2003 HONDA CIVIC ect

Engine Lubrication
Oil Pump Overhaul {cont'dl
Oil Pump Inspection
1. Remove the pump housing.
Check the inner-to-outer rotor radial clearance
between the inner rotor (A) and outer rotor {B). lf
the inner-to-outer rotor radial clearance exceeds
the service limit, replace the oil pump.
Inner Rotor-to-Outer Botor Radial Clearance
Standard {New): 0.02 0.16 mm (0.001 -0.006 in.)
Service Limit: 0.20 mm (0.008 in.,
1'[1e-\1.-,-2
1 'a - :.: ,-'r'
8-10
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4.
3. Check th e h ousing-to-roto r axia I clearance between
the rotor (A) and pump housing (B). lf the housing-
to-rotor axial clearance exceeds the service limit.
replace the oil pump.
Housing"to-Rotor Axial Clearance
Standard (New): 0.02 0.07 mm (0.001 -0.003 in.l
Service Limit: 0.12 mm (0.005 in.l
Check the housing-to-outer rotor radial clearance
between the outer rotor (A) and pump housing (B).
lf the housing-to-outer rotor radial clearance
exceeds the service limit, replace the oil pump.
Housing-to-Outer Rotor Radial Clearance
Standard lNewl: 0.15 0.21 mm (0.006-0.008 in.l
Service Limit; 0.23 mm (0.009 in.)
Inspect both rotors and the pump housing for
scoring or other damage. Replace parts if
necessary.
\,

1.
Balancer Shaft Inspection
Seat the balancer shaft by pushing it away from the
oil pump sprocket end ofthe oil pump.
Zero the dial indicator against the end of the
balancer shaft, then push the balancer shaft back
and forth and read the end olav.
Balancer Shaft End Play:
Fronl Balancer Shaft:
Standard {Newl: 0.070 0.135 mm
{0.0028 0.0053 in.}
Service Limit: 0.15 mm (0.006 in.)
Rear Balancer Shaft:
Standard {New): 0.070-0.135 mm(0.0028 0.0053 in.l
Service Limit: 0.15 mm (0.006 in.)
2.
3. Remove the baffle plate (A) and upper balancer
shaft holder {with bearings) (B), then remove the
front balancer shaft (C) and rear balancer shaft (D).
9H.A''/.r L=] j/
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3I] UUr Be
+-
(cont'd)
8-11

8.
9.
6. Clean both balancer shaft No. 2 journals and
bearing halves with a clean shop towel.
7. Place one strip of plastigage across each No.2journal.
Reinstall the bearings and upper balancer shaft
holder, then torque the bolts.
NOTE; Do not rotate the balancer shaft durinq
insDection.
Remove the uooer balancer shaft holder and
bearings again, and measure the widest part of the
plastigage. lf the balancer shaft No. 2 journal oil
clearance is out-of-tolerance. install the new
bearings, and recheck. lf it is still out-of-tolerance,
replace the balancer shafts.
No. 2 Journal Oil Clearance:
Standard lNewl; 0.060 0.120 mm
Service Limit:
(0.0024 0.0047 in.l
0.15 mm {0.006 in.)
10. Align the punch mark on the rear balancer shaft
with the center of the two punch marks on the front
balancer shaft, then install'the balancer shafts in
the lower balancer shaft holder
Apply engine oil to the threads of the 8 mm bolts(A).
6x1.0mm'12 N.m(1.2 kgt.m, 8.7 lbt ft)
11.
Installthe upper balancer shaft holder (B) and
bafile plate (C).
(cont'd)
12.
8-13

Engine Lubrication
Oil Pump Overhaul (cont'dl
10. Remove the set clip from the oil pumpchain
tensioner.
11. Install the oil pan (see pageT-27).
8-16
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(Oif Pressure Switch Replacement
1. Discon nect the oil pressure switch connector, then
remove the oil pressure switch.
2. Apply liquid gasket to the oil pressure switch
threads, then installthe oil pressure switch.
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Removal:
'1. Remove the intake manifold cover.
2.Remove the evaporative emission (EVAP) canister
hose (A), brake booster vacuum hose (B), and
vacuum hoses {C).
3. Disconnectthe intake airtemperature (lAT) sensor
connector (A), and remove the breather hose (B),
then remove the air cleaner housing cover/intake
air duct assembly (C).
4.Fully open the throttle link and cruise control link
by hand, then remove the throttle cable (A) and
cruise control cable (B) from the links. Loosen the
locknuts {C). and remove the cables from the
bracket.
(cont'd)
(
9-3

Intake Manifold and Exhaust System
Intake Manifold Removal and Installation (cont'dl
5. Be prepared to catch and clean up spilled coolant.
Remove the water bypass hoses, then plug the
water bypass hoses.
6. Relievefuel pressure (see page 11-'144).
7. Remove the fuel line (seepagell-149).
8. Remove the positive crankcase ventilation (PCV)
hose (A), harness holder mounting bolt (B) and
harness clamp mounting bolt (C).
9-4
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9.Remove the engine wire harness connectors and
wire harness clamps from the intake manifold.
. Four injector connectors. ldle air control (lAC) valve connector. Throttle position (TP) sensor connector. fvlanifold absolute pressure {lvlAP) sensor
connector. Evaporative emission (EVAP)canister purge
valve connector
Remove the bolt securing the intake manifold and
bracket.
'1 0.
11.Remove allthe intake manifold mounting bolts/
nuts.
Remove the two stud bolts (A), then remove the
intake manifold (B).
1'>

lntake Manifold and Exhaust System
Intake Manifold Removal and Installation (cont'd)
9. lnstallthe air cleaner housing cover (A), and
connect the IAT sensor connector (B).
BC
Installthe breather hose (C).
lnstallthe EVAP canister hose (A), brake booster
vacuum hose (B), and vacuum hoses {C).
10.
11.
9-6
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12. Installthe intake manifold cover.
6x1.0mm12 N.ml.1.2k91.m,8.7 tbf.ftl
Clean up any spilled engine coolant.
After installation, check that all tubes, hoses, and
connectors are installed correctly.
Inspect for fuel leaks. Turn the ignition switch ON
(ll) (do not operate the starter) so that the fuel pump
runs for about 2 seconds and pressurizes the fuel
line. Repeat this operation two or three times, then
check for fuel leakage at any point in the fuel line.
Refill the radiator with engine coolant, and bleed
air from the cooling system with the heater valve
open (see page 10-6).
to.
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Engine Cooling
Cooling System
Component Location Index ......................................... 10-2
Radiator Cap Test ..................... .......... 10-3
RadiatorTest ............. 10-3
Fan Motor Test .......... l0-4
Thermostat Test ...................... ........... 10-4
Water Pump Inspection ..................... 10-5
Water Pump Replacement ................. 10-5
Coolant Check .............. ....................... 10-6
Coolant Replacement ......................... 10-6
Thermostat Replacement .................. 10-8
Water Passage Installation ................ 10-9
Water Outlet Installation .................... 10-9
Radiator and Fan Replacement ................................... 10-10
Fan Controls
Component Location Index ......................................... 10-11
Symptom Troubleshooting Index ............................... 10-12
Circuit Diagram ......... 10-13
Radiator Fan CircuitTroubleshooting ........................ 10-14
Radiator Fan Switch Circuit Troubleshooting
(Open) ............ ........ 10-16
Radiator Fan Switch Circuit Troubleshooting
(Short) ............ ........ 10-16
Radiator Fan Switch Test ................... 10-17
Radiator Fan Switch Reolacement .............................. 10-17