2003 HONDA CIVIC Engine removal

1.
2.
Water Pump Inspection
Remove the drive belt (see page 4-26),
Turn the water pump pulley counterclockwise.
Check that it turns freely.
Check for signs of seal leakage. A small amount of"weeping" from the bleed holes (A) is normal.
Water Pump Replacement
1. Remove the drive belt (see page 4-26).
2. Drain the engine coolant {see page 10-6).
3. Remove the crankshaft pulley (see page 6-11).
4. Remove the six bolts securing the water pump,
then remove the water pump (A).
6x1.0mm12 N m {1.2 kgt m,8.7 rbf.ft)
Inspect and clean the O-ring groove and mating
surface with the water passage.
Installthe water pump with new O rings in the
reverse order of removal.
7. Clean up any spilled engine coolant.
8. Installthe crankshaft pulley (see page 6-12).
L Refill the radiator with engine coolant, and bleed
air from the cooling system with the heater valve
open {see page 10-6}.
10-5

Cooling System
Radiator and Fans Replacement
1. Drain the engine coolant (see page 10-6).
2. Remove the front bumper {see page 20,85).
3. Remove the bulkhead.
4. Remove the upper radiator hose and lower radiator hose.
DRAIN PLUG
UPPER BADIATOR HOSE
BAOIATOA FANASSEMBLY
{
O.RINGRADIATOR CAP
BADIATOB
LOWERCUSHION
\-
RADIATOR FANswtTcH24Nm{2.1t kgl m. 17lbl hl
LOWER FADIATORHOSE
RESERVETANK
A/C CONDENSERFAN ASSEMBLY
9.8 N m {1.0 kgf m,7.2 lbf ft)CONNECTORSRADIATOB FAN SWITCHCONNECTOB
5. Disconnect the fan motor connectors and radiator fan switch connector, then pull the radiator up and out.
6. Remove the fan shroud assemblies and other parts from the radiator.
7. Installthe radiator in the reverse order of removal. Make sure the upper and lower cushions are set securelV.
8. Install the bulkhead in the reverse order of removal. Apply body paint to the bulkhead mounting bolts.
9. Fill the radiator with engine coolant and bleed the air (see page 10-6).
10-10
\.

Fuel and Emissions Systems
General Troubleshooting Information (cont'dl
How to Reset the ECM
You can reset the ECM in either of two ways:
. Use the OBD ll scantool or Honda PGMTesterto
reset the ECM memory.
See the OBD ll scan tool or Honda PGI\4 Tester user's
manuals for specific instructions.' Turn the ignition switch OFF, and remove the No. 6
ECU {ECM} (15A) fuse (A)from the under-hood fuse/
relav box (Blfor 10 seconds.
How to End a Troubleshooting Session
(required after any troubleshootingl
1. Reset the ECM as described above.
2. Do the ECM idle learn procedure (see page 11-139)
3. Turn the ignition switch OFF.
4. Disconnectthe OBD ll scan tool or Honda PGM
Tester from the DLC.
NOTE: The ECM is part of the immobilizer system.
lf vou replace the ECM, it will have a different
immobilizer code. In order for the engine to start,
you must rewrite the immobilizer code with the
Honda PGM Tester.
11-4
\- ta
J
How to Remove the ECM for Testing
1. Remove the passenger's dashboard lower cover
{see page 20-63), the passenger's kick panel (see
page 20-63), and the glove box (see page 20-63).
2. Remove the ECM mounting bolts (B) and the ECM
(c),
9.8 N.m{1.0 kgf.m,7.2lbt.ft}
3. Remove the ECM (B).
4. Installthe ECM in the reverse order of removal.
L

WC OilControl Solenoid Valve Removal/Test
1. Remove the WC oilcontrol solenoid valve (A).
NOTE: lnstall the valve in the reverse order of
removal with a new o-ring (B), then check these
tlems:
Clean and dry the VTC oil control solenoid valve
mating surface.
Coat the O-ring with engine oil.
Do not install the VTC oilcontrol solenoid valve
while wearing fibrous gloves,
Be careful not to contaminate the cylinder head
openrng.
Check the VTC oil control solenoid valve filter for
clogging. lf it is clogged, replace the VTC oil control
solenoid valve.
Check the clearance between the port (advance
side) and the valve. The clearance (A) should be at
least 2.8 mm (1/8 in.).
Connect the battery positive terminal to VTC oil
control solenoid valve 2P connector terminal No. 2.
VTC OIL CONTROL SOLENOIDVALVE 2P CONNECTOR
Terminal side oJmale terminals
Connect the battery negative terminal to VTC oil
control solenoid valve 2P connector terminal No. 1,
then make sure the valve (A) opens fully.
BATTERY
11-127

VTEC/WC
1.
CMP Sensor A Replacement
Remove the air cleaner (see page 1 1-162).
Disconnect the CMP sensor A 3P connector.
Remove the CMP sensor A (A).
Installthe sensor in the reverse order of removal
with a new o-ring (B).
B-'-----'-l:,",14*
11-128
WEC Solenoid Valve Removal/
Inspection
1.Disconnect the VTEC solenoid valve 2P connector.
Measure resistance between VTEC solenoid valve
connector terminals No. 1 and No. 2.
Resistance: 14-30 Q
3. lf the resistance is within specifications, remove the
VTEC solenoid valve assemblv (A)from the
cylinder head, and check the VTEC solenoid valve
filter (B)for clogging. lf it is clogged, replace the
solenoid valve filter, the engine oilfilter, and the
engine oil.
6x1.0mm9.8 N.m (1.0 kgf.m, 7,2 lbf.ftl
L

Fuel Supply System
Fuel Pulsation Damper Replacement
1. Relieve the fuel pressure(seepagell-144).
2. Remove the engine cover.
3. Remove the fuel rail mounting nuts from the fuelrail.
4. Remove the ground cable (G 101.
5. Raise the fuel rail.
6. Place awrench (A) onthefuel rail (B).
7. Place a wrench (C) onthefuel pulsation damper (D).
8. Remove the pulsation damper.
9. Installthe fuel pulsation damper in lhe reverse
order of removal with new washers.
NOTE:. Replace all washers wheneve r the fuel pulsation
damper is loosened or removed,. lf the drain hole (A) ofthefuel pulsationdamper
cover does not face bottom, reinstall it as shown.
11-154

Intake Air System
Throttle Cable Removal/lnstallation
1. Fully open the throttle valve, then remove the
throttle cable (A) from the throttle link (B).
Remove the cable housing (C)from the cable
bracket (D).
Remove the throttle cable (A)from the accelerator
pedal (B).
2.
3.
SILICONE GREASE B(P/N 08798-9002)
(P/N 08?98-9002)
11-164
5.
Install in the reverse order of removal.
After installing, start the engine. Hold the engine at
3,000 rpm with no load (in neutral) untilthe radiator
fan comes on, then let it idle.
Hold the cable, removing all slack from it.
Set the locknut on the cable bracket {A).Turn the adjusting nut (B) so that its free play is
0 mm.
The should beno crearance.
Remove the cable from the cable bracket (A). Set
the adjusting nut on the other side of the throttle
bracket, then tighten the locknut {C}.
With the cable properly adjusted, check the throttle
valve to be sure it opens fully when you push the
accelerator pedal to the floor. Also check the
throttle valve to be sure it returns to the idle
position whenever you release the accelerator
Deoat.
7.
!
8.
9.
('1.0 kgf.m,7.2 tbf.ftl

Clutch Master Cylinder Replacement
NOTE: Do not spill brake fluid on the vehicle; it may
damage the paint; if brake fluid does contact the paint,
wash it off immediatelV with water.
1. Pry out the lock pin (A), and pullthe pedal pin (B)
out of the yoke. Remove the master cylinder
mounting nuts (C).
Remove the air cleaner housing cover and the air
cleaner housing (see step 6 on page 5-2).
Remove the brake fluid from the clutch master
cylinder reservoir with a syringe.
Remove the clutch line bracket from the frame rail,
and remove the clutch line clip.
Remove the clutch master cylinder (A), and pull it
toward the middle of the engine compartment.
Remove the retaining clip (B). Disconnect the clutch
line (C). Plug the end of the clutch line with a shop
towelto prevent brake fluid from coming out.
g-E
3.
6. Disconnect the reservoir hose (D) fromtheclutch
master cylinder reservoir. Plug the end of the
reservoir hose with a shop towel to prevent brake
fluid from coming out.
7. Remove the O-ring (E) and the clutch master
cylinder seal (F) from the master cylinder.
8. Installthe clutch master cylinder in the reverse
order of removal. Install a new O-ring.
9. Make sure the hose clamps (A) are positioned on
the master cylinder (B) and reservoir (C) as shown.
(cont'd)
UP
i
12-5