2003 HONDA CIVIC seat

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, 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

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2-11
Design Specifications
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|temMeasurementOualificationSpecilication
DIMENSIONSOveralllength4,210 mm {165.8 in.)
Overallwidth1,695 mm 166.7 in.)
Overallheight1,440 mm (56.7 in.)
2,570 mm (101.2 in.)
Trackrront1,470 mm (57.9 in.)
Rear'1,470 mm (57.9 in.i
Ground clearance152 mm (5.98 in.)
Seating capacityfour {4)
wEtGt-iT {u.s.A.)Gross Vehicle Weight Rating
(GVWR)
3,660 rbs
WEIGHT
(CANADA)
Gross Vehicle Weight Rating
{GVWR)
1,660 kg
ENGIN ETvpeWater cooled. 4 stroke DOHC V-EC engin(
Cylinder arrangementInline 4'cylinder, transverse
Bore and stroke86 x 86 mm (3.39 x 3.39 in.)
Displacement1,998 cm'(122 cu in.)
Compression ratio9.8
Valve trainChain drive. DOHC VTEC 4 valves per cylinder
Lubrication systemForced, wet sump, with trochoid pumP
Oil pump displacementAt 6,000 engine
rpm
54.3 0 (57.4 US qo/minute
Water pump displacementAt 3,400 engine82 0 (87 US qt)/minute
F!el requiredUNLEADED gasoline with 86 pump octane number or higher
STARTERTvpeGear reduction
Normaloutput
Nominalvoltage12V
Hour rating30 seconds
Direction of rotationClockwise as viewecl from gear end
CLUTCHClutch tvpeSinqle plate dry, diaphragm spring
Clutch friction material surface area174 cm'{26.97 sq in.)
I\,1AN UAL
TRANSMISSION
TvpeSvnchronized, s-speed forward, 1 reverse
Primarv reductionDirect 1:1
Gear ratiolst3.062
2nd1.769
3rd1.212
4th0.921
5th0.738
Reverse3.583
FinalreductionTypeSinole helicalgear
Gear ratio4.164

Starting System
Starter Overhaul (cont'dl
Planetary Gear Inspection
16. Check the planetary gears (A) and ring gear {B).Replace them if they are worn or damaged.
Overrunning Cluich Inspection
17. Slide the overrunning clutch along the shaft.
Replace it if it does not slide smoothly.
18. Rotate the overrunning clutch (A) both ways.
Does it lock in one direction and rotate smoothly inreverse? lf it does not lock in either direction or it
locks in both directions, replace it.
lf the starter drive gear (B) is worn or damaged,
replace the overrunning clutch assembly; the gear
is not available separately.
Check the condition of the flywheel ring gear.
Replace it if the starter drive gear teeth are
oamageo.
19.
4-14
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Starter Reassembly
20, Pry back each brush spring with a screwdriver, thenposition the brush about halfway out of its holder,
and release the spring to hold it there.
NOTE: To seatthe new brushes. slip a strip of #5OO
or # 600 sandpaper. with the grit side out, be&veen
the commutator and each brush, and smoothly
rotate the armature. The contact surface of the
brushes will be sanded to the same contour as the
commutator.
21lnstallthe armature in the housing, and installthe
brush holder. Next, pry back each brush spring
again, and push the brush down until it seats
against the commutator, then release the spring
against the end of the brush.
s
Install the starter end cover to retain the brush
holder.

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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

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Engine Mechanical
Cylinder Head
Special Tools
Comoonent Location Index
Engine Compression Inspection
VTEC Rocker Arm Test ........... ............ 6-7
VTC Actuator Inspection .................... 6-8
Valve Clearance Adjustment ............. 6-9
Crankshaft Pulley Removal and Installation .............. 6-11
Cam Chain Removal ........................... 6-12
Cam Chain Installation ....................... 6-15
Auto-Tensioner Removal/1nsta11ation ......................... 6-19
Chain Case Oil Seal Installation ........ 6-21
Cyf inder Head Cover Removal .......... 6-22
Cylinder Head Removal ..................... 6-23
WC Actuator. Exhaust Camshaft Sorocket
Repf acement .........6-24
Cylinder Head Inspection for Warpage ...................... 6-25
Rocker Arm Assembly Removal ................................. 6-26
Rocker Arms and Shafts
Disassembly/Reassembly .............. 6-27
Rocker Arms and Shafts Inspection ............................ 6-28
Camshaft Inspection .......................... 6-29
Valves, Springs, and Valve Seals Removal ................ 6-31
Valve Insoection ...................... ........... 6-32
Valve Stem-to-Guide Clearance Insoection ............... 6-32
Valve Guide Reolacement ................. 6-33
Valve Seat Reconditioning ................ 6-35
Valves, Springs, and Valve Seals Installation ............ 6-37
Rocker Arm Assemblv Installation .... 6-38
Cvlinder Head Installation ........................................... 6-39
Cylinder Head Cover Installation ...... 6-41
6-2
6-3
b-t'

Cylinder Head
Engine Compression Inspection
1. Warm up the engine to normal operating
temperature (cooling fan comes on).
2. Turn the ignition switch OFF.
3. Remove the intake manifold cover (see step 1 onpage 6-22).
4, Disconnect all four injector connectors.
5. Start the engine, and let it run until it stalls.
6. Remove the iour ignition coils (see page 4-18).
7. Remove the four spark plugs.
8. Attach the compression gauge to the spark plug
note.
6-6
V,
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9.
10.
Open the throttle fully, then crank the engine with
the starter motor and measure the compression.
Compression Pressure
Above 930 kpa (9.5 kgf/cm', 135 psi)
Measure the compression on the remaining
cylinders,
Maximum vadation
Within 200 kPa (2.0 kgf/cm', 28 psi)
lf the compression is not within specifications,
check these items, then remeasure the
compressron.
. Damaged orworn valves and seats. Damaged cylinder head gasket. Damaged or worn piston rings. Damaged orworn piston and cylinder bore
11.
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Gamshaft Inspection
NOTE: Do not rotate the camshaft during inspection.
1. Remove the rocker arm assembly (see page 6-26).
and disassemble it (see page 6-27).
2. Put the rocker shaft holders, camshaft, and
camshaft holders on the cylinder head, then tighten
the bolts to the specified torque.
Specified torque:
I mm bolis:
22 N.m {2.2 kgt m, 16lbf.ft}
6 mm bolts:
12 N.m {1.2 kgf.m,8.7 tbf.ftl
6 mm bolts: @, €0, @
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3. Seat the camshaft by pushing it away from the
camshaft pulley end ofthe cylinder head.
4. Zero the dial indicator against the end of the
camshaft, then push the camshaft back and forth
and read the end play. lf the end play is beyond the
service limit, replace the camshaft head and
recheck. lf it is still beyond the service limit, replace
the cylinder.
Camshaft End Play:
Standard {New}: 0.05 0.20 mm(0.002 0.008 in.l
Service Limit: 0.4 mm (0.02 in.)
(cont'd)
6-29

Valve Guide Replacement
Special Tools Required. Valve guide driver, 5.5 mm 07742-0010100. Valve guide reamer, 5.5 mm 07HAH-PJ7o108
1.Inspect valve stem-to-guide clearance (see page 6-
32t.
As illustrated below, use a commercially available
air-impact valve guide driver (A) modified to fit the
diameter of the valve guides. In most cases, the
same procedure can be done using the special tool
and a conventional hammer.
10.8 mm{0.,|2 in.)
3. Select the proper replacement guides, and chill
lhem in the freezer section of a refriqerator for
about an hour.
4. Use a hot plate or oven to evenly heat the cylinder
head to 300'F (150"C). Monitor the temperature
with a cooking thermometer. Do not getthe head
hotterthan 300'F (150"C); excessive heat may
loosen the valve seats.
-_|Jfillr-.-4fi'11., -
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7.
Working from the camshaft side. use the driver and
an aar hammerto drive the guide about 2 mm (0.1
in.)towards the combustion chamber. This will
knock off some of the carbon and make removal
easier. Hold the air hammer directly in line with the
valve guide to prevent damaging the driver.
Turn lhe head over, and drive the guide out toward
the camshaft side of the head.
lf a valve guide won't move, drill it out with a I mm
(5/16 inch) bit. then try again. Drill guides only in
extreme cases;you could damage the cylinder
head if the guide breaks.
Remove the new guide(s) from the freezer, one at a
time, as vou need them.
(cont'd)
6-33