2003 HONDA CIVIC COIL

Heating and Air Gonditioning
1.
Compressor Clutch Check
Check the armature plate for discoloration, peeling,
or other damage. lf there is damage, replace the
clutch set (see page 21-49),
Check the rotor pulley bearing play and drag by
rotating the rotor pulley by hand. Beplace the
clutch set with a new one if it is noisy or has
excessive play/drag (see page 21-49).
Measure the clearance between the rotor pulley (A)
and the armature plate (B) all the way around. lf the
clearance is not within specified limits, remove the
armature plate (see page 21-49) and add or remove
shims as needed to increase or decrease clearance.
Clearance: 0.510.15 mm {0.02010.006 in.)
NOTE: The shims are available in four thicknesses:
0.1 mm.0.2 mm,0.4 mm, and 0.5 mm.
21-48
a
4. Release the field coil con nector f rom the holder,
then disconnect it. Check the thermal protector for
continuity. lf there is no continuity, replace the
thermal protector (see page 21-51).
NOTE: The thermal Drotector will have no
continuity above 252to270"F \122lo 132'C). When
the temperature drops below 241 to 219'F (116 to
104'C), the thermal protector will have continuity.
Check resistance of the field coil. lf resistance is not
within specifications, replace the field coil
(see page 21-49).
Field Coil Resistance: 3.05 3.35ohmsat68"F
t20"c)
,\.

Compressor Clutch Overhaul
Special Tool Required
A,/C clutch holder, Robinair 10204. Kent-Moore J37872,
or Honda Tool and Equipment KMT-J33939,
commercially available
1. Remove the center nut (A) while holding the
armature plate with a commercially available A,/C
clutch holder (B).
17.6 N.m{1.8 kgf.m,13 tbt.ft)
Remove the armature plate (A) and shim(s) (B),
taking care not to lose the shim(s). lf the clutch
needs adjustment, increase or decrease the
number and thickness of shims as necessary, then
reinstallthe armature Dlate, and recheck its
clearance (see page 21-481.
NOTE: The shims are available in four thicknesses:
0.1 mm,0.2 mm,0.4 mm, and 0.5 mm.
9-=-g
3. lf you are replacing the field coil, remove the snap
ring (A) with snap ring pliers, then remove the rotor
pulley (B). Be careful not to damage the rotor pulley
or tne compressor.
4. Remove the bolt and holder (A). then disconnect
the field coil connector (B). Loosen the clamp screw(C) to iree the field coil wire. Remove the snap ring
{D)with snap ring pliers, then remove the field coil(E). Be careful not to damage the field coil or the
comoressor.
\ot
-@
/@h"
.ffi
7.4 N.m(0.75 kgf m,5 tbf.ft)---------------- ")
(cont'd)
21-49

Heating and Air Gonditioning
Compressor Clutch Overhaul (cont'd)
5. Reassemble the clutch in the reverse order of
disassembly, and note these items:
. Installthe field coil with the wire side facing
down, and align the boss on the field coil with the
hole in the compressor.. Clean the rotor pulley and compressor sliding
surfaces with contact cleaner or other
non-petroleum solvent..Install new snap rings, note the installation
direction, and make sure they are fully seated in
the groove.
. Make sure that the rotor pulley turns smoothly
after it's reassembled,. Route and clamp the wires properly or they can
be damaged by the rotor pulley.
21-50

Compressor Thermal Protector
Replacement
1. Remove the bolt, the ground terminal (A), and the
holder (B). Disconnect the field coil connector (C).
then remove the thermal protector (D).
Replace the thermal protector (A) with a new one,
and apply silicone sealant (B) to the bottom of the
thermal Drotector.
A
3. lnstall in the reverse order of removal.
7.4 N.m(0.75 kgf.m,5 rbf.ftl
Compressor Relief Valve
Replacement
2.
1.
4.
Recover the refrigerant with a recovery/recycling/
charging station (see page 21-53).
Remove the relief valve (A) and the O-ring (B). Plug
the opening to keep foreign mafter from entering
the system and the compressor oil from running
out.
A9,8 N.m(1.0 kgf m,7.2lbf.ft)
Clean the mating surfaces.
Install a new O-ring on the relief valve, and apply a
thin coat of refrigerant oil to the O-ring.
Remove the plug, and install and tighten the relief
valve.
Charge the system (see page 21-55).
21-51

Connectors and Harnesses
Engine Wire Harness
Camshaft position (CMP) sensorLllr sensorEC[,4 connector AECI/l connector BEngine coolant temperature (ECT)
sensorEngine oil pressure switchEVAP canister purge valveldle air control (lAC)valve
lgnition coil No. llgnition coil No. 2lgnition coil No. 3lgnition coil No. 4Iniector No. 1Inlector No.2Iniector No.3Iniector No. 4Intake air temperature {lAT) sensor
TDC sensorThrottle position (TP) sensorVehicle speed sensor (VSSI
VTC oil control solenoid valveVTEC oil pressure switchVTEC solenoid valvec 101
c102
233
242
Transmission housingLeft side of engineRight side ofengineUnder glove boxUnder glove boxLeft side of engine
Bight side oI engineLeft side of intake manifoldLeft side of intake manifoldMiddle of engine compartmentMiddle of engine compartmentMiddle of engine compartmentMiddle of engine compartmentMiddle of engine compartmentMiddle of engine compartmentMiddle of engine compartmentMiddle of engine companment
28
1845672524201912
811102729303
22
12333332222233
322220
Left side of intake manifoldLeft side of engineLeft side of intake manifoldTransmission housingRight side o{ engineRight side of engineRight side of engineUnder right side of dash
Front of engine companment
Front of engine compartment
ECM wire harness {see page22-321Starter subharness (see page22-15)Starter subharness (see page22 151
Connector to Harness Index (cont'dl
22-16

Under-dash Fuse/Relay Box
Fuse
Number
AmpsWire ColorComponent(s) or Circuit(s) Protected
115ABLKA/VHTlgnition coils
2204WHT/REDAirlfuel ratio sensor, ECM
310ARED/BLUDaytime running Iights control unit {Canada)10ABLI(ORNAir/fuel ratio sensor relay, Alternator, CMP sensor, Cruise control main
switch, Cruise control unit. ELD unit, Evaporative emission (EVAP) bypass
solenoid valve, Evaporative emission (EVAP)canister purge valve,
Evaporative emission (EVAP) canister vent shut valve, Secondary H02S,
Vehicle speed sensor
5Not used
67.5AYEUGRNMoonroof control unit, Moonroof open and close relay, Power window
relaV
7204GRNMoonroof motor
I7.5AYEUREDAudio unit
910AGRNOPDS unit, Rear window wiper motor, Rear window washer motor, Rear
window wiper intermittent control unit
107.54YELBack-up lights, Cruise indicator light, EPS control unit, Gauge assembly,
Keyless receiver unit, Multiplex control unit, Security control unit
connector (optional)
117.5ABLIVORNABS modulator-control unit
127.5AYEUREDDaytime runnino liohts control unit (Canada)
1310APNKSRS unit't410ABLK/YE LA,,/C compressor clutch relay, Blower motor relay, Condenser fan relay,
Heater control panel, Power mirror actuator, Power mirror defogger(Canada), Radiator fan relay, Rear window defogger relay, Recirculation
control motor1ENot used
loNot used
1715AYE L/B LKECM, Fuel pump
B LK/YE L>H> Unrr
1815AYEUGRNAccessory power socket
197.5AYEUBLKTurn siqnal/hazard relav, Turn siqnal liohts
2030AGRN/BLKMultiplex control unit, Windshield washer motor. Windshield wioer motor21Not used
22204GRN/BLKPassenqer's window motor
2320A.G R N,A/VHTDriver's window motor
24Not used
25Not used
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22-47

Ground Distribution
Ground to Components Index
GroundComponent or circuit qrounded
Batterv, Transmission housinq
E ngine
G 101ECM (PG is BLK; LG is BRN/YEL)
BLK: IAC valve, lgnition coils, Vehicle speed sensor, VTEC solenoid valve
BRNA/EL: Camshaft oosition (CMP) sensor. CKP sensor, TDC sensor. VTEC oil pressure switch
G 15']EPS control unit
G201ELD unit. Multiplex control inspection connector, Multiplex control unit, Power window relay, Rear
window washer motor, Right front parking light, Right front side marker light, Right front turn signal
light, Turn signal/hazard relay, Washer fluid level sensor (Canada) , Windshield washer motor,
Windshield wiDer motor
G202ABS modulator-control unit
G301
G401
Blower motor relay, Brake fluid level switch, Condensor fan motor, Cruise control actuator, Left front
parking light, Left front side marker light, Left front turn signal light, Radiator fan motor, Radiator fan
swrtcn
Combination liqht switch, lqnitlon kev srvitch, Wiper/wasfrer sr,virch
G402Left and riqht airbaq sensors, SRS unit
G 451Data link connector (DLC)
G501Clutch interlock switchm Clutch pedal position switch (for cruise control), Cruise control main switch,
Cruise control unit, Daytime running lights control unit (Canada), Driver's door lock knob switch,
Driver's door lock switch, Driver's power window motor, Heater control panel, Left power mirror
defogger (Canada), left side turn signal light, Moonroof control unit, Monroof open and close relays,
Moonroof position sensor '1, Moonroof seitch, Power mirror switch, Power transistor, Power window
master switch. SDotliqhts
G502Accessory power socket, Gauge assembly, Keyless receiver unit, lvlultiplex control unit, Right power
mirror defogger {Canada)
G503Audio unit
G551Driver's seat belt switch, Fuel gauge sending unit, Fuel pump, Memory erase signal (IMES) connector,
OPDS unit. Rioht seat belt switch
G552High mount brake light, License plate lights, Rear window defogger, Rear window defogger noise
condenser. Rear window wioer motor, Hatch latch switch
Back-up lights, Brake lights, Rear side marker lights, Rear turn signal lights, Rear window wiper noise
condenser, Rear window wiper intermittent control unit, Taillights
22-48

Rear Window Defogger
Function Test
NOTE:. Be careful not to scratch or damage the defogger
wires with the tester probe.
. Before testing, check the No. 11 (30A) fuse in the
under-hood fuse/relay box and No. '14 ('10A) fuse in
the under-dash fuse/relay box.
1. Check for voltage between the ve rtica I dividersand
body ground with the ignition switch and defogger
switch ON.
There should be voltage as shown.
. lf there is no voltage. checkfor:- faulty defogger relay.- an open in the BLK, BLK,/YEL, or YEL/BLK wire.- taulty heater control panel.
. lf there is battery voltage, goto step 2.
6V
Check for continuity between the negative terminal(B) and body ground.
lf there is no continuity, check for:. an open in the BLK wire.. Poor body ground at the window antenna coil
mounting bolt.
Touch the voltmeter positive probe to the halfway
point of each defogger wire. and the negative
probe to the negative terminal,
There should be about 6 V with the ignition switch
and the defogger switch ON.
. lf thevoltage is asspecified, the defoggerwlre is
oK.. lf the voltage is not as specified, repair the
defogger wire.- lf it is more than 6 V, there is a break in the
negative half of the wire.- lf it is less than 6 V, there is a break in the
positive half of the wire.
2.
22-106
2.
Defogger Wire Repair
NOTE: To make an effective repair, the broken section
must be no longer than one inch.
1. Lightly rub the area around the broken section (A)
with fine steel wool, then clean it with alcohol.
Carefully mask above and below the broken portion
of the defogger wire (B) with transparent tape {C).
Mix the silver conductive paint thoroughly. Using a
small brush, apply a heavy coat of paint extending
about 1/8 inch on both sides of the break. Allow 30
minutes to dry.
Check for continuity in the repaired wire.
Apply a second coat of paint in the same way. Let it
dry 3 hours before removing the tape.
5.