tow HONDA CIVIC 2002 7.G User Guide

8.
9.
6. Clean both balancer shaft No. 2 journals and
bearing halves with a clean shop towel.
7. Place one strip of plastigage across each No.2journal.
Reinstall the bearings and upper balancer shaft
holder, then torque the bolts.
NOTE; Do not rotate the balancer shaft durinq
insDection.
Remove the uooer balancer shaft holder and
bearings again, and measure the widest part of the
plastigage. lf the balancer shaft No. 2 journal oil
clearance is out-of-tolerance. install the new
bearings, and recheck. lf it is still out-of-tolerance,
replace the balancer shafts.
No. 2 Journal Oil Clearance:
Standard lNewl; 0.060 0.120 mm
Service Limit:
(0.0024 0.0047 in.l
0.15 mm {0.006 in.)
10. Align the punch mark on the rear balancer shaft
with the center of the two punch marks on the front
balancer shaft, then install'the balancer shafts in
the lower balancer shaft holder
Apply engine oil to the threads of the 8 mm bolts(A).
6x1.0mm'12 N.m(1.2 kgt.m, 8.7 lbt ft)
11.
Installthe upper balancer shaft holder (B) and
bafile plate (C).
(cont'd)
12.
8-13

FuelSupply System
Fuel Pressure Relieving
Before disconnecting fuel lines or hoses, relieve
pressure from the system by disconnecting the fuel
tube/quick connect fitting in the engine compartment.
1. Turn the ignition switch OFF,
2. Remove the PGM-Fl main relay 2 (A).
Startthe engine, and let it idle until it is stalls.
NOTE: The DTCS or Temporary DTCS P0301. P0302,
P0303, P0304 may come on during this procedure.
lf any DTCS are stored, ignore them.
Turn the ignition switch OFF.
Remove the fuel fill cap, and relieve fuel pressure
in the fueltank.
Remove the engine cover.
Disconnect the negative cable from the battery.
Check the fuel quick-connect fitting for dirt, and
clean it if necessary.
3.
4.
6.
7.
8.
11-144
11
10.
9. Place a rag or shop towel over the quick-connect
fitting (A).
Disconnect the quick-connect fifting (A): Hold the
connector (B) with one hand and squeeze the
retainer tabs (C) with the other hand to release
them from the locking pawls {D). Pullthe connector
off.
NOTE:. Prevent the remaining fuel in the fuel feedlineor
hose from flowing out with a rag or shop towel.. Be careful notto damage the line (E) or other
pa rts.. Do not use tools.. lf theconnectordoes not move, keepthe retainer
tabs pressed down, and alternately pull and push
the connector until it comes off easily.. Do not remove the retainer from the line; once
removed, the retainer must be replaced with a
new one.
After disconnecting the quick-connect fifting, check
it for dirt or damage (see page 1 1-149).

Fuel Supply System
Fuel Line/Ouick-Connect Fittings Precaution
The fuel tube/quick-connect fittings connect the fuel rail(A)to fuel feed hose (B), the fuel feed hose (B) to the
fuel line (C), and the fueltube (D) to the fuel pump
assembly (E). When removing or installing the fuelfeed
hose, fuel pump assembly, or fuel tank, it is necessary
to disconnect or connect the quick-connect fittings.
Pay attention to the following:
. The fuel feed hose (B), fuel tube (D), and quick-
connect fittings (F) are not heat-resistanU be careful
not to damage them during welding or other heat-
generalrng proceoures.
. The fuelfeed hose (B), fueltube (D) andquick-
connect fittings (F) are not acid-proof; do not touch
them with a shop towel which was used for wiping
battery electrolyte. Replace them if they came into
contact with electrolyte or something similar.
. When connecting or disconnecting the fuel feed hose(B), fuel tube (D), and quick'connect fittings (F). be
careful not to bend or twist them excessivelv. ReDlace
them it they are damaged.
11-148
A disconnected quick-connect fitting can be
reconnected, but the retainer on the mating line cannot
be reused once it has been removed from the line.
Replace the retainer when
. replacing the fuel rail.. replacing the fuel line.. replacing the fuel pump.
. replacing the fuel filter,. replacing the fuel gauge sending unit.. it has been removed from the line.. it is damaged.
PARTI\4ANUFACTUREBRETAINER
COLOR
E NG INE
COI\4PARTMENT(FUEL FEED
HOSE; FU EL
LINE SIDE)
TOKAIGREEN
EN G INE
COIVIPARTMENT(FUEL FEED
HOSE: FUEL
RAIL SIDE)
TOKAIBLU
FUEL TANK
UNIT
SANOHWHITE
I

Clutch 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 immediatelV with water.
1. Pry out the lock pin (A), and pullthe pedal pin (B)
out of the yoke. Remove the master cylinder
mounting nuts (C).
Remove the air cleaner housing cover and the air
cleaner housing (see step 6 on page 5-2).
Remove the brake fluid from the clutch master
cylinder reservoir with a syringe.
Remove the clutch line bracket from the frame rail,
and remove the clutch line clip.
Remove the clutch master cylinder (A), and pull it
toward the middle of the engine compartment.
Remove the retaining clip (B). Disconnect the clutch
line (C). Plug the end of the clutch line with a shop
towelto prevent brake fluid from coming out.
g-E
3.
6. Disconnect the reservoir hose (D) fromtheclutch
master cylinder reservoir. Plug the end of the
reservoir hose with a shop towel to prevent brake
fluid from coming out.
7. Remove the O-ring (E) and the clutch master
cylinder seal (F) from the master cylinder.
8. Installthe clutch master cylinder in the reverse
order of removal. Install a new O-ring.
9. Make sure the hose clamps (A) are positioned on
the master cylinder (B) and reservoir (C) as shown.
(cont'd)
UP
i
12-5

Slave Cylinder Replacement
NOTE:. Use fender covers to avoid damaging painted
surfaces.. 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. Write down the frequencies for the radio's preset
buttons. Disconnect the negative ( ) cable first,
then the positive (+)cable from the battery.
Remove the battery.
2. Remove the battery tray.
a
Remove the air cleaner housing cover and the air
cleaner housing (see step 6 on page 5-2).
Remove the intake air duct (see step 8 on page 5-3) .
Remove the clutch line bracket (A).
4.
5.
6. Remove the mounting bolts (A) andtheslave
cylinder (B).
Remove the roll pins (C). Disconnect the clutch line(D), and remove the O-ring (E). Plug the end of the
clutch line with a shop towel to prevent brake fluid
f rom coming out.
Installthe slave cylinder in the reverse order of
removal. Install a new O-ring (A).
7.
,,6NJ'
=--#.q!4sEn(P/N 08798-90021
9.
(Brak6 Assembly Lube)
Pullthe boot (B) back, and apply brake assembly
lube to the boot and slave cylinder rod (C). Reinstall
the boot.
Apply super high temp urea grease (P/N 08798-
9002) to the push rod of the slave cylinder. Tighten
the slave cylinder mounting bolts to 22 N m (2.2
kgf m, 16lbf.ft).
(cont'd)
12-7
10.

Manual Transmission
Change Lever Assembly Disassembly/Reassembly
Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surface.
BREATHER CAPTurn the arrow toward the {ronto{ the vehicle, and install it.
SELECT LEVERBe careful not to damage the dust sealwhen installing it.@).1 IlLrl
rrl
I
DUST COVEB
a^^
7 Fr"irr6-rooa
(P/N 08798-9002)
ROLLER
6x1.0mm12 N.m(1.2 kgl.m,8.7 lbf.ft)
'^ E-='-Fl !-d 1sr/2Noq )-=^l sELEcr
i €2 sPntruc
,.* (A)tace. ix#,,l
H\
lV srxSELECT-z:-=:l-': SPRING
r\
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,/u
/
\op
(g)'
' -, OIL SEAL,/ ReDlace./-r,s
\__/
INTERLOCK
SHIFT ARM
SELECT STOPPLATE
REVERSE LOCK CAMSTRIKER
SHIFT ARM COVER
WASHER
9.8Nm{1.0 kgf.m, 7.2 lbf.ft)
13-20

13. Attach the special tool to the mainshaft as follows:
. Back-out the mainshaft holder bolt {A) andloosen
the two hex bolts (B).
. Fit the holder over the mainshaft so its lip is
towards the transmission.. Align the mainshaft holder's lip around the
groove at the inside of the mainshaft splines,
then tighten the hex bolts.
14.
07GAJ-PG20130
Seat the mainshaft fully by tapping its end with a
plastic hammer.
Thread the mainshaft holder bolt in until it just
contacts the wide surface of the mainshaft base.
16. Zero a dial gauge {A) on the end ofthe mainshaft.
Turn the mainshaft holder bolt (B) clockwise; stop
turning when the dial gauge (A) has reached its
maximum movement. The reading on the dial
gauge is the amount of mainshaft end play
NOTE: Do not turn the mainshaft holder bolt more
than 60 degrees after the needle of the dial gauge
stops moving, this may damage the transmission.
lf the reading is within the standard, the clearance
is correct. lf the reading is not within the standard,
recheck the shim thickness.
Standard: 0.11 -0.17 mm (0.004 0.007 in.)
17.
18.
07GAJ-PG20130
13-45

Gearshift Mechanism Replacement
SHIFT CABLE CLIPReplace.
8 x 1.25 mm22 N.m (2.2 kgf.m, 16 lbt ftl
--SHIFT LEVER KNOB
/ ,.-,'-' 8 N m {0.8 ksr.m. 5.8lbf.ft}
l'/
SHIFT LEVER HOUSING
{P/N 08798-9002}
r-Ll Rotate the shift cabletoward the opening.
6x1.0mm9.8Nm(1.0 kgf.m,7.2 tbf.fr)
COTTER PINS
qrBemove the shift cablefrom the shift lever bracket.{P/N 08798-9002)
13-51

Driveline/Axle
Driveshafts Disassembly {cont'd)
Make a mark (A) on each roller (B) and inboard joint
(C) to identify the locations of rollers and grooves
in the inboard joint. Then remove the lnboard joint
on the shop towel (D). Be careful not to drop the
rollers when separating them from the inboard
Jornt.
N4ake a mark (A) on the rollers (B) and spider (C) to
identify the locations of rollers on the spider, then
remove the rollers.
Remove the circlip {D).
Mark the spider (C) and driveshaft (E) to identify the
position of the spider on the shaft,
Remove the spider (C).
6.
7.
16-6
8. Wrap the splines on the driveshaft with vinyl tape(A) to prevent damage to the boot.
9. Remove the inboard boot. Be careful nottodamaoe
the boot.
10. Remove the vinyl tape.
\

Steering Gearbox Removal
Special Tool Required
Ball ioint remover,2S mm 0TlvlAC-S100200
1. Raise the front of vehicle, and make sure it is
securely supponed.
2. Remove the front wheels.
Remove the driver's airbag (seepage23-113).
Remove the steering wheel (see page 17-6).
Remove the motor on the steering gearbox (see
page l T-49).
Remove the driver's dashboard lower cover (see
page 20-59) and under cover {see page20-60).
Remove the steering joint bolts (A), and disconnect
the steering joint by moving the steering joint (B)
toward the column.
4.
5.
6.
7.
'il
_t\
l- '/
,a.: --L -
8. Remove the cotter pin (A)from the tie-rod balljoint
nut {B), and loosen the nut.
r0 mm HEX NUT07MAC-S100200
Separate the tie-rod balljoint and damper steering
arm using the special tool (see page 18-10). Repeat
on the other side of the vehicle.
Grasp the right side tie-rod, and pull the rack all the
way to the passenger's side,
Remove the heat shield (A) mounting bolts from
the body stiffener, and let the heat shield lay
against the exhaust.
11.
9.
10.
(cont'd)
17-51