2003 HONDA CIVIC connector

lntake Manifold and Exhaust System
Intake Manifold Removal and Installation (cont'd)
9. lnstallthe air cleaner housing cover (A), and
connect the IAT sensor connector (B).
BC
Installthe breather hose (C).
lnstallthe EVAP canister hose (A), brake booster
vacuum hose (B), and vacuum hoses {C).
10.
11.
9-6
\
12. Installthe intake manifold cover.
6x1.0mm12 N.ml.1.2k91.m,8.7 tbf.ftl
Clean up any spilled engine coolant.
After installation, check that all tubes, hoses, and
connectors are installed correctly.
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.
Refill the radiator with engine coolant, and bleed
air from the cooling system with the heater valve
open (see page 10-6).
to.
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Cooling System
Fan Motor Test
1. Disconnect the 2P connectors from the radiator fan
motor and condenser fan motor.
Test the motor by connecting battery power to the
B terminal and ground to the A terminal.
lf the motor fails to run or does not run smoothly,
reptace rL
10-4
\
Thermostat Test
Replace the thermostat if it is open at room
remperalure.
To test a closed thermostatl
1. Suspend the thermostat (A) in a container of water.
Do not let the thermometer {B) touch the bottom of
the hot container.
(\
2.
3.
Heat the water, and check the temDerature with a
thermometer. Check the temperature at which the
thermostat first opens, and at which it is fully open.
Measure the lift height of the thermostat when it is
fullv ooen.
STANDARD THERMOSTAT
Lift height; above 8.0 mm (0.31 in.)
Starts opening: 169 176"F(76 80"C)
Fully open: 194"F {90'Cl
\.

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
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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
\.

Fan Controls
Symptom Troubleshooting Index
Before performing any troubleshooting procedures check:. Fuses. Grounds. Cleanliness and tightness of all connectors
\{
\,4
SYMPTOMPROCEDURE
Radiator fan does not run at allRadiator Fan Circuil Troubleshooting (see page 1O-14).
Radiator fan does not run for engine cooling, but it runswith A,/C ON
Radiator Fan Switch Circuit Troubleshooting (Open)
(see page 10-16).
Radiator fan runs with ignition switch ON (ll), Ay'C OFF,
and engine temperature below 199"F (93"C)Radiator Fan Switch Circuit Troubleshooting (Short)
(see page 10-'16).
10-12
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7.
Disconnect the radiator fan motor 2P connector.
Check for continuity between the No. 1 terminal of
the radiator fan relay 4P socket and the No. 2
terminal of the radiator fan motor 2P connector.
RAOIATOR FAN REI-AY 4P SOCKET
Terminal side offemale terminals
RADIATOR FAN MOTOR 2P CONNECTOR
ls thete continuity?
YES-Go to step 8.
NO Repair open in the wire between the under-
hood fuse/relay box and the radiator fan motor 2P
connector terminal No. 2,I
8. Check for continuity between the No, 1terminal of
the radiator fan motor 2P connector and bodv
g rou nd.
RADIATOR F
Wire side of female terminals
ls there continuity?
YES Replace the radiator fan motor.l
NO Check for an open in the wire between
radiator fan motor 2P connector terminal No. 1 and
body ground. lf the wire is OK, check for a poor
ground at G301.1
AN MOTOR 2P CONNECTOR
rftr
T-
Y
9.
10.
Reinstall the radiator fan relay.
Disconnect the radiator fan switch 2P connector.
Connect the No. 1 and No. 2 terminals, of the
radiator fan switch 2P connector with a jumper wire.
RAOIATOR FAN SWITCH2P CONNECTOR
11.
5\- IJUMPERf-; 'fl I wrRE
--
Wire side of female terminals
Does the radiator fan run?
YES- Replace the radiator fan switch.l
NO-Go to step 12.
Remove the jumper wire, and measure the voltage
between the No, 2 terminal of the radiator fan
switch connector and body ground,
RADIATOR FAN SWITCH2P CONNECTOR
ls there battery voltage?
YES Check for an open in the wire between
radiator fan switch 2P connector terminal No. 1 and
body ground. lf the wire is OK, check for a poor
ground at G301.1
NO Repair open in the wire between the radiator
fan switch terminal No. 2 and the under-hood
fuse/relay box.l
10-15

Fan Controls
Radiator Fan Switch Circuit
Troubleshooting (Openl
1. Disconnect the radiator fan switch 2P connector.
2. Turn the ignition switch ON (ll).
3. Measure voltage between the No.2 terminal ofthe
radiator fan switch 2P connector and body ground.
RADIATOR FAN SWITCH 2PCONNECTOR
ls there battety voltage?
YES-Go to step 4.
NO- Repair open in the wire between the radiator
fan switch 2P connector terminal No. 2 and under-
hood fuse/relay box.l
Turn the ignition switch OFF, and check for
continuity between the No. '1 terminal of the
radiator fan switch 2P connector and body ground.
RADIATOB FAN SWITCX 2PCONNECTOR
ls there continuity?
YES Replace the radiator fan switch. t
NO Check for an open in the wire between theradiator fan switch 2P connector terminal No. 1 and
body ground. lf the wire is OK, check for a poor
ground at G301.1
10-16
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Radiator Fan Switch Circuit
Troubleshooting (Short)
NOTE: After troubleshooting, perform the engine
control module (ECM)idle learn procedure (see page
1 1,139).
1. Remove the radiator fan relay from the under-hood
fuse/relay box, and test it (see page 22-51).
ls the relay OK?
YES Go to step 2.
NO Replace the radiator fan relay.I
2. Remove the radiator fan switch, and test it (see
page 10-17 ).
Is the radiatot tan switch OK?
4.
YES Go to step 3.
NO Replace the radiator fan switch.I
Disconnect the battery negative cable from the
battery.
Disconnect engine control module {ECM) connector
B (24P) and the under hood fuse relay box 14P
connector.
Check for continuity between the No. 2 terminal of
the radiator fan switch 2P connector and bodygrouno.
RADIATOR FAN SWITCH2P CONNECTOR
lstnere continuity?
YES Repair short in the wire between the radiator
fan switch 2P connector terminal No. 2 and under-
hood fuse/relay box.l
NO Replace the under-hood fuse/relay box.t
\I
\

Radiator Fan Switch Test
NOTE: Bleed air from the cooling system after installing
the radiator fan switch (see page 10-6).
1, Remove the radiator fan switch from the radiator
(see page 10-17).
2. Suspend the radiator fan switch (A) inacontainer
of water as shown.
3. Heat the water, and check the temperature with a
thermometer. Do not let the thermometer (B) touch
the bottom of the hot conlainer.
4. Measure the continuity between terminal No. 1 and
terminal No. 2 according to the table.
Termina
Operation lTemperature1
swtTcH
ON196" 203'F(91" gs"C)
OFF5' 15'F {3' 8'C) lowelthan the temoeraturewhen it goes on
Radiator Fan Switch Replacement
1.Disconnect the radiator fan switch connector, then
remove the radiator fan switch (A).
A24 N m (2.4 kgt.m, 17 lbt.ftl
2. Installthe radiator fan switch with a new O-ring (B).
10-17

General Troubleshooting Information
Intermittent Failures
The term "intermittent failure" means a svstem mav
have had a failure. but it checks OK now. lf the
Malfunction Indicator Lamp (MlL) on the dash does not
come on, check for Door connections or loose terminals
at all connectors related to the circuit that Vou are
troubleshooting.
Opens and Shorts
"Ooen" and "Short" are common electrical terms. An
open is a break in a wire or at a connection. A short is
an accidental connection of a wire to ground or to
another wire. In simple electronics, this usually means
something won't work at all. With complex electronics(such as ECMs)this can sometimes mean something
works, but not the way it's supposed to.
How to Use the PGM Tester or a Scan Tool
lf the MIL {Malfunction Indicator Lamp} has come on
'1. Start the engine and check the MIL {A).
NOTE: lf the ignition switch is turned ON (ll), and
the engine is not started, the MIL will stay on for
15 20 seconds (see page 11-46).
K-> ;"PN/.- -::: - -d V-: !
w:ix&K#
2. lf the MIL stays on, connect the Honda PGM Tester(A) or an OBD ll scan tool to the Data Link
Connector {DLC) (B) located under the driver's side
of the dashboard.
3.
5.
Turn the ignition switch ON (ll).
Check the Diagnostic Trouble Code (DTC) and note
it. Also check the freeze data. Refer to the DTC
Troubleshooting Index, and begin the appropriate
troubleshooting procedure.
lf you do not find any DTCS, go to MIL circuit
troubleshooting (see page 11-97).
NOTE:. Freeze data indicates the engine conditions when the
first malfunction, misfire, or fuel trim malfunction
was detected.. The scan tool and the Honda PGM Tester can read the
DTC, freeze data, current data, and other Engine
Control l\4odule {EClvl) data.. For specific operations, refer to the user's manual
that came with the scan tool or Honda PG l\4 Tester.
lf the MIL did not stay
lf the MIL did not come on but there is a driveability
problem, refer to the Symptom Troubleshooting Index
in this section.
lf you can't duplicate the DTC
Some of the troubleshooting in this section requires
you to reset the ECM and try to duplicate the DTC. lf rhe
problem is intermittent and you can't duplicate the code,
do not continue through the procedure. To do so will
only result in confusion and, possibly, a needlessly
replaced ECM.
(cont'd)
11-3