2003 HONDA CIVIC headlights

ItemMeasulementOualificationStandard or New Service LimitFuel pressure
regulator
Pressure with fuel pressure gauge
connected
320-370 kPa 13.3-'3.8 kgtcm', 47 52psi)
FueltankCapacity50 4 (13.2 US galiEngine idleldle speed with headlights and radiator
fan off
Neutral750 50 rpm
Fast idleNeutral1,600150 rpm
Standards and Service Limits
Fuel and Emissionsf
.\
ra
Clutch
ItemMea3urem€nlOualificationSlandard or NewService LimitClutch pedalHeight from the floor193 mm (7.60 in.)Stroke130 140 mm 15.1 5.5in.)
10 16 mm (0.39 0.63 in.)Disengagement height from the floor1'15 mm (4.53 in.) min.Bunout on clutch mating surface0.05 mm 10.002 in.) max.0.15 mm (0.006 in.)Clutch discBivet head depth1.65 2.25 mm (0.065 0.089 in.)0.7 mm {0.03 in.)Ihickness8.3 8.9 mm (0.33 0.35 in.)6.0 mm (0.24 in.)Pressure plateWarpage0.03 mm (0.001 in.)max.0.15 mm (0.001 in.)Height of diaphragm spring fingersMeasured with
specialtool and
feeler gauge
0.6 mm (0.02 in.) max.0.8 mm (0-03 in.)
2-6
\

L
A
I
Do the items in parts A, B, C, D, E, F, and G as required for mileage/time interval listed.
Feplace engine oil(see pageS 5). Capacity withoutlilter change:4.0 q (4.2 US qt,3.5lmp qt)
Replace engjne oil filter (see page I 6). Capacity with filter change: 4.2 0 14.4 US qt, 3.7 lmp qt)Insoect front and rear brakes,. Check pads and discsforwearlthickness), damage, andcracks.. Check calipers for damage, leaks, and tightness of mount bolts.Lubricate door locks, latches and hinges with Honda white lithium grease.Rotate tires, if the vehicle has been driven the distance listed. Follow the pattern shown in the Owner's Manual-Check tire inflaron aoocondition,Inspecttie rod ends, steering gearbox, and boots (see page 17,5).. Check rack grease and steering linkage.. Check boots for damage and leaking grease.. Checklluid linefordamage and leaks.Inspect suspensron components. Check bolts for tightness.. Check condition of ball joint boots for deterioration and damage.Inspect driveshaft boots. Check boots for cracks and boot bands for tightness (see page 16-3).
Check parking brake adjustment. Should be fully applied within 7 to 9 clicks.Insp€ct brake hoses and lioes. (including ABS). Check the master cylinder, proportioning control valve, and ABS modulator for damageand leakage (see page 19-24).Check all fluid levels and condition ot lluids; check for leaks. lf necessary, add MTF (see page 13 3), engine coolant, brake fluid, andwindshield washer f luid.Inspect exhaust system*. Check catalytic converter heat shield, exhaust pipe and muffler for damage, leaks, and tightness (see page 9 8).Inspect fuel lines and connections*. Check for loose connections, cracks and deterioration; retighten loose connections and replacedamaged pans (seo page 11'146).Check alllights. Checkfunction otallinterior and exterior lights, andthe position ofthe headlights (see page 22-68).Inspect the v€hicle underbody. Check the paint for damage, scratches, stone chippin0, and dents.
L
D
E
F
H
InsDect and adiust drive belt.. Look tor cracks and damage, and inspect auto tensioner {needs no adjustment).Reolace dust and oollen filter.
Replace air cleaner element every 15,000 miles 124,000 km) in dustv condition {independent ol timei otherwise use Normal Conditionsscredule (see page 11-162).
lReplaceaircleanerelementevery30,000miles(48,000km)(independento{timei(seepagell-162).
Replace brake fluid every 3 years (independent oJ mileagei.
Replacethe dust and pollen Iilter every 15,000 miles ifvehicle is driven mostlywhere air has high concentration olsootfrom industryanddiesel powered vehiclesj also replace the dust and pollen filter anytime aarflow is less than ussal (see pags 21-39).
According to state and federal regulations, failure to do the maintenance items marked with asterisk (*) will not void customer's emissionswarranties. However, Honda recommends that all maintenance services be done at the recommended interval to ensure long-term reliability,
3-7

lgnition Timing Inspection
1.
4.
5.
Connect the Honda PGM Tester to the data link
connector (DTC), and check for DTC'S. lf a DTC is
present, diagnose and repair the cause before
inspecting the ignition timing.
Startthe engine. Hold the engine at 3,000 rpm with
no load (in Neutral) until the radiator fan comes on,
then let it idle.
Check the idle speed (see page 11-138).
Follow the tester's prompts in the "SCS" menu
{see the tester operator's manual),
Connect the timing light to the service loop.
o
6. Point the light toward the pointer (A) on the cam
chain case. Check the ignition timing under no load
conditions: headlights, blower fan. rear window
defogger, and air conditioner are not operaling. lf
the ignition timing differs from the specification,
and there are no engine control module {ECM)DTcs,
replace the ECM (see page 11-4)
lgnition Timing:
8"+2" BTDC {RED mark {B)) during idling in neutral
A
7. Turn the ignition switch OFF.
Disconnectthe Honda PGM Tester and thetiming
light.
4-17

Gharging System
Charging Circuit Troubleshooting (cont'd)
6. Start the engine. Hold the engine at 3,000 rpm with
no load (in Neutral) until the radiator fan comes on,
then let it idle.
7. Raise the engine speed to 2,000 rpm, and hold it
there.
8. Turn the headlights (high beam) on, and measure
voltage at the under-hood fuse/relay box terminal.
ls the voltage between 13.9 and 15.1 v?
YES-Go to step 9.
NO Repair or replace the alternator components
(see page 4-30).1
9. Read the amperage at '13.5 V.
NOTE: Adjust the voltage by turning the blower
motor, rear window defogger, brake lights. etc. ON.
ls the amperage 604 ot morc?
YES-Alternator/regulator operation is OK. I
NO Repair or replace the alternator components(see page 4-30).1
4-24
\,
Alternator Control System Test
NOTE: After troubleshooting, perform the engine
control module (ECM) idle learn procedure (see page
11-139).
1 . Check for proper operation of the electrical load
detector (ELD) by checking the malfunction
indicator lamp (MlL) (see page 1 l-3). lf a DTC is
present, diagnose and repair the cause before
continuing with this test.
2. Disconnect the engine wire harness 6P connector
from the starter sub harness 6P connector.
3. Start the engine, and turn the headlights (high
beam) ON,
4. Measure voltage between the engine wire harness
6P connector terminal No. 2 and the positive
terminal of lhe battery.
C {WHT/GRN)
ENGINE WIRE HARNESS 6P CONNECTOR
Wire side of female terminals
ls there 1 V or less?
YES Go to step 8.
NO-Go to step 5.
Turn the headlights and ignition switch OFF.
Disconnect ECM connector B (24P).
5.
6.
BATTERY

\
L
7, Check for continuity between ECM connector
terminal 818 and body ground.
ECM CONNECTOR B {24PI
123 t4 t561
8910,/1,/35
11ont,/2123
ACGC {WHT/GRN}
o
Wire side ot female terminals
9.
ls there continuity?
YES-Repair short to ground in the wire between
the alternator and the ECM.I
NO-Check that the terminals are firmly seated at
the ECM connector B. lf OK, substitute a known-
good ECM, and recheck (see page 11-6).
lf prescribed voltage is now available. replace the
original ECM,I
Turn the headlights and ignition switch OFF.
Disconnect ECM connector B (24P).
10. Check for continuity between ECM connector
terminal 818 and engine wire harness 6P connector
terminal No.2.
ACGC (WHT/GRN)
ECM CONNECTOR B l2,lPI
12314l5lll67
8910t.)15
11on2123
oC (WHT/GRN)
23
56
ENGINE WIRE HARNESS 6P CONNECTOR
Wire side oI lemale terminals
ls therc continuity?
YES Repair or replace the starter subharness or
the alternator (see page 4-30).I
NO Repair open in the wire between the
alternator and the ECM.I
4-25

PGM-FI System
I
a
DTC Troubleshooting (cont'dl
DTC Pl297: ELD Circuit Low Voltage
1. Reset the ECM {see page 11-4).
2. Start the engine.
3. Turn on the headlights.
ls DTC P1297 indicated?
YES Go to step 4.
NO Intermittent failure, system is OK at this time.
Check for poor connections or loose terminals at
the ELD and at the ECM.I
4. Turn the ignition switch and the headlights OFF.
5. Disconnectthe ELD 3P connector.
6. Turn the ignition switch ON {ll).
7. Measure voltage between body ground and ELD 3P
connector terminal No. 3.
ELO 3P CONNECTOB
{GRN/REDI
Wire side of female terminals
ls there about 5 V?
YES Replace the ELD. t
NO-Go to step 8.
Z3ELD
11-92
8. Turn the ignition switch OFF.
9. Disconnect ECM connector E {31P).
10. Check for continuity between body ground and
ECM connector terminal E15.
ECM CONNECTOR E 131PI
I l2l3456178I
totd/ 12021,2 2al2/tA31
ELD(GRN/RED}7\'
Wire side of female terminals
ls there continuity?
YES-Repair short in the wire between the ECM(E 15) and the ELD. r
NO- U pdate the ECM if it does not have the latest
software, or substitute a known-good ECM, then
recheck (see page 1 1-6). lf the symptom/indication
goes away with a known-good ECM, replace the
original ECM.I

DTC Pl298: ELD Circuit High Voltage
1. Resetthe ECM (see page 11-4)
2. Stan the engine.
3. Turn on the headlights.
ls DTC P1298 indicated?
YES-Go to step 4.
NO- Intermittent failure. system is OK at this time.
Check for poor connections or loose terminals at
the ELD and at the ECM.I
4. Turn the ignition switch and headlights OFF.
5. Disconnectthe ELD 3P connector.
6. Turn the ignition switch ON (ll).
7. Measure voltage between body ground and ELD 3P
connector terminal No. 1.
ELD 3P CONNECTOR
IG1 IBLK/ORNI
Wire side ot {emale terminals
ls there battery voltage?
YES-Go to step 8.
NO-Checkthe No. 4 ACG (10A)fuse in the under-
dash fuse/relay box. lf the fuse is OK, repair open in
the wire between the No. 4 ACG (10A) fuse and the
ELD.I
8.
9.
10.
11.
Turn the ignition switch OFF.
Connect ELD 3P connector terminal No. 3 to body
ground with a jumper wire.
Disconnect ECM connector E (31P).
Check for continuity between body ground and
ECM connector terminal E15.
ECM CONNECTOR E 131PI
1 21345ot/II
14LC6l/ 182C21
22123 2421 ./2Q30J
ELDIGRN/RED)i1'
Wire side of female terminals
Is thete continuity?
YES-Go to step 12.
NO Repair open in the wire between the ECM
(E15) and the ELD.
(cont'd)
ELD 3P CONNECTOR
---F-------
l1l2 :rlELD(GRN/RED)
IJUMPER wrRE
II
Wire side of temale terminals
11-93

PGM-FI System
DTC Troubleshooting (cont'dl
12, Check for continuity between ELD 3P connector
terminal No.2 and body ground.
ELD3P CONNECTOR
Wire side of female terminals
ls there continuity?
YES Go to step 13.
NO- Repair open in the wire between the ELD and
G201. I
Reconnect the ELD 3P connector and ECM
connector E (31P).
Start the engine and let it idle.
While measuring voltage between ECM connector
terminals 424 and E15, turn the headlights on
th igh).
ECM CONNECTORS
Wi.e side of female terminals
Does the voltage drop?
YES-Update the ECM if it does not have the latest
software, or substitute a known-good ECM, then
recheck {see page 1 1-6). lf the symptom/indicationgoes away with a known-good ECM, replace the
original ECM.I
NO Replace the ELD.I
14.
t5_
11-94