coolant capacity HONDA CIVIC 2002 7.G Workshop Manual

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Lubrication
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|temMeasurementOualificalionStanderd or New Service Limil
Engine oilCapacity5.3 0 (5.6 US qt)for engine overhaul
4.2 0 (4.4 US qt) for oil change, including filter
4.0 0 (4.2 US qt)for oil change, without filter
Oilpumplnner-to outer rotor clearance0.02 0.16 mm {0.001 0.006 in.)0.20 mm (0.008 in.)
Pump housing to outer rotor
clearance
0-15 0.21 mm {0.006-0.008 in.)0.23 mm (0.009 in.)
Pump housing-to-rotor axial
clearance
0.02 0.07 mm (0.001 0.003 in.)0.12 mm (0.005 in.)
Balancer shafts, journal diameterNo. 1 journal, front
shaft
19.938 19.950 mm 10.7850 0.7854 in.)19.92 mm (0.784 in.)
No 1 journal, rear shaft23.938 23.950 mm (0.9424 0.9429 in.)23.92 mm (0.942 in.)
No. 2 journal, front and
rear shaft
32.949 32.961 mm 11.2912 1.2911 in.l32.93 mm (1.296 in.)
Ealancer shafts, journal taper0.005 rnm (0.0002 in.) max.
Balancer shafts, end playFront0.070 0.135 mm (0.0028 0.0053 in.)0.15 mm (0.006 in.)
Rear0.070 0.135 mm (0.0028 0.0053 in.)0.15 mm (0.006 in.)
Balancer shatts, shaft-to'bear;ng
clearance
No. 1 iournal, front
shaft
0.050 0.082 mm (0.0020 0.0032 in.)0.10 mm (0.004 in.)
No. 1 Journal, rear shaft0.050 0.082 mm (0.0020 0.0032 in.) 0.10 mm (0.004 in.i
No. 2 journal, front and
rear shafl
0.060 -0.120 mm (0.0024 0.0047 in.) 0.15 mm (0.006 in.)
Balancer shaft bearings, LD.No. 1 journal, front
shaft
No. 1 iournal, rear shaft
20.000 20.020 mm (0.1814 0.7442 in.l
Z+.OOO ZI.OZO m- tOSa+e- OSa57 ir'.)
20.03 mm (0.789 in.)
24.03 mm (0.946 in.)
No. 2 journal, front and
rear shaft
33.021 33.069 mm (1.3000 1.3019 in.)33.09 mm {1.303 in.)
Reliefvalve, oil pressure with oil
temperature at 176'F (80"C)
At idle70 kPa (0.7 kq?cm , 10 psr) min.
At 3,000 rpm300 kPa {3.1 ksf/cm',44 psi)min.
Standard or New Service Limit
6.7 L (7.1 USCoolant capacity {includes engine,
heater, hoses, and reservoir)
0.53 L (0.56 US
93 123 kPa (0.95 1.25 kqtcm , 14 18 psi)'t69 176'F (76 80'C)Thermostat OPeningtemPerature
8.0 mm {0.31 in.) min.
Turns OFF Subtract 5 15'F (3 8"C)from actual ON

Maintenance Schedule
Listed by Distance/Time for Normal Conditions
This two page l/lanitenance Schedule outlines the minimun required maintenance. Service at the indicated distance or time, whichever comesfirst. use the lvlaintenance Schedule for Severe conditions if the vehicle meets any of the qualifiers in the Severe Conditions schedule or if thevehicle is normally driven in Canada.
Inspect valve clearance. (cold) (see page 6-321r Intake: 0.21-0.25 mm (0.008 0.010 in.) Exhaust: 0.28 0.32 mm (0.011 0.013 in.)Replace spark plugs. Use IZFR6K'11 (NGK) or SKJ20DR-M11 (DENSO).1.0 1.1 mm
! Do items in A,B, alqq.,
120,000 mi/ 192,000 km/ 6 yearsI Replace transmission fluid.Use Honda MTF (see page 13-3).
/ / Y vcdrs120,000 mil 192,000Beplace coolant (see page 10 6). Capacity: 5.0 0 (5.3 US qt). Use Honda All Season Antifreeze/Coolant Type 2.
According to state and lederal regulations, tailure to do the maintenance items marked with an asterisk {*) will not void the customer'semissions warranties, However, Honda recommends that all maintenance services be done at the recommended interval to ensure long-termreliability.
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Do the items in parts A, B, C, D, and E as required for mileage/time interval listed.
AReplace engine oillsee page 8-5i. Capacity without lilter change: 4.0 S (4.2 US qt, 3.5 lmp qt)Rotate tires. Follow the pattern shown in the Owner's Manual Checktire information and condition.
BReplace engine oil filter lsee page 8-6). Capacity with filter change: 4.20 (4.4 US qt, 3.7 lmp qt)Inspect front and rear brakes (see page 19 3i.. Check pads and djscs for wear (thickness), damage, and cracks.' Check calipers tor damage, leaks, and tjghtness ot mount bolts.Check parking brake adjustment. Should be Iully applied within 7 to I clicks.Inspect tie rod ends, steering gearbox, and boots {see page 17 5).. Check rack grease and steering linkage.. Check boots for damage and leaking grease. Chack fluid line {or damage and leaks.lnspect suspension components.. Chock bolts fo r tig htness.. Check condition of ball ioint boots lor deterioration and damage.Inspect driveshaft boots. Check boots for cracks and boot bands for tightness (see page 16-3).Insp€ct brake hoses and lines {including ABS). Checkthe mastercylinder, proponioning control valve, and ABS modulator{or damageand leakage.Check all fluid levels and condition ot tluids; check for leaks. lf necessary, add MTF lsee page 13'3), engioe coolant, brake fluid, and
Lwindshield washer fluid.lnspectexhaust system*. Check catalytic converter heatshield, exhaust pipe and mufflerfordamage,leaks, and tightness {soe page 9,8).lnspect {uel lines and connections*. Check for loose connections, cracks and deterioration; retighten loose connoctions and replacedamaged parts (s€e page 11 146).
InsDect and adiust drive belt.. Look for cracks and damage, and inspect auto tensioner (needs no adjustment).Replace the dust and pollen lilter (see page 21 39).. Replacethe dustand pollen filter whenever airf low lrom the heating and cooling system is lessthan normal.
Replace air cleaner element every 30,000 miles (48,000 km) (independent of time).
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Ei I Replace brake fluid every 3 years (independent oI mileage).
According to state and federal regulations, failure to do the maintenance items marked with asterisk( * ) will not void customer's emissionswarranties. However, Honda recommends that all maintsnance service be done at the recommended interval to ensure long term reliability.
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Maintenance Schedule
Listed by Distance/Time for Severe Conditions
Service at the indicated distance or time, whichever comes first. Use this schedule if the vehicle is driven MAINLY in Canada or in any of thetollowing conditions; il only OCCASIONALLY driven in these conditions, use the Normal Conditions schedule (see page 3-4).Severe Driving Conditions. Driving less than 5 miles {8 km) per trip or, in freezing temperatures, driving less than 10 miles (16 km) per trip. Driving in extremely hot (over 90"F/32"C) conditions. Extensive idl;ng or long periods of stop and go driving, such as a taxi or a commercial delivery vehicle.. Trailer towing, driving with a car-top carrier, or driving in mountainous conditions.. Driving on muddy, dusty, or de'iced roads
Replace transmission fluid. Use Honda MTF {see page 13 3).
Inspect valve clearance. (cold) (see page 6 32): lntake: 0.21 0.25 mm (0.008 0.010 in.) Exhaust: 0.28 0.32 mm (0.011 0.013 in.)Replace spark plugs.Use IZFR6K 1 1 (N GK) or SKJ20DR'M 1 1 {DENSO)
km/ 6 yearsReplace transmission fluid. Use Honda MTF (see page 13 3).
mil 192,000 km/ 10 years, then every 60,000 mi/ 96,000 km/ 5 yearsReplace coolant (see page 10-6). Capacity: 5.0 015.3 US qt) Use Honda All Season Antifreeze/coo lant Type 2.
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Do the items in parts A, B, C, D, E, F, and G as required for mileage/time interval listed.
Feplace engine oil(see pageS 5). Capacity withoutlilter change:4.0 q (4.2 US qt,3.5lmp qt)
Replace engjne oil filter (see page I 6). Capacity with filter change: 4.2 0 14.4 US qt, 3.7 lmp qt)Insoect front and rear brakes,. Check pads and discsforwearlthickness), damage, andcracks.. Check calipers for damage, leaks, and tightness of mount bolts.Lubricate door locks, latches and hinges with Honda white lithium grease.Rotate tires, if the vehicle has been driven the distance listed. Follow the pattern shown in the Owner's Manual-Check tire inflaron aoocondition,Inspecttie rod ends, steering gearbox, and boots (see page 17,5).. Check rack grease and steering linkage.. Check boots for damage and leaking grease.. Checklluid linefordamage and leaks.Inspect suspensron components. Check bolts for tightness.. Check condition of ball joint boots for deterioration and damage.Inspect driveshaft boots. Check boots for cracks and boot bands for tightness (see page 16-3).
Check parking brake adjustment. Should be fully applied within 7 to 9 clicks.Insp€ct brake hoses and lioes. (including ABS). Check the master cylinder, proportioning control valve, and ABS modulator for damageand leakage (see page 19-24).Check all fluid levels and condition ot lluids; check for leaks. lf necessary, add MTF (see page 13 3), engine coolant, brake fluid, andwindshield washer f luid.Inspect exhaust system*. Check catalytic converter heat shield, exhaust pipe and muffler for damage, leaks, and tightness (see page 9 8).Inspect fuel lines and connections*. Check for loose connections, cracks and deterioration; retighten loose connections and replacedamaged pans (seo page 11'146).Check alllights. Checkfunction otallinterior and exterior lights, andthe position ofthe headlights (see page 22-68).Inspect the v€hicle underbody. Check the paint for damage, scratches, stone chippin0, and dents.
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InsDect and adiust drive belt.. Look tor cracks and damage, and inspect auto tensioner {needs no adjustment).Reolace dust and oollen filter.
Replace air cleaner element every 15,000 miles 124,000 km) in dustv condition {independent ol timei otherwise use Normal Conditionsscredule (see page 11-162).
lReplaceaircleanerelementevery30,000miles(48,000km)(independento{timei(seepagell-162).
Replace brake fluid every 3 years (independent oJ mileagei.
Replacethe dust and pollen Iilter every 15,000 miles ifvehicle is driven mostlywhere air has high concentration olsootfrom industryanddiesel powered vehiclesj also replace the dust and pollen filter anytime aarflow is less than ussal (see pags 21-39).
According to state and federal regulations, failure to do the maintenance items marked with asterisk (*) will not void customer's emissionswarranties. However, Honda recommends that all maintenance services be done at the recommended interval to ensure long-term reliability,
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1.
After the coolant has drained, tighten the radiator
drain plug securely. and installthe reserve tank
drain cap securely.
Fill the reserve tank to the MAX mark (A) with
Honda All Season Antifreeze/Coolant Tvpe 2
(P/N O1999-9001).
8. Pour Honda All Season Antifreeze/Coolant Type 2
into the radiator up to the base of the filler neck.
NOTE:. Always use Honda All Season Antifreeze/Coolant
Type 2 {P/N 01999-9001). Using a non-Honda
coolant can result in corrosion, causing the
cooling system to malfunction or fail.. Honda All Season Antifreeze/Coolant Type 2 is a
mixture of 50% antifreeze and 507o water. Pre-
mixing is not required.
Engine Coolant Refill Capacity including the
reserve tank capacity of 0.53 4 (0.56 US gtl :
5.0 0 (s.3 US qt)
Installthe radiator cap loosely.
Start the engine, and let it run until it warms up (the
radiator fan comes on at least twice).
Turn off the engine. Check the level in the radiator,
and add Honda All Season Antifreeze/Coolant Type
2 if needed.
Put the radiator cap on tightly, then run the engine
again and check for leaks.
lnstall the splash shield (see step 22 on page 5-12).
10.
11.
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\Body Electrical
Body ElectricalSpecialToolsGeneral Troubleshooting tntorrnaiion.'......
Relay and Control Unit Locations .....
Connectors and Harnesses
Fuse/Relay Boxes ...............................
Power Distribution .............................
Ground Distribution ...........................
Under-dash Fuse/Relay Box ..............
Battery ..............
Relays ................
*lgnition Switch ..............
*Gauges
Component Location Index .......................Self-diagnostic Procedure ..........................Circuit DiagramGauge Bulb Replacement ..........................Gauge Assembly ReplacementCoolant Temperature
Gauge Troubleshooting .... ....................Vehicle Speed Signal CircuitTroubleshootingVSS Replacement
Exterior LightsComponent Location Index .......................Circuit DiagramDaytime Running Lights ControiUnit Input Test (Canada) ........................Headlight Ad,ustment .................. .. .....Headlighr Replacement ..............................Combination Light SwitchTest/ReplacementBulb ReplacementTaillight Replacement ..........................High Mount Brake Light Replacement ......License Plate Light Replacement ..............Side Marker Light Replacement ................Brake Pedal Position Switch Test ..............Side Turn Signal Light Replacement ........
Turn Signal/HazardFlasher SystemComponent Location Index .......................Circuit DiagramTurn Signal/Hazard Relay lnputTest ........Hazard Warning Switch Test
22,3
22-7
22-13
22-44
22-46
22-4A
22-49
22-50
22-51
22-53
22-5422-5622-5422 6322-64
22-64
22-6522 61
22-6822--71
22-7 622-7422-79
22-AO22-4122-8222-4222-4322-4322-4422-84
22-8522 A622-8722-88
22-10422-105
22-10622-107
Entry Lights control systemComponent Location Index ....................... 22-89Circuit Diagram ......... 22 90lgnition Key Switch Test .....................,...... 22-9'llgnition Key Light Test ............................... 22-91Control Unit Input Test ..........,.................... 22 92
Interior LightsComponent Location Index ....................... 22-94Circuit Diagram ......... 22-95Ceiling LighVSpotlightsTesVReplacement ................................... 22-96Rear Ceiling Light TesVReplacem ent ........ 22-96Cargo Area Light Test/Replacem ent ......... 22-97Hatch Latch Switch Test ..,..,....................... 22-97
*Audio SystemComponent Location Index ....................... 22-98Circuit Diagram ......... 22,99Audio Unit Removal/lnstallation ............... 22-1OOAudio Unit Connector Replacement ......... 22-101Speaker Replacement ................................ 22-102Roof Antenna Rep1acement ....................-.. 22-103
Rear Window DefoggerComponent Location Index ...........Circuit Diasram .. ....... .. ..... ....... ...:::::.::.::.Function TestDefogger Wire Repair .................................Noise Condenser CapacityTest ................
MoonroofComponent Location Index ....................... 22-1OBCircuit Diagram ......... 22-109Moonroof Control Unit Input Test ............. 22-'l10Switch TesVReplacement ........,.....,........... 22-1 12Motor Test ................. 22-112Limit Swilch Test ...... 22-'l'13Auto-stop Switch Test ................................ 22-1 13
Power MirrorsComponent Location Index ....................... 22-114Circuit Diagram ......... 22-115Function Test ............. 22-116Power Mirror Switch Test .......................... 22-ll7Power Mirror Actuator Test ....................... 22-117Power Mirror Actuator Replacement ........ 22-11A
* HornsComponent Location Index ....................... 22-120Circuit Diagram ......... 22-121Horn TesVReplacement ...........................-. 22-122Horn Switch Test .,.... 22-122
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