2003 HONDA CIVIC limit

ItemM€asurementOualificationStandard or NewService LimitParking brake
lever
Distance traveled when lever pulled
with 196 N (20 kgf, 44 lbs) ol force
7 8 clicks
Brake pedalPedal height (carpet removed)184 mm (7 4/16 in.)
Free play0.4 3.0 mm (0 016 0 '118 in.)Master cylinderPiston-to-pushrod clearance0 0.4 mm (0 0.02 in.)Erake discThicknessFront21.0 mm (0.83 in.)19.00 mm (0.75 in.)
Rear9.0 mm {0.35 in.)8-0 mm (0.31 in.iRunoutFront0.10 mm (0.004 in.)
Rear0.10 mm (0.004 in.)ParallelismFront and rear0.015 mm (0.0006 in.)Brake padsThicknessFront10.0 mm (0.39 in.)1.6 mm (0.06 in.)
llear9.0 mm {0.35 in.)1.6 mm (0.06 in.)
Standards and Service Limits
Brakes
a
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Air Gonditionin
ItemMoasurementOualilicationStandard or New Service LimitRefrige.antTvpeHFC 134 a (B-134 a)
Capacity of system500 550 g 117.6 19.4 oz)Refrigerant oilTypeSP 1O
(P/N 38897-P13-A01AH or 38899-P13-A01 )Capacity ofcomponentsCondenser25 m0, 15/6 fl ozl
Evaporator45 mA 11 1/2 fl ozt
Each line and
hose
10 m0 (1/3 fl or)
Compressor130 150 m014 1/3 5floz)CompressorStarter coil resistanceAt 68"F (20"C)3.05 3.35 0Pulley-to-pressure plate clearance0.35 0.6 mm (0.014 0.024 in.)Drive beltAuto tensioner lneeds no adjustment)
2-10
q

\
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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

Starting System
Starter Overhaul (cont'dl
7. Check the mica depth (A). lf the mica is too high {B),undercut the mica with a hacksaw blade to theproper depth. Cut away allthe mica (C) between
the commutator segments. The undercut should
not be too shallow, too narrow, or V-shaped (D).
Commutator Mica Depth
Standard (New): 0.50-0.80 mm {0.020-0.031 in.)
Service Limit: 0.20 mm (0.008 in.)
Check for continuity between the segments of the
commutator. lf an open circuit exists between any
segments, replace the armature.
M
4-12
\
9. Place the armature (A) on an armature tester (B).
Hold a hacksaw blade (C) on the armature core. lf
the blade is attracted to the core or vibrates while
the core is turned, the armature is shoned. Replace
the armature.
Check with an ohmmeter that no continuity exists
between the commutator (A) and armature coll
core (B), and between the commutator and
armature shaft (C). lf continuity exists, replace the
armature.
10,

Starter Brush Inspection
11. lvleasure the brush length. lf it is not within the
service limit, replace the brush holder assembly.
Brush Length
Standard {New): 14.0-14.5 mm (0.55-0.57 in.)
Service Limit: 9.0 mm {0.35 in.)
Starter Field Winding Test
12. Check for continuity between the brushes (A). lf
there is no continuity. replace the armature
housing (B).
Check for continuity between each brush (A) and
the armature housing (B). li there is continuity,
replace the armature housing.
13.
Starter Brush Holder Test
14, Check that there is no continuity between the (+ )
brush holder {A) and ( ) brush holder (B}. lfthere
is continuity, replace the brush holder assembly.
Brush Spring Inspection
15. Insen the brush (A) into the brush holder, and bring
the brush into contact with the commutator, then
attach a spring scale (B) to the spring (C). Measure
the spring tension at the moment the spring lifts off
the brush. lf the spring tension is not within
specification, replace the spring.
Spring Tension: 13.7-17.7 N {1.40-1.80 kgf,
3.09 3.97 lbf)
(cont'd)
4-13

Spark Plug Inspection
1.Inspect the electrodes and ceramic insulator.
Burned or worn electrodes may be caused by:. Advanced ignition timing. Loose spark plug
. Plug heat range too hot.Insufficientcooling
Fouled plug may be caused by:. Retarded ignition timing. Oil in combustion chamber. Incorrect spark plug gap
. Plug heat range too cold. Excessive idling/low speed running. Clogged air cleaner element. Deteriorated ignition coils
Worn or deformedelectrodes
Do not adjust the gap of iridium tip plugs (A);
replace the spark plug if the gap is out of
specification.
Electrode Gap:
Standard (New): 1.0 1.1 mm
{0.039-0.0€ in.)
Service Limit: 1.3 mm {0.051 in.l
f .lmproper gap
I J.Oil-toulingr- 1 . Cs6on deposits' I . Cracked center electrode insulator
L
3. Replace the plug at the specified interval, or if the
center electrode is rounded {A). Use onlV the spark
plugs listed below.
Spark Plugs: lZFR6Kl1 (NGK)
SKJ2ODR-M11 (DENSO)
Apply a small quantity of anti-seize compound to
the plug threads, and screw the plugs into the
cylinder head finger-tight. Then torque them to
18 N m (1.8 kgf.m, 13lbf ft).
4.
4-19

\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

Charging System
Alternator Overhaul (cont'd)
Rectitier Test
16. Check for continuity in each direction, between the
B terminal and P terminals, and between the E
terminal and P terminals of each diode pair.
All diodes should have continuity in only one
direction. Because the rectifier diodes are designed
to allow current to pass in one direction, and the
rectifier is made up of eight diodes (four pairs). you
musttest each diode in both directions for
continuity with an ohmmeter that has diode
checking capability: a total of 16 checks.
. lf any diode is faulty. replace the rectifier
assembly. {Diodes are not available separately.)' lf all the diodes are OK, go to step 17.
/--:',t- -L . --- -o \-- l'-=
BP"
P,
P.
P,
P.
4-34
19.
'a
Alternator Brush Inspection
17. Measure the length of both brushes (A)with a
vernier caliper {B).
. lf either brush isshorterthanthe service limit,
replace the brush assembly.. lf brush length is OK, go to step '18.
Alternator Brush Length:
Standard (New): 10.5 mm (0.41 in.)
Service Limit: 1.5 mm (0.06 in.)
Rotor Slip Bing Test
18. Check that there is continuity between the slip rings
{A).
. lf there is continuity, go to step 19.. lf there is no continuity, replacethe alternator.
Check that there is no continuity between each slip
ring and the rotor (B) and the rotor shaft (C).
. lf there is no continuity, goto step 20.. lf there is continuity, replace the alternator.
\"

Installation:
1. Install the VTC actuator and exhaust camshaft
sprocket.
2. Apply engine oil to the th reads of the VTC actuato r
mounting bolt and exhaust camshaft mounting bolt,
then install them.
3. Hold the camshaft with an open-end wrench, then
tighten the bolts.
Specified torque:
VTC actuator mounting bolt:
113 N.m (11.5 kgl.m,83 lbl.ft)
Exhaust camshaft sprocket mounting bolt:
72 N m (7.3 kgf.m, 53 lbf.ft)
4. Install the cam chain {see page 6-15).
1,
Cylinder Head Inspection for
Warpage
Remove the cylinder head {see page 6-23).
Inspect the camshaft (see page 6-29).
Check the cylinder head for warpage. Measure
along the edges, and three ways across the center.
. lf warpage is less than 0.05 mm (0.002 in.)
cylinder head resurfacing is not required.. lf warpage is between 0.05 mm (0.002 in.) and
0.2 mm (0.008 in.), resurface the cylinder head.. Maximum resurface limit is 0.2 mm (0.008 in,)
based on a height of 104 mm (4.09 in.).
Cylinder Head Height;
Standard {New}: 103.95 104.05 mm
{4.093 4.096 in.}
6-25