Page 1


INTRODUCTION How to Use This Manual This manualis dividedinto 23 sections.The first pageof each seclionis markedwith a blacktab that linesup with its corresponding thumb indextab on this pageand the backcover. You can quicklyfind the first pageof eachsectionwithout lookingthrougha full tableof contents.The symbolsprintedat the top cornerof each pagecan also be used as a quick re{erencesystem.

S p e c i fi c a ti o n s

1)ll:{l+'

M a i n te n a n c e

Eachsectionincludes: 1. A tableof contents,or an explodedview index showingl . Partsdisassemblysequence. . Bolttorquesand threadsizes. . Pagereferencesto descriptionsin text. proceduresand tools. 2. Disassembly/assembly 3 . Inspefiron. g. 4. Testing/troubleshootin 5. Repair. 6. Adjustments.

Safety Your safety,and the satetyof others,is very important.To help you makeinformeddecisions,we have providedsafety messages,and othersafetyinformationthroughoutthis manual. Of course,it is not practicalor possibleto warn you aboutall the hazardsassociated with servicingthis vehicle.You must use your own good judgment.

Emissions

You will find impoftantsafetyinformationin a varietyof forms including: . SatetyLabels- on the vehicle. . Satetv Messages preceded by a salety alert symbol A and one of threesignalwords, DANGEF,WARNING,or CAUTION. Thesesignalwords mean:

tmEnEErily;,:H,ll i":5*i5"?;rsERIousLYHuBrir HURT ir E$EEEE ys,: f#,ff ,:hl:3,:JjERrousLY tlGtltT]llilll

YoucAN bâ‚Ź HUBTif vou don'tfollow

. lnstructions - howto service thisvehiclecorrectlv andsafelv. All informationcontainedin this manualis basedon the latest productinformationavailableat the time of printing.We reserve the right to makechangesat any time without notice.No part of this Oublication maVbe reDrodLrced, or storedin a retrieval system,or transmitted,in any form by any means,electronic, photocopying,recording,or otherwise,without the mechanical, priorwritten permissiono{ the publisher.This includestext, figures,and tablesAs vou readthis manual,vou will tind informationthat is precededby a @ symbol.The purposeof this messageis to help preventdamageto your vehicle,other property,or the environment,

*Body

z-tl! ^ t

FirstEdition8/2002 1,168pages HONDAMOTORCO..LTD. All RightsReserved ServicePublicationOffice Specifications applyto U.S.A.and Canada As seclion3 with *inclode SRS comoonentsi special precautionsare required when servicing.

*Restraints

l


GeneralInformation Ghassisand PaintCodes - 2 0 0 2M o d e l

. . . . . . . . . . . . . 1. .-.2.

Chassisand PaintCodes - 2 0 0 3M o d e l

. . . . . . . . . . . . .1. .-.3.

ldentification NumberLocations ........1-4 Warning/Caution LabelLocations......1-5

)

Under-hoodEmission ControlLabel ...........

.... 1-7

L i f ta n dS u p p o r P t o i n t s. . . . . . . . . , . . . . , . . .1. .-.8. , . Towing

......1-9

PaftsMarkingLocations...................... 1-10


GeneralInformation Model Chassisand PaintCodes- 2OO2 VehicleldentfficationNumber S H H E P 33 5 ' 2

U 300001

[[tttrtF

c d e f g h

a. Manufacturer, Make and Type of Vehicle S H H ; H O N D A O F T H EU . K .M F G . ,L T D .U . K . H O N D AP a s s e n g evre h i c l e b. Line, Body and EngineType EP3: CIVIC/K20A3 c. Body Type and Transmission Type Manual 3: 2-door HatchbacUs-speed d. VehicleGrade lSeries) 5:Si {U.S.} 5 ; S i R( C a n a d a ) 6: Si with side airbagsystem (U,S.) 6: SiR with side airbagsystem (Canada) e. CheckDigit l. ModelYear 2i 2002 g. Factory Code U : H o n d ao f U . K .M a n u f a c t u r i nign S w i n d o n , En gl a n d h. Serial Number U . S , :3 0 0 0 0 1 1-

EngineNumber K2OA3 1700001 a a. EngineType K20A3: 2.0 0 DOHCVTECSequentialMultiport Fuel-injectedengine b. Serial Number

Transmission Number NBH3

1000001

I

a TransmissionType N R H 3 ; s - s D e eM danual

0

t

PaintCode Code

B-92P NH-578 NH-623M R-81

Y-62P

Color Niqhthawk BlackPearl TaffetaWhite Satin Silver lvletallic M i l a n oR e d E u r oY e l i o wP e a r l

u.s.

Canada

V€hicle ldentif ication Numbo. and Federal Motor Vehicle Safety Standard Certification/ Color Label.

I

1-2


Chassisand PaintCodes- 2003Model VehicleldentificationNumber S H H E P 33 5 * 3

U 400001

[--t-rlF

c d e fg h

Manufacturer, Make and Type of Vehicle S H H : H O N D A O F T H EU . K .M F G . ,L T D .U . K . HONDAPassengervehicle Line. Body and EngineType EP3: CIVIC/K20A3 G . Body Type and Transmission Type Manual 3: 2-door HatchbacldS-speed d . Vehicle Grade (Series) 5:Si (U.S.) 5 : S i R( C a n a d a ) 6: Si with side airbagsystem (U.S.) 6: SiRwith side airbagsystem (Canada) Check Digir f. Model Year 3: 2003 Factory Code U: Hondaof U.K. Manufacturingin Swindon, England SerialNumber U.S.:400001 :700001

EngineNumber K2OA3 2700001

I a a. EngineType K20A3: 2.0 0 DOHCVTECSequentialMultiport Fuel-injectedengine b. SerialNumber

Transmission Number NRH3 - 2000001

I a TransmissionType N R H 3 : 5 - s p e eM d anual SerialNumber

PaintCode Code

B-92P B-520P NH-578

NH-623M R-81

Y-62P

Color Niohthawk BlackPearl V i v i d B l u eP e a r l Taffeta White Satin Silver N4etallic M i l a n oR e d EuroYellow Pearl

U , S . Canada

VehicleldentificationNumber and FederalMotor Vehicle Saletv Standard Certif ication/ Color Label.

)_.

1-3


GeneralInformation ldentificationNumber Locations

Vehicle ldentif ication Number {vlN}

(

Vehicle ldentificalion Numbe.lvlN)

0

I

EngineNumber

t)

1-4


, I O

warning/cautionLabelLocations NOTE:FRONTPASSENGER AIRBAG WARNING TAG (CHILD SEAT)is installedon the glovebox on the U.S. mooet. Passenger's Compartment: SRSINFORMATION U.Sm . odel

Steering Wheel: DRIVERMODULE DANGER CABLEREEL CAUTION

SRS WARNING INFORMATION FRONTPASSENGER MODULE DANGER

MONITOR NOTICE

! ,/ FRONT SEATBELT TENSIONER CAUTION SIDEMODULE DANGER

SIDEAIRBAG CAUTION Located on driver's ano passen9ers doorjamb(not shown)

..r' (cont'd)

1-5


GeneralInformation Warning/CautionLabelLocations(cont'dl

SRSWARNING LABEL

SERVICEINFORMATIONLABEL (Undor-hood Emission Control Informationlab€l)and ENGINE COOLANTINFORMATION

TIREINFORMATION

RADIATOR CAPCAUTION

BATTERY CAUTION

c

t

1-6


Under-hoodEmissionControlLabel EmissionGroupldentification

Families: Engineand Evaporative

Example:2002model

EngineFamily:

2 HNX V O2.O VBP

rr-tt--[ t t l a b

. P AT I E R2 B I N5 T H I SV E H I C LCEO N F O R MTSO U . S E APPLICABLE TO 2002 LEV REGULATIONS AND NLEV CARSAND MODELYEARNEWPASSENGER TO 2OO2 APPLICABLE REGULATIONS CALIFORNIA CARS. MODELYEARNEWLEVIi LEVPASSENGER

c. d. e.

Example:2003model

c d

e

ModelYear 2:2002 3: 2003 ManulacturerSubcode H N X :H O N D A FamilyType V: LDV Displacement SequenceCharacters V B P2: 0 0 2 X K C 2: 0 0 3

Evaporative Family:

rH/

@

THISVEHICLECONFORMSTO U.S. EPATIER2 BIN 5 TO 2O03 APPLICABLE AND NLEVLEVREGULATIONS CARSAND MODELYEARNEWPASSENGER TO2OO3 APPLICABLE REGULATIONS CALIFORNIA CARS, MODELYEARNEWLEVII LEVPASSENGER

2 HNX R OO99 AAH

t[-l=[

a b

c d

Model Year 2t 2002 3: 2003 Manufacturer Subcode H N X :H O N D A c. Family Type R: EVAP/ORVR d . Canister Work Capacity e . Sequence Charactets AAH: 2002 AAA: 2003

1-7


GeneralInformation Lift and Support Points NOTE:If you are going to remove heavycomponents such as suspensionor the fuel tank from the rear of the vehicle,first supportthe front ofthe vehiclewith tall safetystands.When substantialweightis removed from the rear of the vehicle,the centerof gravity can changeand causethe vehicleto tip forward on the hoist.

FrameHoist 1. Positionthe hoist lift blocks(A),or safetystands, under the vehicle'sfront support points (B)and rear support points (C).

FloorJack 1. Set the parkingbrake. 2. Blockthe wheels that are not being lifted. 3. When liftingthe rear of the vehicle.put the gearshiftIever in reverse. 4. Positionthe floor jack underthe front jacking bracket(A) or rearjackingbracket(B),centerthe jacking bracketin the jack lift ptatform(C),and jack up the vehiclehigh enoughto fit the safetystands u n d e ri t .

0 2. Raisethe hoist a few inches,and rock the vehicle gentlyto be sure it is firmly supported. 3. Raisethe hoistto full height,and inspectthe lift pointsfor solid contactwith the lift blocks.

Safety Stands

c Positionthe safetystandsunderthe support points and adjustthem so the vehiclewill tevet. Lower the vehicleonto the stands.

To supportthe vehicleon safetystands.use the same suppon points (B and C) as for a frame hoist,Always use satetystandswhen working on or under any vehiclethat is supportedonly by a jack.

J

1- 8

t


Towing lf the vehicleneedsto be towed, call a professional towing service.Nevertow the vehiclebehind another vehiclewith just a rope or chain.lt is very dangerous. EmergencyTowing T h e r ea r et h r e ep o p u l a rm e t h o d so f t o w i n g a v e h i c l e . Flat-bedEquipment The operatorloadsthe vehicle on the backof a truck.This is the bestway of transportingthe vehicle. To accommodateflat-bedequipment.the vehicleis equippedwith towing hooks(A)and tie down hooks{B). The towing hook can be usedwith a winch to pull the vehicleonto the truck, and the tie down hooks slotscan be used to securethe vehicleto truck.

Wheel Lift Equipment The tow truck usestwo pivoting arms that go underthe tires (front or rear)and lifts them off the ground.The other two wheels remain on the ground.This is an acceptableway of towing the vehicle. Sling-typeEquipment The tow truck uses metal c a b l e sw i t h h o o k so n t h e e n d s .T h e s eh o o k sg o a r o u n d parts of the frame or suspensionand the cableslift that e n d o f t h e v e h i c l eo f f t h e g r o u n d .T h e v e h i c l e ' s suspensioa n n d b o d y c a n b e s e r i o u s l yd a m a g e di f t h i s method of towing is attemPted. lf the vehiclecannot be transportedby flat-bed,it should be towed with the front wheels off the ground lf due to damage,the vehiclemust be towed with the front wheels on the ground, do the following: . Releasethe parkingbrake. . s h i f t t h e t r a n s m i s s i o inn N e u t r a l . It is bestto tow the vehicleno farther than 50 miles (80 km), and keepthe speed below 35 mph (55 km/h).

. l m p r o p e rt o w i n g p r e p a r a t i ow n i l l d a m a g et h e transmission.Follow the above procedureexactly.lf you cannot shift the transmission,the vehicle must be transDortedon a flat-bed. . Trying to lift or tow the vehicle by the bumperswill , h e b u m p e r sa r e n o t c a u s es e r i o u sd a m a g e T designedto supportthe vehicle'sweight.

1-9


GeneralInformation PartsMarking To deter vehicletheft, certainmajor componentsare markedwith the vehicleidentificationnumber (VlN).Original partshave self-adhesivelabels.Replacementbody parts have genericself-adhesivelabels.The originalengrneor transmissionVIN plate is transferredlo a replacementengine or transmissionand attachedwith break-offbolts. NOTE:Be careful not to damagethe parts marking labelsduring body repair.Maskthe labelsbefore repairingthe part.

r a

1-10


ra Specifications

L


Standardsand ServiceLimits Enqine ne Electrical

I

Item

Measurement

lgnitioncoil

Rated voltage

Sparkplug

Type

Oualification

F i r i n go r d e r

Gap l g n i t i o nt i m i n g

Alternator

A t i d l e ( c h e c kr h e

Output

Coillrotor)resistance 5|lp flng u.u.

Starter

Brushlength Brushspringtension Output Commutator micadepth Commutator tunout Commutator O.D. Brushlength

Standard or New

12V 1 3-4 2 N G K t: Z F B 6 K 1 1 DENSO: SKJ20DR-M11 1 . 0 1 . 1 m m ( 0 . 0 3 90 . 0 4 3 in.) in neutral:8t2' ETDCat 650150rpm

Service Limit

(

1 . 3 m m ( O . OiSn 1. )

At 13.5V and 80A normalengine temperature At 68.F(20'C) 2.2 3.0 A 14.4mm {0_57 in.) 14.0mm (0.55in.) 10.5mm (0.41in.l 1.5mm {0.06in.) 2.9 3.5N (0.30 0.36kgf,0.7-0.8tbs) 0.50 0.80mm (0.020-0.031 in.)

0.20mm 1O.OO8 in.)

o:BlalqryL4i) max

o.o5mm(0.002 in.)

2 8 . 0m m ( 1 . 1 0 in.) 14.0 14.5mm {0.55 0.57in.)

2 7 . 0m m ( 1 . 0 6 in.) 9.0mm {0.35in.)

Enqtne Item Measurement Compression Pressurecheckat 250rpm with wide openthroftle. (SeeDesignSpecsfor rato,

Oualification

Minimum Maximum vanatton

Standard or New

Service Limit

930kPa(9.5kgflcmr,135psi) 200kPa{2.0kgf/cm',28psi)

e_

.l 2-2


a

nder Head Item Head

Camshaft

Measur6ment

Oualification

'103.95104.05 mm (4.093 4.096in.) 0.05 0.20mm (0.002 0.008in.)

Endplay No.l journal N o . 2 , 3 ,4 , 5 journals

Totalrunout Cam lobe height

Intake,primary Intake, Exhaust

(cold) clearance

lntake

Exhaust StemO.D-

lnlaKe

Exhaust

L

o

S t e m - t o - g L r i d cel e a r a n c e

lntake

height stem installed

Exhaust lntake Exhaust lntake Exhaust lntake Exhaust

Valvesprings

Freelength

Valveguides

LD.

Intake Exhaust

I n s t a l l e dh e i g h t

lntaKe

Exhaust Rockerarms

Arm-to-shaftclearance

lntaKe Exhaust

v

Service Limit

0.05mm {0.002in.)

Warpage Height

C a m s h a f tt o h o l d e r o i l c l e a r a n c e

Standard or New

0.030 0.069mm {0.001 0.003in.) 0.060 0.099mm (0.002-0.004in.) 0.03mrn (0.001in.)max. in.) 33.925mm (1.3356 in.) 2 9 . 6 3m 8 m (l.1668 in.) 34.092mm (1.3422 0.21 0.2smm 10.0080.010in.) 0.28 0.32mm (0.011 0.013in.) 5.475 5.485mm 10.21560.2159in.) 5.450 5.460mm (0.2146 0.2150in ) 0.030 0.055mm (0.0012 0.0022in.| 0.055 0.080mm (0.0022 0.0031in ) 1.25 1.55mm (0.049 0.061in.) 1.25 1.55mm (0.049 0.061in.) 4 0 . 8 -4 1 . 0m m ( 1 . 6 0 6 1 . 6 1 4 i n . ) in.) 5 4 . 6 5 4 . 8m m ( 2 . 1 5 02 . 1 5 7 (1.874 in.) 47.61mm 49.64mm (1.954in.)

0.4mm (0.02in.) 0 . 1 5m m { 0 . 0 0i6n . ) 0.15mm (0.006in.) 0.04mm {0.002in.)

5.445mm (0.214in.) 5 . 4 2m m ( 0 . 2 1i3n . ) 0.08mm (0.003in.) 0.11mm (0.004in.) 2.00mm {0.079in.) 2.00mm {0.079in.)

5.515 5.530mm |.0.21710.21174n.1 mm 5.515 5.530 \0.2111 0.2177in.l 1 5 . 2" 1 6 . 2m m ( 0 . 5 9 80 . 6 3 8 i n . ) 15.5 16.5mm (0.610 0.650in.)

5.55mm (0.219in.)

0.025 0.052mm (0.00'100.0020in.) 0.018 0.056mm (0.0007 0.0022in.)

0.08mm (0.003in.)

5 . 5 5m m { 0 . 2 1i9n . )

0.08mm (0.003in.)

lo 2-3


Standardsand ServiceLimits Enqine n q t n e Block Item Block

Measurement I Warpageof deck tsorediameter

Oualification

Aori Borll

Standardor New 0.07mm (0.003in.)max. 86.010 86.020mm (3.3862 3.3866in.)

ServiceLimir

foro.. (ulur^^-"1

_

f

86.070mm (3.3886 in.)

86.000 86.010mm (3.3858 3.3862in.)

86.070mm (3.3886 in.) 0 . 0 5m m ( 0 . 0 0 2I n . J

R e b o r i n gl r m i t

Piston

Pistonring

SkirtO.D.at 11mm (0.4in.)from bottom of skirt

",";"* lFis,.â‚Ź-"'"

L-

Ringend gap

0 . 2 5m m ( 00 l i n . ) 85.980 85.990mm (3.3850 3.3854in.) 85.930mm (3.383'l in.) F" LetterB â‚Źs.980 r"i33846 85.920mm (3.3827 l-il?0 in.) 0.020 0.040mm (0 0008 0.0016in.) 0.05mm {0.002in.) Top 1.220 1.230mm (0.0481 0.0484in.) 1.25mm 10.049 rn ) Second 1 . 2 2 0 1 . 2 3 0m m ( 0 . 0 4 8 1 0 0 a 8 4 I n . ) 1.25mm 10.049 in.) i 2.005 2.025mm (0.0789 0.0797in.) ?.09rrl9.091lt ) i.'.f 0.13mm (0.005in ) fo.o:s o.oto.rnlo.oorao.ooza i") 0 . 1 3m m ( 0 . 0 0i5n . ) EO3t 0 056rn. {OJ01rOOO2 Second(FEDEHAL 0.025 0.060mm (0.0010 0.0024in.) 0.13mm (0.005in ) I\4OGUL) Top 0.20 0.35mm (0.008 0.014in.) 0.60mm (0.024in.)

btt"' "' A

Second

OiI(REKEN) OiI(FEDERAL I\4OG UL) Pistonpin

o.D.

0.40 0.55mm {0.016 0.022in.) 0.25 0.65mm (0.010 0.026in.) 0 20 0.70mm i0.008 0.028in.)

0.70mm (0.028in.) 0.75mm (0.030in.) 0.80mm 10.031 in.)

21.961 21.965mm {0.8646 0.8648in.) 2 1 . 9 5 3m m l 0 8 6 4 3 i n 0.005-*0.002 mm( 0.00020+ 0.005mm (0.0002 in.)

Pin'to-piston clearance

0.00008 in.) Connecting rod

Pin to-rod clearance Small end bore diameler L a r g e - e n db o r e d i a m e t e r ( N o r m a l )

Endplayinslalledon crankshaft Crankshaft

Main journal diameter

No. l journal No.2 journal N o .4 j o u r n a l No.5 journal No.3 journal

0.005 0.015mm (0.0002 0.0006in.) 0 . 0 2 m m l O 0 O O 8i n I 21.970 21.976mm (0.8650 0.8652in.) 4 8 . 0m m ( 1 . 8 9 in.) 0.15 0.30mm (0.006 0.012in.) 0 . 4 0m m ( 0 . 0 1i6n . ) s4.e84 s5.008mm (2.1648=16illl

5 4 . 9 7 65 5 . 0 0 m 0 m ( 2 . 1 6 4 42 - 1 6 5 4 i n )

Rodjournal diameter

4 4 . 9 7 6 4 5 . 0 0 0m m ( 1 . 1 7 0 7 1 . 1 7 1 7i n . l

Rod/main

0.005mm 10.0002 in.)max. 0.005mm (0.0002 in.)max. 0.10 0.35mm (0.004 0.0'14 in.) 0.03mm (0.0012 in.)max. 0.017 0.041 m m ( 0 . 0 0 0 70 . 0 0 1i6n . )

Rod/mainiournalout of,round E n dp l a y Runout . . - ' . : - - ' +

M a r n o e a r , n 9 - t o J o u r n ao t t t c t e a r a n c e No. l journal Deaflngs

c_

0.010mm (0.0004 in.) 0.010mm (0.0004 in.) 0 . 4 5m m 1 0 . 0 1i 8 n.) 0.04mm {0.0016 in.) 0.050mm (0.0020 in.)

No.2 journal No.4 journal No.5

No.3 journa/ Bodbearingclearance

q0rr034, -rn {O'o010 0-o01r|"tl 0.055mm (0.0022in.) 0.021 0.049mm (0.0008 0.0019in.)

0.060mm (0.0024 in.)

-

2-4


o i

nqlne

Lubrication

|tem

Measurement

Engineoil

Capacity

Oilpump

lnner-toouterrotorclearance Pumphousingto outerrotor clearance axial Pumphousing-to-rotor clearance Balancer shafts,journaldiameter

Oualificalion

ServiceLimil Standerdor New 5.30 (5.6US qt)for engineoverhaul 4.20 (4.4US qt)for oil change,includingfilter 4.00 (4.2US qt)for oil change,withoutfilter 0.20mm (0.008in.) 0.02 0.16mm {0.001 0.006in.) in.) 0.23mm (0.009in.) 0-15 0.21mm {0.006-0.008 0.02 0.07mm (0.001 0.003in.)

No.1 journal,front shaft

0.12mm (0.005in.)

19.938 19.950mm 10.78500.7854in.) 19.92mm (0.784in.)

23.938 23.950mm (0.9424 0.9429in.) 23.92mm (0.942in.) in.l 32.93mm (1.296in.) No.2 journal,frontand 32.949 32.961mm 11.29121.2911 rearshaft in.)max. 0.005rnm (0.0002 0.070 0.135mm (0.0028 0.0053in.) 0.15mm (0.006in.) Front 0.070 0.135mm (0.0028 0.0053in.) 0.15mm (0.006in.) Rear 0.050 0.082mm (0.0020 0.0032in.) 0 . 1 0m m ( 0 . 0 0i4n . ) No. 1 iournal,front No 1 journal,rearshaft

Ealancer shafts,journaltaper shafts,end play Balancer Balancershatts,shaft-to'bear;ng clearance

shaft N o . 1 J o u r n a l ,r e a r s h a f t N o . 2 j o u r n a l ,f r o n t a n d

0.050 0.082mm (0.0020 0.0032in.) 0.060-0.120mm (0.0024 0.0047in.)

0.10mm (0.004in.i 0.15mm (0.006in.)

rear shafl

L

a

LD. shaftbearings, Balancer

20.000 20.020mm (0.1814 0.7442in.l 20.03mm (0.789in.) No. 1 journal,front shaft ZI.OZO m- tOSa+e-OSa57ir'.) 24.03mm (0.946in.) No. 1 iournal,rearshaft Z+.OOO in.) 33.09mm {1.303in.) No.2 journal,frontand 33.021 33.069mm (1.3000 1.3019 rearshaft

R e l i e f v a l v e ,o i l p r e s s u r ew i t h o i l t e m p e r a t u r ea t 1 7 6 ' F ( 8 0 " C )

At idle

7 0 k P a ( 0 . 7k q ? c m , 1 0 p s r )m i n .

At 3,000rpm

300kPa{3.1ksf/cm',44psi)min.

Standardor New 6 . 7L ( 7 . 1U S

engine, Coolantcapacity {includes heater,hoses,and reservoir)

Thermostat

ServiceLimit

0.53L (0.56US 93 123kPa(0.95 1.25kqtcm , 14 18psi) 't69 176'F(76 80'C)

OPeningtemPerature

8.0mm {0.31in.)min. TurnsOFF

v

Subtract5 15'F(3 8"C)fromactualON

a 2-5


Standardsand ServiceLimits Fueland Emissions Item Fuelpressure regulator Fueltank Engineidle

Measulement Oualification Pressurewith fuel pressuregauge connected Capacity ldlespeedwith headlights and radiator Neutral fan off F a s ti d l e

Neutral

Standardor New ServiceLimit 320-370kPa13.3-'3.8 kgtcm',47 52psi)

f .

\

5 04 ( 1 3 . 2U Sg a l i 750 50 rpm 1,600150rpm

Clutch Item Clutchpedal

Mea3uremâ‚Źnl Heightfromthe floor Stroke

Oualification

D i s e n g a g e m e n th e i g h t f r o m t h e f l o o r

Clutchdisc Pressureplate

Bunouton clutchmatingsurface Bivetheaddepth Ihickness Warpage Heightof diaphragm spring fingers

Measured with specialtooland feelergauge

Slandardor New 193mm (7.60in.) 1 3 0 1 4 0m m 1 5 . 1 5 . 5 i n . ) 10 16mm (0.39 0.63in.) 1'15 mm (4.53 i n . )m i n . 0.05mm 10.002 in.)max. 1.65 2.25mm (0.065 0.089in.) 8.3 8.9mm (0.33 0.35in.) 0.03mm (0.001in.)max. 0.6mm (0.02in.)max.

ServiceLimit

0.15mm (0.006in.) 0.7mm {0.03in.) 6.0mm (0.24in.) 0 . 1 5m m ( 0 . 0 0i1n . ) 0.8mm (0-03in.)

r a

\ < c 2-6


nualTransmissionand M/T Differential

O E

Adiust 20.75mm 10.817 in.) 3 ' 1 . 9m 3 m ( 1 . 2 5i7n . ) 27.92 m m ( 1 . 0 9i9n . )

'1.5354 in.)

38.93mm (1.5334n.)

27.987 28.000mm (1.10'191.1024in.)

2 7 . 9 3m m { 1 . 1 0i0n . )

0.02mm (0.001in.)max. in.) 44.009 44.025mm 11.73261.7333 0.06 0.16mm {0.002 0.006;n.) 23.92 23.97mm (0.94'10.944in.) in.) mm (1.3780 '1.3785 35.000-35.015

0.05mm (0.002in.) 44.08mm (1.735in.) 0 . 2 5m m ( 0 . 0 1i0n . ) 23.80mm (0.937in.) 34.95mm (1.376in.)

39.937 39 950mm (1.5723 1.512ain.|

39.88mm (1.570in.)

D i a m e t e ro f b a l l b e a r i n gc o n t a c t a r e a ( t r a n s m i s s i o nh o u s i n g s i d e )

30.020-30.0m 3 3m ( 1 . 1 8 1 91- . 1 8 2i4n . )

29.97 m m ( 1 . 1 8i0n . )

Runout innerrace 35 mm shim-to'bearing

0.02mm {0.001in.)max. 0.04 0.10mm (0.0016 0.0039in.)

0.05mm (0.002in.) Adjust

in.i 52.010 52.029mm (2.0476-2.0484 0.06 0.16mm (0.002 0.006in.) -0.904in.) 22.92 22.91$m 10.902 52.010 52.029mm (2.0476 2.0484in.) 0.06 0.16mm (0.002 0.006in.) 21.92 27.91mtn \1.099 1.101in.) 39.95 39.96mm (1.572a 1.5132in.) in.) 46.989-47.000mm (1.8499-1.8504 in.i 23.03 23.08mm (0.907-0.909 in.l 39.95 39.96mm {1.5728'-1.5732 in.) 46.989 47.000mm (1.8499 1.8504 mm (l.104 1.106in.) 28.03 28.08

52.08mm (2.050in.) n.) 0 . 2 5m m 1 0 . 0 1i 0 22.87mm (0.900in.) 52.08mm {2.050in.} 4n.) 0.25mm 10.010 in.) 27.87mm 11.097 39.97mm (1.574in.) 46.94mm (l.848in.)

Transmission Capacity fluid Endplav Mainshaft Diameter of bushingsurface D i a m e t e ro f d i s t a n c ec o l l a r

Diameter of ballbearingcontactarea (clutchhousingside) Diameter of needlebearingcontact area Diameter of ballbearingcontactarea (transmission housingside) Runout Mainshaft 3rd, t.D. 4th and sth Endplay gears Thickness Countershaft Diameterof needlebearingcontact area(clutchhousingside) of distance collarcontact Diameter alea

L

a

Countershaft

clearance LD. End play

Thickness Countershaft 2ndgear Countershaft 'lst gear

t.D. Endplay Thickness LD.

o.D.

collar Length distance Countersha{l l . D . o.o. 2ndgear distance coliar L e n g t h

v

Se.viceLimit

Standardor New Forfluidchange:1.50 (1.6US qt) F o ro v e r h a u1l :. 70 1 1 . 8 U Sq t ) ' l 0 . 1 7 ( 0 . 0 0 4 mm 0.007in.) 0.1 20.80 20.85mm {0.819 0.821in.) mm (1.2594 1.2598 in.) 31.984-32.000 2 7 . 9 7 72 7 s 9 0m m \ 1 . 1 0 1 -51 . 1 0 2i0n . )

Mâ&#x201A;Źasurement

Item

Oualification

38.984 39.000mm (1.5348

39.97mm (1.574in.) 46.94mm (1.848in.)

o 2-7


Standardsand ServiceLimits ?

Manual anuatTransmission I ransm and Differentialcont' Measutemenl

Item

Nlainshaft4th and5thgears

Oualification

LD.

o.D.

distance collar L e n g t h B

MBSdistance LD. Len9th

t.D.

Reverseidler gear

G e a r l o r e v e r s eg e a r s h a f i c l e a r a n c e

Synchroring

Bingto'gearclearance

Triplecone

Outersynchroring-tosynchrocone clearance Synchrocone-to-gear clearance

Shift fork Reverseshift fork Shiftarm

Outersynchroring-to-gear cone clearance Fingerthickness Forkto-synchro sleeveclearance Fingerthinkness Fork-to-reverse idlergear clearance

t.D. S h i f t f o r k d i a m e t e ra t c o n l a c ta r e a S h i f t a r m ' t o - s h i f t l e v e rc l e a r a n c e

Selectlever Shiftlever

Mfi differential carrier Mfi differential pinionqear 80 mm shim

Fingerwidth Shaft-to-selectleverclearance Groove{to selectlever) Shaftto shiftarm clearance Pinionshaftcontactareal.D. C a r r i e r - t o - p i n i o ns h a f t c l e a r a n c e

DriveshaftcontactareaLD. Backlash

t.D. P i n i o ng e a r t o p i n i o n s h a f t c l e a r a n c e

80 mm shim to-bearing outerrace clearance in transmission housing

Ringpushed againstgear Ringpushed againstqear Ringpushed againstgear Ringpushed againstgear

Standardor New 32.00-32.01mm (1.2598 1.2602 in.) 38.989 39.000mm (1.5350 1.5354 in.) 51.95 52.05mm (2.045 2.049in.) 24.03 24.08mm (0.946-0.947 in.)

ServiccLimit 3 2 . 0 2m m ( 1 . 2 6i1n . ) 38.94mm (1.533in.)

28.00 28.01mm(1.102 1.103in.) 23.95 24.05mm (0.943 0.947in.) 20.016 20.043mm (0.7880 0.7891in.) 0.036 0.08amm (0.0014 0.0033in.) 0.70 1.49mm (0.028 0 059in )

2 8 . 0 2m m ( 1 . 1 0i3n . ) 20.90mm (0.832in.) 0 . 1 6m m { 0 . 0 0i6n . ) 0.4mm (0.0164n.)

0.70- '1.19 mm {0.028 0.047in.)

0.3mm (0.012in.)

0.50 1.04mm (0.020 0.041in.)

0.3mm (0.012in.)

0.95 1.68mm (0.037 0.066in.)

0.6mm (0.024in.)

7.4 7.6mm 10.29 0.30in.) 0.35 0.65mm (0.014 0.026in.i 13.4 13.7mm (0.527 0.539in.) 0.20 0.59mm (0.007 0.024in.) 13.973 '14.000 mm (0.5501 0.5512in.) 16.9 '17.0 mm (0.665 0.669in.) 0.2 0.5mm (0.008 0.020in.) 14.85 '14.95 mm (0.585 0.589in.) 0.05 0.25mm (0.002 0.010in.) 15.00 15.10mm {0.591 0.594in.) 0.013 0.07mm (0.0005 0.003in.) 18.010 18.028 mm (0.7091 0.7098in.) 0.027 0.057mm (0.0011 0.0022in.) 28.025 28.045mm (1.1033 1.1041 in.) 0.05 0.15mm {0.002 0.006in.) 1 8 . 0 4 21 8 . 0 6m 6 m ( 0 . 7 1 0 30 . 7 1 1 3 i n . ) 0.059 0.095mm (0.0023 0.0037in.) 0 0.10mm (0 0.0039in.)

1.0mm (0.039in.) 1.3mm (0.051in.)

0 . 6 2m m ( 0 . 0 2i4n . )

L O

0.50mm (0.020in.) 0.1mm {0.004in.) 0.1mm (0.004in.l

0.15mm (0.006in.) Adjust

-

2-8


o

Rotational at outside olavmeasured

0 10mm (0 0.39in.)

at outside Startingloadmeasured

2 9 N ( 3 . 0k g f . 6 . 6 l b s )

A n g l e o f r a c kg u i d e s c r e w l o o s e n e d

n Item W h e e l a l i g n m e nCamber t

Measurement

Caster TotalToe

Oualitication Front Rear Front

lrytt Rear

Frontwheelturningangle

l n s i d ew h e e l

Aluminumwheelrunout

Axial

Outsidewheel Radial Wheelbearing

Endplay

Front

Rear

Standardor New 0'00' 45' 0'45'- 45

ServiceLimit

1"33' 11"

in.) 0-3 mm(0::0.12 lN 2 ' , mm (0.08"' ,, in.) 37'40'-2' 29'50'(Reference) 0 0.7mm (0 0.03in.) 0 - 0 . 7m m ( 0 0 . 0 3 i n . ) 0 0.05mm (0 0.002in.) 0 0.05mm (0 0.002in.)

2.0mm (0.08in.) l.5mm{0.06in.)

o

Y

a 2-9


Standardsand ServiceLimits Brakes Item Parkingbrake lever Brakepedal Mastercylinder Erakedisc

Mâ&#x201A;Źasurement Distance traveledwhen leverpulled with 196N (20kgf, 44 lbs) ol force Pedalheight(carpetremoved) Freeplay Piston-to-pushrod clearance Thickness

Standardor New 7 8 clicks

ServiceLimit

a

1 8 4m m ( 7 4 / 1 6i n . )

Parallelism

Front Rear Front Rear Frontand rear

Thickness

Front

Runout

Brakepads

Oualification

llear

0 . 4 3 . 0m m ( 00 1 6 0 ' 1 1 8 in.) 0 0.4mm (0 0.02in.) 2 1 . 0m m ( 0 . 8 3 in.) 9.0mm {0.35in.)

10.0mm (0.39in.) 9.0mm {0.35in.)

19.0m 0 m (0.75 in.) 8-0mm (0.31in.i 0.10mm (0.004in.) 0.10mm (0.004in.) 0.015mm (0.0006 in.) 1 . 6m m ( 0 . 0 6 in.) 1 . 6m m ( 0 . 0 6 in.)

Air Gonditionin Item Refrige.ant

Tvpe

Refrigerant oil

Capacityof system Type

Moasurement

Capacity ofcomponents

Oualilication

Condenser Evaporator Eachline and

Standard or New

Service Limit

H F C1 3 4a ( B - 1 3a4) 500 550g 117.6 19.4oz) S P1 O (P/N38897-P13-A01AH or 38899-P13-A01 ) 25 m0,15/6fl ozl 45 mA111/2fl ozt 10m0 (1/3fl or)

hose

Compressor Drivebelt

Startercoil resistance plateclearance Pulley-to-pressure

Compressor At 68"F(20"C)

1 3 0 1 5 0m 0 1 41 / 3 5 f l o z ) 3.05 3.350 0.35 0.6mm (0.014 0.024in.) Autotensioner lneedsno adjustment)

e-

q

2-10


DesignSpecifications

O

Measurement

|tem

DIMENSIONS

Overallwidth Overallheight

Track

rront Rear

Groundclearance G r o s s V e h i c l eW e i g h t R a t i n g (GVWR)

WEIGHT (CANADA)

GrossVehicleWeightRating

ENGINE

1,660kg

{GVWR) Tvpe Cylinderarrangement Boreand stroke Displacement

ratio Compression Valvetrain system Lubrication Oil pumpdisplacement Waterpumpdisplacement

At 6,000engine rpm At 3,400engine

L

o

82 0 (87US qt)/minute

Tvpe Normaloutput

12V 30 seconds

Nominalvoltage

Hourrating Directionof rotation CLUTCH

C l o c k w i s ea s v i e w e c lf r o m g e a r e n d S i n q l e p l a t ed r y , d i a p h r a g m s p r i n g

C l u t c ht v p e

Clutchfrictionmaterialsurfacearea

Tvpe I\,1AN UAL TRANSMISSIONPrimarvreduction Gearratio

lst 2nd 3rd 4th

Finalreduction

v

Watercooled.4 strokeDOHCV-ECengin( transverse Inline4'cylinder, 86 x 86 mm (3.39x 3.39in.) cuin.) 1 , 9 9 c8 m ' ( 1 2 2 9.8 Chaindrive.DOHCVTEC4 valvespercylinder Forced, wet sump,withtrochoidpumP (57.4 54.30 US qo/minute

gasolinewith 86 pumpoctanenumberor higher UNLEADED Gearreduction

F!el required STARTER

4 , 2 1 0m m { 1 6 5 .i8n . ) in.) 1,695mm 166.7 in.) 1,44m 0 m (56.7 m m ( 1 0 1 .i2n . ) 2,570 1,470mm (57.9in.) '1,470 mm (57.9in.i 152mm (5.98in.) four {4) 3,660rbs

S e a t i n gc a p a c i t y

wEtGt-iT {u.s.A.)

Specilication

Oualification

Overalllength

5th Reverse Type Gearratio

1 7 4c m ' { 2 6 . 9s7q i n . ) forward,1 reverse s-speed Svnchronized, D i r e c1t : 1 3.062 1.769 1.212 0.921 0.738 3.583 Sinolehelicalgear 4.164

o 2-11


DesignSpecifications cont' Item

Measuremeni Type Overallratio Turns,lockto-lock Steeringwheeldiameter Type

STEERING

SUSPENSION

Shockabsorber

WHEEL ALIGNMENT

Camber

BRAKES

AIR

I n d e p e n d e n ts r r u l w i t h s t a b i l i T e rc. o i l s p r i n g

Rear Front Rear

Caster Totaltoe

Front

Typeof servicebrake

Rear Front Bear

Sizeoffront and reartires Sizeo{ sparetire Compressor

CONDITIONING

Front Rear

Type Numberof cylinders Capacity Maximumspeed

D o u b l ew i s h b o n e

Telescopic, hydraulic. nitrogengas-frlled Telescopic, hydraulic, nitrogengas,filled

0"00' 0.45' 1'33' 0 mm (0 in.) I n 2 m m ( 1 / 1 6i n . ) P o w e r a s s i s t e ds e l f - a d j u s l i n gv e n t i l a t e dd i s c

Power-assisted self-adjusting soliddisc Mechanical actuating, rearwheels 4 5c m ' ( 7 . 0s q i n . ) x 2 2 8c m ' ( 4 . 3s q i n . )x 2 Pl95/6081588V T125r0 D1595M Scroll

Type Motor type

85.7m015.23 cu in.)/rev. 12,000rpm 130m0 {4 1/3floz) SP-10(P/N38897'P13-A01AH or38899-P13 A01) Corrugated fin Corrugatedfin Siroccofan 220 Wl12 V

Speed control

4 Speeo

L u b r i c a n tc a p a c i t y

Condenser Evaporator Blower

C

Specilication Electric, Powerassisted rackand pinion 15.1 3 6 0m m ( 1 4 . 2 in)

Front Bear Front

Typeof parkingbrake Padfriction surfacearea TIRES

Oualification

Lubricanttype Type

Tvpe

L

a

M a x i m u m c a p a c i t y 480m" 116.900 cu ft)/h T e m p e r a t u r ec o n t r o l

Compressor clutch

Tvpe

Refrigerant

Electricalpower cons!mptronat 68"F(20.C) Type Capacity

Airmixtype Dry,singleplate,poly-Vbeltdrive 42W maximumat 12V

HFC134a(R-134a) 500 550g (17.6 19.4oz)

../a 2-12


o

Item ELECTRICAL RATINGS

Measurement

Under-hood fuse

Specitication 1 2 V 3 6A H / 5h o u r s 1 2V - . 1 . 1k W ,1 . 2k W 12V 95A,90A 80A, 60A, 50A, 40A, 30A, 20A, 15A, 10A, 7.5A

Under'dash Iuse

3 04 , 2 0 a , 1 5A , 1 0A , 7 . 5A

Oualilication

Battery Starter Alternator Fuses

Light bulbs

Headlight high beam Headlight low beam Frontturnsignal liqhts Front parlinq lights

Bearturn signal lights FronVrear side markerlights Brale/taillighls H i g h m o L r n tb r a k e

'12v.' 60w 12V 55W 12V 21W 12V 5W 1 2 V" 2 1 W

12V 5W 12V 21/5W 12V 5W

light

t

o

v

a

Backup lights platelight License Ceilinglight

12V 21W 12V 5W

Cargoarea light

12V 5W 12V 5W

Spotlights

'12v'.8 w

Gauge lights I n d i c a t o rl i g h t s

Sideturn signal light

LED 12V 5W

2-13


Body Specifications

Unit: mm {in.) 1.555{61.6) 1,i140(56.71

2-14


I

Maintenance Lubricantsand Fluids MaintenanceSchedulefor Normal Conditions Listed by Distance/Time

MaintenanceSchedulefor Severe Gonditions Listedby Distance/Time

t

\.4

MaintenanceSchedule Listedby Maintenance ltemfor Normal Conditions ................... 3-8 Listedby Maintenance ltem for Severe Conditions ...................3-9


Lubricantsand Fluids

For detailsof lubricationpoints and type of lubricantsto be applied,referto the illustratedindex and variouswork o v e r h a u l .l n s t a l l a t i o ne.t c . )c o n t a i n e di n e a c hs e c t i o n . ures{suchasAssem

LUBBICANT

LUBBICATION POINTS

NO. 1

Eng ine

The oil container Honda Motor Oil (P/N08798-9023). must disolavthe API Cenificationseal shown below. " AE M a k es u r ei t s a y s" F o r G a s o l i n eE n g i n e s . S Viscositv:See chart below.

2 3

Transmission

HondaMTF*'(P/N08798-9016)

Brakesvstem (includesABS line) C l u t c hl i n e Release f o r k ( m a n u a tl r a n s m i s s i o n l Throftlecableend (throttleIink) Shift and selectcable ends (manual transmission) Throttlecable end (dashboardlower panel hole) Brakeboosterclevis CIutchboosterclevis Shift lever pivot Pedalinkage Batteryterminals F u e lf i l l d o o r H o o dh i n g e sa n d h o o d l a t c h H a t c hh i n g e s , o D e ra n d l o w e r D o o rh i n o e s u Caliperpiston boot, caliperpins and boots A i r c o n d i t i o n i n cg o m p r e s s o r

HondaDOT 3 BrakeFluid*' (P/N08798-9008)

4

5 6 7 I 9 10 11 1'

14 16 17 18 19

S u p e rH i g hT e m p U r e aG r e a s e{ P / N0 8 7 9 8 - 9 0 0 2 ) S i l i c o n eg r e a s e

grease Multi-purpose

HondaCaliDerGrease(P/N08C30-80234lvl) o rH C o m p r e s s o r o iS l : P - 1 0( P / N3 8 8 9 7 - P 1 3 - A 0 1 A 38899-P'13-A01) a ( R - 1 3 4a ) F o rr e f r i q e r a nH t;FC'134

Recommond6dEngineOil fanges E n g i n eo i l v i s c o s i l yf o r a m b e n t t e m p e r a l u r e

-30 -20

-10

0

t0

20

* 1 : Always use HondaManualTransmissionFluid (MTF).Using motor oii can causestiffershifting becauseit does not containthe Drooeradditives. " 2 : Always use HondaDOT 3 BrakeFluid.Using a non-Hondabrakefluid can causecorrosionand decreasethe life of the system.

3-2

I


t o o o o o

o@@ a9

Y

3-3


MaintenanceSchedule Listedby Distance/Timefor Normal Conditions Thistwo pagel/lanitenance Schedule outlinesthe minimunrequiredmaintenance. Serviceat the indicated distance or time,whichevercomes if the vehiclemeetsanyof the qualifiers in the SevereConditions first.use the lvlaintenance Schedule for Severeconditions schedule or if the vehicleis normallydrivenin Canada.

(cold)(seepage6-321r Intake: 0.21-0.25mm (0.008 0.010in.)Exhaust: 0.28 0.32mm (0.011 0.013in.) Inspectvalveclearance. (NGK)or SKJ20DR-M11 (DENSO). Replace sparkplugs.UseIZFR6K'11 1 . 0 1 . 1m m km/6 years 120,000 mi/ 192,000 fluid.UseHondaMTF(seepage13-3). I Replace transmission ! Do items in A,B,alqq., /

/ Y vcdrs

120,000 mil 192,000 Type2. 5.00 (5.3US qt).UseHondaAll SeasonAntifreeze/Coolant Beplace coolant(seepage106).Capacity: tailureto do the maintenance itemsmarkedwith an asterisk According to stateandlederalregulations, {*) will not voidthe customer's intervalto ensurelong-term warranties, However,Hondarecommends thatall maintenance services be doneat the recommended emissions reliability.

3-4

I


Dothe itemsin partsA, B, C, D, andE as requiredfor mileage/time intervallisted. A Replace engineoillseepage8-5i. Capacity withoutlilterchange:4.0S (4.2US qt, 3.5lmp qt) Rotatetires.Followthe patternshownin the Owner'sManual Checktireinformationandcondition. B Replace engineoil filterlseepage8-6). Capacity with filterchange:4.20(4.4US qt,3.7lmp qt) Inspect frontandrearbrakes(seepage19 3i. . Checkpadsand djscsfor wear(thickness), damage,andcracks. ' Checkcalipers tor damage,leaks,andtjghtnessot mountbolts. Checkparkingbrakeadjustment. ShouldbeIullyappliedwithin7 to I clicks. Inspect tie rod ends,steeringgearbox,and boots{seepage17 5). . Checkrackgreaseandsteeringlinkage. . Checkbootsfor damageand leakinggrease . Chackfluidline{or damageand leaks. lnspectsuspensioncomponents. . Chockboltsfor tightness. . Checkconditionof balliointbootslor deterioration and damage. Inspectdriveshaftboots.Checkbootsfor cracksand boot bandsfor tightness(seepage16-3). proponioning Inspâ&#x201A;Źctbrakehosesandlines{including ABS). Checkthemastercylinder, controlvalve,andABSmodulator{ordamage andleakage. Checkall fluidlevelsandconditionot tluids;checkfor leaks.lf necessary, add MTFlseepage13'3),engioecoolant,brakefluid,and windshield washerfluid. system*.Checkcatalytic L lnspectexhaust converterheatshield, exhaustpipeand mufflerfordamage,leaks, andtightness{soepage9,8). lnspect{uellinesandconnections*. Checkfor looseconnections, cracksand deterioration; retightenlooseconnoctions and replace damagedparts(sâ&#x201A;Źepage11 146). andadiustdrivebelt. l InsDect . Lookfor cracksanddamage,andinspectautotensioner(needsno adjustment). Replace the dustandpollenlilter(seepage21 39). . Replacethe dustandpollenfilterwheneverairflow lrom the heatingandcoolingsystemis lessthannormal.

D

Replace air cleanerelementevery30,000miles(48,000 km)(independent of time).

E

i I Replace brakefluidevery3 years(independent oI mileage).

* ) will not voidcustomer's According to stateandfederalregulations, failureto do the maintenance itemsmarkedwith asterisk( emissions warranties. However,Hondarecommends thatall maintsnance servicebe doneat the recommended intervalto ensurelongterm reliability.

Y

3-5


MaintenanceSchedule Listedby Distance/Timefor SevereConditions or time,whichevercomesfirst.Usethisscheduleif the vehicleis drivenMAINLYin Canadaor in anyof the Serviceat the indicated distance (seepage3-4). il onlyOCCASIONALLY tollowingconditions; drivenin theseconditions, usethe NormalConditions schedule SevereDrivingConditions . Drivinglessthan5 miles{8 km) pertrip or, in freezingtemperatures, drivinglessthan 10miles(16km)pertrip . Drivingin extremelyhot (over90"F/32"C) conditions . Extensive deliveryvehicle. idl;ngor longperiodsof stopand go driving,suchasa taxior a commercial . Trailertowing,drivingwith a car-topcarrier,or drivingin mountainous conditions. . Drivingon muddy,dusty,or de'icedroads

R e p l a c et r a n s m i s s i o nf l u i d . U s e H o n d a M T F { s e e p a g e 1 3 3 ) .

(cold)(seepage6 32):lntake:0.21 0.25mm (0.008 0.010in.)Exhaust: 0.28 0.32mm (0.011 0.013in.) Inspectvalveclearance. 11 (NGK)or SKJ20DR'M 11 {DENSO) Replace sparkplugs.Use IZFR6K

km/ 6 years R e p l a c et r a n s m i s s i o nf l u i d . U s e H o n d a M T F ( s e ep a g e 1 3 3 ) .

mil 192,000 km/ 10years,thenevery60,000mi/ 96,000km/5 years 5.0015.3US qt) UseHondaAll SeasonAntifreeze/coo lantType2. Replace coolant(seepage10-6).Capacity:

3-6


Dothe itemsin partsA, B, C,D, E,F,and G as requiredfor mileage/time intervallisted. A q (4.2US qt,3.5lmpqt) Feplaceengineoil(seepageS5). Capacity withoutlilterchange:4.0 I Replace engjneoil filter(seepageI 6). Capacity with filterchange:4.20 14.4US qt,3.7lmp qt) Insoectfrontand rearbrakes, . Checkpadsanddiscsforwearlthickness), damage,andcracks. . Checkcalipers for damage,leaks,andtightnessof mountbolts. Lubricate doorlocks,latchesand hingeswith Hondawhitelithiumgrease. Rotatetires,if the vehiclehasbeendriventhe distancelisted.Followthe patternshownin the Owner'sManual-Checktire inflaronaoo condition, Inspecttierod ends,steeringgearbox,and boots(seepage17,5). . Checkrackgreaseandsteeringlinkage. . Checkbootsfor damageand leakinggrease. . Checklluidlinefordamageandleaks. L Inspectsuspensron components . Checkboltsfor tightness. . Checkconditionof balljointbootsfor deterioration anddamage. Inspectdriveshaft boots.Checkbootsfor cracksand bootbandsfor tightness(seepage16-3). Checkparkingbrakeadjustment. Shouldbe fullyappliedwithin7 to 9 clicks. Inspâ&#x201A;Źctbrakehosesandlioes.(including ABS). Checkthe mastercylinder,proportioning controlvalve,andABSmodulatorfor damage (seepage19-24). and leakage (see page13 3),enginecoolant,brakefluid,and Checkall fluidlevelsandconditionot lluids;checkfor leaks.lf necessary, add MTF windshield washerf luid. Inspectexhaustsystem*.Checkcatalytic converterheatshield,exhaustpipeand mufflerfor damage,leaks,andtightness(seepage9 8). Inspect fuel linesandconnections*. Checkfor looseconnections, cracksand deterioration; retightenlooseconnections and replace damagedpans(seopage11'146). (seepage22-68). Checkalllights.Checkfunction otallinteriorandexteriorlights,andthepositionofthe headlights Inspect the vâ&#x201A;Źhicleunderbody. Checkthe paintfor damage,scratches, stonechippin0,anddents.

L D

InsDectand adiustdrive belt. . Looktor cracksanddamage,and inspectautotensioner {needsno adjustment). Reolace dustand oollenfilter.

E Replace aircleanerelementevery15,000 miles124,000 km) in dustvcondition{independent ol timei otherwiseuseNormalConditions (seepage11-162). scredule F

lReplaceaircleanerelementevery30,000miles(48,000km)(independento{timei(seepagell-162). Replace brakefluidevery3 years(independent oJmileagei. H

Replacethe dustandpollenIilterevery15,000 milesifvehicleis drivenmostlywhereair hashighconcentration olsootfrom industryand dieselpoweredvehiclesj alsoreplace the dustand pollenfilteranytimeaarflowis lessthanussal(seepags21-39). A c c o r d i n gt o s t a t e a n d f e d e r a l r e g u l a t i o n s ,f a i l u r e t o d o t h e m a i n t e n a n c ei t e m s m a r k e d w i t h a s t e r i s k( * ) w i l l n o t v o i d c u s t o m e r ' s e m i s s i o n s w a r r a n t i e s .H o w e v e r , H o n d a r e c o m m e n d s t h a t a l l m a i n t e n a n c es e r v i c e sb e d o n e a t t h e r e c o m m e n d e d i n t e r v a lt o e n s u r e l o n g - t e r m r e l i a b i l i t y ,

3-7


MaintenanceSchedule

c

Listedby Maintenanceltem for NormalConditions on the nextpagedo for SevereConditions in the lMaintenance Schedule if the severedrivingconditions specified Followthe NormalSchedule drivenin severedrivingconditions. not apply,and if onlyOCCASIONALLY scheduleif the vehicleis drivenMAINLYin Canada. Followthe SevereConditions ortime, distance Serviceatthe indicated whichevercomesfirst.

milesx 1,000

t0

20

30

40

50

km x 1,000

16

32

48

64

80

12

months Replace engineoil

o

24

o

o

96

70

80

90

100

112

128

144

160

48

3

o

a

o

o

110

192 12

60

a

a

r20

o

O

a

R o t a t et i r e s { C h e c kt i r e i n t l a t i o na n d c o n d i t i o n a t l e a s t o n c e p e r m o n t h )

Replace engineoil filter

o

o

a

a

a

a

Inspect frontand rearbrakes C h e c kp a r k i n g b r a k e a d j u s t m e n t

Visuallyinspectthefollowingitems: . Tie-rodends,steeringgearboxand boots . Suspension components . Driveshaftboots . Brakehosesand lines(including ABSi . Allfluidlevelsandconditionof{luids . Exhaust system* . Fuellinesandconnections*

a

Inspectandadjustdrivebelt

a

a

a

Replace dustand pollenfilter

a

fluid Reolace transmission Servicethefollowing items at the recommendedintervals R e p l a c ea i r c l e a n e re l e m e n t

km) Every 30,000 miles(48,000

Replace sparkplugs

Lm) Every 110,000 miles(176,000

Inspectvalveclearance

km),otherwise adiusl onlyif noisy. Inspect miles{176,000 every110,000

I n s p e c ti d l e s p e e d *

km)or8 years Every 160.000 mres1256,000

R e p l a c ee n g i n e c o o l a n t

km)or5 miles(96,000 km)or 10years, thenevery60,000 At 120,000 miles(192,000

brakefluid Replace

Every3 years

(*) will not voidcustomer's emissions * : According itemsmarkedwith asterisk failureto do the maintenance to stateandlederalregulations, intervalto ensurelong-termreliabilityservicebe doneat the recommended thatall maintenance However,Hondarecommends warranties.

3-8


Listedby Maintenanceltem for SevereConditions Usethisschedule if the vehicleis drivenMAINLYin Canadaor in anvof thefollowinaconditions. NOTE:it onlyOCCASIONALLY drivenin these conditions, usethe NormalConditions schedute. SovereDrivingConditions . Drivinglessthan5 miles(8 km)pertrip or, in lreezingtemperatures, drivinglessthan 10miles(16km)pertrip. . Drivingin extremely hot over90 "F 132'C)conditions. . Extensive idling,or longperiodsot stop-and-go-driving, suchas a taxior a commercial deliveryvehicle. . Trailertowing,drivingwith a cartop carrier,or drivingin mountainous conditions. . Drivingon muddy,dusty,or de icedroads. Serviceat the indicated distance or time, whichevercomesfirst.

milesx 1,000

10

km x 1,000

16

months Replace engineoil Rotatetires intlationandconditionat leastonceper monthi {Checktire

20

30

40

50

60

70

80

90

100

110

120

48

64

80

96

112

128

144

160

176

192

12

24

36

60

48

72

Replace every 5,000 miies18,000 km)or6 months

a

o

a

a

o

a

a

o

a

a

a

o

R e p l a c ee n g i n e o i l f i h e r

Inspectfrontand rearbrakes L u b r i c a t ea l l l o c k s ,h i n g e s ,a n d l a t c h e s

Visuallyinspectthe followingitems: . Tie rod ends,steeringgearboxand boots . Suspension components ' Driveshaftboots Checlparkingbraleadjuslment

a

a

O

a

o

a

Visuallyinspectthefollowingitems: . Brakehosesand lines{including ABSi . Allfluidlevelsandconditionoflluids . Exhaust system* . Fuellinesandconnections* . Lightsandcontrols, vehicleunderbody

o

Inspectand adjustdrivebeh

a

o

a

R e p l a c ed u s t a n d p o l l e n f i l t e r " o ' t '

a

Replace transmission lluid

a

Servicethe following items atthe recommendedinteruals Replace aircleanerelement

Every15,000 miies(24,000 km)in dustyconditions, otheMiseusenormalschedule.

Replace sparkplugs

Every 110,000 miles(176,000 km)

Inspectvalveclearance

Inspect every110,000 miles(176,000 km),otheMise adiust onlyif noisy.

I n s p e c ti d l e s p e e d '

Every 160,000 miles(256,000 km)or8vears

Replace enginecoolant

At 120,000 miles(192,000 km)of 10years,lhen every miles(96,000 60,000 km)or5

Replace brakefluid

Every3 years

* : A c c o r d i n gt o s t a t e a n d f e d e r a l r e g u l a t i o n s ,f a i l u r e t o d o t h e m a i n t e n a n c ei t e m s m a r k e d w i t h a s t e r i s k1 * ) w i l l n o t v o i d c u s t o m e r ' s e m i s s i o n s w a r r a n t i e s .H o w e v e r , H o n d a r e c o m m e n d st h a t a l l m a i n t e n a n c es e r v i c eb e d o n e a t t h e r e c o m m e n d e d i n t e r v a lt o e n s u r e l o n g { e r m r e l i a b i l i t v . N O T E 1 : R e p l a c et h e d u s t a n d p o l l e n f i l t e r a t 1 5 , 0 0 0m i l e s / 2 4 , 0 0 0k m i f t h e v e h i c l e i s d r i v e n m o s t l y i n u r b a n a r e a st h a t h a v e h i g h c o n c e n t r a t i o n s o f s o o t i n t h e a i r f r o m i n d u s t r v a n d d i e s e l - D o w e r e dv e h i c l e s .

t,

3-9


EngineElectrical EngineElectrical SpecialTools

4-2

StartingSystem Comoonent Location Index ............... CircuitDiagram StarterCircuit Troubleshooting ClutchInterlockSwitchTest StarterSolenoid Test .............. StarterPerformance Test StarterReolacement ............... StarterOverhaul.......................

4-J

4-4 4-5 4-6 4-7 4-8 4-9 4-10

lgnition System Component LocationIndex ............... 4-15 CircuitDiagram 4-16 lgnitionTimingInspection 4-17 lgnitionCoilRemoval/1nsta11ation ....................... 4-18 SparkPlugInspection 4-19

ChargingSystem Component LocationIndex .................................. 4-2O CircuitDiagram ........................... 4-21 Charging ....................... 4-22 CircuitTroubleshooting DriveBeltInspection ................... 4-26 DriveBeftReplacement .............. 4-26 DriveBeftAuto-tensioner Inspection.................. 4-27 DriveBeftAuto-tensioner Replacement .............. 4-28 Alternator Reolacement ............. 4-29 Alternator ................ .... 4-30 Overhaul

CruiseControl Component Location Index .................................. 4-36 CircuitDiagram ........................... 4-37 Index ....................... 4-38 SymptomTroubleshooting CruiseControlUnitlnDutTest ............................. 4-40 MainSwitchTesVReolacement ........................... 4-42 .. 4-42 SeVResume/Cancel SwitchTesVReplacement CruiseControlActuatorTest ......4-43 CruiseControlActuator/Cable Replacement ......4-44 ActuatorCableAdjustment.................................. 4-45 ClutchPedalPositionSwitchTest ....................... 4-45 \.

-

+

ENGINE


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2003 Honda Civic Si Hatchback Service Repair Manual  
2003 Honda Civic Si Hatchback Service Repair Manual  
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