2003 HONDA CIVIC Indicator

Intake Air System
Throttle Body Test
NOTE:. Do not adjust the throttle stop screw. lt is preset at the
factory.. lf the malfunction indicator lamp (MlL) has been
reported on, check for diagnostic trouble codes(DLCS) (see page 11 3).
1. With the engine off, check the throttle cable
movement. The cable should move without binding
or sticking.
. lf lhe cable moves OK, goto step 2.. lf the cable binds or sticks, check it and its routing.. lf the cable isfaulty, reroute itor replace itand
adjust it (see page 11-163), then go to step 2.
2. l\4ove the throttle lever by hand to see if the throftle
valve and/or shaft are too loose or too tight.
. lf there is excessive play in the throttle valve
shaft, or any binding in the throttle valve at the
fully closed position, replace the throttle body.. lf thethrottlevalve and shaft are OK, goto step3.
3. Connect the scan toolto the DLC.
Turn the ignition switch ON (ll).
Check the throttle position with the scan tool. The
reading should be about 10% when the throttle is
fully closed and about 90% when the throttle is fully
openeo.
. lf the throttle position is correct, the throttle body
is OK.. lf thethrottle position is notcorrect, replace the
throttle body.
5.
11-160
!

Flywheel Inspection
1. Inspect the ring gear teeth for wear and damage.
2. Inspect the clutch disc mating surface on the
flywheel for wear, cracks, and burning.
3. Measure the flywheel (A) runout using a dial
indicator (B) through at least two full turns. Push
against the flywheel each time you turn it to take up
the cra nksh aft th rust washer clea rance. lf the
runout is more than the service limit, replace the
flywheel and recheck the runout. Resurfacing the
flywheel is not recommended.
Standard (New): 0.05 mm (0.002 in.) max.
Service Limit: 0.15 mm (0.006 in.)
Flywheel Replacement
1. Installthe special tool.
2.
3.
4.
Remove the flywheel mounting bolts in a crisscross
pattern in several steps, then remove the tlywheel.
Installthe flywheel on the crankshaft, and install
the mounting bolts fingertight.
Installthe specialtool, then torque the flywheel
mounting bolts in a crisscross pattern in several
sreps.
12 x 1.0 mm103 N.m(10,s kst.m. 76 lbf ftl
(cont'd)
12-11

Mainshaft Assembly Clearance Inspection
NOTE: lf replacement is required, always replace the
synchro sleeve and hub as a set.
1. Support the bearing inner race with an appropriate
sized socket (A). and push down on the mainshaft(B).
Measure the clearance bet\iveen 2nd (C) and 3rd (D)
gears with a feeler gauge {E).
. lf the clearance is more than the service limit. go
to step 3.. lf the clearance is within the service limit, go to
step 4.
Standard:0.06 0.16 mm
{0.002 0.006 in.l
Service Limit: 0.25 mm (0.010 in.l
Measure the thickness of 3rd gear.
. lf thethickness of 3rd gearis lessthanthe service
limit, replace 3rd gearwith a new one.. lf thethickness of 3rd geariswithintheservice
limit, replace the 3rd/4th synchro hub with a new
one.
Standard: 23.92-23.97 mm(0.941 0.944 in.)
Service Limit: 23.80 mm (0.937 in.)
4. Measure the clearance between 4th gear (A) and
the distance collar (B) with a dial indicator (C).
. lf the clearance is more than the service limit, go
to step 5.. lf the clearance is within the service limit, go to
step 7.
Standard: 0.06 0.16 mnl(0.002 0.006 in.)
Service Limit: 0.25 mm {0.010 in.)
Measure distance O on the distance co[ar.
. lf distance't is notwithin the standard, replace
the distance collar with a new one.. lf distance e is within the standard, go to step 6.
Standard:24.03 24.08 mm
{0.946-0.9/u in.}
(cont'd)
13-23

Manual Transmission
Mainshaft Assembly Clearance Inspection (cont'd)
6. Measure the thlckness of 4th gear.
. lf thethickness of 4th gear is lessthantheservice
limit, replace 4th gear with a new one.. lf thethicknessof 4th geariswithin the service
limit. replace the 3rd/4th synchro hub with a new
one.
Standard: 23.92 23.97 mm
(0.941 0.944 in.)
Service Limit: 23.80 mm (0.937 in.)
7. l\4easure the clearance between the distance collar
(A) and sth gear (B) with a dial indicator (C). lfthe
clearance is more than the service limit. go to step
8. lf the clearance is with in the service limit, go to
steD 10.
Standard: 0.06 0.16 mm(0.002-0.006 in.)
Service Limit: 0.25 mm (0.010 in.)
13-24
Standard:
Standard:
Service Limit:
8. Measure distance O on the distance collar.
. lf distance O is notwithinthestandard, replace
the distance collar with a new one.' lf distanceO iswithinthe standard, gotostep9.
24.03 24.08 mm
(0.946 0.947 in.)
9. Measure the thickness of 5th gear.
. lf thethicknessof 5th gearis lessthantheservice
limit, replace 5th gear with a new one.. lf the thickness of sth gear iswithin the service
limit. replace the 5th synchro hub with a new one.
23-92 23.97 mm
10.941 0.944 in.l
23.80 mm (0.937 in.l

\
Backlash lnspection
1.Place the differential assembly on V-blocks (A), and
install both axles.
Measure the backlash of both pinion gears (B) with
a dial indicator (C). lf the backlash is not within the
standard, replace the differential carrier.
Standard (New): 0.05 0.15 mm (0.002 0.006 in.)
Final Driven Gear/Carrier
Replacement
1. Remove the bolts (left-hand threads) in a crisscross
pattern in several steps, then remove the final
driven gear (A)from the differential carrier {B).
t x t.o mm {to)121 Nm(12.3 kgf m,89 rbt.ft)
Install the final driven gear with the chamfer on the
inside diameter facing the carrier. Align the marks
on the final driven gear and the carrier. Tighten the
bolts in a crisscross pattern in several steps.
13-53

EPS Components
aGeneral Troubleshooting Information
EPS Indicator
Under normal conditions, the EPS indicator comes on when
the ignitlon switch is turned to the ON (ll) position, then goes
off after the engine is started. This indicates that the bulb and
its circuit are operating correctly.
lf there is any trouble in the system after the engine is started,
the EPS indicator will stay on, and the power assist is turned
off.
When EPS indicator light comes on, the control unit
memorizes the DTC. In this case, the control unit will not
activate the EPS system after the engine starts again, but it
keeps the EPS indicator on.
When DTC 12, 16, 17, 18 or 67 is stored in the control unit, the
EPS indicator will stay on until the DTC is erased. When a
problem is detected and the EPS indicator comes on, there are
cases when the indicator stays on untilthe ignition switch is
turned 0FF, and cases when the indicator goes off
automatically when the system returns to normal. Even though
the system is operating normally, the EPS indicator will come
on under the following conditions:
Condition '1:
. The vehicle was traveling at least 12.4 mph (20 km/h), then. A rapid change in vehicle speed was detected, then. The vehicle (or the vehicle speed sensor signal) stopped for
at least 5 seconds. The engine speed was still 'l,640rpmorhigherforatleastS
seconds
Condition 2:
After the vehicle (or the vehicle speed sensor signal) has
stopped for at least 10 seconds, yet the engine speed was still
1,640 rpm or higherfor at least 20 seconds.
Condition 3:
When the engine speed is 280 rpm or less, and the vehicle is traveling at
a speed of 6,2 mph (10 km/h) or more for 3 seconds.
To determine the actual cause ofthe problem, question the
customer about the conditions during which the problem
occured, taking the above conditions into consideration.
Diagnostic Trouble Code (DTCI
. lf the CPU cannot be activated, or itfails,the EPS indicator
comes on, but the DTC is not memorized.. The memory can hold any number of DTCS. However, when
the same DTC is detected more than once, the most recent
DTC is written over the prior DTC, therefore only one
occurrence is memorized.. The DTCS are indicated repeatedly untilthe ignition switch is
turned OFF.. lf the DTC is not memorized,the EPS indicator blinks.
. The DTCS are memorized in the EEPRO| (non-volatile
memory) therefore the memorized DTCS cannot be erased
by disconnecting the battery. Perform the specified
procedures to clear DTCS.
Self-diagnosis
Self-diagnosis can be classified into two categories:.Initial diagnosis: performed right after the engine
starts and until the EPS indicator goes off.. Regular diagnosis: performed right after the initial
diagnosis until the ignition switch is turned OFF.
The EPS control unit performs the following functions
when a problem is detected by self-diagnosis;
'1. Turns on the EPS indicator.
2. Memorizes the DTC.
3. Stops power assist and manual steering operation
begrns.
NOTE:. When DTC 23 (a problem with the circuit for
engine speed signal) is detected, the power
assist will return to normal when the vehicle
speed is 0.62 mph (1 km/h) or above.. Fot DfCs 22,23, 64, or 66 the EPS indicator goes
off automatically when the system relurns to
normal. For all other codes, the EPS indicator
goes off when the system is OK after the ignition
switch is turned from OFF to ON (ll).
Restriction on Power Assist Operation
Repeated extreme steering force. such as turning the
steering wheel continuously back-and-forth with the
vehicle stopped, causes an increase of power
consumption in the EPS motor. The increase of electric
current causes the motor to heat up. Because this heat
adversely affects the system, the control unit monitors
the electric current of the motor.
When the control unit detects heat build-up in the motor,
it reduces the electric current to the motor gradually to
protect the system, and it restricts the power assist
operation. The EPS indicator does not come on during
this function.
When steering torque is not applied to the steering
wheel, or when the ignition is turned off, and the motor
cools, the control unit will restore the power assist
gradually until it's fully restored (after approximately 15
minutes maximum).
17-18

How to Troubleshoot EPS DTCs
The troubleshooting flowchart procedures assume that
the cause of the problem is still present and the EPS
indicator is still on, Following the flowchart when the
EPS indicator does not come on can result in incorrect
diagnosis.
The connector iliustrations show the female terminal
connectors with a single outline and the male terminal
connectors with a double outline.
1. Ouestion the customer about the conditions when
the problem occured, and try to reproduce the
same conditions for troubleshooting. Find out
when the EPS indicator came on, such as while
turning. afterturning, when the vehicle was at a
ce rta in speed, etc.
2. When the EPS indicator does not come on during
the test drive, but troubleshooting is done based on
the DTC, check for loose connectors, poor terminal
contact. etc in the affected circuit, before you start
troubleshooting.
3. After trou bleshooting, clear the DTC and test-drive
the vehicle. Be sure the EPS indicator does not
come on.
How to Retrieve EPS DTCs
Honda PGM Tester Method:
1, With the ignition switch OFF, connect the Honda
PGM Tester (A) to the 16P data link connector (DLC)
(B) located under the dash on the driver's side of
the vehicle.
2. Turn the ignition ON (ll), and follow the prompts on
the PGM Tester to display the DTC(s) on the screen.
After determining the DTC, refer to the DTC
Troubleshooting Index.
NOTE: See the Honda PGM Tester user's manual
for specific instructions.
Service Check Signal Circuit Method:
1. With the ignition switch OFF, connect the Honda
PGM Tester (A)to the 16P data link connector (DLC)
(B) located under the dash on the driver's side of
the vehicle.
Short the SCS circuit to body ground using the
Honda PGN4 Tester.
Turn the ignition switch ON {ll).
Record the DTC.
(cont'd)
17-19

Service Check Signal Circuit Method:
NOTE: Use this procedure when the PGM Tester
software does not match the yearlmodel vehicle you
are working on.
1. With the ignition switch OFF, connect the Honda
PGM Tester (A) to the 16P data link connector {DLC)(B) located under the dash on the driver's side of
the vehicle.
With the vehicle on the ground, set the front wheels
in the straight ahead driving position.
Short the SCS circuit to body ground using the
Honda PGM Tester.
Turn the ignition switch ON (ll). The EPS indicator
comes on for about 6 seconds. Within 4 seconds of
turning the switch ON, while the EPS indicator is on,
turn the steering wheel 45 degrees to the left from
the straight ahead driving position, and hold the
steering wheel in that position until the EPS
indicator goes off.
Within 4 seconds afterthe EPS indicator goes off,
return the steering wheel to the straight ahead
driving position and release the steering wheel.
The EPS indicator comes on again 4 seconds after
releasing the steering wheel,
Within 4 seconds after the EPS indicator comes on,
turn the steering wheel 45 degrees to the left again
and hold it in that position.
The EPS indicator goes off after 4 seconds.
4.
1.Within 4 seconds after the EPS indicator goes off,
return the steering wheel to the straight ahead
driving position again and release the steering
wheel. The EPS indicator blinks twice 4 seconds
after releasing the steering wheel, indicating that
the DTC was erased.
NOTE: If the EPS indicator does not blink twice, an
error was made in the procedure and the DTC was
not erased. Turn the ignition switch OFF, and
repeat the operation from step 3.
Turn the ignition switch OFF afterthe EPS indicator
blinks twice.
9. Disconnect the Honda PGM Tester from the DLC.
10. Perform the DTC code output operation, and be
sure that the code has been erased.
17-21