2003 HONDA CIVIC fuel cap

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
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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.
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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

18.
19.
Remove the drive belt (see page 4-26).
Remove the lvC line mounting bolt.
20. Remove the radiator cap.
21. Raise the hoist to full height.
22. Remove the front tires/wheels.
23. Remove the splash shield.
o@
24. Loosen the drain plug in the radiatorto drain the
engine coolant (see page 10-6).
25. Drain the transmission fluid (see page 13'3).
26. Drain the engine oil {see page 8-5).
27. Disconnect the stabilizer links (see page 18-18).
28. Disconnect the suspension lower arm ball joints
(see step 3 on page 18-19).
29. Remove the driveshafts {see page 16-3). Coat all
precision finished surfaces with clean engine oil.
Tie plastic bags over the driveshaft ends.
30. Disconnect the air fuel ratio {4,/F) sensor connector
(A) and secondary heated oxygen sensor
(secondary HO2S) connector (B), then remove the
three way catalytic converter {TWC) assembly {C).
31. Remove the lower hose.
(cont'd)
5-5

Fuel and Emissions Systems
System Descriptions (cont'dl
ECM lnputs and Outputs at Connector E (31P}
L
u
1iMoFPR
2sr-{]zs3LG34SG3
6$1025HTC
1M RLY
8AFSHTCR
I
14FTP15ELD
16EPSLD
18ACC20Z/VBS21VSV
22BKSW23K-LINE24SEFMJ26NEP
21rMoCD
29scs30WEN31MIL
Wire side of female terminals
NOTE: Standard battery voltage is '12 V.
TerminalnumberWire colorferminal nameDescription Signal
GRNI/ELIMO FPR (IMMOBILIZERFLJEL PUMP RELAYIDrives PGM Fl main relay 20Vfor2 seconds after turning ignition switch ON{ll). then batterv voltaoe2WHT/REDSHO2S (SECONDARYHEATED OXYGEN SENSOR(SECONDARY HO2S),SENSOR 2r
Detects secondary HO2S{sensor 2) signalWith throttle Jully opened from idle with fullywarmed up engine: above 0.6VWith throttle quickly closed: below 0.4 V
3BRN/YELLG3 (LOGIC GROUND)cround forthe ECM/PCMcontrolcircuitLess than 1.0 V at all times
4PNKSG3 {SENSOR GBOUND)Sensor oroundLess than 1.0 V at all times5YEUELUVCC3 {SENSOR VOLTAGE)Provides sensor voltageWith ignition switch ON (ll): about 5 VWith ionition switch OFF: about 0 V6BLKATr'HTSO25HTC (SECONDARYHEATED OXYGEN SENSOR(SECONDARY H02S)HEATER CONTROL)
Drives secondary HO2SheaterWith ignition switch ON (ll): baftery voltageWilh fullv warmed up engine running: dul,controlled
1REDA/ELMRLY (PGM.FI MAINRELAY}Drives PGM-Flmain relay 1Power source forthe DTCWith ignition switch ON (ll): about 0 VWith ignition switch OFF: battery voltage
IORNAFSHTCR {AIR FUEL BATIO(Iy'F)SENSOR HEATERCONTROL RELAY)
Drives air fuel ratio sensorheater relayWith ignition swirch ON {ll): 0 V
IYEUBLKIGl (IGNITION SIGNAL)Detecrs ignition signalWith ignition switch ON (ll): battery voltageWith iqnition switch OFF: about 0 V't4LT GRNFIP lFUEL TANKPRESSURE (FTP) SENSOR)Detects FTP sensor signalWith ignition switch ON (ll) and fuel fill cap open:about 2.5 VGRN/REDELD (ELECTRICAL LOADDETECTOF)Detects ELD signalWith ignition swjtch ON itt):aOoutO.t V l-gV(deDendino on electrical load)LT GRN/8LKEPSLD (ELECIRICALPOWEB STEEBING LOADDETECT)
Detects Power steering loadsrgnalAt idle with steering wheel in straight aheadposition: about 0 VAt idle with steering wheelatfull lock: momentary
'18REDACC (Ay'C CLUTCH RELAY)Drives P,/C clutch relayWith compressor ON: about 0 VWith comoressor OFF: batterv voltaoe
11-22
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Fuel and Emissions Systems
System Descriptions (cont'dl
Gatalytic Converter System
Three Way Catalytic Converter (TWC)
The TWC converts hydrocarbons (HC), carbon
monoxide {CO), and oxides of nitrogen (NOx) in the
exhaust gas to carbon dioxide (C02), dinitrogen (N2),
and water vaDor.
THREE WAYCATALYST
FRONT OFVEHICLE
11-34
Positive Crankcase Ventilation (PCVI System
The PCV valve prevents blow-by gasses from escaping
into the atmosphere by venting them into the intake
manifo ld.
:: BLOW-BY VAPOR€: FRESH AIR
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BREATHER PIPE
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Evaporative Emission (EVAPI Control Diagram
The EVAP controls minimize the amount of fuel vapor escaping to the atmosphere. Vapor from the fuel tanK rstemporarily stored in the EVAP canister until it can be purged from the canister into the engine and burneo.
. The EVAP canister is purged by drawing fresh air through it and into a port on the intake manifold.The purging vacuum is controlled by the EVAP canister purge valve, which operates whenever engine cootanttemperature is above 149'F (65"C).
'WhenvaporpressureinthefueltankishigherthanthesetvalueoftheEVAPtwowayvalve,thevalveopensano
regulates the flow of fuel vapor to the EVAP canister.'Duringrefueling,thefueltankvaporcontrol valve opens with the pressure in the fuel tank, and feeds the fuel vaDorto the EVAP canister.
FUEL TANKVAPORRECIRCULATIONVALVE
FUEL TANKVAPORSIGNAL TUBE
BLU/RED
FUEL FILL CAP
BLK
+EVAPCANISTER
FUEL TANKVENT SHUTVALVE
BLK/YELFrom-- FUEL TANKVAPORRECIRCULATIONTUBE
EVAPCANISTER
EVAP TWO WAYVALVE
(cont'd)
11-37

Fuel Supply System
{
a
Component Location Index
FUEL FEED LINEFUEL PULSATION DAMPERReplacement, page 1 1'154
PGM.FI MAIN RELAY 2Troubleshooting, page'l'l-141
FUEL TUBE/OUICK.CONNECT FITTINGSPrecautions, page 1 1-148Removal, page 11-'149Installation, page 1 1-'l50
FUEL VAPOR LINE
i../
PUMPTest, page 11-141
FUEL FILL CAP
FUEL TANKReplacement, page'l 1-155
PGM.FI MAIN RELAY 1
Fleplacement, page 1 1'1 53FUEL FILTERReplacement, page 1 1-1 52FUEL GAUGE SENDING UNITTest, page 11-156Replacement, page 1 1-153FUEL PRESSUN REGULATORReplacement, page'1 1-'152
11-140

Fuel Pump Circuit Troubleshooting
lf you suspect a problem with the fuel pump, check that
the fuel pump actually runs; when it is on, you will hear
some noise if you listen to the fuel fill port with the fuel
fill cap removed. The fuel pump should run for 2
seconds when the ignition switch is first turned on. lf
the fuel pump does not make noise, check as follows:
1. Turn the ignition switch OFF.
2. Remove the glove box {see page 20-63), then
remove the PGM-FI main relay 2 (A).
Turn the ignition switch ON {ll).
Measure voltage between PGM-Fl main relay 2 5P
connector lerminal No. 5 and body ground.
PGM.FI MAIN RELAY 25P CONNECTOR
IGPl(YEL/BLK}
Wire side of female terminals
ls there battery voltage?
YES-Go to step 5.
NO Repair open in the wire between the PGM'Fl
main relay 1 and the PGM-Fl main relay 2.t
3.
5. N4easure voltage between PGM-Fl main relay 2 5P
connector terminal No. 1 and body ground.
PGM.FI MAIN RELAY 25P CONNECTOR
Wire side oJ female terminals
ls there battery voltage?
YES Go to step 6.
NO Repair open in the wire between the under-
dash fuse/relay box and PGM-Fl main relay 2.1
6. Turn the ignition switch OFF.
7. Disconnect ECM connector E (31P).
8. Check for continuity between PGM-FI mainrelay2
5P connector terminal No. 3 and ECM connector
terminal E1.
PGM-FI MAIN RELAY 2 5P CONNECTOB
Wire side of female terminals
ls there continuity?
YES-Go to step 9.
NO-Repair open in the wire between the PGM Fl
main relay 2 and the ECM (E1).1
IMOFPR(GBN/YEL)
(cont'd)
11-141
Et2lFtxm
7-
z
ECM CONNECTOR E 131P}