ECU HONDA CIVIC 2002 7.G Workshop Manual

Towing
lf the vehicle needs to be towed, call a professional
towing service. Never tow the vehicle behind another
vehicle with just a rope or chain. lt is very dangerous.
Emergency Towing
There are three popular methods of towing a vehicle.
Flat-bed Equipment The operator loads the vehicle
on the back of a truck. This is the best way of
transporting the vehicle.
To accommodate flat-bed equipment. the vehicle is
equipped with towing hooks (A)and tie down hooks {B).
The towing hook can be used with a winch to pull the
vehicle onto the truck, and the tie down hooks slots can
be used to secure the vehicle to truck.
1-9
Wheel Lift Equipment The tow truck uses two
pivoting arms that go under the tires (front or rear) and
lifts them off the ground. The other two wheels remain
on the ground. This is an acceptable way of towing the
vehicle.
Sling-type Equipment The tow truck uses metal
cables with hooks on the ends. These hooks go around
parts of the frame or suspension and the cables lift that
end of the vehicle off the ground. The vehicle's
suspension and body can be seriously damaged if this
method of towing is attemPted.
lf the vehicle cannot be transported by flat-bed, it
should be towed with the front wheels off the ground lf
due to damage, the vehicle must be towed with the
front wheels on the ground, do the following:
. Release the parking brake.. shift the transmission in Neutral.
It is best to tow the vehicle no farther than 50 miles (80
km), and keep the speed below 35 mph (55 km/h).
. lmproper towing preparation will damage the
transmission. Follow the above procedure exactly. lf
you cannot shift the transmission, the vehicle must
be transDorted on a flat-bed.. Trying to lift or tow the vehicle by the bumpers will
cause serious damage, The bumpers are not
designed to support the vehicle's weight.

Starter Replacement
1. Make sure you have the anti-theft code for the radio.
then write down the frequencies for the radio's
preset buttons.
2. Disconnect the negative cable from the battery first,
then disconnect the positive cable.
3. Disconnect the knock sensor connector.
4. Remove the bolt (A) securing the harness bracket,
then remove the intake manifold bracket (B).
A6x1,0mm12 N.m {1.2 kgf.m,8.7 tbt.ft)
8 x 1.25 mm22 N,m 12.2 kgt.m,16 rbf.ftl
L't2.
4-9
5. Disconnect the starter cable (A)from the B terminal
on the solenoid, then disconnect the BLK,/WHT wire
{B) from the S terminal.
10 x 1.25 mm44 N.m {a.5 kgf.m,33lblft)
8 x 1.25 mm9Nm10.9 kgf.m,7 lbl ft)
7.
9.
'10.
11.
2
S'-12x12smm6ilNm{6.5 kgl m,47lbfft)
Remove the two bolts holding the starter, then
remove the starter.
lnstall the starter in the reverse order of removal.
Make sure the crimped side of the ring terminal (A)
is facing out.
Connect the positive cable and negative cable to
the batterY.
Start the engine to make sure the starter operates
propeny.
Enter the anti-theft code for the radio, then enter
the customer's radio station presets.
Set the clock.
Perform the engine control module (EcM) idle learn
procedure (see page 1 '1- 139 ).
I

l\-Alternator Replacement
1. Make sure you have the anti-theft code for the radio,
then write down the frequencies for the radio'spreset buttons,
2. Disconnect the negative cable from the battery first,
then disconnect the positive cable.
3. Remove the front bumper (see page 20-85).
4. Remove the right side headlight (see page 22-79).
5. Remove the reserve tank from the bracket.
6. Remove the drive belt (see page 4-26).
7. Remove the three bolts securing the alternator.
8 x 1.25 mm22 N.n 12.2 kgl.m,
Disconnect the alternator connector (A) and BLK
wire (B) from the alternator.
8 N.m10.8 kgf.m,6lbf.ft)
\
6
'I 1.
9.
10.
13.
14.
Remove the alternator.
Installthe alternator and drive belt in the reverse
order of removal.
Connect the positive cable and negative cable to
the battery.
Enter the anti-theft code for the radio, then enter
the customer's radio station presets.
Set the clock.
Perform the engine control module {ECM) idle learn
procedure (see page 11-139).
tt.
4-29

Cruise Control
Cruise Control Actuator/Cable Replacement
1.Fully open the cruise control link by hand, then
remove the cruise control cable {A) from link.
Loosen the locknut (B), and remove the cable from
the bracket.
Disconnect the 4P connector, and remove the three
bolts securing the cruise control actuator.
2.
6x1,0mm12 N.m (1.2 kgf.m,8.7 lbf.ft)
4-44
la
3.Remove the actuator cover (A), then remove the
actuator cable (B) from the cruise control actuator.
Install in the reverse order of removal, and adjust
the free play at the throttle linkage after connecting
the actuator cable.
4.

Engine Assembly
I
Engine Removal
Special Tools Required
Front subframe adapter EOS02C00001 1
NOTE:. Use fender covers to avoid damaging painted
surfaces.. To avoid damage, unplug the wiring connectors
carefully while holding the connector portion.. Mark all wiring and hoses to avoid misconnection.
Also, be sure that they do not contact other wiring orhoses, or interfere with other parts.
1. Secure the hood in the wide open position (support
rod in the lower hole).
2. Make sure you have the anti-theft code for the radio,
then write down the frequencies for the radio'spreset buttons.
3. Disconnect the negative cable from the battery first,then disconnect the positive cable.
4. Remove the battery.
5. Remove the intake manifold cover.
II
5-2
\,
6. Disconnectthe intake airtemperature (lAT) sensorconnector (A), remove the breather hose (B) and
vacuum hose (C), then remove the air cleaner
housing cover/intake air duct assemblv (D).
AC
7. Remove the air cleaner housing.

Cylinder Head
14.
Cam Chain Removal (cont'd)
Loosely install the crankshaft pulley.
Turn the crankshaft counterclockwise to compress
the auto-lensioner,
Align the holes on the lock (A) and the auto-
tensioner (B), then insen a 1.5 mm (0.06 in.)
diameter pin (C) into the holes. Turn the crankshaft
clockwise to secure the Din.
t5.
6-14
\-
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16. Remove the auto-tensioner.
a
17. Remove the cam chain guide B.
gffi
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UU

Gylinder Head
Auto-Tensioner Removal/l nstallation
3. Align the holes on the lock (A) and the auto-
tensioner (B), then insert a 1.5 mm (0.06 in.)
diameter pin (C) into the holes. Turn the crankshaft
clockwise to secure the oin.
4. Remove the auto-tensioner.
6-20
\-
(cont'dl
Installation:
1. Install the auto-tensioner.
\
6x1.0mm12 N.m {1.2 kgt.m, 8.7 lbt.tt)
Remove the pin from the auto-tensioner.
a\

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

Piston Installation
lf the crankshaft is already installed
1. Setthe crankshaftto bottom dead center (BDC) for
each cylinder.
2. Remove the connecting rod caps, then install the
ring compressor, and check that the bearing is
securely in place,
3. Position the arrow {A) facing the cam chain side of
rne engtne.
Position the piston in the cylinder, and tap it in
using the wooden handle of a hammer (A).
N4aintain downward force on the ring compressor(B) to prevent the rings from expanding before
entering the cylinder bore.
Stop after the ring compressor pops free, and
check the connecting rod-to-crank journal
alignment before pushing the piston into place.
Check the connecting rod bearing clearance withplastigage (see page 7-8).
lnspect the connecting rod bolts (see page 7 241.
Apply engine oil to the bolt threads, then install the
rod caps with bearings. Torque the bolts to 20 N.m
{2.0 kgf m, 14 lbf ft) + 90'.
6.
7.
2.
1.
lf the crankshaft is not installed
Remove the connecting rod caps. then install the
ring compressor, and check that the bearing is
securely in place.
Position the arrow (A)facing the cam chain side of
Ine engrne.
Position the piston in the cylinder, and tap it in
using the wooden handle of a hammer (A),
Maintain downward force on the ring compressor(B) to prevent the rings from expanding before
entering the cylinder bore.
4. Position all pistons attop dead center.
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7-23

Intake Manifold and Exhaust System
Intake Manifold Removal and Installation (cont'dl
5. Be prepared to catch and clean up spilled coolant.
Remove the water bypass hoses, then plug the
water bypass hoses.
6. Relievefuel pressure (see page 11-'144).
7. Remove the fuel line (seepagell-149).
8. Remove the positive crankcase ventilation (PCV)
hose (A), harness holder mounting bolt (B) and
harness clamp mounting bolt (C).
9-4
\-
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9.Remove the engine wire harness connectors and
wire harness clamps from the intake manifold.
. Four injector connectors. ldle air control (lAC) valve connector. Throttle position (TP) sensor connector. fvlanifold absolute pressure {lvlAP) sensor
connector. Evaporative emission (EVAP)canister purge
valve connector
Remove the bolt securing the intake manifold and
bracket.
'1 0.
11.Remove allthe intake manifold mounting bolts/
nuts.
Remove the two stud bolts (A), then remove the
intake manifold (B).
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