maintenance 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

I
t
\.4
Maintenance
Lubricants and Fluids
Maintenance Schedule for Normal
Conditions
Listed by Distance/Time
Maintenance Schedule for Severe
Gonditions
Listed by Distance/Time
Maintenance Schedule
Listed by Maintenance ltem for Normal
Conditions ................... 3-8
Listed by Maintenance ltem for Severe
Conditions ...................3-9

Maintenance Schedule
Listed by Distance/Time for Normal Conditions
This two page l/lanitenance Schedule outlines the minimun required maintenance. Service at the indicated distance or time, whichever comesfirst. use the lvlaintenance Schedule for Severe conditions if the vehicle meets any of the qualifiers in the Severe Conditions schedule or if thevehicle is normally driven in Canada.
Inspect valve clearance. (cold) (see page 6-321r Intake: 0.21-0.25 mm (0.008 0.010 in.) Exhaust: 0.28 0.32 mm (0.011 0.013 in.)Replace spark plugs. Use IZFR6K'11 (NGK) or SKJ20DR-M11 (DENSO).1.0 1.1 mm
! Do items in A,B, alqq.,
120,000 mi/ 192,000 km/ 6 yearsI Replace transmission fluid.Use Honda MTF (see page 13-3).
/ / Y vcdrs120,000 mil 192,000Beplace coolant (see page 10 6). Capacity: 5.0 0 (5.3 US qt). Use Honda All Season Antifreeze/Coolant Type 2.
According to state and lederal regulations, tailure to do the maintenance items marked with an asterisk {*) will not void the customer'semissions warranties, However, Honda recommends that all maintenance services be done at the recommended interval to ensure long-termreliability.
I
3-4

Do the items in parts A, B, C, D, and E as required for mileage/time interval listed.
AReplace engine oillsee page 8-5i. Capacity without lilter change: 4.0 S (4.2 US qt, 3.5 lmp qt)Rotate tires. Follow the pattern shown in the Owner's Manual Checktire information and condition.
BReplace engine oil filter lsee page 8-6). Capacity with filter change: 4.20 (4.4 US qt, 3.7 lmp qt)Inspect front and rear brakes (see page 19 3i.. Check pads and djscs for wear (thickness), damage, and cracks.' Check calipers tor damage, leaks, and tjghtness ot mount bolts.Check parking brake adjustment. Should be Iully applied within 7 to I clicks.Inspect tie rod ends, steering gearbox, and boots {see page 17 5).. Check rack grease and steering linkage.. Check boots for damage and leaking grease. Chack fluid line {or damage and leaks.lnspect suspension components.. Chock bolts fo r tig htness.. Check condition of ball ioint boots lor deterioration and damage.Inspect driveshaft boots. Check boots for cracks and boot bands for tightness (see page 16-3).Insp€ct brake hoses and lines {including ABS). Checkthe mastercylinder, proponioning control valve, and ABS modulator{or damageand leakage.Check all fluid levels and condition ot tluids; check for leaks. lf necessary, add MTF lsee page 13'3), engioe coolant, brake fluid, and
Lwindshield washer fluid.lnspectexhaust system*. Check catalytic converter heatshield, exhaust pipe and mufflerfordamage,leaks, and tightness {soe page 9,8).lnspect {uel lines and connections*. Check for loose connections, cracks and deterioration; retighten loose connoctions and replacedamaged parts (s€e page 11 146).
InsDect and adiust drive belt.. Look for cracks and damage, and inspect auto tensioner (needs no adjustment).Replace the dust and pollen lilter (see page 21 39).. Replacethe dustand pollen filter whenever airf low lrom the heating and cooling system is lessthan normal.
Replace air cleaner element every 30,000 miles (48,000 km) (independent of time).
l
D
Ei I Replace brake fluid every 3 years (independent oI mileage).
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 maintsnance service be done at the recommended interval to ensure long term reliability.
Y
3-5

Maintenance Schedule
Listed by Distance/Time for Severe Conditions
Service at the indicated distance or time, whichever comes first. Use this schedule if the vehicle is driven MAINLY in Canada or in any of thetollowing conditions; il only OCCASIONALLY driven in these conditions, use the Normal Conditions schedule (see page 3-4).Severe Driving Conditions. Driving less than 5 miles {8 km) per trip or, in freezing temperatures, driving less than 10 miles (16 km) per trip. Driving in extremely hot (over 90"F/32"C) conditions. Extensive idl;ng or long periods of stop and go driving, such as a taxi or a commercial delivery vehicle.. Trailer towing, driving with a car-top carrier, or driving in mountainous conditions.. Driving on muddy, dusty, or de'iced roads
Replace transmission fluid. Use Honda MTF {see page 13 3).
Inspect valve clearance. (cold) (see page 6 32): lntake: 0.21 0.25 mm (0.008 0.010 in.) Exhaust: 0.28 0.32 mm (0.011 0.013 in.)Replace spark plugs.Use IZFR6K 1 1 (N GK) or SKJ20DR'M 1 1 {DENSO)
km/ 6 yearsReplace transmission fluid. Use Honda MTF (see page 13 3).
mil 192,000 km/ 10 years, then every 60,000 mi/ 96,000 km/ 5 yearsReplace coolant (see page 10-6). Capacity: 5.0 015.3 US qt) Use Honda All Season Antifreeze/coo lant Type 2.
3-6

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

Maintenance Schedule
Service atthe indicated distance ortime,whichever comes first.miles x 1,000t020304050708090 100110r20
km x 1,000163248648096112128144 160192
months12243486012
Replace engine oilooooaooaaoOa
Rotate tires{Check tire intlation and condition at least once per month)
Replace engine oil filterooaaaa
Inspect front and rear brakes
Check parking brake adjustment
Visually inspect the following items:. Tie-rod ends, steering gearbox and boots. Suspension components. Driveshaft boots. Brake hoses and lines (including ABSi. Allfluid levels and condition of{luids. Exhaust system*. Fuel lines and connections*
Inspect and adjust drive beltaaaa
Replace dust and pollen filter
Reolace transmission fluid
Servicethe following items at the recommended intervals
a
Replace air cleaner elementEvery 30,000 miles (48,000 km)
Replace spark plugsEvery 110,000 miles (176,000 Lm)
Inspect valve clearanceInspect every 110,000 miles {176,000 km), otherwise adiusl only if noisy.
Inspect idle speed*Every 160.000 mr es 1256,000 km) or 8 years
Replace engine coolantAt 120,000 miles (192,000 km) or 10 years, then every 60,000 miles (96,000 km) or 5
Replace brake fluidEvery 3 years
Listed by Maintenance ltem for Normal Conditions
Follow the Normal Schedule if the severe driving conditions specified in the lMaintenance Schedule for Severe Conditions on the next page do
not apply, and if only OCCASIONALLY driven in severe driving conditions.Follow the Severe Conditions schedule if the vehicle is driven MAINLY in Canada.
* : According to state and lederal regulations, failure to do the maintenance items marked with asterisk (*) will not void customer's emissions
warranties. However, Honda recommends that all maintenance service be done at the recommended interval to ensure long-term reliability-
c
3-8

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

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

Engine Lubrication
Oil Pump Overhaul (cont'd)
13. lnstallthe pump housing.
6x1,0mm12 N.m(1.2 kgt.m,8.7 lbf.ft)
8-14
!
Oil Pump Installation
1. Make sure the No. 1 piston is at TDC (see step 1 on
page 6-12).
2. Align the dowel pin{A} on the rear balancer shaft
with the mark (B) on the oil pump.
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.\,-
9%ttrc
+:.:4.4 / t \
o/.-lY\
:aa:'
-rr
dv
f,o-;