Honda Civic Ep3 02 03 Service Manual-25h17278

How to UseThis Manual -

Thismanualisdividedinto23sections.Thefirstpageofeach seclionismarkedwithablacktabthatlinesupwithits correspondingthumbindextabonthispageandthebackcover. Youcanquicklyfindthefirstpageofeachsectionwithout lookingthroughafulltableofcontents.Thesymbolsprintedat thetopcornerofeachpagecanalsobeusedasaquick re{erencesystem.

2. 3. 4. 5. 6.

Safety

Yoursafety,andthesatetyofothers,isveryimportant.Tohelp youmakeinformeddecisions,wehaveprovidedsafety messages,andothersafetyinformationthroughoutthismanual. Ofcourse,itisnotpracticalorpossibletowarnyouaboutallthe hazardsassociatedwithservicingthisvehicle.Youmustuse yourowngoodjudgment.

Youwillfindimpoftantsafetyinformationinavarietyofforms including: SatetyLabels-onthevehicle. SatetvMessages precededbyasaletyalertsymbolA and oneofthreesignalwords,DANGEF,WARNING,orCAUTION. Thesesignalwordsmean:

Specifications

- howtoservicethisvehiclecorrectlvandsafelv.

Allinformationcontainedinthismanualisbasedonthelatest productinformationavailableatthetimeofprinting.Wereserve therighttomakechangesatanytimewithoutnotice.Nopartof thisOublicationmaVbereDrodLrced,orstoredinaretrieval system,ortransmitted,inanyformbyanymeans,electronic, mechanical,photocopying,recording,orotherwise,withoutthe priorwrittenpermissiono{thepublisher.Thisincludestext, figures,andtables-

Asvoureadthismanual,vouwilltindinformationthatis precededbya@ symbol.Thepurposeofthismessageis tohelppreventdamagetoyourvehicle,otherproperty,orthe environment,

FirstEdition8/20021,168pages HONDAMOTORCO..LTD. AllRightsReserved ServicePublicationOffice SpecificationsapplytoU.S.A.andCanada

As seclion3with *inclode SRScomoonentsi special precautionsare required when servicing.

*Body

*Restraints

ldentificationNumberLocations

Vehicleldentification Number{vlN}

Vehicleldentificalion Numbe.lvlN)

EngineNumber

warning/cautionLabelLocations

EmissionGroupldentification

Example:2002model

THISVEHICLECONFORMSTOU.S.EPATIER2BIN5 ANDNLEVLEVREGULATIONSAPPLICABLETO2002 MODELYEARNEWPASSENGERCARSAND CALIFORNIAREGULATIONSAPPLICABLETO2OO2 MODELYEARNEWLEVIiLEVPASSENGERCARS.

Example:2003model

THISVEHICLECONFORMSTOU.S.EPATIER2 BIN5

LiftandSupportPoints

NOTE:If you aregoingto removeheavycomponents suchassuspensionorthe fueltankfrom the rearof the vehicle,firstsupportthefrontofthe vehiclewith tall safetystands.Whensubstantialweightis removed from the rearof thevehicle,thecenterof gravitycan changeandcausethe vehicleto tip forwardon the hoist.

FrameHoist

1. Positionthe hoistliftblocks(A),or safetystands, underthevehicle'sfrontsupportpoints(B)and rear supportpoints(C).

FloorJack

1. Setthe parkingbrake.

2. Blockthewheelsthatarenot beinglifted.

3. When liftingthe rearof the vehicle.putthe gearshiftIeverin reverse.

4. Positionthefloorjackunderthefrontjacking bracket(A)or rearjackingbracket(B),centerthe jackingbracketinthejackliftptatform(C),andjack upthe vehiclehighenoughto fit the safetystands underit.

2. Raisethe hoista few inches,androckthe vehicle gentlyto besureit isfirmly supported.

3. Raisethe hoistto full height,andinspectthelift pointsfor solidcontactwith the liftblocks.

Safety Stands

To supportthe vehicleon safetystands.usethe same suppon points(BandC)asfor a frame hoist,Always usesatetystandswhenworkingon or underany vehiclethat issupportedonly by ajack.

c

Positionthe safetystandsunderthesupportpoints andadjustthem sothe vehiclewill tevet.

Lowerthevehicleontothestands.

Towing

lfthe vehicleneedsto betowed,calla professional towing service.Nevertow thevehiclebehindanother vehiclewith just a ropeor chain.lt isvery dangerous.

EmergencyTowing

Therearethreepopularmethodsoftowinga vehicle.

Flat-bedEquipment Theoperatorloadsthe vehicle on the backof a truck.Thisisthe bestway of transportingthe vehicle.

To accommodateflat-bedequipment.thevehicleis equippedwith towing hooks(A)andtie down hooks{B).

Thetowing hookcanbe usedwith a winchto pullthe vehicleontothetruck,andthetie down hooksslotscan beusedto securethevehicleto truck.

WheelLiftEquipment

Thetow truckusestwo pivotingarmsthat go underthetires(frontor rear)and liftsthem offthe ground.Theothertwo wheelsremain on the ground.Thisisan acceptableway of towingthe vehicle.

Sling-typeEquipment

Thetow truckusesmetal cableswithhooksontheends.Thesehooksgo around partsof the frameor suspensionandthe cablesliftthat endofthevehicleofftheground.Thevehicle's suspensionandbodycanbeseriouslydamagedifthis methodof towing isattemPted.

lf thevehiclecannotbetransportedbyflat-bed,it shouldbetowedwith thefrontwheelsoff the ground lf dueto damage,the vehiclemustbetowedwith the frontwheelson the ground,do thefollowing:

Releasethe parkingbrake. shiftthetransmissionin Neutral.

It is bestto tow the vehiclenofartherthan50miles(80 km),andkeepthe speedbelow35 mph (55km/h).

lmpropertowingpreparationwill damagethe transmission.Followthe aboveprocedureexactly.lf you cannotshiftthetransmission,thevehiclemust betransDortedon a flat-bed.

Tryingto liftor tow thevehiclebythe bumperswill causeseriousdamage,Thebumpersarenot designedto supportthevehicle'sweight.

PartsMarking

To detervehicletheft,certainmajorcomponentsaremarkedwith the vehicleidentificationnumber(VlN).Original partshaveself-adhesivelabels.Replacementbodypartshavegenericself-adhesivelabels.Theoriginalengrneor transmissionVIN plateistransferredlo a replacementengineortransmissionandattachedwith break-offbolts.

NOTE:Becarefulnotto damagethe partsmarkinglabelsduringbodyrepair.Maskthe labelsbeforerepairingthe part.

Specifications

EnqineElectrical

ne

Item Measurement Oualification Standard or

Limit lgnitioncoil Rated voltage Firingorder 12V 1 3-4 2

Sparkplug Type Gap lgnitiontiming At idle(checkrhe inneutral:8t2' ETDCat650150rpm

Alternator Output

At13.5Vand normalengine temperature

NGK:tZFB6K11 DENSO:SKJ20DR-M11 1.01.1mm(0.0390.043in.) 1.3mm(O.OS1in.)

80A 2.2 3.0A

Coillrotor)resistance At68.F(20'C) 5|lp flng u.u. 14.4mm{0_57in.) 14.0mm(0.55in.) Brushlength 10.5mm(0.41in.l 1.5mm{0.06in.) Brushspringtension 2.9 3.5N(0.300.36kgf,0.7-0.8tbs)

Starter Output

Commutatormicadepth 0.500.80mm(0.020-0.031in.) 0.20mm1O.OO8in.) Commutatortunout o:BlalqryL4i) max o.o5mm(0.002in.) CommutatorO.D. 28.0mm(1.10in.) 27.0mm(1.06in.) Brushlength 14.014.5mm{0.550.57in.) 9.0mm{0.35in.)

nqtne

Item

Measurement

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

E e_a

ead o

nderH

Item Measur6ment

Oualification Standard or New Service Limit

Head Warpage 0.05mm{0.002in.) Height '103.95104.05mm (4.0934.096in.)

Camshaft Endplay 0.050.20mm(0.0020.008in.) 0.4mm(0.02in.)

Camshaftto holderoil clearance No.l journal 0.0300.069mm {0.0010.003in.) 0.15mm{0.006in.) No.2,3,4,5 journals 0.0600.099mm (0.002-0.004in.) 0.15mm(0.006in.)

Totalrunout 0.03mrn(0.001in.)max. 0.04mm{0.002in.)

Cam lobe height Intake,primary 33.925mm(1.3356in.) Intake, 29.638mm(l.1668in.) Exhaust 34.092mm(1.3422in.)

clearance(cold) lntake 0.210.2smm10.0080.010in.) Exhaust 0.280.32mm(0.0110.013in.)

StemO.D- lnlaKe 5.4755.485mm10.21560.2159in.) 5.445mm(0.214in.) Exhaust 5.4505.460mm(0.21460.2150in) 5.42mm(0.213in.)

Stem-to-gLrideclearance lntake 0.0300.055mm(0.00120.0022in.| 0.08mm(0.003in.) Exhaust 0.0550.080mm(0.00220.0031in) 0.11mm(0.004in.) lntake 1.251.55mm(0.0490.061in.) 2.00mm{0.079in.) Exhaust 1.251.55mm(0.0490.061in.) 2.00mm{0.079in.)

steminstalledheight lntake 40.8-41.0mm(1.6061.614in.) Exhaust 54.654.8mm(2.1502.157in.)

Valvesprings Freelength lntake 47.61mm(1.874in.) Exhaust 49.64mm(1.954in.)

Valveguides LD.

Installedheight

Intake 5.5155.530mm |.0.21710.21174n.1 5.55mm(0.219in.) Exhaust 5.5155.530mm \0.21110.2177in.l 5.55mm{0.219in.)

lntaKe 15.2"16.2mm(0.5980.638in.) Exhaust 15.516.5mm(0.6100.650in.)

Rockerarms Arm-to-shaftclearance lntaKe 0.0250.052mm (0.00'100.0020in.)

0.08mm(0.003in.) Exhaust 0.0180.056mm (0.00070.0022in.) 0.08mm(0.003in.)

nqtne

EnqineBlock

Item

Measurement

Oualification

ServiceLimir Block

IWarpageofdeck

StandardorNew

0.07mm(0.003in.)max. foro.. (ulur^^-"1 tsorediameter Aori

86.01086.020mm (3.38623.3866in.) 86.00086.010mm

Borll (3.38583.3862in.)

86.070mm(3.3886in.)

86.070mm(3.3886in.)

Piston

Reboringlrmit SkirtO.D.at11mm(0.4in.)from bottomofskirt

F" btt"'"' A LetterB

85.98085.990mm(3.38503.3854in.) l-il?0 €s.980r"i33846

Pistonring

lFis,.€-"'"",";"*

Connectingrod

L-Ringendgap o.D.

Crankshaft

0.25mm(00lin.) 85.930mm(3.383'lin.)

0.05mm (0.002In.J 85.920mm(3.3827in.)

0.0200.040mm(000080.0016in.) 0.05mm{0.002in.)

Top 1.2201.230mm(0.04810.0484in.) 1.25mm10.049rn)

Second 1.220 1.230mm (0.0481 0 0a84In.) 1.25mm10.049in.)

i2.0052.025mm(0.07890.0797in.) fo.o:s o.oto.rnlo.oorao.oozai.'.f EO3t 0056rn. {OJ01rOOO2i")

Second(FEDEHAL I\4OGUL)

Top

?.09rrl9.091lt ) 0.13mm(0.005in) 0.13mm(0.005in.)

0.0250.060mm(0.00100.0024in.) 0.13mm(0.005in)

0.200.35mm(0.0080.014in.) 0.60mm(0.024in.)

Second 0.400.55mm{0.0160.022in.) 0.70mm(0.028in.) OiI(REKEN)

0.250.65mm(0.0100.026in.) 020 0.70mmi0.0080.028in.) 0.75mm(0.030in.)

OiI(FEDERAL I\4OGUL) 0.80mm10.031in.)

Pistonpin 21.953mm l0 8643in

Deaflngs

21.96121.965mm{0.86460.8648in.)

Pin'to-pistonclearance 0.005-*0.002mm( 0.00020+ 0.00008in.) 0.005mm(0.0002in.)

Pin to-rod clearance

0.0050.015mm(0.00020.0006in.) 0.02mm lO0OO8in I

Small end bore diameler 21.97021.976mm(0.86500.8652in.)

Large-endbore diameter(Normal) 48.0mm(1.89in.)

Endplayinslalledoncrankshaft 0.150.30mm(0.0060.012in.) 0.40mm(0.016in.)

Mainjournaldiameter

No.ljournal No.2journal No.4journal No.5journal No.3journal

s4.e84s5.008mm(2.1648=16illl

Rodjournal diameter

54.97655.000mm(2.16442-1654in) 44.976 45.000mm (1.1707 1.1717in.l

Rod/main 0.005mm10.0002in.)max. 0.010mm(0.0004in.)

Rod/mainiournaloutof,round 0.005mm(0.0002in.)max. 0.010mm(0.0004in.)

Endplay 0.100.35mm(0.0040.0'14in.) 0.45mm10.018in.)

Runout ..-'.: --'+ 0.03mm(0.0012in.)max. 0.04mm{0.0016in.)

Marnoear,n9-toJournatottctearance No.ljournal No.2journal No.4journal No.5 No.3journa/

0.0170.041mm(0.00070.0016in.)

q0rr034, -rn{O'o0100-o01r|"tl

0.050mm(0.0020in.) 0.055mm(0.0022in.)

Bodbearingclearance 0.0210.049mm(0.00080.0019in.) 0.060mm(0.0024in.)

oi

nqlne

|tem

Engineoil Capacity

Lubrication a a

Measurement

Oilpump lnner-toouterrotorclearance

Oualificalion

StanderdorNew ServiceLimil

5.30(5.6USqt)forengineoverhaul 4.20(4.4USqt)foroilchange,includingfilter 4.00(4.2USqt)foroilchange,withoutfilter

0.020.16mm{0.0010.006in.) 0.20mm(0.008in.)

Pumphousingtoouterrotor clearance 0-150.21mm{0.006-0.008in.) 0.23mm(0.009in.)

Pumphousing-to-rotoraxial clearance

0.020.07mm(0.0010.003in.) 0.12mm(0.005in.)

Balancershafts,journaldiameter No.1journal,front shaft 19.93819.950mm10.78500.7854in.)19.92mm(0.784in.) No 1journal,rearshaft 23.93823.950mm(0.94240.9429in.)23.92mm(0.942in.) No.2journal,frontand rearshaft 32.94932.961mm11.29121.2911in.l32.93mm(1.296in.)

Ealancershafts,journaltaper

0.005rnm(0.0002in.)max. Balancershafts,endplay Front 0.0700.135mm(0.00280.0053in.) 0.15mm(0.006in.) Rear 0.0700.135mm(0.00280.0053in.) 0.15mm(0.006in.)

Balancershatts,shaft-to'bear;ng clearance No.1iournal,front shaft 0.0500.082mm(0.00200.0032in.) 0.10mm(0.004in.) No. 1Journal,rearshaft 0.0500.082mm(0.00200.0032in.) 0.10mm(0.004in.i No.2 journal,front and rear shafl 0.060-0.120mm(0.00240.0047in.) 0.15mm(0.006in.)

Balancershaftbearings,LD. No.1journal,front shaft No.1iournal,rearshaft

Reliefvalve,oil pressurewith oil temperatureat 176'F(80"C)

20.03mm(0.789in.) 24.03mm(0.946in.) No.2journal,frontand rearshaft 33.02133.069mm(1.30001.3019in.)33.09mm{1.303in.)

20.00020.020mm(0.18140.7442in.l Z+.OOOZI.OZOm- tOSa+e-OSa57ir'.)

At idle 70 kPa(0.7kq?cm , 10psr)min. At3,000rpm 300kPa{3.1ksf/cm',44psi)min.

StandardorNew ServiceLimit 6.7L(7.1US Coolantcapacity{includesengine, heater,hoses,andreservoir) 0.53L(0.56US 93 123kPa(0.951.25kqtcm,14 18psi) 't69 176'F(7680'C)

Thermostat OPeningtemPerature 8.0mm{0.31in.)min.

TurnsOFF Subtract5 15'F(3 8"C)fromactualON

StandardsandServiceLimits

FuelandEmissions

Item Measulement

Oualification

StandardorNew

Fuelpressure regulator Pressurewithfuelpressuregauge connected 320-370kPa13.3-'3.8kgtcm',47 52psi)

Fueltank Capacity 504(13.2USgali

Engineidle ldlespeedwithheadlightsandradiator fanoff Neutral 750 50rpm Fastidle Neutral 1,600150rpm

Clutch

Item Mea3urem€nl

Clutchpedal

ServiceLimit

Oualification

SlandardorNew ServiceLimit

Heightfromthefloor 193mm(7.60in.) Stroke 130140mm15.15.5in.) 10 16mm(0.390.63in.)

Disengagementheightfrom the floor 1'15mm(4.53in.)min. Bunoutonclutchmatingsurface 0.05mm10.002in.)max. 0.15mm(0.006in.)

Clutchdisc Bivetheaddepth 1.652.25mm(0.0650.089in.) 0.7mm{0.03in.) Ihickness 8.3 8.9mm(0.330.35in.) 6.0mm(0.24in.)

Pressureplate Warpage 0.03mm(0.001in.)max. 0.15mm(0.001in.)

0.6mm(0.02in.)max. 0.8mm(0-03in.) \<c

OE a

nualTransmissionandM/T Differential

Item M€asurement

Transmission fluid Capacity

Oualification

StandardorNew Se.viceLimit

Forfluidchange:1.50(1.6USqt) Foroverhaul:1.7011.8USqt)

Mainshaft Endplav 0.1'l-0.17mm(0.0040.007in.) Adiust

Diameterofbushingsurface 20.8020.85mm{0.8190.821in.) 20.75mm10.817in.)

Diameterof distancecollar 31.984-32.000mm(1.25941.2598in.) 3'1.93mm(1.257in.)

Diameterofballbearingcontactarea (clutchhousingside) 27.97727s90mm\1.1015-1.1020in.) 27.92mm(1.099in.)

Diameterofneedlebearingcontact area 38.98439.000mm(1.5348'1.5354in.) 38.93mm(1.5334n.)

Diameterofballbearingcontactarea (transmissionhousingside) 27.98728.000mm(1.10'191.1024in.) 27.93mm{1.100in.)

Runout 0.02mm(0.001in.)max. 0.05mm(0.002in.) Mainshaft3rd, 4thandsth gears

t.D. 44.00944.025mm11.73261.7333in.) 44.08mm(1.735in.) Endplay 0.060.16mm{0.0020.006;n.) 0.25mm(0.010in.)

Thickness 23.9223.97mm(0.94'10.944in.) 23.80mm(0.937in.)

Countershaft Diameterofneedlebearingcontact area(clutchhousingside) 35.000-35.015mm(1.3780'1.3785in.) 34.95mm(1.376in.)

Diameterofdistancecollarcontact alea 39.93739950mm(1.57231.512ain.| 39.88mm(1.570in.)

Diameterof ballbearingcontactarea (transmissionhousingside) 30.020-30.033mm(1.1819-1.1824in.) 29.97mm(1.180in.)

Runout 0.02mm{0.001in.)max. 0.05mm(0.002in.) 35mmshim-to'bearinginnerrace clearance 0.040.10mm(0.00160.0039in.) Adjust

Countershaft LD. 52.01052.029mm(2.0476-2.0484in.i 52.08mm(2.050in.) Endplay 0.060.16mm(0.0020.006in.) 0.25mm10.010in.) Thickness 22.9222.91$m10.902-0.904in.) 22.87mm(0.900in.)

Countershaft 2ndgear t.D. 52.01052.029mm(2.04762.0484in.) 52.08mm{2.050in.} Endplay 0.060.16mm(0.0020.006in.) 0.25mm10.0104n.) Thickness 21.9227.91mtn\1.0991.101in.) 27.87mm11.097in.)

Countershaft 'lstgear distancecollar

Countersha{l 2ndgear distancecoliar

LD. 39.9539.96mm(1.572a1.5132in.) 39.97mm(1.574in.) o.D. 46.989-47.000mm(1.8499-1.8504in.) 46.94mm(l.848in.) Length 23.0323.08mm(0.907-0.909in.i

l.D. 39.9539.96mm{1.5728'-1.5732in.l 39.97mm(1.574in.) o.o. 46.98947.000mm(1.84991.8504in.) 46.94mm(1.848in.) Length 28.0328.08mm(l.1041.106in.)

anuatIransm cont'

Item Measutemenl Oualification StandardorNew ServiccLimit Nlainshaft4th and5thgears distancecollar

LD. 32.00-32.01mm(1.25981.2602in.) 32.02mm(1.261in.) o.D. 38.98939.000mm(1.53501.5354in.) 38.94mm(1.533in.) Length 51.9552.05mm(2.0452.049in.) B 24.0324.08mm(0.946-0.947in.)

MBSdistance LD. 28.0028.01mm(1.1021.103in.) 28.02mm(1.103in.) Len9th 23.9524.05mm(0.9430.947in.) Reverseidler gear t.D. 20.01620.043mm(0.78800.7891in.) 20.90mm(0.832in.) Gearlo reversegear shaficlearance 0.0360.08amm(0.00140.0033in.) 0.16mm{0.006in.) Synchroring Bingto'gearclearance Ringpushed againstgear 0.701.49mm(0.0280059in) 0.4mm(0.0164n.)

Triplecone

Outersynchroring-tosynchrocone clearance Ringpushed againstqear 0.70-'1.19mm{0.0280.047in.) 0.3mm(0.012in.)

Synchrocone-to-gearclearance Ringpushed againstgear 0.501.04mm(0.0200.041in.) 0.3mm(0.012in.)

Outersynchroring-to-gearcone clearance Ringpushed againstgear 0.951.68mm(0.0370.066in.) 0.6mm(0.024in.)

Shiftfork Fingerthickness 7.4 7.6mm10.290.30in.) Forkto-synchrosleeveclearance 0.350.65mm(0.0140.026in.i 1.0mm(0.039in.)

Reverseshift fork Fingerthinkness 13.413.7mm(0.5270.539in.)

Fork-to-reverseidlergearclearance 0.200.59mm(0.0070.024in.) 1.3mm(0.051in.)

Shiftarm t.D. 13.973'14.000mm(0.55010.5512in.)

Shift forkdiameterat conlactarea 16.9'17.0mm(0.6650.669in.)

Shiftarm'to-shiftleverclearance 0.2 0.5mm(0.0080.020in.) 0.62mm(0.024in.)

Selectlever Fingerwidth 14.85'14.95mm(0.5850.589in.) Shiftlever Shaft-to-selectleverclearance 0.050.25mm(0.0020.010in.) 0.50mm(0.020in.) Groove{toselectlever) 15.0015.10mm{0.5910.594in.) Shafttoshiftarmclearance 0.0130.07mm(0.00050.003in.) 0.1mm{0.004in.)

Mfi differential carrier

Honda Civic Ep3 02 03 Service Manual-25h17278 Full download: http://manualplace.com/download/honda-civic-ep3-02-03-service-manual-25h17278/ This is the cut pages sample. Download all 1139 page(s) at: ManualPlace.com

Pinionshaftcontactareal.D. 18.01018.028mm(0.70910.7098in.) Carrier-to-pinionshaftclearance 0.0270.057mm(0.00110.0022in.) 0.1mm(0.004in.l DriveshaftcontactareaLD. 28.02528.045mm(1.10331.1041in.)

Backlash 0.050.15mm{0.0020.006in.) t.D. 18.04218.066mm(0.71030.7113in.) Piniongearto pinion shaftclearance 0.0590.095mm(0.00230.0037in.) 0.15mm(0.006in.) 80mmshim 80mmshimto-bearingouterrace clearanceintransmissionhousing 0 0.10mm(0 0.0039in.) Adjust -