key HONDA CIVIC 2003 7.G Workshop Manual

Starter Circuit Troubleshooting
NOTE:. Airtemperature must be between 59'and 100'F (15'
and 38'C) during this procedure.
. After this test, or any subsequent repair, reset the
engine controle module (ECM) to clear any diagnostlc
trouble codes (DTCS) {see page 11-4).. The battery must be in good condition and fully
charged.. lf you disconnect the baftery, do the ECM idle learn
procedure (see page 11-139).
Recommended Procedure:. Use a starter system tester.. Connect and operate the equipment in accordance
with the manuf acturer's instructions.
Alternate Procedure
1. Hook up the following equipment:. Ammeter, 0 400 A. Voltmeter, 0 20 V (accurate within 0.1 volt). Tachometer,0 1200 rpm
2.Remove the No. 17 (15A) fuse from the under-dash
fuse/relay box.
With the clutch pedal pressed, turn the ignition
switch to start (lll).
Did the starter crank the engine normally?
YES-The starting system is OK.I
NO-Go to step 4.
3.
L
4-5
4. Check the battery condition. Check electrical
connections at the battery, the negative baftery
cable to body, the engine ground cables and the
starter for looseness and corrosion. Then try
starting the engine again.
Did the statter crank the engine?
YES Repairing the loose connection fixed the
problem. The starting system is now OK.!
NO lf starterwill notcranktheengine atall, goto
step 5. lf it cranks the engine erratically or too
slowly, go to step 7. lf it won't disengage from the
flywheel ring gear when you release the key, check
for the following until you find the cause.
. Solenoid plunger and switch malfunction. Dirty drive gear or damaged overrunning clutch
5. Make sure the transmission is in neutral, then
disconnect the starter subharness 1P connector (A)
from the engine wire harness 'lP connector (B).
Connect a jumper wire from the battery positive
terminal to the starter subharness 'l P connector.
Did the starter crank the engine?
YES-Go to step 6.
NO Check the BLK,ANHT wire between the starter
subharness 1P connector and the starter. lf wire is
OK, remove the starter, and repair or replace as
necessary.
(cont'd)

Engine Block
Crankshaft lnspection
Out-ol-Round and Taper
1. Remove the crankshaft from the cylinder block (see
page 7-121.
2. Clean the crankshaft oil passages with pipe
cleaners or a suitable brush.
3. Clean the keyway and threads.
4. Measure out-of round at the middle of each rod and
main journal in two places. The difference between
measurements on each journal must not be more
than the service Iimit.
Journal Out-ot-Round
Standard (New): 0.005 mm (0.0002 in.) max.
Service Limit; 0.010 mm (0.0004 in.)
5. Measure taper at the edges of each rod and mainjournal. The difference between measurements on
each journal must not be more than the service
limit.
JournalTaper
Standard lNewl: 0.005 mm (0.0002 in.) max.
Service Limit: 0.010 mm {0.0004 in.)
I_JJ
fl
7-14
\
Straightness
6. Place the cylinder block on the surface plate.
7. Clean and installthe bearigns on the No.1 and No.5journal of the cylinder block.
8. Lower the crankshaft into the block.
9. Measure runout on all main journals. Rotate the
crankshaft two complete revolutlons. The
difference between measurements on each journal
must not be more than the service limit.
Crankshaft Total Runout
Standard (New): 0.03 mm 10.0012 in.l max.
Service Limit: 0.04 mm (0.0016 in.l
(L
{

Steering
Steering Lock Replacement
NOTE: Do not try to re-key a replacement steering lock.
lf necessary, re-key the other locks.
1. Remove the steering column (see page 17-9).
2. Center punch each ofthe two shear bolts (A), and
drill their heads off with a 5 mm (3i 16 in.) drill bit.
Be careful not to damage the switch body when
removing the shear bolts,
3. Remove the shear bolts from the switch body.
4. Installthe switch body without the key inserted.
5. Loosely tighten the new shear bolts.
6. Insert the ignition key, and check for proper
operation of the steering wheel lock and that the
ignition key turns freely.
:..'-":'
17-12
7. Tighten the shear bolts (A) untilthe hex heads (B)
twist off.
I
A
I

\Body Electrical
Body ElectricalSpecialToolsGeneral Troubleshooting tntorrnaiion.'......
Relay and Control Unit Locations .....
Connectors and Harnesses
Fuse/Relay Boxes ...............................
Power Distribution .............................
Ground Distribution ...........................
Under-dash Fuse/Relay Box ..............
Battery ..............
Relays ................
*lgnition Switch ..............
*Gauges
Component Location Index .......................Self-diagnostic Procedure ..........................Circuit DiagramGauge Bulb Replacement ..........................Gauge Assembly ReplacementCoolant Temperature
Gauge Troubleshooting .... ....................Vehicle Speed Signal CircuitTroubleshootingVSS Replacement
Exterior LightsComponent Location Index .......................Circuit DiagramDaytime Running Lights ControiUnit Input Test (Canada) ........................Headlight Ad,ustment .................. .. .....Headlighr Replacement ..............................Combination Light SwitchTest/ReplacementBulb ReplacementTaillight Replacement ..........................High Mount Brake Light Replacement ......License Plate Light Replacement ..............Side Marker Light Replacement ................Brake Pedal Position Switch Test ..............Side Turn Signal Light Replacement ........
Turn Signal/HazardFlasher SystemComponent Location Index .......................Circuit DiagramTurn Signal/Hazard Relay lnputTest ........Hazard Warning Switch Test
22,3
22-7
22-13
22-44
22-46
22-4A
22-49
22-50
22-51
22-53
22-5422-5622-5422 6322-64
22-64
22-6522 61
22-6822--71
22-7 622-7422-79
22-AO22-4122-8222-4222-4322-4322-4422-84
22-8522 A622-8722-88
22-10422-105
22-10622-107
Entry Lights control systemComponent Location Index ....................... 22-89Circuit Diagram ......... 22 90lgnition Key Switch Test .....................,...... 22-9'llgnition Key Light Test ............................... 22-91Control Unit Input Test ..........,.................... 22 92
Interior LightsComponent Location Index ....................... 22-94Circuit Diagram ......... 22-95Ceiling LighVSpotlightsTesVReplacement ................................... 22-96Rear Ceiling Light TesVReplacem ent ........ 22-96Cargo Area Light Test/Replacem ent ......... 22-97Hatch Latch Switch Test ..,..,....................... 22-97
*Audio SystemComponent Location Index ....................... 22-98Circuit Diagram ......... 22,99Audio Unit Removal/lnstallation ............... 22-1OOAudio Unit Connector Replacement ......... 22-101Speaker Replacement ................................ 22-102Roof Antenna Rep1acement ....................-.. 22-103
Rear Window DefoggerComponent Location Index ...........Circuit Diasram .. ....... .. ..... ....... ...:::::.::.::.Function TestDefogger Wire Repair .................................Noise Condenser CapacityTest ................
MoonroofComponent Location Index ....................... 22-1OBCircuit Diagram ......... 22-109Moonroof Control Unit Input Test ............. 22-'l10Switch TesVReplacement ........,.....,........... 22-1 12Motor Test ................. 22-112Limit Swilch Test ...... 22-'l'13Auto-stop Switch Test ................................ 22-1 13
Power MirrorsComponent Location Index ....................... 22-114Circuit Diagram ......... 22-115Function Test ............. 22-116Power Mirror Switch Test .......................... 22-ll7Power Mirror Actuator Test ....................... 22-117Power Mirror Actuator Replacement ........ 22-11A
* HornsComponent Location Index ....................... 22-120Circuit Diagram ......... 22-121Horn TesVReplacement ...........................-. 22-122Horn Switch Test .,.... 22-122
\

Power WindowsComponent Location Index ..........
circuit Diagram . .. ............... .........:.::::.::::.:Master Switch Input Test ...........................Master Switch TestDriver's Window Motor Test .....................
Passenger's Window Switch lnput Test ...Passenger's Window Switch Test .............
Passenger's Window Motor Test ..............
lMaster Switch Replacement ......................
Passenger's Window SwitchReplacement
Wipers/WashersComponent Location Index .......................
Circuit DiagramRear Window Wiper Intermiftent
Control Unit Input Test ...........................Wiper/Washer SwitchTesVReplacementControl Unit Input Test ...............................Wiper Motor Test
Washer Motor TestWasher Fluid Level Switch TesV
Replacement (Canadal ..........................
Windshield Wiper Motor Replacement ....
Rear Window Wiper MotorReplacementWasher Reservoir Replacement ................
Washer Tubes Beplacement ......................
Accessory Power SocketCircuit Diagram ......... 22-149
Accessory Power Socket
TesVReplacement ................................... 22-1 49
Keyless/Power Door Lock System
Component Location Index ....................... 22-150
Circuit Diagram ......... 22-151Keyless Receiver Unit InputTest ............... 22-153
Control Unit Input Test ............................... 22-155
Door LockActuatorTest .........,.......,..,.,..... 22-158Hatch LockActuatorTest ........................... 22-159
Door Lock Knob Switch Test ...................... 22-160
Door Lock Switch Test ................................ 22-160
Transmitter Test ....... 22-161
Transmitter Programming ......................... 22-161
Multiplex Control SystemComponent Location Index ...........
circuit Diagram ...... ........................::.:..:.::.:
Svstem DescriDtionTroubleshootingMultiolex Control Unit InDut Test .............
22 12422-12522-12622-12822-129
22- t30
22-13222 13222-133
22-133
22-134
22-138
22-14022-14122-14322-144
22-14422-145
22-14622-14622 147
22,16422-16922-17'l22,11222-175
lmmobilizer Systemcomponent Location Index ...........
System Description ....... ............. ..:..:..:.:...
Circuit DiagramTroubleshootinglmmobilizer Control Unit-Receiver Replacement ...........................
22-16222-16322-164
22-167

Body Electrical
General Troubleshooting Information (cont'dl
Five-step Troubleshooting
'1. Verify The Complaint
Turn on allthe components in the problem circuit
to verify the customer complaint. Note the
symptoms. Do not begin disassembly or testing
until you have narrowed down the problem area.
2. Analyze The Schematic
Look up the schematic for the problem circuit.
Determine how the circuit is supposed to work by
tracing the current paths from the power feed
through the circuit components to ground. lf
several circuits fail at the same time, the fuse or
ground is a Iikely cause.
Based on the symptoms and your understanding of
the circuit operation, identify one or more possible
causes of the problem.
3. lsolate The Problem By Testing The Circuit
Make circuit tests to check the diagnosis you made
in step 2. Keep in mind that a logical, simple
procedure is the key to efficient troubleshooting.
Test for the most likely cause of failure first, Try to
make tests at points that are easily accessible.
4. Fix The Problem
Once the specific problem is identified. make the
repair. Be sure to use proper tools and safe
proceoures.
5. Make Sure The Circuit Works
Turn on all components in the repaired circuit in all
modes to make sure you've fixed the entire
problem. lf the problem was a blown fuse, be sure
to test all of the circuits on the fuse. Make sure no
new problems turn up and the original problem
does not recur.
22-6
Wire Color Codes
The following abbreviations are used to identify wire
colors in the circuit schematics:
wHT....................,.,.............
YEL......................,,.......,......
B1K......................................
BLU ....,................................
GRN.....................................
RED ....................................,
oRN.....................................
PNK..........................,..........
BRN.....................................
GRY....................................,
PUR.....................................
1T81U..........................,.....
1TGRN...........................,...
White
Yellow
Black
Blue
Green
Red
Orange
Pink
Brown
Gray
Purple
Light Blue
Light Green
The wire insulation has one color or one color with
another color stripe. The second color is the stripe.

Relay and Gontrol Unit Locations
Dashboard
_DAYTIME RUNNING LIGHTS EELAY lCanada)lWire colorsr RED, RED/YEL, ILRED/BLK and RED/8LU I_LOW BEAM CUT RELAY lcanada) _lWire colors: REDMHT, RED/BLK, ILBEDA/EL and RED/BLU I
KEYLESS RECEIVER UNIT
CRUISE CONTROL UNIT
'
'-.:- ':
..? ;,
POWER WINOOW RELAY
TURN SIGNAL/HAZARD RELAY
TAILLIGHT RELAYUNDER.DASHFUSE/RELAY BOX; .[:_- -
-l:r --
22-8
MULTIPLEX CONTROL UNIT

Connectors and Harnesses
Dashboard Wire Harness A {Left branchl
Connector or TerminalffiAccessory power socketAudio antennaBrake pedal position switchClutch interlock switchClutch pedal poistion switchCruise control unitCruise main switchDaytime r!nning lights control unitDaytime running lights relayGauge assembly connector AGauge assembly connector BHazard warning switchHeater control panel connector AHeater control panel connector BHVAC push switch assemblyKeyless receiver unitLow beam cut relayOptional security connectorPower mirror switchUnder-dash fuse/relay boxconnector K (see page 22-45)Under'dash fuse/relay box
L {see page 22-45}Underdash fuse/relay boxconnector M lsee page 22'45)Under-dash fuse/relay boxconnector N (see page 22-45)UndeFdash fuse/relay boxconnector O (see page 22-45)UndeFdash fuse/relay boxconnectorY (see page 22 45)c504
c505
c506
c507
c508
c509
c510
22226
3029628
I820111819105327
,I4
12
11
34
1
24
25
2 Under middle of dash2 Under left side of dash4 ] Under left side of dash2 ] Under left srde of dash2 | Under left side of dash14 I Under left side of dash5 Under left side of dash14 Under lett side of dash4 Under lett side of dash22 I Behind gauge assembly22 i Behind gauge assembly10 Behind hazard warnning switch22 Behind heater control panel'14 Behind heater control panel10 ] Behind HVAC switch assembly5 I Under middle of dash5 lUnderleftsideofdash16 Under lefr side of dash13 Under left side oI dash17 ln the under-dash fuse/relay box
CanadaCanada
l0In the under-dash fuse/relay box
In the undeFdash fuse/relay box
In the underdash fuse/relay box
In the under-dash fuse/relay box
In the under-dash fuse/relay box
Under left side of dash
Under left side ot dash
Under left side of dash
Under left side of dash
Under middle of dash
Under middle of dash
Under middle ol dash
Driver's door wire harness(see page 22'40)Driver's door wire harness(see page 22-40)Left side turo signal lightsuonarnessRoof wire harness (see page22 3AlFloor wire harness {see page22-341Floor wire harness (see page22 34JDashboard wire harness B(see oaoe 22-30)
12
12
G501
G503
1
21
Under gauge assembly
Under left side of dash
Body ground via dashboard
Body ground via dashboard
Left Side Turn Signal Light Sub harness
Connector to Harness Index (cont'd)
L
Connector or TerminalCavitiesLocationConnects toNolesLeft side turn signal lightc506353422Behind left side turn signal lightUnder left side of dashDashboard wire harness A
22-26

Connectors and Harnesses
Connector to Harness Index (cont'd)
Dashboard Wire Harness B
Collqctor or TerminalCavitiesLocatiol|ConnectstoNotesCableCombination light switchDriver's airbag inflatorlgnition key switchlgnition switchlmmobilizer control unit receiverPassenger's airbag inf latorSRS unit connector AWiper/washer switchUnder dash fuse/relay boxconnectorA lsee page 22,45)Under dash luse/relay boxconnector B (see page 22-45)Under'dash fuse/relay boxconnector C (see page 22-45)Under-dash fuse/relay boxconnector S lsee page 22-45)Under'dash fuse/relay boxconnectorX (see page 22 45)c401
c402
c403
G510
reel211716't9
18I
35
6
1
8
10
12
11
14
5
4
11418145
6
14
2
8
10
4
12
In steering column coverIn steering column coverIn steering column coverIn steering column coverIn steering column coverIn steering column coverUnder middle of dashUnder middle ofdashIn steering column coverUnder left side of dash
Under left side ofdash
Under left side of dash
Under lett side of dash
Under left side of dash
Under right side of dash
Under middle of dash
Under middle of dash
Under middle side of dash
Engine compartment wireharness (see page 22-'18)Floor wire harness (see page22-34JFloor wire harness (see page22-341Dashboard wire harness A(see oaoe 22-26)G40lUnder gauge assemblyBody ground via dashboard
22-30

Power Distribution
Fuse to Components lndex
Under-hood Fuse/Relay Box
Fuse
Number
AmpsWire ColorComponent(sl or Circuit(s) Protected
'I204BLUI/ELCondenser fan motor
BLU/REDAy'C compressor clutch
15AWHT/GRNDash lights, Front parking lights, Front side marker lights, License plate
liqht, Rear side marker liqhts, Tailliqhts
7.5AWHT/BLUCarqo area liqht, Ceilinq liqhts. lqnition Kev liqht. Sootliohts
204BLU/BLKRadiator fan motor
510AWHT/BLKTurn siqnal/hazard relav, Turn siqnal liqhts
15AWHT/BLKCKP sensor, ECM, IAC valve, lmmobilizer control unit-receiver, Injectors,
PGM-FI main relav 1 and 2. TDC sensor
715AWHT/GRNBrake lights, Brake signals (to ABS modulator-control unit, Cruise control
unit, ECM)
BLU/REDi1 Orns
820AWHT/GRNABS modulatorcontrol unit
910AWHT/REDAudio unit, Data link connector (DLC), Gauge assembly, lmmobilizer
control unit-receiver, lmmobilizer indicator light. Keyless receiver unil,
lvlultiDlex control unit
1040AWHT/REDABS modulator-control unit
1130AB LK/YE LNoise condenser, Rear window defoqqer
40ABLU^^/HTBlower motor
IJ40AWHT/BLKNo. 7 fuse (in the under-dash fuse/relav box), Power window relav
1440AWHT/REDNo.2 and No.3 fuses (in the under-dash fuse/relav box)
t515AREDI/ELDaytime running lights control unit (Canada), Daytime running lights relay
{Canada), Hioh beam indicator liqht. Left headliqht
16204WHTMultiplex control unit
1715AREDDavtime runninq liqhts control unit (Canada). Rioht headlioht
1860AWHTiBLUEPS control unit
1980ABatterv. Power distribution
2040A'
50A'?
WHTlgnition switch (BAT)
* 1: USA" 2. Canada
O: Spare fuse
t t"| lll Itt 4t I
l l---- E'l E,l E,l r--r r---r t__J i; i6'!/'
E,l E,l E,l Eol E l f__--lI l'lr]n | |I r L__J,a ,..r^{-------l^-,
n[:]$"Lrt " N2, nf - r^l
22-46