2003 HONDA CIVIC %27

Chassis and Paint Codes - 2003 Model
Vehicle ldentif ication Number
SHHEP3 35*3 U 400001
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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

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.)
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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

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
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2-4
-

L
v
2-7
OE
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nual Transmission and M/T Differential
ItemM€asurementOualificationStandard or NewSe.vice Limit
Transmission
fluid
CapacityFor fluid change: 1.5 0 (1.6 US qt)
For overhaul: 1.7 011.8 US qt)
MainshaftEnd plav0.1 'l -0.17 mm (0.004 0.007in.)Adiust
Diameter of bushing surface20.80 20.85 mm {0.819 0.821 in.)20.75 mm 10.817 in.)
Diameter of distance collar31.984-32.000 mm (1.2594 1.2598 in.)3'1.93 mm (1.257 in.)
Diameter of ball bearing contact area
(clutch housing side)
27.977 27s90 mm \1.1015 - 1.1020 in.)27.92 mm (1.099 in.)
Diameter of needle bearing contact
area
38.984 39.000 mm (1.5348 '1.5354 in.)38.93 mm (1.533 4n.)
Diameter of ball bearing contact area
(transmission housing side)
27.987 28.000 mm (1.10'19 1.1024 in.)27.93 mm {1.100 in.)
Runout0.02 mm (0.001 in.) max.0.05 mm (0.002 in.)
Mainshaft 3rd,
4th and sth
gears
t.D.44.009 44.025 mm 11.7326 1.7333 in.)44.08 mm (1.735 in.)
End play0.06 0.16 mm {0.002 0.006;n.)0.25 mm (0.010 in.)
Thickness23.92 23.97 mm (0.94'1 0.944 in.)23.80 mm (0.937 in.)
CountershaftDiameter of needle bearing contact
area (clutch housing side)
35.000-35.015 mm (1.3780 '1.3785 in.)34.95 mm (1.376 in.)
Diameter of distance collar contact
alea
39.937 39 950 mm (1.5723 1.512ain.|39.88 mm (1.570 in.)
Diameter of ball bearing contact area
(transmission housing side)
30.020-30.033 mm (1.1819- 1.1824 in.)29.97 mm (1.180 in.)
Runout0.02 mm {0.001 in.) max.0.05 mm (0.002 in.)
35 mm shim-to'bearing inner race
clearance
0.04 0.10 mm (0.0016 0.0039 in.)Adjust
CountershaftLD.52.010 52.029 mm (2.0476-2.0484 in.i52.08 mm (2.050 in.)
End play0.06 0.16 mm (0.002 0.006 in.)0.25 mm 10.010 in.)
Thickness22.92 22.91 $m 10.902 -0.904 in.)22.87 mm (0.900 in.)
Countershaft
2nd gear
t.D.52.010 52.029 mm (2.0476 2.0484 in.)52.08 mm {2.050 in.}
End play0.06 0.16 mm (0.002 0.006 in.)0.25 mm 10.010 4n.)
Thickness21.92 27.91 mtn \1.099 1.101 in.)27.87 mm 11.097 in.)
Countershaft'l st gear
distance collar
LD.39.95 39.96 mm (1.572a 1.5132 in.)39.97 mm (1.574 in.)
o.D.46.989- 47.000 mm (1.8499- 1.8504 in.)46.94 mm (l.848 in.)
Length23.03 23.08 mm (0.907-0.909 in.i
Countersha{l
2nd gear
distance coliar
l.D.39.95 39.96 mm {1.5728'- 1.5732 in.l39.97 mm (1.574 in.)
o.o.46.989 47.000 mm (1.8499 1.8504 in.)46.94 mm (1.848 in.)
Length28.03 28.08 mm (l.104 1.106in.)

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
-

\.
Engine Electrical
Engine Electrical
SpecialTools
Starting System
Comoonent Location Index ...............
Circuit Diagram
Starter Circu it Troubleshooting
Clutch Interlock Switch Test
Starter Solenoid Test ..............
Sta rter Performance Test
Starter Reolacement ...............
Starter Overhaul .......................
lgnition System
Component Location Index ...............
Circuit Diagram
lgnition Timing Inspection
lgnition Coil Removal/1nsta11ation .......................
Spark Plug Inspection
Charging System
Component Location Index .................................. 4-2O
Circuit Diagram ........................... 4-21
Charging Circuit Troubleshooting ....................... 4-22
Drive Belt Inspection ................... 4-26
Drive Beft Replacement .............. 4-26
Drive BeftAuto-tensioner Inspection .................. 4-27
Drive Beft Auto-tensioner Replacement .............. 4-28
Alternator Reolacement ............. 4-29
Alternator Overhaul ................ .... 4-30
Cruise Control
Component Location Index .................................. 4-36
Circuit Diagram ........................... 4-37
Symptom Troubleshooting Index ....................... 4-38
Cruise Control Unit lnDut Test ............................. 4-40
Main Switch TesVReolacement ........................... 4-42
SeVResume/Cancel Switch TesVReplacement .. 4-42
Cruise Control Actuator Test ...... 4-43
Cruise Control Actuator/Cable Replacement ...... 4-44
Actuator Cable Adjustment .................................. 4-45
Clutch Pedal Position Switch Test ....................... 4-45
4-2
4-J
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-15
4-16
4-17
4-18
4- 19
-+
ENGINE

\
?.-
Armature Inspection and Test
1. Remove the starter (see page 4-9).
2. Disassemble the starter as shown atthe beginning
of this procedure.
3. Inspect the armature for wear or damage from
contact with the permanent magnet. lf there is wear
or damage, replace the armature.
Check the commutator (A) surface. lf the surface is
dirty or burnt, resurface with emery cloth or a lathe
within the specifications in step 5, or recondition
with # 500 or # 600 sandpaper (B).
6.
5. Check the commutator diameter. lf the diameter is
below the service limit, replace the armature.
Commutator Diameter
Standard (Newl: 28.0 mm (1.10 in.l
Service Limit: 27.0 mm (1.06 in.)
Measure the commutator (A) runout.
. lf the commutator runout is within the service
limit, check the commutator for carbon dust or
brass chips between the segments.. lf the commutator runout is not within the service
limit, reolace the armature.
Commutator Runout
Standard lNew): 0.02 mm 10.001 in.) max.
Service Limit: 0.05 mm (0.002 in.)
(cont'd)
4-11

\Drive Belt Auto-tensioner Inspection
1.Check whether there is a change in the position of
the auto-tensioner indicator before starting the
engine and after starting the engine. lf there is a
change in the position, replace the auto-tensioner.
3.
Check for abnormal noise from the tensioner pulley.
lf abnormal noise is heard, replace the tensioner
pulley.
Remove the drive belt (see page 4-26).
lMove the auto-tensioner within its limit with the
belt tension release tool in the direction shown.
Check that the tensioner moves smoothly and
without any abnormal noise. lf the tensioner does
not move smoothly or there is abnormal noise,
replace the auto-tensioner.
7.
8.
Remove the auto-tensioner (see page 4-28).
Install the tensioner pulley.
Clamp the auto-tensioner (A) by using two 8 mm
bolts (B) and a vise (C) as shown. Do not clamp the
auto-tensioner itself .
Set the torque wrench (D) on the pulley bolt.
Align the indicator {E) on the tensioner base with
center mark (F) on the tensioner arm by using the
torque wrench, and measure the torque. lf the
torque value is out of specification, replace the
auto-tensioner,
NOTE; lf the indicator exceeds the center mark,
recheck the torque.
Auto-tensioner spring torque:
26.5-36.3 N.m 12.7-3.7 kg.m, 19.5-26.8lbt.ft)
9.
4-27