2003 HONDA CIVIC air

INTRODUCTION
Safety
Your safety, and the satety of others, is very important. To helpyou make informed decisions, we have provided safetymessages, and other safety information throughout this manual.Of course, it is not practical or possible to warn you about all thehazards associated with servicing this vehicle. You must useyour own good judgment.
You will find impoftant safety information in a variety of formsincluding:. Satety Labels - on the vehicle.. Satetv Messages preceded by a salety alert symbol A andone of three signal words, DANGEF, WARNING, or CAUTION.These signal words mean:
tmEnEEril y;,: H,ll i": 5* i5"?;r s E R I o u s LY H u Br ir
E$EEEE ys,: f#,ff ,:hl:3,:JjERrousLY HURT ir
tlGtltT]llilll You cAN b€ HUBT if vou don't follow
. lnstructions - how to service this vehicle correctlv and safelv.
All information contained in this manual is based on the latestproduct information available at the time of printing. We reservethe right to make changes at any time without notice. No part ofthis Oublication maV be reDrodLrced, or stored in a retrievalsystem, or transmitted, in any form by any means, electronic,mechanical, photocopying, recording, or otherwise, without theprior written permission o{ the publisher. This includes text,figures, and tables-
As vou read this manual, vou will tind information that ispreceded by a @ symbol. The purpose of this message isto help prevent damage to your vehicle, other property, or theenvironment,
*Bodyz-tl!^t l
First Edition 8/2002 1,168 pages HONDA MOTOR CO.. LTD.All Rights Reserved Service Publication OfficeSpecifications apply to U.S.A. and Canada
As seclion3 with *inclode SRS comoonentsispecial precautionsare required when servicing.
How to Use This Manual -
This manual is divided into 23 sections. The first page of eachseclion is marked with a black tab that lines up with itscorresponding thumb index tab on this page and the back cover.You can quickly find the first page of each section withoutlooking through a full table of contents. The symbols printed atthe top corner of each page can also be used as a quickre{erence system.
Each section includes:1. A table of contents, or an exploded view index showingl. Parts disassembly sequence.. Bolt torques and thread sizes.. Page references to descriptions in text.Disassembly/assembly procedures and tools.Inspefiron.Testing/troubleshootin g.Repair.Adjustments.
2.3.4.5.6.
Specifications1)ll:{l+'
Maintenance
Emissions
*Restraints

General Information
Chassis and Paint Codes - 2OO2 Model
Vehicle ldentffi cation Number
SHHEP3 35'2 U 300001
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a. Manufacturer, Make and Type of Vehicle
SHH; HONDAOFTHE U.K. MFG., LTD. U.K.
HONDA Passenger vehicle
b. Line, Body and Engine Type
EP3: CIVIC/K20A3
c. Body Type and Transmission Type
3: 2-door HatchbacUs-speed Manual
d. Vehicle Grade lSeries)
5: Si {U.S.}
5; SiR (Canada)
6: Si with side airbag system (U,S.)
6: SiR with side airbag system (Canada)
e. Check Digit
l. ModelYear
2i 2002
g. Factory Code
U: Honda of U.K. Manufacturing in Swindon,
E ng land
h. Serial Number
U.S,: 300001 -
1-
V€hicle ldentif ication Numbo.and Federal Motor VehicleSaf ety Standard Certif ication/Color Label.
1-2
I
1700001K2OA3
a
a. Engine Type
K20A3: 2.0 0 DOHC VTEC Sequential Multiport
Fuel-injected engine
b. Serial Number
Engine Number
Transmission Number
Paint Code
CodeColoru.s.Canada
B-92PNiqhthawk Black Pearl
NH-578Taffeta White
NH-623MSatin Silver lvletallic
R-81Milano Red
Y-62PEuro Yeliow Pearl
NBH3
I
a
Transmission Type
NRH3; s-sDeed Manual
1000001
t0

Chassis and Paint Codes - 2003 Model
Vehicle ldentif ication Number
SHHEP3 35*3 U 400001
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cdef gh
G.
d.
Manufacturer, Make and Type of Vehicle
SHH: HONDAOFTHE U.K. MFG., LTD. U.K.
HONDA Passenger vehicle
Line. Body and Engine Type
EP3: CIVIC/K20A3
Body Type and Transmission Type
3: 2-door HatchbacldS-speed Manual
Vehicle Grade (Series)
5: Si (U.S.)
5: SiR (Canada)
6: Si with side airbag system (U.S.)
6: SiR with side airbag system (Canada)
Check Digir
Model Year
3: 2003
Factory Code
U: Honda of U.K. Manufacturing in Swindon,
England
Serial Number
U.S.: 400001
f.
:700001
Vehicle ldentification Numberand Federal Motor VehicleSaletv Standard Certif ication/Color Label.
)_.
2700001K2OA3
I
a
a. Engine Type
K20A3: 2.0 0 DOHC VTEC Sequential Multiport
Fuel-injected engine
b. Serial Number
Engine Number
Transmission Number
NRH3
I
a
Transmission Type
NRH3: 5-speed Manual
Serial Number
- 2000001
Paint Code
CodeColorU,S.Canada
B-92PNiohthawk Black Pearl
B-520PVivid Blue Pearl
NH-578Taffeta White
NH-623MSatin Silver N4etallic
R-81Milano Red
Y-62PEuro Yellow Pearl
1-3

!
..r'
, I O warning/cautionLabelLocations
NOTE: FRONT PASSENGER AIRBAG WARNING TAG(CHILD SEAT) is installed on the glove box on the U.S.
mooet.
Passenger's Compartment:
SRS INFORMATIONU.S. model
SRS WARNINGINFORMATION
FRONT PASSENGERMODULE DANGER
MONITORNOTICE
SIDE AIRBAG CAUTIONLocated on driver'sano passen9er sdoorjamb (not shown)
SIDE MODULEDANGER
,/
FRONTSEATBELTTENSIONERCAUTION
Steering Wheel:
DRIVER MODULEDANGER
CABLE REELCAUTION
(cont'd)
1-5

General Information
Parts Marking
To deter vehicle theft, certain major components are marked with the vehicle identification number (VlN). Originalparts have self-adhesive labels. Replacement body parts have generic self-adhesive labels. The original engrne ortransmission VIN plate is transferred lo a replacement engine or transmission and attached with break-off bolts.
NOTE: Be careful not to damage the parts marking labels during body repair. Mask the labels before repairing the part.
ra
1-10

ItemM€asurementOualificationStandard or NewService LimitParking brake
lever
Distance traveled when lever pulled
with 196 N (20 kgf, 44 lbs) ol force
7 8 clicks
Brake pedalPedal height (carpet removed)184 mm (7 4/16 in.)
Free play0.4 3.0 mm (0 016 0 '118 in.)Master cylinderPiston-to-pushrod clearance0 0.4 mm (0 0.02 in.)Erake discThicknessFront21.0 mm (0.83 in.)19.00 mm (0.75 in.)
Rear9.0 mm {0.35 in.)8-0 mm (0.31 in.iRunoutFront0.10 mm (0.004 in.)
Rear0.10 mm (0.004 in.)ParallelismFront and rear0.015 mm (0.0006 in.)Brake padsThicknessFront10.0 mm (0.39 in.)1.6 mm (0.06 in.)
llear9.0 mm {0.35 in.)1.6 mm (0.06 in.)
Standards and Service Limits
Brakes
a
e-o
Air Gonditionin
ItemMoasurementOualilicationStandard or New Service LimitRefrige.antTvpeHFC 134 a (B-134 a)
Capacity of system500 550 g 117.6 19.4 oz)Refrigerant oilTypeSP 1O
(P/N 38897-P13-A01AH or 38899-P13-A01 )Capacity ofcomponentsCondenser25 m0, 15/6 fl ozl
Evaporator45 mA 11 1/2 fl ozt
Each line and
hose
10 m0 (1/3 fl or)
Compressor130 150 m014 1/3 5floz)CompressorStarter coil resistanceAt 68"F (20"C)3.05 3.35 0Pulley-to-pressure plate clearance0.35 0.6 mm (0.014 0.024 in.)Drive beltAuto tensioner lneeds no adjustment)
2-10
q

cont'
ItemMeasuremeniOualificationSpecilicationSTEERINGTypeElectric, Power assisted rack and pinion
Overall ratio15.1Turns,lock to-lock
Steering wheel diameter360 mm (14.2 in)SUSPENSIONTypeIndependent srrul with stabiliTer. coil springRearDouble wishboneShock absorberFrontTelescopic, hydraulic. nitrogen gas-frlled
RearTelescopic, hydraulic, nitrogen gas,filledWHEEL
ALIGNMENT
CamberFront0"00'
Bear0.45'
CasterFront1'33'TotaltoeFront0 mm (0 in.)
RearIn 2 mm (1/16 in.)BRAKESType of service brakeFrontPowerassisted self-adjusling ventilated disc
BearPower-assisted self-adjusting solid discType of parking brakeMechanical actuating, rear wheelsPad friction surface areaFront45 cm'(7.0 sq in.)x2
Rear28 cm'(4.3 sq in.) x 2TIRESSize offront and reartiresPl95/60 815 88VSize o{ spare tireT125r0 D15 95MAIR
CONDITIONING
CompressorTypeScroll
Number of
cylinders
Capacity85.7 m015.23 cu in.)/rev.
Maximum speed12,000 rpm
Lubricant capacity130 m0 {4 1/3 floz)
LubricanttypeSP-10 (P/N 38897'P13-A01AH or38899-P13 A01)CondenserTypeCorrugated finEvaporatorTvpeCorrugated fin
BlowerTypeSirocco fan
Motor type220 Wl12 V
Speed control4 Speeo
Maximum capacity480 m" 116.900 cu ft)/hTemperature controlAirmixtype
Compressor clutchTvpeDry, single plate, poly-V belt drive
Electricalpower
cons!mptron at
68"F (20.C)
42 W maximum at 12 V
RefrigerantTypeHFC 134a (R-134a)
Capacity500 550 g (17.6 19.4 oz)
Design Specifications
C
aL
2-12
../ a

Lubricants and Fluids
For details of lubrication points and type of lubricants to be applied, refer to the illustrated index and various work
ures {such as Assemoverhaul. lnstallation. etc.) contained in each section.
NO.LUBBICATION POINTSLUBBICANT
1E ng ineHonda Motor Oil (P/N 08798-9023). The oil container
must disolav the API Cenification seal shown below.
Make sure it says "For Gasoline Engines." SAE
Viscositv: See chart below.
2TransmissionHonda MTF*' (P/N 08798-9016)
3Brake svstem (includes ABS line)Honda DOT 3 Brake Fluid*' (P/N 08798-9008)
4Clutch line
5
6
Release fork (manual transmissionl
Throftle cable end (throttle Iink)
Super High Temp Urea Grease {P/N 08798-9002)
7
I
Shift and select cable ends (manual
transmission)
Throttle cable end (dashboard lower panel hole)
Silicone grease
9
10
111'
14
16
17
Brake booster clevis
CIutch booster clevis
Shift lever pivot
Pedal linkage
Battery terminals
Fuel f ill door
Hood hinges and hood latch
Hatch hinges
Door hinoes, uoDer and lower
Multi-purpose grease
18Caliper piston boot, caliper pins and bootsHonda CaliDer Grease (P/N 08C30-80234lvl)
19Air conditioning compressorCompressoroil: SP-10 (P/N 38897-P13-A01AH or
38899-P'13-A01)
For refriqerant; HFC'134 a (R-134 a)
I
Recommond6d Engine OilEngine oilviscosily for amb enttemperalure fanges
-30 -20 -10 0 t0 20
*1:
"2:
Always use Honda Manual Transmission Fluid (MTF). Using motor oii can cause stiffer shifting because it does
not contain the Drooer additives.
Always use Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of
the system.
3-2