battery replacement HONDA CIVIC 2002 7.G Workshop Manual

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

Gharging System
Component Location Index
CHARGING SYSTEM INDICATOR(ln the gauge assembly)
q*o
DRIVE BELTInspection, page 4 26Replacement, page 4 26
BATTERYTest, page 22-50
ALTEBNATORTroubleshooting, page 4-22Replacement, page 4-29Overhaul, page 4-30
4-20

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

Fuel and Emissions Systems
General Troubleshooting Information (cont'd)
ECM Updating and Substitution for Testing
Special Tools Bequired
Honda Interface Module (HlM) EOS05435570
Use this procedure when you have to substitute a
known-good ECM in a troubleshooting procedure.
U pdate the ECM only if the ECN4 does not already have
the latest software loaded,
NOTE;. lMake sure the battery is fully charged before you
update the ECN4.. To prevent ECM damage during the update, do not
turn the ignition switch OFF, and do not use any of
the vehicle's electrical devices (light, horn, radio, etc. ).
How to Update the ECM
1. Turn the ignition switch ON (ll). Do not startthe
eng Ine.
2. Connect the Honda lnterface Module (HlM) to the
Data Link Connector {DLC) (A) located under the
driver's side of dashboard.
EOS05A35570
Do the ECM update procedure as described on the
HlN4 label and in the ECM update system.
11-6
\-
How to Substitute the ECM
'1. Remove the ECM f rom the vehicle.
2. Install a known-good ECM in the vehicle.
3. Rewrite the immobilizer code with the ECM
replacement procedure from the Honda PGM
Tester. lt allows you to start the engine.
4. After completing your tests, reinstall the original
ECM and rewrite the immobilizer code with the
ECM replacement procedure on the Honda PGM
Tester again.
L
(
I

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.

Clutch
Slave Cylinder Replacement (cont'd)
11. Bleed the clutch hydraulic system.
. Aftach a hose to the bleeder screw (A), and
suspend the hose in a container of brake fluid.. Make sure there is an adequate supply offluid in
the clutch master cylinder, then slowly pump the
clutch pedal until no more bubbles appear atthe
bleeder hose.. lt may be necessary to llmit the movement of the
release fork (B) with a block of wood to remove
all the air from the system.. Tighten the bleed screw to I N.m (0.8 kgf.m, 6 lbf
ft); do not ovenighten it,. Refill the clutch master cylinder with fluid when
done.. Always use only Honda DOT 3 brake fluid.
Install the intake air duct (see step 36 on page 5-14).
Installthe air cleaner housing (see step 37 on page
5-15).
Install the battery tray.
Install the battery, connect the positive (+) cable
first, then the negative (- ) cable.
Reset the frequencies for the radio station preset
buttons,
12.
13.
14.
t5.
16.
12-8
L

Dashboard
Dashboard Removal/lnstallation
(cont'd)
11. From outside the driver's door, remove the caps (A),
then remove the bolts (8, C, D), and lift up on the
dashboard (E) to release it from the guide pins
(F. G) on the body.
Fastener Locations
B>rBolt.3 C>: Bolt,2 D>: Bolt,2
m6[-,,,,",",,-,F6't---'' ffi'!--v{/- Kr* w-
B
$7:
^/761:
/,-,. r:; 8 x 1.25 mm22Nm(2.2 kgf.m, 16lbf.ft)
13.
{2.2 kgf m, 16lbf.ftl
Carefully remove the dashboard through the front
door opening.
lnstall the dashboard in the reverse order of
removal, and note these items:
. Make sure the dashboard fits onto the guide pins
correctly.. Apply liquid thread lock to the dashboard
mounting bolts of the middle portion before
reinstallation.. Before tightening the bolts, make sure each wire
harness and control cables are not pinched.
. Make sure the connectors are plugged in
properly, and the antenna lead is connected
propeny.. Reconnect the negative cable to the battery.. Enter the anti-theft code for the radio, then enter
the customer's radio station presets.
. Reset the clock.. Do the ECM/PCM idle learn procedure isee page
1 '1-139).
20-68
Steering Hanger Beam
Replacement
NOTE: Put on gloves to protect your hands.
1, Remove the dashboard (see page 20-66).
2. Remove these items from the dashboard:
. lnstrument panel (see page 20-59). Driver's pocket (see page 20-60). Gauge assembly (see page 22-64). Passenger's airbag (see page 23-'l 14)
Remove the screws, then remove the glove box
striker (A).
Fastenea Locations
):Screw,4
\

Heating and Air Conditioning
A/C Service Tips and Precautions
Compressed air mixed with R- 134a forms a
combustible vapor.
The vapor can burn or explode causing serious
injury.
Never use compressed air to pressure test
R-134a service equipment or vehicle air
conditioning systems.
Air conditioning refrigerant or lubricant vapor
can irritate your eyes, nose, or throat.
Be careful when connecting service equipment.
Do not breathe refrigerant or vapor.
The air conditioning system uses HFC-134a (R-134a)
ref rigerant and polyalkyleneglycol (PAG) ref rigerant oil,
which are not compatible with CFC'12 (R-12) refrigerant
and mineral oil. Do not use R-'12 refrigerant or mineral
oil in this system, and do not aftempt to use R 12
servicing equipment; damage to the air conditioning
system or your servicing equipment will result.
Use only service equipment that is U.L.-listed and is
certified to meet the requirements of SAE J2210 to
remove R-134a from the air conditioning system.
lf accidental system discharge occurs, ventilate the
work area before resuming service.
R-134a service equipment or vehicle air conditioning
systems should not be pressure tested or leak tested
with compressed air.
Additional health and safety information may be
obtained from the refrigerant and lubricant
manufacturers.
. Always disconnect the negative cable from the
battery whenever replacing air conditioning parts.
. Keep moisture and dirt out of the system. When
disconnecting any lines, plug or cap the fittings
immediately; don't remove the caps or plugs until
iust be{ore you reconnect each line.' Before connecting any hose or line, apply a few drops
of relrigerant oil to the O-ring.. When tightening or loosening a fitting, use a second
wrench to support the matching fitting.. When discharging the system, use a R-'134a
ref rigerant recovery/recycling/charging station; don't
release refrigerant into the atmosphere.
21-6
A: 130 m0 {4 l/3 tl.oz,4.6 lmp.oz)
],^
A/C Refrigerant Oll Replacement
Recommended PAG oil: KEIHIN SP 10:
. P/N 38897-P l3-A01AH: '120 m0 i4 fl oz). P/N 38899-P13'A01: 40 m0 i1 1/3 fl oz)
Add the recommended refrigerant oil in the amount
listed if you replace any of the following parts.
. To avoid contamination. do not return the oilto the
container once dispensed, and never mix it with other
refrigerant oils.. lmmediately af'ter using the oil, reinstallthe cap on
the container, and seal it to avoid moisture
aosorpron.. Donotspill the refrigerant oil on the vehicle; it may
damage the paint. lf it gets on the paint, wash it off
immediately.
Condenser ...........25 mA \516 tl.oz, 0.9 lmp.oz)
Evaporator ........... 45 m0 (1 113Il.oz, '1.4 lmp.oz)
Line or hose ......... '10 m0 {1/3 fl.oz,0.4 lmp.oz)
Receiver/Dryer .... '10 m0 ('113 fl.oz,0.4 lmp.oz)
Leakage repai r .... 25 m0, 1516 Il oz, 0.9 lmp.oz)
Compressor ......... For compressor replacemenl,
subtract the volume of oil drained
from the removed compressor from
130 m0 (4 1/3fl.oz, 4.6lmp.oz), and
drain the calculated volume of oil
f rom the new compressor: '130 m0
i.4113 fl.oz,4.6 lmp.oz) Volume of
removed compressor = Volume to
drain from new compressor.
NOTE: Even if no oil is drained from
the removed compressor, don't
d rain more than 50 m0 \1 2/3 fl.oz,'1.8 lmp oz)from the new
compressor.
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REMOVEDCOMPBESSOR
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NEWCOMPRESSOR
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I I I DRAINING_*lH I voLUME

Heating and Air Conditioning
Air Mix Control Motor Test
1. Disconnect the 5P connector from the air mix
control motor.
2. Connect battery powertothe No. l terminal ofthe
air mix control motor, and ground the No. 2
terminal; the air mix control motor should run, and
stop at Max Cool. lf it doesn't, reverse the
connections;the air mix control motor should run,
and stop at Max Hot. lf the air mix control motor
does not run, remove it. then check the air mix
control linkage and door for smooth movement.
. lf the linkage and door move smoothly, replace
the air mix control motor.. lf the linkage ordoorstickor bind, repairthem as
needed.. lf the air mix control motor runs smoothly, go to
step 3.
AIR MIX CONTROL MOTOR
3.
4.
Measure the resistance between the No. 4 and
No. 5 terminals. lt should be between 2.1 k to
3.9 kQ.
Reconnect the air mix control motor 5P connector,
then turn the ignition switch ON {ll).
Using the Backprobe Set, measure the voltage
between the No. 3 and No. 4 terminals.
Max Cool about 1V
Max Hot about 4 V
lf either the resistance or voltage readings are not
as specified, replace the air mix cotrol motor.
21-34
Air Mix Control Motor Replacement
1.Remove the under-dash fuse/relay box (see page
22-491.
Disconnect the 5P connector {A) from the air mix
control motor (B). Remove the self-tapping screws
and the air mix control motor from the heater unit.
Remove the rod (C) from the arm (D) of the air mix
controi motor.
Install the motor in the reverse order of removal.
After installation, make sure the motor runs
smoothly.
3.
\'
,.,:l'

Mode Control Motor Test
Disconnect the 10P connector from the mode
control motor.
Connect battery power to the No. 1 terminal of the
mode control motor, and ground the No. 2
terminal; the mode control motor should run
smoothly and stop at Defrost. lf it doesn't, reverse
the connections; the mode control motor should
run smoothly and stop at Vent. When the mode
control motor stops running, disconnect battery
power immediately.
'1.
4.
MODE CONTROL MOTOR
3. lfthe mode control motor does not run in step 2,
remove it, then check the mode control linkage and
doors for smooth movement.
. lf the linkage and doors move smoothly. replace
the mode control motor.. lf the linkage ordoorsstick or bind, repairthem
as neeoeo.. lfthe mode control motor runs smoothly, go to
step 4.
Use a digital multimeter with an output of 1 mA or
less at the 20 k Q range. With the mode control
motor running as in step 2, check for continuity
between the No. 4,5,6,7,8, and 9 terminals and
the No. 10 terminal individually. There should be
continuity for a moment at each terminal as the
motor moves past each mode position.
lf there is no continuity for a moment at each
terminal. replace the mode control motor.
Mode Control Motor Replacement
2.
3.
1.Remove the ECM (see page 11-4).
Remove the relay mount bracket bolt, and move
the relays out of the way.
Disconnect the 10P connector {A) from the mode
control motor (B). Remove the self-tapping screws
and the mode control motor from the heater unit.
lnstallthe motor in the reverse order of removal.
lvlake sure the pin on the linkage is properly
engaged with the motor. After installation. make
sure the motor runs smoothly.
4.
21-35