engine HONDA CIVIC 2002 7.G Repair Manual

14. Installthe water bvpass hose.
15. Installthe air cleaner housing (see step 37 on page
5-15).
16. Installthe intake manifold (see page 9-5).
17. Installthe exhaust manifold (see page 9-7).
'18. Installthe cam chain (see page 6-15).
19. Adjust the valve clearance (seepage6-9).
20. Installthe drive belt (see page 4-26).
21. Clean the battery posts and cable terminals with
sandpaper, then assemble them and apply grease
to prevent corrosion.
22. After installation, checkthatall tubes, hosesand
connectors are installed correctly.
23. Inspectforfuel leaks. Turn the ignition switch ON
{ll) {do not operate the starter) so that the fuel pump
runs for about 2 seconds and pressurizes the fuel
line. Repeat thls operation two or three times, then
check for fuel leakage at any point in the fuel line.
24. Refillthe radiator with engine coolant, and bleed
air from the cooling system with the heater valve
open (see page 10-6).
25. Inspect the idle speed (see page 11-'138).
26. Inspect the ignition timing (see page 4-17).
Gylinder Head Cover lnstallation
1. Thoroughly clean the head cover gasket and the
groove.
2. Installthe head cover gasket (A) in the groove of
the cylinder head cover (B).
Check that the mating surfaces are clean and dry.
Apply liquid gasket. P/N 08718-0009, on the chain
case and the No.5 rocker shaft holder mating areas.
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.
(cont'd)
6-41

9.
10.
Install the four ignition coils (see page 4-'18).
Check that all tubes, hoses, and connectors are
installed correctly.
lnstallthe intake manifold cover.11.
6x 1,0 mm'12 N.m {1.2 kgf m.8.7 tbf.ftl
12. After assemblv, wait at least 30 minutes before
filling the engine with oil.
6-43

Engine Mechanical
Engine Block
Soecial Tools ............. 7 -2
Comoonent Location Index ......................................... 7-3
Connecting Rod and Crankshaft End Play
InsDection .............. 7-5
Crankshaft Main Bearing Replacement ...................... 7-6
Connecting Rod Bearing Replacement ...................... 7-8
Oil Pan Removal ....................... .......... 7-11
Crankshaft and Piston Removal ........ 7-12
Crankshaft Inspection ........................ 7-14
Block and Piston Insoection ........................................ 7-15
Cyfinder Honing ............ .".................... 7 -'17
Piston, Pin and Connecting Rod Replacement .......... 7-18
Piston Ring Replacement ................... 7 -21
Piston lnstallation .................... ........... 7-23
Connecting Rod Bolt Inspection .......' 7 -24
Crankshaft lnstallation .....................'. 7-24
Oil Pan lnstallation .................. ........... 7 -27
Transmission End Crankshaft Seal
lnstallation-ln Car ................... ........' 7 -28

Engine Block
SpecialTools
I
{\
Ref.No.Tool Number
OTZAD-PNAAlOO
07746-0010700
07749,0010000
Description
Oil Seal Driver Attachment 96
Attachment, 24 x 26 mm
Driver
Oty
6
@
1
1
1
o
{\
{
7-2

Engine Block
Component Location Index (cont'd)
/^., \
D->< | _,-ersroru nrrucs
Y1 l-"t Benlacement. Page 7-21
rkrej, I
ffil
rG AalQ
[=l^oJ
\
PISTONRemoval, page 7-'12Measurement, page 7-15
PISTON PINRemoval, page 7-18Inspection, page 7-19Installation, page 7,20
f,
6
CONNECTING RODEnd play, page 7-5Small end measurement, page 7-19
CONNECTING ROD
ENGINE BLOCKCylinder bore inspection, page 7-'15Warpage inspection, page 7-15Cylinder bore honing, page 1-11Ridge removai, step 13 on page 7-13
(\
CONNECTING ROD BOLTlnspectaon, page 7 24
7-4

Engine Block
Crankshaft Main Bearing Replacement
Main Bearing Clearance Inspection
1. To check main bea ring-to-jou rna I oil clearance.
remove the lower block and bearing halves (see
page 1 -12)..
2, Clean each main journal and bearing half witha
clean shop towel.
3. Place one strip of plastigage across each main
lou rnal.
4. Reinstallthe bearings and lower block, then torque
the bolts to 29 N.m {3.0 kgf.m,22 lbf.ft) + 56'.
NOTE: Do not rotate the crankshaft during
Inspeclton.
5. Remove the lower block and bearings again, and
measure the widest part of the plastigage.
Main Bearing-to-Journal Oil Clearance
No. 1,2, 4,5 Journals:
Standard (New): 0.017 0.041 mm
Service Limit:
No.3 Journal:
10.0007 0.0016 in.l
0.050 mm {0.0020 in.)
Standard {Newl: 0.025 - 0.049 mm(0.0010 0.0019 in.)
Service Limit: 0.055 mm (0.0022 in.l
7-6
\.
6. lf the plastigage measures too wide or too narrow,
remove the crankshaft. and remove the upper half
ofthe bearing. Install a new, complete bearing with
the same color code{s), and recheck the clearance.
Do not file, shim, or scrape the bearings or the caps
to adjust clearance.
7. lf the plastigage shows the clearance is still
incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and check
again. lf the proper clearance cannot be obtained
by using the appropriate larger or smaller bearings,
replace the crankshaft and start over.

Engine Block
Crankshaft Main Bearing
Replacement (cont'd)
3. Use the crank bore codes and crank journal codes
to select the appropriate replacement bearings
from the following table.
NOTE:. Color code is on the edge of the bearing.. When using bearing halves of different colors. it
does not matter which color is used in the top or
bottom.
Mainiournslcooe
Crank ---=-> Lalger crank bore
bore | 1or 2ot 3or c oi__-lcode IAorl Borll Corlll Dortttt I-- --> Smaller bearing {Thickerl
(Thicker)
1
2
4
5
Pink f!1f;* v"rro* c,""n
ll
f111f;,," v"no* c,""" $;;fl
cr""n $ffi ero-n
ffi#Tr,.*" i.,""*Creen ; g=jiff;i Brown Black
;;lT]*
'---l-'o"*,
Brown Black 6il;
Brack !l;kr ar*
7-8
Connecting Rod Bearing
Replacement
Rod Bearing Clearance lnspection
1. Remove the oil pump (see page 8-9).
2. Bemove the baffle plates (see step 6 on page 7-12).
3. Remove the connecting rod cap and bearing half.
4. Clean the crankshaft rod journal andbearinghalf
with a clean shop towel.
5. Place plastigage across the rod journal.
6. Reinstallthe bearing half and cap, and torque the
bolts to 20 N.m (2.0 kgf.m, 14lbf.ft) -l 90 ".
NOTE: Do not rotate the crankshaft during
inspection.
7. Remove the rod cap and bearing half, and measure
the widest part of the plastigage.
Connecting Rod Bearing-to-Journal Oil
Clearance:
Standard {Newl: 0.020 0.050 mm(0.0008 --0.0020 in.l
Service Limit: 0.060 mm (0.0024 in.)
\
\-
{

8.
9.
lf the plastigage measures too wide or too narrow,
remove the upper half of the bearing, install a new,
complete bearing with the same color code(s), and
recheck the clearance. Do not file. shim, or scrape
the bearings or the caps to adjust clearance.
lf the plastigage shows the clearance is still
incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and check
clearance agaln. lf the proper clearance cannot be
obtained by using the appropriate larger or smaller
bearing, replace the crankshaft and stan over.
Rod Bearing Selection
1. Inspect each connecting rod for cracks and heat
damage.
Connecting Rod Big End Eore Code Locations
2. Each rod has a tolerance range from 0 0.024 mm
(0.0009 in.), in 0.006 mm (0.0002 in.) increments,
depending on the size of its big end bore. lt's then
stamped with a number or bar (1, 2,3 or 4/1, ll,lll, ol
llll) indicating the range. You may find any
combination of numbers and bars in any engine.(Half the number or bar is stamped on the bearing
cap, the other half on the rod.)
lf you can't read the code because of an
accumulation of oil and varnish. do not scrub it
with a wire brush or scraper. Clean it only with
solvent or detergent.
Normal Bore Size: 48.0 mm 11.89 in.l
(cont'd)
7-9

Engine Block
Connecting Rod Bearing Replacement (cont'dl
Connecting Rod Journal Code Location
3. The connecting rod journalcodes are stamped on
the crankshaft.
Connecting Rod Journal Code Location (Letters or
Bars)
No.l JOURNAL No. 4 JOURNAL
7-10
\{
4. Use the big end bore codes and rod journalcodes
to select appropriate replacement bearings from
the following table.
NOTE:. Color code is on the edge of the bearing.. When using bearing halves of different colors, it
does not matter which color is used in the top or
bottom.
Big end ----------> Larger big end boreborecodolorl2oJll3 ol lll4 orllll
---------> Smallsrb.aring {Thickerl
PinkPink/YellowYollow/GrecnGreen
YellowYellow/GreenGreen/BrownBrown
GreenGreen/BrownErown/BlackBlack
BrownBrown/BlackBlack/BlueBlue
Rod
B
c
D
{\
(Thicker)
{

1.
OilPan Removal
Drain the engine oil (see page 8-5).
lf the engine is still in the vehicle, remove the
subframe.
-1 Attach the chain hoist to the engine (see step
35 on page 5-6).-2 Disconnectthe suspension lower arm balljoints (see step 3 on page 18-19).-3 Remove the rear mounl mounting bolts (see
step 39 on page 5-7).-4 Remove the front mount mounting bolt (see
step 40 on page 5-7).-5 Use a marker to make alignment marks on the
reference lines that align with the centers of
the rear subframe mounting bolts. Remove the
front subframe (see step 43 on page 5-8).
Remove the bolts/nuts securing the oil pan.
Drive an oil pan seal cutter between the oil pan and
cylinder block.
5. Cut the oil panseal bystrikingthesideofthecutter
to slide the cutter along the oil pan.
6. Remove the oil pan.
7-11