height HONDA CIVIC 2002 7.G Owner's Manual

Clutch
Clutch Pedal, Clutch
Adjustment
NOTE:. To check the clutch pedal position switch(see page 4-45).. To check the clutch interlock switch (see page 4-6).. Remove the driver's side floor mat before adjusting
the clutch pedal.. The clutch is self-adjusting to compensate for wear.. lf there is no clearance betweenthe mastercylinderpiston and push rod, the release bearing will be held
against the diaphragm spring. which can result in
clutch slippage or other clutch problems.
1. Loosen the clutch pedal position switch locknut (A),
and back off the clutch pedal position switch (B)
until it no longer touches the clutch pedal (C).
J9.8 N.m(1.0 kgf.m,7.2 lbf.ft)
A9.8 N.m11.0 kgf.m, 7.2 lbf.ft)
o18 N.m{1.8 kgf.m,13 tbf.ftl
Loosen the clutch push-rod locknut (D). and turn
the push rod (E) in or out to get the specified height(F), stroke (G). free play (H) and disengagement
height (l) atthe clutch pedal.
Clutch PedalStroke: 130 140 mm(5.12 5.51 in.l
Clutch Pedal Free Play: l0 16 mm (0.39-0.63 in.)
Clutch Pedal Height: 193 mm (7.60 in.)
Disengagement
Height: 115 mm (4.53 in.)
Between Floor And
Carpet Height(Approximate Valuel: 38 mm {1.50 in.l
12-4
Pedal Position Switch, and Clutch Interlock Switch
3. Tighten the clutch push-rod locknut (D).
4. With the clutch pedal released. turn the clutchpedal position switch (B) in until it contacts the
clutch pedal (C).
5. Turn the clutch pedal position switch {B) in an
additional 3/4 to 1 turn.
6. Tighten the clutch pedal position switch locknut (A).
7. Loosen locknut (J)and the clutch interlock switch(K).
8. Press the clutch pedal to the floor.
9. Release the clutch pedal 10 'l6mm(0,39 0.63in.)
from the fully pressed position, and hold it there.
Adjust the position of the clutch interlock switch (K)
so that the engine will start with the clutch pedal in
thls position.
10. Tighten the clutch interlock switch locknut (J).

Clutch Replacement
Spscial Tools Required. Clutch alignment disc 07JAF-PM701 1A. Ring gear holder 07LAB-PV00100 or
07924-PD20003. Clutch alignment shaft 07ZAF-PR8A100. Remover handle 07936-3710100
Pressure Plate and Glutch Disc Removal
1. Check the diaphragm spring fingers for height
using lhe special lool and feeler gauge. lf the height
is more than the service limit, replace the pressure
ptate.
Standard lNewl: 0.6 mm (0.02 in.) max.
Service Limit: 0.8 mm {0.03 in.)
07zAF-PR8A10007936-3710100OTJAF-PM7O11A
2. Installthe special tools.
A
\-
A-.- nl I\ffim9fra-I tP|-
07LAB-PV00100 or07924-PD20003
To prevent warping, unscrew the pressure plate
mounting bolts (A) in a crisscross pattern in several
steps, then remove the pressure plate (B).
Inspect the fingers of the diaphragm spring (A) for
wear at the release bearing contact area.
5. Inspect the pressure plate 1A) surfaceforwear,
cracks. and burning.
(cont'd)
12-9

Glutch
Clutch Replacement (cont'dl
Clutch Disc and Pressure Plate Installation
'L Temporarily install theclutch disc ontothesplines
of the transmission mainshaft, Make sure the clutch
disc slides freely on the mainshaft.
2. lnstallthe ring gear holder.
{P/N 08798-9002)
07LAB-PVo0'100 or0792,1-PD20003
Apply super high temp urea grease (P/N 08798-
9002) to lhe splines (A) of the clutch disc (B), then
install the clutch disc using the special tools.
Installthe pressure plate (A) and the mounting
bolts (B) finger-tig ht.
\---,
/v
07936-3710100
3.
O?ZAF.PRSAIOO
12-12
5. Torque the mounting bolts in a crisscross pattern,
Tighten the bolts in several steps to prevent
warping the diaphragm spring.
PRESSURE PLATE MOUNTING BOLT TOROUE:
25 N.m {2.6 kgt.m, 19 lbt.ft)
o
Remove the special tools.
Make sure the diaphragm spring fingers are all the
same height.
1.

Conventional Brake Components
Brake Pedaland Brake PedalPosition Switch Adjustment
Pedal Height
1.Disconnect the brake pedal position switch
connector, turn the brake pedal position switch (A)
counterclockwise, and pull it back until it is no
longer touching the brake pedal.
Lift up the carpet and the insulator cutout (B).
l\4easure the pedal height (C) from the middle of
the left side of the pedal pad (D).
Standard Pedal Height (with carpet removed):
184 mm (7 4/16 in.)
Loosen the pushrod locknut (A), and screw the
pushrod in or out with pliers until the standard
pedal height from the floor is reached. After
adjustment, tighten the locknut firmly. Do not
adjust the pedal height with the pushrod pressed.
15 N.m(1.5 kgl m. 11 lbl ft)
19-6
7. Check the brake pedal free play as described below.
Pedal Free Play
4. With the engine off, inspect the play (A) on the
pedal pad (B) by pushing the pedal by hand.
Free Play: 0.4- 3.0 mm {0.016 0.'l18in.)
lf the pedal free play is out of specification, adjust
the brake pedal position switch (C). lf the pedal free
play is insufficient, it may result in brake drag.
Push in the brake oedal oosition switch until its
plunger is fully pressed (threaded end (A)touching
the pad (B) on the pedal arm). Then, turn the switch
45" clockwise to lock it. The gap between the brake
pedal position switch and the pad is automatically
adjusted to 0.4 to 3.0 mm (0.016 0.118 in.) by
locking the switch. Make sure the brake lights go
otf when the pedal is released.
t
6.

Master Cylinder Replacement
NOTE: Do not spill brake fluid on the vehicle; it may
damage the paint; if brake fluid does contact the paint,
wash it off immediately with water,
1, Remove the air cleaner assembly (A).
2, Disconnect the brake fluid level sensor connector
(A).
15 N.m{1.5 kgt.m, 11 lbt.ft)
3. Remove the clutch reservoir (B) andenginewire
harness clip (C)from the master cylinder mounting
base (D).
4. Remove the reservoir cap and brake fuid from the
reservoir.
5. Remove the reservoir (E) on the master cylinder
mountrng Dase.
6, Disconnect the brake lines (F)from the master
cylinder (G). To prevent spills, cover the hose joints
with rags or shop towels.
7. Remove the master cylinder mounting nuts {H) and
washers.
8. Remove the master cylinder from the brake booster.
Be careful not to bend or damage the brake lines
when removing the master cylinder.
9. Remove the rod seal (l) from the master cylinder.
10. Installthe master cylinder in the reverse order of
removal, and note these items:
. Replace all the rubber parts with new ones
whenever the master cylinder is removed.
. Check the pushrod clearance before installing the
master cylinder. and adjust it if necessary (see
page 19-16).. Use a new rod seal on reassemblY. Coat the inner bore lip and outer circumference
of the new rod seal {A) with the recommended
seal grease in the master cylinder set.
. Installthe rod seal ontothe master cylinder with
its grooved side (B)toward the master cylinder.
. Check the brake pedal height and free play after
installing the master cylinder, and adjust it if
necessary (see page 19-6).
19-15

Gonventional Brake Components
IBrake Booster Test
Functional Test
1. With the engine stopped, press the brake pedal
several times to deplete the vacuum reservoir, thenpress the pedal hard, and hold itfor 15 seconds. lfthe pedal sinks, either the master cylinder is
bypassing internally, or the brake system (master
cylinder, lines. modulator, or calipers) is leaking.
2. Start the engine with the brake pedal pressed. lf thepedal sinks slightly, the vacuum booster is workingproperly. lf the pedal height does not vary, thebooster or check valve is faulty.
3. With the engine running, press the brake pedal
lightly. lfthe brake pedal sinks more than 1O mm
{3/8 in, ) in 3 minutes, the master cylinder is faulty.A slight change in pedal height when the Ay'C
compressor cycles on and off is normal. (The A,/C
compressor load changes the vacuum available tothe booster.)
Leak Test
1. Press the brake pedal with the engine running, thenstop the engine. lf the pedal height does not vary
while pressed for 30 seconds, the vacuum boosteris OK. lf the pedal rises, the booster is faulty.
2. With the engine stopped, press the brake pedal
several times using normal pressure. When thepedal is first pressed, it should oe row.
On consecutive applications, the pedal height
should gradually rise. lfthe pedal position does notvarv, check the booster check valve.
19-18
3. Disconnect the brake booster vacuum hose (check
valve built-in) (A) at the booster side.
5.
4.Start the engine, and let it idle. There should bevacuum available. lf no vacuum is available, thecheck valve is not working properly. Repiace thebrake booster vacuum hose and check valve, andrelesI.
Reconnect the brake booster vacuum nose.
Start the engine, and then pinch the brake boostervacuum hose between the check valve and thebooster,
Turn the ignition switch OFF, and wait 30 seconds,Press the brake pedal several times using normalpressu re,
When the pedal is first pressed, it should be low.On consecutive applications, the pedal height
should gradually rise.
. lf the pedal position does notvary, replacethe
brake booster.. lf the pedal position varies, replace the brake
booster vacuum hose/check valve assembly.

Brake Booster Replacement
1.Remove the master cylinder (see page 19-15).
Remove the master cylinder brake lines {A) from
the brake line clip.
c
6x1.0mm9.8 N.m(1.0 kgf.m,7.2 tbf.ft)
Remove the vacuum hose mounting bracket (B).
Disconnect the vacuum hose {C) from the brake
booster.
'-/
.,.,....
alu
i '..
5. Remove the clip (A) and the joint pin (B). and
disconnectthe yoke from the brake pedal.
7.
{'l.3 kgf.m,9 lbf.ftl
Remove the brake booster mounting nuts (C).
Remove the brake booster (A)from the engine
comparlmenr.
INdAdEI. Be careful not to damage the booster
surfaces and threads of the booster stud
bolts.. Be careful not to bend or damage the
brake lines.
lnstallthe brake booster in the reverse order of
removal, and note these items:
. Adjust the pushrod clearance before installing
the brake booster (see page 19-16).. Use a new clip whenever installing.. After installing the brake booster and master
cylinder, fill the reservoir with new brake fluid,
bleed the brake system (see page 19-8), and
adjust the brake pedal height and free play (see
page 19-6),
19-19

Body
DoorsComponent Location Index ...........Door Panel Removal/lnstallation .....,..........Door Outer Handle ReplacementDoor Latch ReplacementDoor Glass and RegulatorReplacementDoor Sash Trim Replacement .......................
Door Glass Outer WeatherstripReplacement
Door Weatherstrip Beplacement
Door Glass Adjustment .................................Door Position Adjustment .............................Door Striker Adiustment ................................MirrorsComponent Location Index ...........................Power Mirror Replacement ...........................Mirror Holder Replacement ...........................Rearview Mirror Rep1acement ......................
GlassComponent Location Index ...........................Windshield Replacement
Bear Window Rep1acement ...........................
Ouarter Glass Replacement ..........................MoonroofComponent Location Index ...........................Symptom Troubleshooting Index
Glass Height Adjustment ...............................
Glass ReplacementWind Def lector 8ep1acement ........................Drain Channel Rep1acement ..........................Sunshade Replacement .................................Motor ReplacementFrame and Drain Tube Replacement ............Drain Channel Slider and Cable AssemblyReplacementLimit Switch Adjustment ...............................Closino Force and ODenina Draq Check ......lnterioi TrimComponent Location Index ...........................Trim Removal/lnstallation DoorArea ..........Trim Removal/lnstallation-Rear Side AreaTrim Removal/lnstallation-Cargo Floor AreaTrim Removal/lnstallation-Hatch Area .........Headliner Removal/lnstallation* Carpet Rep1acement .......................................ConsolesConsoles, Front and RearRemova l/lnsta llationFront Console Disassembly/Reassembly .....
20-220,420-620-7
20-920 t0
20- 10
20-1120-1120-1220 13
20-1420-1520-1520-16
20 1120-1920-2520-29
20,3520-3620-3720-3120-3820 3920-4020-4120,42
20 4420-4620,44
20-4920 50
20-51
DashboardInstrument Panel Removal/lnstallation ........Driver's Dashboard Lower CoverRemovat InstallationDriver's Dashboard Under CoverRemova t Insta llation
Oriver's Pocket Removal/lnstallation ............Shift Lever Trim Removal/lnstallation ..........Center Panel Removal/lnstallation ...............Passenger's Dashboard Lower CoverRemova l/lnsta llat ionx Glove Box Removal/lnstallationDashboard Side VentRemoval/lnstallation .................................. 20-64Beverage Holder Removal/lnstallation ........ 20-64Driver'sTray Removal/lnstallation ............... 20-65Passenger's Tray Removal/lnstallation ........ 20 65* Dashboard Removal/lnstallation .................. 20-66Steerinq Hanqer Beam Reolacement ........... 20-68Seats "
Component Location Index ........................... 20-10* Front Seat Removal/lnstallation ................... 20-11* Front Seat Disassembly/Reassembly-Driver's .................................. 20-73* Front Seat Disassembly/Reassembly-Passenger's ........................... 20-74* Front Seat Cover Replacement ..................... 2O-75Rear Seat Removal/1nsta11ation ..................... 20-80Rear Seat-back Latch Replacement .............. 20-81Rear Seat-backStriker Replacement ............ 20-81
20-59
20-59
Rear Seat-back Cover Replacement ............. 20-82Rear Seat Cushion Cover Replacement ....... 20.84BumpersFront Bumper Removal/lnstallation .............Rear Bumoer Removal/lnstallation ...............HoodAdjustmentHood Seal ReplacementHood Insulator Rep1acement .........................Hatch
20-6020,6020 6120-62
20-63
20-63
20,8520-86
20-4720,8820,89
20-5220-5320-5420-55
20-5720-58
Adjustment ................... 20-90Hatch Suppon Strut Replacement ................ 20-91Hatch WeatherstriD Reo1acement ................. 20-92
Fuel Fill DoorAdiustment ................... 20-93Exterior TrimFront Grille Replacement ..............Cowl Covers Replac"rn""t .. . .....................A pillar Corner Trim Replacement ................Roof lMolding Replacement ...........................Rear License Trim ReplacementHatch Spoiler 8ep1acement ...........................Emblem Rep1acement .........................
20-9420-9520-9620-9720,9820-9920-100

Moonroof
Component Location Index
WIND DEFLECTORReplacement, page 20-38
GLASSHeight Adjustment, page 20 37Replacement, paqe 20-37Closino Force and Ooenino DraoCheck; page 20-48 "
DRAIN CHANNELReplacement, page 20-39
,5
?a<&,
@
..t'- ?.@-@c
_a
@
/,BR^CKEI
COVER
LIMIT SWITCH(AUTO.STOP SWITCH)Adjustment, page 20-46ER
I
CABLE TUBEREAR BRACKETE@
E STOP
.a'
MOONROOFCONTROL UNIT
FRAMEReplacement, page 20-42
CABLE ASSEMBLYBeplacement, page 20-44
*\
)REAR DRAIN VAI-VE
_-""-\q
Replacement, page 20'41
gJ -.- REAR DRA'N TUBE
20-35

Moonroof
Symptom Troubleshooting Index
SymptomDiagnostic procedureAlso check for
Water leaks'1. Check for a clogged drain tube.
2. Check for a gap between the glass weatherstrip and the roof
panel.
3. Check for a defective or an improperly installed glass
weatherstrip or drain channel.
4. Check for a gap between the drain seal and the roof panel.
G lass height
adJustment
Wind nolse1. Check for excessive clearance between the glass weatherstrip
and the root panel.
Glass height
adjustment
Deflector noise1. Check for a imDrooer clearance between deflector seal and
roof panel.
2, Check for a insufficient deflector extension.
3. Check for a deformed deflector.
Motor noise1. Check for a loose motor.
2. Check for a worn gear or bearing.
3. Check for a deformed cable assembly.
Check closing force
Glass does not move,
but motor turns
1. Check for a defective gear or inner cable.
2. Check for foreign matter stuck between the guide rail and the
slide r.
3. Check for a loose inner cable.
4. l\,4ake sure the cable assembly is attached properly.
Glass does not move
and motor does nol
turn (glass can be
moved with
moonroof wrench)
1. Check for a blown fuse.
2. Check for a faulty moonroof switch.
3. Check the limit switch.
4. Check for a run down battery.
5. Check for a defective motor.
6. Check for a faulty relay.
20-36