2003 HONDA CIVIC air intake

Engine Assembly
I
Engine Removal
Special Tools Required
Front subframe adapter EOS02C00001 1
NOTE:. Use fender covers to avoid damaging painted
surfaces.. To avoid damage, unplug the wiring connectors
carefully while holding the connector portion.. Mark all wiring and hoses to avoid misconnection.
Also, be sure that they do not contact other wiring orhoses, or interfere with other parts.
1. Secure the hood in the wide open position (support
rod in the lower hole).
2. Make sure you have the anti-theft code for the radio,
then write down the frequencies for the radio'spreset buttons.
3. Disconnect the negative cable from the battery first,then disconnect the positive cable.
4. Remove the battery.
5. Remove the intake manifold cover.
II
5-2
\,
6. Disconnectthe intake airtemperature (lAT) sensorconnector (A), remove the breather hose (B) and
vacuum hose (C), then remove the air cleaner
housing cover/intake air duct assemblv (D).
AC
7. Remove the air cleaner housing.

8. Remove the intake air duct.
9. Remove the battery cables {A) fromthe under-hood
fuse/relay box. then remove the harness clamp (B)
and ground cable (C).
10. Fullv ooen the throttle link and cruise control link
by hand, then remove the throttle cable (A) and
cruise control cable (B)from the links. Loosen the
locknuts {C), and remove the cables from the
bracket.
11. Relievefuel pressure (see page 11-144).
12. Remove the fuel line(seepagell-149).
13. Remove the evaporative emission (EVAP) canister
hose {A) and brake booster vacuum hose (B).
(cont'd)
5-3

Engine Assembly
Engine Installation {cont'dl
Install the select cable (A) and shift cable (B) using
the plastic washers (C), washers (D), and new cotter
pins (E).
6x1.0mm9.8 N.m (1.0 kgf.m,7.2 tbl.ftl
Install the clutch slave cylinder (A) and clutch line
bracket mounting bolt (B).
6x1.0mm9.8 N.m{1.0 kgf.m,7.2 tbt.ft)
"-.----->)
"------'6
8 x '1.25 mm24 N.m (2.4 kgl.m,
5-14
37. Installthe battery cables (A) on the under-hood
fuse/relay box, then install the harness clamp (B).
Installthe ground cable (C).
Installthe intake air duct.
6x1.0mm12Nm{1.2kgf.m,8.7 tbf.ft)
39.
\"
\-
a
6x1.0mm12Nm{1.2kgt.m,8.7 rbf.ft)

40. Install the air cleaner housinq.
6x1.0mm12 N m (1.2 kgf.m,8.7 lbt.ft)
Install the air cleaner housing cover (A) and
connect the intake air temperature (lAT) sensor
connector (B),
42. Installthe breather hose (C) and vacuum hose 1D).
41.
43. Installthe intake manifold cover.
6x1.0mm12Nm11.2kgf.m.8.7 tbf.ft)
Installthe battery. Clean the battery posts and
cable terminals with sandpaper, then assemble
them and apply grease to prevent corrosion.
Check that the transmission shifts into gear
smoothly.
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.
Refillthe engine with engine oil (see page 8-5).
Refill the transmission with fluid (see page 13-3).
Refill the radiator with engine coolant, and bleed
air from the cooling system with the heater valve
open (see page 10-6).
Perform the engine control module (ECM) idle learnprocedure (see page 11-139).
Inspect the idle speed (see page 1 1-138).
Inspect the ignition timing (see page 4-17).
Check the wheel alignment {see page 18-4).
Enter the anti-theft code for the radio, then enter
the customer's radio station presets.
Set the clock.
YE
44.
41.
]tE
46.
48.
49.
52.
53.
54.
50.
51.
55.
5-15

WEC Rocker Arms Test
Special Tools Required. Air pressure regulator 07AAJ-PNAA100. VTEC air adaoter 07ZAJ-PNAA100. WEC air stoDoer 07ZAJ-PNAA200. Air joint adapter 07ZAJ-PNAA300
1. Remove the cylinder head cover (see page 6-22).
2. Set the No. 1 piston at top dead center (TDC) (see
step 1 on page 6-12).
3. Verify that the intake primary rocker arm (A) moves
independently of the intake secondary rocker arm
(B).
. lf the intake primary rockerarm does not move,
remove the primary and secondary rocker arms
as an assembly and check that the pistons in the
secondary and primary rocker arms move
smoothly. lf any rocker arm needs replacing,
replace the primary and secondary rocker arms
as an assemblv, and test.. lfthe intake primary rocker arm moves freely, go
to step 4.
6.
Repeat step 3 on the remaining intake primary
rocker arms with each piston at TDC. When all the
primary rocker arms pass the test, go to step 5.
Check that the air pressure on the shop air
compressor gauge indicates over 400 kPa
(4 kgflcm', 57 psi).
Inspect the valve clearance (see page 6-9).
Remove the sealing bolt (A)from the relief hole,
and install the VTEC air stopper (B).7.
OTAAJ.PNAAlOODOTZAJ-PNAA3OO
Remove the No. 2 and No. 3 camshaft holder bolts,
and installthe VTEC air adapters (C) finger-tight.
Connect the air joint adapter (D), and air pressure
regulator with a 0-100 psi gauge (E).
(cont'd)
OTZAJ.PNAAlOO
6-7

Cylinder Head
WEC Rocker Arms Test (cont'dl
'10. Loosen the valve on the regulator, and apply thespecified air pressure.
Specified air pressure:
290 kPa 13.0 kgt/cm', 42 psi)
NOTE: lf the synchronizing piston does not moveafter applying air pressure; move the primary orsecondary rocker arm up and down manually byrotating the crankshaft clockwise.
11. With the specified air pressure applied, move theintake primary rocker arm (A)forthe No, 1 cylinder.The primary rocker arm and secondary rocker arm(B) should move together.
lf the intake secondary rocker arm does not move,
remove the primary and secondary rocker arms asan assembly, and check that the pistons in theprimary and secondary rocker arms move
smoothly. lf any rocker arm needs replacing,
replace the primary and secondary rocker arms asan assembly, and test.
Remove the special tools.
Tighten the camshaft holder mounting bolts lo22N m 12.2 kgf.m, 16 lbf.ft).
Tighten the sealing boltto 20 N.m (2.0 kgf.m,
14 tbf.ft).
Installthe cylinder head cover (see page 6-41).
12.
13.
14.
t5.
6-8
VTG Actuator Inspection
'11. Remove the cylinder head cover (see page 6-22lr.
2. Remove the auto-tensioner (see page 6-19).
3. Loosen the rocker arm adjusting screws lsee step 2on page 6-26).
4. Remove the camshaft holder (see step 3 on page 6-
26t.
5. Remove the intake camshaft.
6, Check that the variable valve timing control (VTC)
actuator is locked by turning the VTC actuator
clockwise and counterclockwise. lf the VTC actuatoris not locked, replace the VTC actuator.
7. Seal the advance holes (A)and retard holes (B) in
the No. 1 camshaft journal with tape.
Punch a hole through the tape over one of theadvance holes.

Gylinder Head Removal
NOTE:. Use fender covers to avoid damaging painted
surfaces.
To avoid damage, unplug the wiring connectors
carefully whlle holding the connector portion.
To avoid damaging the cylinder head, wait until the
engine coolant temperature drops below 100'F (38"C)
betore loosening the cylinder head bolts.
Mark all wiring and hoses to avoid misconnection.
Also, be sure that they do not contact other wiring or
hoses, or interfere with other parts.
'1.
2.
3.
Drain the engine coolant (see page 10-6).
Remove the drive belt (see page 4-26).
Remove the intake manifold {see page 9-3).
Remove the air cleaner housing (see step 7 on page
5-2t.
5. Remove the water bypass hose (A).
Remove the exhaust manifold (see page 9-7
Remove the cam chain (see page 6-12).
6.
7.
).
8. Remove the engine wire harness connectors and
wire harness clamps from the cylinder head.
. Engine coolant temperature (ECT) sensor
conneclor. Camshaft position (Cl\4P) (top dead center (TDC))
sensor B connector. Camshaft posilion (CMP) sensor A connector
9. Remove the upper radiator hose (A) and heater
hose (B).
'10. Remove the harness holder (A)from the bracket,
then remove the connecting pipe mounting boh {B)
and brake booster vacuum line mounting bolts {C).
(cont'd)
1 1. Remove the water bvpass hose (D).
6-23

14. Installthe water bvpass hose.
15. Installthe air cleaner housing (see step 37 on page
5-15).
16. Installthe intake manifold (see page 9-5).
17. Installthe exhaust manifold (see page 9-7).
'18. Installthe cam chain (see page 6-15).
19. Adjust the valve clearance (seepage6-9).
20. Installthe drive belt (see page 4-26).
21. Clean the battery posts and cable terminals with
sandpaper, then assemble them and apply grease
to prevent corrosion.
22. After installation, checkthatall tubes, hosesand
connectors are installed correctly.
23. Inspectforfuel 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 thls operation two or three times, then
check for fuel leakage at any point in the fuel line.
24. Refillthe radiator with engine coolant, and bleed
air from the cooling system with the heater valve
open (see page 10-6).
25. Inspect the idle speed (see page 11-'138).
26. Inspect the ignition timing (see page 4-17).
Gylinder Head Cover lnstallation
1. Thoroughly clean the head cover gasket and the
groove.
2. Installthe head cover gasket (A) in the groove of
the cylinder head cover (B).
Check that the mating surfaces are clean and dry.
Apply liquid gasket. P/N 08718-0009, on the chain
case and the No.5 rocker shaft holder mating areas.
NOTE: Do not install the parts if 5 minutes or more
have elapsed since applying liquid gasket. Instead,
reapply liquid gasket after removing old residue.
(cont'd)
6-41