2003 HONDA CIVIC valve

Listed by Maintenance ltem for Severe Conditions
Use this schedule if the vehicle is driven MAINLY in Canada or in anv of the followina conditions.NOTE: it only OCCASIONALLY driven in theseconditions, use the Normal Conditions schedute.Sovere Driving Conditions. Driving less than 5 miles (8 km) per trip or, in lreezing temperatures, driving less than. Driving in extremely hot over 90 "F 132 'C)conditions.10 miles (16 km) per trip.
. Extensive idling, or long periods ot stop-and-go-driving, such as a taxi or a commercial delivery vehicle.. Trailer towing, driving with a cartop carrier, or driving in mountainous conditions.. Driving on muddy, dusty, or de iced roads.
Service at the indicated distance or time,whichever comes first.miles x 1,000102030405060708090100110120
km x 1,0001648648096112128144160176192
months122436486072
Replace engine oilReplace every 5,000 miies 18,000 km)or 6 months
Rotate tires{Checktire intlation and condition at leastonce per monthiaoaaoaaoaaao
Replace engine oil fiher
Inspect front and rear brakes
Lubricate all locks, hinges, and latches
Visually inspect the following items:. Tie rod ends, steering gearbox and boots. Suspension components' Driveshaft boots
Checl parking brale adjuslmentaaOaoa
Visually inspect the following items:. Brake hoses and lines {including ABSi. Allfluid levels and condition oflluids. Exhaust system*. Fuel lines and connections*. Lights and controls, vehicle underbody
Inspect and adjust drive behoaoa
Replace dust and pollen filter"o't'
Replace transmission lluidaa
Service the following items atthe recommended interuals
Replace air cleaner elementEvery 15,000 miies (24,000 km) in dusty conditions, otheMise use normal schedule.
Replace spark plugsEvery 110,000 miles (176,000 km)
Inspect valve clearanceInspect every 110,000 miles (176,000 km), otheMise adiust only if noisy.
Inspect idle speed'Every 160,000 miles (256,000 km)or8 vears
Replace engine coolantAt 120,000 miles (192,000 km) of 10 years,lhen every 60,000 miles (96,000 km)or 5
Replace brake fluidEvery 3 years
* : According to state and federal regulations, failure to do the maintenance items marked with asterisk 1*)will not void customer's emissionswarranties. However, Honda recommends that all maintenance service be done at the recommended interval to ensure long{erm reliabilitv.
NOTE 1: Replace the dust and pollen filter at 15,000 miles/24,000 km if the vehicle is driven mostly in urban areas that have high concentrationsof soot in the air from industrv and diesel-Dowered vehicles.
t,
3-9

40. Install the air cleaner housinq.
6x1.0mm12 N m (1.2 kgf.m,8.7 lbt.ft)
Install the air cleaner housing cover (A) and
connect the intake air temperature (lAT) sensor
connector (B),
42. Installthe breather hose (C) and vacuum hose 1D).
41.
43. Installthe intake manifold cover.
6x1.0mm12Nm11.2kgf.m.8.7 tbf.ft)
Installthe battery. Clean the battery posts and
cable terminals with sandpaper, then assemble
them and apply grease to prevent corrosion.
Check that the transmission shifts into gear
smoothly.
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.
Refillthe engine with engine oil (see page 8-5).
Refill the transmission with fluid (see page 13-3).
Refill the radiator with engine coolant, and bleed
air from the cooling system with the heater valve
open (see page 10-6).
Perform the engine control module (ECM) idle learnprocedure (see page 11-139).
Inspect the idle speed (see page 1 1-138).
Inspect the ignition timing (see page 4-17).
Check the wheel alignment {see page 18-4).
Enter the anti-theft code for the radio, then enter
the customer's radio station presets.
Set the clock.
YE
44.
41.
]tE
46.
48.
49.
52.
53.
54.
50.
51.
55.
5-15

\
Engine Mechanical
Cylinder Head
Special Tools
Comoonent Location Index
Engine Compression Inspection
VTEC Rocker Arm Test ........... ............ 6-7
VTC Actuator Inspection .................... 6-8
Valve Clearance Adjustment ............. 6-9
Crankshaft Pulley Removal and Installation .............. 6-11
Cam Chain Removal ........................... 6-12
Cam Chain Installation ....................... 6-15
Auto-Tensioner Removal/1nsta11ation ......................... 6-19
Chain Case Oil Seal Installation ........ 6-21
Cyf inder Head Cover Removal .......... 6-22
Cylinder Head Removal ..................... 6-23
WC Actuator. Exhaust Camshaft Sorocket
Repf acement .........6-24
Cylinder Head Inspection for Warpage ...................... 6-25
Rocker Arm Assembly Removal ................................. 6-26
Rocker Arms and Shafts
Disassembly/Reassembly .............. 6-27
Rocker Arms and Shafts Inspection ............................ 6-28
Camshaft Inspection .......................... 6-29
Valves, Springs, and Valve Seals Removal ................ 6-31
Valve Insoection ...................... ........... 6-32
Valve Stem-to-Guide Clearance Insoection ............... 6-32
Valve Guide Reolacement ................. 6-33
Valve Seat Reconditioning ................ 6-35
Valves, Springs, and Valve Seals Installation ............ 6-37
Rocker Arm Assemblv Installation .... 6-38
Cvlinder Head Installation ........................................... 6-39
Cylinder Head Cover Installation ...... 6-41
6-2
6-3
b-t'

Cylinder Head
aSpecialTools
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Ref. No. Tool NumberDescription Oty
O OTAAJ.PNAA'IOO
.D OTHAH-PJ7O1OB
o I oz..rae-oot ozoa
@ 07JAB-0010204
o 07NAB-0010404
G) 07VAE-001010A
OTZAJ.PNAAlOO
E] OTZAJ-PNAA2OO
O I 07ZAJ-PNAA300
tro 07742-0010100
@ 07746-001o4oo(D 07749-0010000
Air Pressure Regulator
Valve Guide Reamer, 5.5 mm
Socket, 19 mm
Holder Handle
Holder Attachment, 50 mm
Valve Spring Compressor Attachment
VTEC Air Adapter
VTEC Alr Stopper
Air Joint Adapter
Valve G uide Driver,5.5 mm
Attachment, 52 x 55 mm
Driver
1
1
1
1
1
1
2
1
1
6-2

Component Location lndex
TENSIONERARM
AUTO.TENSIONERReplacement, page 6-'l I
IGNITION COILCOVER
CYLINDER HEADCOVERRemoval, page 6-22lnstallation, page 6-41
CAM CHAINBemoval, page 6-'12Installation, page 6-15
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CAM CHAIN GUIDE B
CAM CHAIN GUIDE A
VARIABLE VALVETIMING CONTROLtwc) olL soLENotDVALVE
CRANKSHAFT PULLEYReplacement, page 6 11
O-RING
(cont'd)
6-3

SPRINGRETAINER
EXHAUST VALVESEAL
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wcsrRArNER
CYLINDER HEADRemoval, page 6'23Inspection, page 6-25Installation, page 6-39
EXHAUST VALVERemoval, page 6-31Installation, page 6-37
INTAKE VALVERemoval, page 6 31Installation, page 6 37
CYLINDER HEADGASKET
,H v .-- spntruc>il( G\-r_
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| | g -/ TNTAKE vALVE
II ^-'-- 9E4LI I U- Replacement, Page 6-31
He,tl E- _-/ |NTAKE VALVEY I 1.- GUIDE
U Replacement, page 6-33
i
HEAT SHIELD
6-5

Cylinder Head
Engine Compression Inspection
1. Warm up the engine to normal operating
temperature (cooling fan comes on).
2. Turn the ignition switch OFF.
3. Remove the intake manifold cover (see step 1 onpage 6-22).
4, Disconnect all four injector connectors.
5. Start the engine, and let it run until it stalls.
6. Remove the iour ignition coils (see page 4-18).
7. Remove the four spark plugs.
8. Attach the compression gauge to the spark plug
note.
6-6
V,
\
9.
10.
Open the throttle fully, then crank the engine with
the starter motor and measure the compression.
Compression Pressure
Above 930 kpa (9.5 kgf/cm', 135 psi)
Measure the compression on the remaining
cylinders,
Maximum vadation
Within 200 kPa (2.0 kgf/cm', 28 psi)
lf the compression is not within specifications,
check these items, then remeasure the
compressron.
. Damaged orworn valves and seats. Damaged cylinder head gasket. Damaged or worn piston rings. Damaged orworn piston and cylinder bore
11.
\-

WEC Rocker Arms Test
Special Tools Required. Air pressure regulator 07AAJ-PNAA100. VTEC air adaoter 07ZAJ-PNAA100. WEC air stoDoer 07ZAJ-PNAA200. Air joint adapter 07ZAJ-PNAA300
1. Remove the cylinder head cover (see page 6-22).
2. Set the No. 1 piston at top dead center (TDC) (see
step 1 on page 6-12).
3. Verify that the intake primary rocker arm (A) moves
independently of the intake secondary rocker arm
(B).
. lf the intake primary rockerarm does not move,
remove the primary and secondary rocker arms
as an assembly and check that the pistons in the
secondary and primary rocker arms move
smoothly. lf any rocker arm needs replacing,
replace the primary and secondary rocker arms
as an assemblv, and test.. lfthe intake primary rocker arm moves freely, go
to step 4.
6.
Repeat step 3 on the remaining intake primary
rocker arms with each piston at TDC. When all the
primary rocker arms pass the test, go to step 5.
Check that the air pressure on the shop air
compressor gauge indicates over 400 kPa
(4 kgflcm', 57 psi).
Inspect the valve clearance (see page 6-9).
Remove the sealing bolt (A)from the relief hole,
and install the VTEC air stopper (B).7.
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Remove the No. 2 and No. 3 camshaft holder bolts,
and installthe VTEC air adapters (C) finger-tight.
Connect the air joint adapter (D), and air pressure
regulator with a 0-100 psi gauge (E).
(cont'd)
OTZAJ.PNAAlOO
6-7