2003 HONDA CIVIC Workshop Manual

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).
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(cont'd)
8-11

Engine Lubrication
Oil Pump Overhaul (cont'dl
4. Measure the inner diameter of the No. 1 bearing for
the front balancer shaft hole and the rear balancer
shaft hole.
Bearing Inner Diameier:
Front:
Standard (New): 20.000-20.020 mm(0.7874 0.7882 in.)
Service Limit; 20.03 mm (0.789 in.)
Rear:
Standard (New): 24.000-24.020 mm
10.9/t49-0.9457 in.)
Service Limit: 24.03 mm (0.946 in.)
Front:
Rear:
8-12
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5.Measure the diameters of the No. 1 journals on the
front balancer shaft and rear balancer shaft.
NO.1 Journal Diameter:
Front:
Standard lNew): 19.938 19.950 mm(0.7850 0.7854 in.)
Service Limit: 19.92 mm {0.784 in.)
Rear:
Standard lNewl: 23.938 23.950 mm
{0.9424-0.9/129 in.)
Service Limit: 23.92 mm (0.942 in.)
Front:
a

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'd)
13. lnstallthe pump housing.
6x1,0mm12 N.m(1.2 kgt.m,8.7 lbf.ft)
8-14
!
Oil Pump Installation
1. Make sure the No. 1 piston is at TDC (see step 1 on
page 6-12).
2. Align the dowel pin{A} on the rear balancer shaft
with the mark (B) on the oil pump.
To hold the rear balancer shaft, insert a 6 mm pin
driver {A) into the maintenance hole in the lower
balancer shaft holder and through the rear balancer
shaft.\,-
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4. Apply engine oil to the threads of the oil pump
sprocket mounting bolt (A).
A10 x 1.25 mm{4 N.m(a.5 kg{ m,33 rbf.ftl
10x 1.25 mm,l,t N.m {4.5 kgf.m,33 tbt.ftl
5. Loosely installthe oil
pump sprocket (C).
8 x 1,25 mm22N m l2.2kot m.r6 tbt.fti
pump (B), then installthe oil
7.
Remove the pin driver (D).
Tighten lhe oil pump mounting bolts.
I
8-15
8. Squeeze the new oil pump chain tensioner (A), theninstall the set clip (B) on it as shown.
NOTE: The set clip is supplied with the oil pump
chain tensioner.
9. Install the oil Dum D cha in tensioner.
6x1.0mm12 N.m (1.2 kgf.m,8.7 rbf.ft)
IB
(cont'd)

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.
(

Engine Mechanical
Intake Manifold and Exhaust System
lntake Manifold Removal and Installation ................. 9-2
Exhaust Manifold Removal and Installation .............. 9-7
Exhaust Pipe and Muffler Replacement ..................... 9-8
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r-!i!1

Intake Manifold and Exhaust System
lntake Manifold Removal and Installation
Exploded View:
INTAKE MANIFOLD PLATEReplace if cracked orif mating surface isdamaged.
6x1.0mm12 N.m{1.2 kgf.m,8.7 lbf.ft)
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GASKETReplace.
8 x 1.2522Nm12.2 ksf
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16
.25 mm'mkgf.m, 1
8 x 1.25 mm22 N.m(2.2 kgf m. 16 lbt.ft)
(
8 x 1,25 mm22 N.m {2.2 kgf.m, 16 lbf ft}
INTAKE MANIFOLDReplace if cracked orif mating surface is
9-2
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