2003 HONDA CIVIC thermostat

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Lubrication
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|temMeasurementOualificalionStanderd or New Service Limil
Engine oilCapacity5.3 0 (5.6 US qt)for engine overhaul
4.2 0 (4.4 US qt) for oil change, including filter
4.0 0 (4.2 US qt)for oil change, without filter
Oilpumplnner-to outer rotor clearance0.02 0.16 mm {0.001 0.006 in.)0.20 mm (0.008 in.)
Pump housing to outer rotor
clearance
0-15 0.21 mm {0.006-0.008 in.)0.23 mm (0.009 in.)
Pump housing-to-rotor axial
clearance
0.02 0.07 mm (0.001 0.003 in.)0.12 mm (0.005 in.)
Balancer shafts, journal diameterNo. 1 journal, front
shaft
19.938 19.950 mm 10.7850 0.7854 in.)19.92 mm (0.784 in.)
No 1 journal, rear shaft23.938 23.950 mm (0.9424 0.9429 in.)23.92 mm (0.942 in.)
No. 2 journal, front and
rear shaft
32.949 32.961 mm 11.2912 1.2911 in.l32.93 mm (1.296 in.)
Ealancer shafts, journal taper0.005 rnm (0.0002 in.) max.
Balancer shafts, end playFront0.070 0.135 mm (0.0028 0.0053 in.)0.15 mm (0.006 in.)
Rear0.070 0.135 mm (0.0028 0.0053 in.)0.15 mm (0.006 in.)
Balancer shatts, shaft-to'bear;ng
clearance
No. 1 iournal, front
shaft
0.050 0.082 mm (0.0020 0.0032 in.)0.10 mm (0.004 in.)
No. 1 Journal, rear shaft0.050 0.082 mm (0.0020 0.0032 in.) 0.10 mm (0.004 in.i
No. 2 journal, front and
rear shafl
0.060 -0.120 mm (0.0024 0.0047 in.) 0.15 mm (0.006 in.)
Balancer shaft bearings, LD.No. 1 journal, front
shaft
No. 1 iournal, rear shaft
20.000 20.020 mm (0.1814 0.7442 in.l
Z+.OOO ZI.OZO m- tOSa+e- OSa57 ir'.)
20.03 mm (0.789 in.)
24.03 mm (0.946 in.)
No. 2 journal, front and
rear shaft
33.021 33.069 mm (1.3000 1.3019 in.)33.09 mm {1.303 in.)
Reliefvalve, oil pressure with oil
temperature at 176'F (80"C)
At idle70 kPa (0.7 kq?cm , 10 psr) min.
At 3,000 rpm300 kPa {3.1 ksf/cm',44 psi)min.
Standard or New Service Limit
6.7 L (7.1 USCoolant capacity {includes engine,
heater, hoses, and reservoir)
0.53 L (0.56 US
93 123 kPa (0.95 1.25 kqtcm , 14 18 psi)'t69 176'F (76 80'C)Thermostat OPeningtemPerature
8.0 mm {0.31 in.) min.
Turns OFF Subtract 5 15'F (3 8"C)from actual ON

Engine Cooling
Cooling System
Component Location Index ......................................... 10-2
Radiator Cap Test ..................... .......... 10-3
RadiatorTest ............. 10-3
Fan Motor Test .......... l0-4
Thermostat Test ...................... ........... 10-4
Water Pump Inspection ..................... 10-5
Water Pump Replacement ................. 10-5
Coolant Check .............. ....................... 10-6
Coolant Replacement ......................... 10-6
Thermostat Replacement .................. 10-8
Water Passage Installation ................ 10-9
Water Outlet Installation .................... 10-9
Radiator and Fan Replacement ................................... 10-10
Fan Controls
Component Location Index ......................................... 10-11
Symptom Troubleshooting Index ............................... 10-12
Circuit Diagram ......... 10-13
Radiator Fan CircuitTroubleshooting ........................ 10-14
Radiator Fan Switch Circuit Troubleshooting
(Open) ............ ........ 10-16
Radiator Fan Switch Circuit Troubleshooting
(Short) ............ ........ 10-16
Radiator Fan Switch Test ................... 10-17
Radiator Fan Switch Reolacement .............................. 10-17

Cooling System
Component Location Index
WATER PUMPInspection, page 10-5Replacement. page 10-5
RESERVETANK
RADIATORCAP
RAOIATOR FAN SWITCHTest, page 10-17Replacement, page 10'17
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WATER OUTLET,Installation, page'10-g
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CONNECTING PIPE
WATER PASSAGEInstallation, page 10-9
THERMOSTATTest, page 10 4Replacement, page 10 8
RADIATORReplacement, page 10-'l0
RADIATOR FANASSEMgLYReplacement, page 10-10Fan MotorTest, page 10 4A/C CONDENSERFAN ASSEMBLYReplacement, page 10 10Fan Motor Test, page '10-4
10-2
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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
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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.
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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
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Gooling System
Thermostat Replacement
1. Drain the engine coolant (see page 10-6).
2. Remove the splash shield (see step 23 on page 5-5).
3. Remove the lower hose, then remove the thermostat.
6x 1.0 mm9.8 N.m(1.0 kgf.m,7.2lbf ft)
a
u
i*
-
LOWER HOSE
4. Installthe thermostat with a new O-ring, then installthe lower hose.
5. Installthe splash shield (see step 22 on page 5-12).
6. Refillthe radiator with engine coolant, and bleed air from the cooling system with the heater valve open (see page
10_6).
THERMOSTAT
10-8
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DTC P0116: ECT Sensor Range/Performance
Problem
NOTE: lf DTC P0117 and/or P0118 are stored at the
same time as DTC P0116, troubleshoot those DTCS first,
then recheck for DTC P0116,
1. Stanthe engine. Hold the engine at 3,000 rpm with
no load {in neutral) until the radiator fan comes on,
then let it idle.
2. Check the ECT with the scan tool.
ls 176- 212'F (80 100"C)or0.5 0.8V
indicated?
YES Intermittent failure. system is OK at this time.
Check the thermostat and the cooling system.l
NO-Checkthe thermostat and the cooling system.
lf they are OK, replace the ECT sensor.l
11-57

PGM-FI System
aDTG Troubleshootang (cont'dl
DTC P0128: Cooling System Malfunction
NOTE; lf the DTCS listed below are stored at the same
time as DTC P0128. troubleshoot those DTCS first, thenrecheck for P0128.
P0107, P0108, P1128, P1129: N4anifold absolutepressure (MAP) sensor
P] I06, P1 107, P1 108: Barometric pressure (BARO)
sensor
P1259: VTEC system
P01 16, P01 17, P01 18: Engine coolant temperature (ECT)
sensor
P01 12, P01 13: Intake air temperature (lAT) sensor
P0500: Vehicle speed sensor {VSS)P0335, P0336: Crankshaft position (CKP) sensor
P0300: Random misfire
P0301, P0302, P0303, P0304: No. 1, No. 2, No.3 or No.4
cylinder misfire
P0505: ldle control system malfunction
P1519: ldle air control (lAC)valve
DTC P0128 can occasionally set when the hood is
opened while the engine is running.
1. Check the engine coolant level
Is the engine coolant level low?
VES Refill the engine coolant. lf necessary, repair
the coolant leakage.l
NO Go to step 2.
2. Turn the ignition switch ON (ll), and make sure the
A,/C is off.
11-64
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3. Check the radiator fan.
Does the tadiator fan keep running?
YES Checkthe rad iato r fan circuit (see page 10-
14), the radiator fan switch circuit (Short) (see page
10-'16), and the radiator fan switch (see page 10-17).
Also, inspect the ECT and IAT circuits and terminal
connections. lf the circuits, the switch, and the
connections are OK, update the ECI\4 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
NO Replace the thermostat (see page 10-8).1