2003 HONDA CIVIC length

Cylinder Honing
Only a scored or scratched cylinder bore should be
noneo.
Measure the cylinder bores {see page 7-15).
lf the block is to be reused, hone the cylinders and
remeasure the bores.
Hone the cylinder bores with honing oil and a fine(400 grit) stone in a 60 degree cross-hatch pattern
(A). Use only a rigid hone with 400 grit or finer
stone such as Sunnen, Ammco, or equivalent. Do
not use stones that are worn or broken.
When honing is complete, thoroughly clean the
engine block of all metal particles. Wash the
cylinder bores with hot soapy water, then dry and
oil them immediately to prevent rusting. Never use
solvent, it will only redistribute the grit on the
cylinder walls.
lf scoring or scratches are still present in the
cylinder bores after honing to the service limit,
rebore the cylinder block. Some light vertical
scoring and scratching is acceptable if it is not deep
enough to catch your fingernail and does not run
the full length of the bore.
'L
3.
7-17

Driveline/Axle
Driveshafts Reassembly (cont'd)
Check the alignment of the paint mark (A) with theoutboard joint end (B).
7. Pack the outboard joint (A)with the joint grease
included in the new ioint boot set.
Grease quantity
Outboard ioint: 105 115 g (3.7 4.1 ozl
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16-16
8. Adjust the length of the driveshafts to the figurebelow, then adjust the boots to halfway betweenfull compression and full extension. Make sure theends of the boots seat in the grooves of thedriveshaft and joint.
Left driveshaft:497 502 mm (19.6 19.8in.)
Rightdriveshaft: 475 480 mm {18.7
t
-tTfi'.D.ilTD
18.9 in.l
Fit the boot (A) ends onto the driveshaft (B) andoutboard joinl (C).
9.
{

Front Suspension
Damper/Spring Replacement
Exploded View
DAMPER MOUNTINGBEARING
UPPER SPRING MOUNTINGCUSHIONCheck for deteriorationano oamage,
DAMPER SPRINGCheck for lree length.
./ SELF-LOCK|NG NUT/.' 12 x 1.25inm
,,/ 44 N.m {4.5 kgt.m, 33lbf.ftl,/ neDtace.^atae9
-€.- - DAMPER MOUNTING BASE
1, @-:'\--""' check for delormation
lF \-:-./ - ,
E9-
DAMPER UNITCheck for oil leaks,gas leaks, and smoothoperatron.
\
18-20

5. With a feeler gauge (A), measure the clearance
between the gauge body and the adjusting nut (B)
as snown,
lf the clearance between the gauge body and the
adjusting nut is 0.4 mm (0.02 in.), the pushrod-to-
piston clearance is 0 mm. However. if the clearance
between the gauge body and the adjusting nut is
0 mm, the pushrod-to-piston clearance is 0 4 mm
{0.02 in.) or more. Therefore it must be adjusted
and rechecked.
Clearance: 0-0./t mm (0-0.02 in.)
lf the clearance is incorrect, loosen the star locknut
(A). and turn the adjuster (B) in or out to adjust.
. Adjust the clearance while the specified vacuum
is appiied to the booster.. Hold the clevis (C) while adjusting.
A0 0.4 mm l0 -0.02 in.) 22N.n
07JAG-SO40100
7. Tighten the star locknut securely.
8. Remove the special tool (D).
9. Check the pushrod length (A) asshownifthe
booster is removed, lf the length is incorrect,
loosen the pushrod locknut (B), and turn the clevis
(C) in or out to adjust.
A116 mm {4.6 in.)
10. Installthe master cylinder (see page l9-15)
10 x 1.0 mm1.5 N'm11.5 kgf.m,11 lbf.ftl
19-17