-81Milano Red
Y-62PEuro Yellow Pearl
1-3

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

ne
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.)
(
I
Standards and Service Limits
Enqine Electrical
E
e_a
.l
nqtne
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

nqtne
ItemMeasurementOualificationStandard or NewService LimirBlock
Piston
I Warpage of deck0.07 mm (0.003 in.) max.foro.. (ulur^^-"1tsore diameterAori
Borll
(3.3858 3.3862 in.)
85.980 85.990 mm (3.3850 3.3854 in.)
l-il?0 €s.980 r"i33846
86.010 86.020 mm
(3.3862 3.3866 in.)
86.000 86.010 mm
86.070 mm (3.3886 in.)
86.070 mm (3.3886 in.)
0.05 mm (0.002 In.J
85.920 mm (3.3827 in.)
0.25 mm (0 0l in.)
85.930 mm (3.383'l in.)
Reboring lrmit
Skirt O.D. at 11 mm (0.4 in.) from
bottom of skirtF" btt"' "' A
Letter B
0.020 0.040 mm (0 0008 0.0016 in.)0.05 mm {0.002 in.)Top1.220 1.230 mm (0.0481 0.0484 in.)1.25 mm 10.049 rn )Second1.220 1.230 mm (0.0481 0 0a84In.)1.25 mm 10.049 in.)
Piston ring
lFis,.€-"'"
",";"*
L-Ring end gap
o.D.
i 2.005 2.025 mm (0.0789 0.0797 in.)
fo.o:s o.oto.rn lo.oora o.ooza i.'.f
EO3t 0 056 rn. {OJ01r OOO2 i")
?.09rrl9.091lt )
0.13 mm (0.005 in )
0.13 mm (0.005 in.)Second (FEDEHAL
I\4OGUL)
Top
0.025 0.060 mm (0.0010 0.0024 in.)0.13 mm (0.005 in )
0.20 0.35 mm (0.008 0.014 in.)0.60 mm (0.024 in.)Second0.40 0.55 mm {0.016 0.022 in.)0.70 mm (0.028 in.)OiI (REKEN)
21.961 21.965 mm {0.8646 0.8648 in.)
0.25 0.65 mm (0.010 0.026 in.)
0 20 0.70 mm i0.008 0.028 in.)
0.75 mm (0.030 in.)OiI(FEDERAL
I\4OG U L)0.80 mm 10.031 in.)
Piston pin21.953 mm l0 8643 inPin'to-piston clearance0.005-*0.002 mm ( 0.00020 +
0.00008 in.)
0.005 mm (0.0002 in.)
Connecting rodPin to-rod clearance0.005 0.015 mm (0.0002 0.0006 in.)0.02 mm lO 0OO8 in ISmall end bore diameler21.970 21.976 mm (0.8650 0.8652 in.)Large-end bore diameter (Normal)48.0 mm (1.89 in.)End play inslalled on crankshaft0.15 0.30 mm (0.006 0.012 in.)0.40 mm (0.016 in.)CrankshaftMain journal diameter
Rod journal diameter
No. l journal
No. 2 journal
No. 4 journal
No. 5 journal
No. 3 journal
s4.e84 s5.008 mm (2.1648=16illl
54.976 55.000 mm (2.1644 2-1654in)
44.976 45.000 mm (1.1707 1.1717 in.lRod/main0.005 mm 10.0002 in.) max.0.010 mm (0.0004 in.)Rod/main iournal out of,round0.005 mm (0.0002 in.) max.0.010 mm (0.0004 in.)End play0.10 0.35 mm (0.004 0.0'14 in.)0.45 mm 10.018 in.)Runout..-'.:--'+0.03 mm (0.0012 in.) max.0.04 mm {0.0016 in.)
Deaflngs
Marn oear,n9-toJournat ott ctearanceNo. l journal
No. 2 journal
No. 4 journal
No.5
No. 3 journa/
0.017 0.041 mm (0.0007 0.0016 in.)
q0rr034, -rn {O'o010 0-o01r|"tl
0.050 mm (0.0020 in.)
0.055 mm (0.0022 in.)Bod bearing clearance0.021 0.049 mm (0.0008 0.0019 in.)0.060 mm (0.0024 in.)
Standards and Service Limits
Enqine Block
_f
c_a
2-4
-

ItemMeasulementOualificationStandard or New Service LimitFuel pressure
regulator
Pressure with fuel pressure gauge
connected
320-370 kPa 13.3-'3.8 kgtcm', 47 52psi)
FueltankCapacity50 4 (13.2 US galiEngine idleldle speed with headlights and radiator
fan off
Neutral750 50 rpm
Fast idleNeutral1,600150 rpm
Standards and Service Limits
Fuel and Emissionsf
.\
ra
Clutch
ItemMea3urem€nlOualificationSlandard or NewService LimitClutch pedalHeight from the floor193 mm (7.60 in.)Stroke130 140 mm 15.1 5.5in.)
10 16 mm (0.39 0.63 in.)Disengagement height from the floor1'15 mm (4.53 in.) min.Bunout on clutch mating surface0.05 mm 10.002 in.) max.0.15 mm (0.006 in.)Clutch discBivet head depth1.65 2.25 mm (0.065 0.089 in.)0.7 mm {0.03 in.)Ihickness8.3 8.9 mm (0.33 0.35 in.)6.0 mm (0.24 in.)Pressure plateWarpage0.03 mm (0.001 in.)max.0.15 mm (0.001 in.)Height of diaphragm spring fingersMeasured with
specialtool and
feeler gauge
0.6 mm (0.02 in.) max.0.8 mm (0-03 in.)
2-6
\

anuat I ransmcont'
ItemMeasutemenlOualificationStandard or NewServicc LimitNlainshaft 4th
and 5th gears
distance collar
LD.32.00-32.01 mm (1.2598 1.2602 in.)32.02 mm (1.261 in.)o.D.38.989 39.000 mm (1.5350 1.5354 in.)38.94 mm (1.533 in.)Length51.95 52.05 mm (2.045 2.049 in.)
B24.03 24.08 mm (0.946-0.947 in.)
MBS distanceLD.28.00 28.01mm (1.102 1.103 in.)28.02 mm (1.103 in.)Len9th23.95 24.05 mm (0.943 0.947 in.)Reverse idler
gear
t.D.20.016 20.043 mm (0.7880 0.7891 in.)20.90 mm (0.832 in.)Gear lo reverse gear shafi clearance0.036 0.08a mm (0.0014 0.0033 in.)0.16 mm {0.006 in.)Synchro ringBing to'gear clearanceRing pushed
against gear
0.70 1.49 mm (0.028 0 059 in )0.4 mm (0.016 4n.)
Triple coneOuter synchro ring-to synchro cone
clearance
Ring pushed
against qear
0.70 - '1.19 mm {0.028 0.047 in.)0.3 mm (0.012 in.)
Synchro cone-to-gear clearanceRing pushed
against gear
0.50 1.04 mm (0.020 0.041 in.)0.3 mm (0.012 in.)
Outer synchro ring-to-gear cone
clearance
Ring pushed
against gear
0.95 1.68 mm (0.037 0.066 in.)0.6 mm (0.024 in.)
Shift forkFinger thickness7.4 7.6 mm 10.29 0.30 in.)Fork to-synchro sleeve clearance0.35 0.65 mm (0.014 0.026 in.i1.0 mm (0.039 in.)Reverse shift
fork
Finger thinkness13.4 13.7 mm (0.527 0.539 in.)Fork-to-reverse idler gear clearance0.20 0.59 mm (0.007 0.024 in.)1.3 mm (0.051 in.)Shift armt.D.13.973 '14.000 mm (0.5501 0.5512 in.)Shift fork diameter at conlact area16.9 '17.0 mm (0.665 0.669 in.)Shift arm'to-shift lever clearance0.2 0.5 mm (0.008 0.020 in.)0.62 mm (0.024 in.)Select leverFinger width14.85 '14.95 mm (0.585 0.589 in.)Shift leverShaft -to-select lever clearance0.05 0.25 mm (0.002 0.010 in.)0.50 mm (0.020 in.)Groove {to select lever)15.00 15.10 mm {0.591 0.594 in.)
Shaft to shift arm clearance0.013 0.07 mm (0.0005 0.003 in.)0.1 mm {0.004 in.)Mfi
differential
carrier
Pinion shaft contact area l.D.18.010 18.028 mm (0.7091 0.7098 in.)Carrier-to-pinion shaft clearance0.027 0.057 mm (0.0011 0.0022 in.)0.1 mm (0.004 in.lDriveshaft contact area LD.28.025 28.045 mm (1.1033 1.1041 in.)Mfi
differential
pinion qear
Backlash0.05 0.15 mm {0.002 0.006 in.)
t.D.18.042 18.066 mm (0.7103 0.7113in.)Pinion gearto pinion shaft clearance0.059 0.095 mm (0.0023 0.0037 in.)0.15 mm (0.006 in.)80 mm shim80 mm shim to-bearing outer race
clearance in transmission housing
0 0.10 mm (0 0.0039 in.)Adjust
Standards and Service Limits
Manual Transmission and Differential?
LO
2-8
-

L
v
2-11
Design Specifications
O
o
o
|temMeasurementOualificationSpecilication
DIMENSIONSOveralllength4,210 mm {165.8 in.)
Overallwidth1,695 mm 166.7 in.)
Overallheight1,440 mm (56.7 in.)
2,570 mm (101.2 in.)
Trackrront1,470 mm (57.9 in.)
Rear'1,470 mm (57.9 in.i
Ground clearance152 mm (5.98 in.)
Seating capacityfour {4)
wEtGt-iT {u.s.A.)Gross Vehicle Weight Rating
(GVWR)
3,660 rbs
WEIGHT
(CANADA)
Gross Vehicle Weight Rating
{GVWR)
1,660 kg
ENGIN ETvpeWater cooled. 4 stroke DOHC V-EC engin(
Cylinder arrangementInline 4'cylinder, transverse
Bore and stroke86 x 86 mm (3.39 x 3.39 in.)
Displacement1,998 cm'(122 cu in.)
Compression ratio9.8
Valve trainChain drive. DOHC VTEC 4 valves per cylinder
Lubrication systemForced, wet sump, with trochoid pumP
Oil pump displacementAt 6,000 engine
rpm
54.3 0 (57.4 US qo/minute
Water pump displacementAt 3,400 engine82 0 (87 US qt)/minute
F!el requiredUNLEADED gasoline with 86 pump octane number or higher
STARTERTvpeGear reduction
Normaloutput
Nominalvoltage12V
Hour rating30 seconds
Direction of rotationClockwise as viewecl from gear end
CLUTCHClutch tvpeSinqle plate dry, diaphragm spring
Clutch friction material surface area174 cm'{26.97 sq in.)
I\,1AN UAL
TRANSMISSION
TvpeSvnchronized, s-speed forward, 1 reverse
Primarv reductionDirect 1:1
Gear ratiolst3.062
2nd1.769
3rd1.212
4th0.921
5th0.738
Reverse3.583
FinalreductionTypeSinole helicalgear
Gear ratio4.164

cont'
ItemMeasuremeniOualificationSpecilicationSTEERINGTypeElectric, Power assisted rack and pinion
Overall ratio15.1Turns,lock to-lock
Steering wheel diameter360 mm (14.2 in)SUSPENSIONTypeIndependent srrul with stabiliTer. coil springRearDouble wishboneShock absorberFrontTelescopic, hydraulic. nitrogen gas-frlled
RearTelescopic, hydraulic, nitrogen gas,filledWHEEL
ALIGNMENT
CamberFront0"00'
Bear0.45'
CasterFront1'33'TotaltoeFront0 mm (0 in.)
RearIn 2 mm (1/16 in.)BRAKESType of service brakeFrontPowerassisted self-adjusling ventilated disc
BearPower-assisted self-adjusting solid discType of parking brakeMechanical actuating, rear wheelsPad friction surface areaFront45 cm'(7.0 sq in.)x2
Rear28 cm'(4.3 sq in.) x 2TIRESSize offront and reartiresPl95/60 815 88VSize o{ spare tireT125r0 D15 95MAIR
CONDITIONING
CompressorTypeScroll
Number of
cylinders
Capacity85.7 m015.23 cu in.)/rev.
Maximum speed12,000 rpm
Lubricant capacity130 m0 {4 1/3 floz)
LubricanttypeSP-10 (P/N 38897'P13-A01AH or38899-P13 A01)CondenserTypeCorrugated finEvaporatorTvpeCorrugated fin
BlowerTypeSirocco fan
Motor type220 Wl12 V
Speed control4 Speeo
Maximum capacity480 m" 116.900 cu ft)/hTemperature controlAirmixtype
Compressor clutchTvpeDry, single plate, poly-V belt drive
Electricalpower
cons!mptron at
68"F (20.C)
42 W maximum at 12 V
RefrigerantTypeHFC 134a (R-134a)
Capacity500 550 g (17.6 19.4 oz)
Design Specifications
C
aL
2-12
../ a