Gasket HONDA CIVIC 2002 7.G User Guide

23. Install the baffle plates.
6x1.0mm12 N.m(1.2 ksf m, 8.7 lbf ft)
24. Installthe oil pump (see page 8-14).
25. Installthe oil pan (see page 7-27).
26. Installthe cylinder head (see page 6-39).
27. Installthe transmission (see page 13-8).
28. Installthe engine assembly (see page 5-9).
1.
OilPan lnstallation
Remove old liquid gasket from the oil pan mating
surfaces, bolts, and bolt holes.
Clean and dry the oil pan mating surfaces.
Apply liquid gasket, P/N 08718-0009, evenly to the
cylinder block mating surface of the oil pan and to
the inner threads of the bolt holes.
NOTE: Do not install the parts if 5 minutes or more
have elapsed since applying liquid gasket. Instead,
reapply liquid gasket after removing old residue.
Installthe oil pan.
Tighten the bolts in two or three steps. In the final
step, tighten all bolts, in sequence, to 12 N.m (1.2
kgf m, 8.7 lbf.ft).
(cont'd)
2.
3.
4.
5.
Apply liquid gasketalong the broken line.
(}@
7-27

Engine Lubrication
Oil Pump Overhaul (cont'dl
10. Remove the set clip from the oil pumpchain
tensioner.
11. Install the oil pan (see pageT-27).
8-16
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I
(Oif Pressure Switch Replacement
1. Discon nect the oil pressure switch connector, then
remove the oil pressure switch.
2. Apply liquid gasket to the oil pressure switch
threads, then installthe oil pressure switch.
(

Intake Manifold and Exhaust System
lntake Manifold Removal and Installation
Exploded View:
INTAKE MANIFOLD PLATEReplace if cracked orif mating surface isdamaged.
6x1.0mm12 N.m{1.2 kgf.m,8.7 lbf.ft)
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GASKETReplace.
8 x 1.2522Nm12.2 ksf
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16
.25 mm'mkgf.m, 1
8 x 1.25 mm22 N.m(2.2 kgf m. 16 lbt.ft)
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8 x 1,25 mm22 N.m {2.2 kgf.m, 16 lbf ft}
INTAKE MANIFOLDReplace if cracked orif mating surface is
9-2
\-

1. Install the intake manifold (A)with a new gasket (B),
then install and tighten the two stud bolts (C).
8 x 1.25 mm22 N.m|.2.2k91.m.16 tbt.ft)
8 x 1.25 mm22 N.rn(2.2 kgf m. 16 lbf.ttl
Tighten all intake manifold mountlng bolts/nuts in a
crisscross pattern in two or three steps, beginning
with the inner bolt.
Tighten the bolt securing the intake manifold and
bracket.
8 x 1.25 mm22 N.m (2.2 ksf m, 16lbf.ft)
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2.
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4.
7.
5.
6.
Install the PCV hose {A), harness holder mounting
bolt (B), and harness clamp mounting bolt (C).
e-li*h,r
6x1.0mm12 N.m (1.2 kgf.m,8.7 lbf.ft)
Installthe fuel line (see page 11-150).
Installthe water bypass hoses.
Install the th rottle cable (see page 1 1-164), then
adjust the cable (see page 11-163).
Install the cruise control cable (see page 4-44). then
adjust the cable (see page 4-45).
8.
(cont'd)
9-5

1.
2.
3.
Exhaust Manifold Removal and Installation
Remove the VTEC solenoid valve (see page 1 '1-128).
Remove the driveshaft heat shield (see page 16-19).
Remove the cover and exhaust manifold bracket, then remove the exhaust manifold.
8x 1.25 mm22 N.m(2.2 kgf.m, 16lbt.ftl
#'-.-
GASKETReplace.
SELF-LOCKING NUT10 x 1.25 mm44 N.m {4.5 ksf.m, 33lbt.ftlBeplace.
10 x 1.25 mm44 N.m(4.5 kgt.m, 33 lbl ftlReplace.
WASHEB8 x 1-25 mm22 N.m (2.2 kgI m, 16lbf.ft)Replace.Tighten the bolts in steps,alternating side to side.10 x 1.25 mm14 N.m{4.5 kgl.rn, 33lbf.ft)
5.
Install the exhaust manifold and tighten the bolts/nuts in a crisscross pattern in two or three steps, beginning withthe inner bolt.
Installthe other parts in the reverse order of removal.
9-7

lntake Manifold and Exhaust System
Exhaust Pipe and Muffler Replacement
SELF-LOCKING NUT10 x 1.25 mm33 N.m {3.4 kgf.m,25 rbf.ft)Beplace.
8 x 1.25 mm22 N.m {2.2 kgf m, 16lbf.ft)Replace.Tighten the bolts in steps,alternating side to-side.
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NOTE: Use new gaskets and self-locking nuts when reassembling.
8 x 1.25 mm22 N.m (2.2 kst.m. 16lbf.ftlReplace.Tighten the bolts in steps,alternating side'to side.
EXHAUST PIPE B
HEAT SHIELD\,
6x1.0mm9.8 N.m{1.0 kgt.m, 7.2 lbf ft}
GASKETReplace.
SECONDARY HEATEDOXYGEN SENSOR{SECONDARY HO2SIil4Nm(4.5 ksf.m,33 lbf.ftl
AIR FUEL RATIO {A/F)SENSOR44 N.m (it.s kgf.m, 33 lbf ftl
9-8
\-.

Water Passage Installation
1.Clean and dry the water passage mating surfaces.
Apply liquid gasket P/N 08718-0009, evenly to the
cylinder block mating surface ofthewater passage
and to the inner threads of the bolt holes.
NOTE: Do not installthe parts if 5 minutes or more
have elapsed since applying liquid gasket. Instead,
reapply liquid gasket after removing old residue.
3. Installthe water passage (A)with a new O-ring (B).
10 x 1.25 mm44 N m {4.5 kgt m.33 lbf.ft}
4. After assembly, wait at least 30 minutes before
filling the engine with oil.
.t':.:
Water Outlet lnstallation
Installthe water outlet (A)with a new O-ring {B),
12 N m (1.2 kgt m,8,7lbf ft)
10-9

Fuel Supply System
{Fuel Pressure Regulator
Replacement
Remove the fuel pump (see page 1 1-153).
Remove the fuel pressure regulator (A).
Installthe part in the reverse order of removal witha new o-ring (B).
1.
2.
11-152
Fuel Filter Replacement
The fuel filter should be replaced whenever the fuelpressure drops belowthe specified value {270 320 kpa,2.8 3.3 kgf lcm', 40 47 psi), after making sure that thefuel pump and the fuel pressure regulator are OK.
1. Remove the fuel pump(seepagell-'153).
2. Remove the
Install in the reverse order of removalwith a new
base gasket (B) and a new o-ring (C), then check
these items:
' When connecting the wire harness, make sure
the connection is secure and the terminal (D) is
firmly locked into place.. When installing the fuel gauge sending unit iE),make sure the connection is secure and the
connector is firmly locked into place. Be carefulnot to bend or twist it excessively.
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fuel filter (A).
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Fuel Pump/Fuel Gauge Sending Unit Replacement
SpecialTools Required
Fuel sender wrench 07XAA-001010A
1.Relieve the fuel pressure (see page 11-144).
Remove the fuel fill cap.
Remove the seat cushion (see page 20-80).
Remove the access panel (A)from the floor.
5.
7.
Disconnect the fuel pump 5P connector (B).
Disconnect the quick-connect fitting {C) from the
fuel tank unit.
Using the special tool, loosen the fuel tank unit
locknut (A).
93 N.m19.5 kgf.m,69 lbf.ftl
11-153
8. Remove the locknut (A) andthefuel tankunit.
9. Remove the stopper {O). Release the hook (P) and
remove the fuel filter (B), the fuel gauge sending
unit (C). the case (D), the wire harness (E), and the
fuel pressure regulator (F).
10. When connecting the fuel tank unit, make sure the
connection is secure and the suction filter (G) is
firmly connected to the f uel pump (H).
11. Install the fuel tank unit in the reverse order of
removal with a new base gasket (l)and new o-rings
(J), then check these items:
. When connecting the wire harness, make sure
the connection is secure and the connector (K) is
firmly locked into the place.
. When installing the f uel gauge sending unit,
make sure the connection is secure and the
connector is firmly locked into place. Be careful
not to bend or twist the connector excessively.. When installing the fueltank unit, align the marks
(L) on the fuel tank (M) and the fuel tank unit (Ni

PCV Valve Inspection and Test
2.
1. Check the PCV valve (A), hoses {B), and
connections for leaks or restrictions.
At idle, make sure there is a clicking sound from the
PCV valve when the hose between the PCV valve
and intake manifold is lightly pinched {A)with your
fingers or pliers.
lf there is no clicking sound, check the PCV valve
grommet for cracks or damage. lf the grommet is
OK. reDlace the PCV valve and recheck.
PCV Valve Replacement
'LDisconnect the PCV hose.
Remove the PCV valve (A).
3. Install
with a
(4.5 kgf.m,33 lbf.ft)
the parts in the reverse order of removal
new gasket (B).
11-169