cooling HONDA CIVIC 2002 7.G Workshop Manual

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).
l
D
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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3-5

Spark Plug Inspection
1.Inspect the electrodes and ceramic insulator.
Burned or worn electrodes may be caused by:. Advanced ignition timing. Loose spark plug
. Plug heat range too hot.Insufficientcooling
Fouled plug may be caused by:. Retarded ignition timing. Oil in combustion chamber. Incorrect spark plug gap
. Plug heat range too cold. Excessive idling/low speed running. Clogged air cleaner element. Deteriorated ignition coils
Worn or deformedelectrodes
Do not adjust the gap of iridium tip plugs (A);
replace the spark plug if the gap is out of
specification.
Electrode Gap:
Standard (New): 1.0 1.1 mm
{0.039-0.0€ in.)
Service Limit: 1.3 mm {0.051 in.l
f .lmproper gap
I J.Oil-toulingr- 1 . Cs6on deposits' I . Cracked center electrode insulator
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3. Replace the plug at the specified interval, or if the
center electrode is rounded {A). Use onlV the spark
plugs listed below.
Spark Plugs: lZFR6Kl1 (NGK)
SKJ2ODR-M11 (DENSO)
Apply a small quantity of anti-seize compound to
the plug threads, and screw the plugs into the
cylinder head finger-tight. Then torque them to
18 N m (1.8 kgf.m, 13lbf ft).
4.
4-19

40. Install the air cleaner housinq.
6x1.0mm12 N m (1.2 kgf.m,8.7 lbt.ft)
Install the air cleaner housing cover (A) and
connect the intake air temperature (lAT) sensor
connector (B),
42. Installthe breather hose (C) and vacuum hose 1D).
41.
43. Installthe intake manifold cover.
6x1.0mm12Nm11.2kgf.m.8.7 tbf.ft)
Installthe battery. Clean the battery posts and
cable terminals with sandpaper, then assemble
them and apply grease to prevent corrosion.
Check that the transmission shifts into gear
smoothly.
Inspect for fuel 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 this operation two or three times, then
check for fuel leakage at any point in the fuel line.
Refillthe engine with engine oil (see page 8-5).
Refill the transmission with fluid (see page 13-3).
Refill the radiator with engine coolant, and bleed
air from the cooling system with the heater valve
open (see page 10-6).
Perform the engine control module (ECM) idle learnprocedure (see page 11-139).
Inspect the idle speed (see page 1 1-138).
Inspect the ignition timing (see page 4-17).
Check the wheel alignment {see page 18-4).
Enter the anti-theft code for the radio, then enter
the customer's radio station presets.
Set the clock.
YE
44.
41.
]tE
46.
48.
49.
52.
53.
54.
50.
51.
55.
5-15

Cylinder Head
Engine Compression Inspection
1. Warm up the engine to normal operating
temperature (cooling fan comes on).
2. Turn the ignition switch OFF.
3. Remove the intake manifold cover (see step 1 onpage 6-22).
4, Disconnect all four injector connectors.
5. Start the engine, and let it run until it stalls.
6. Remove the iour ignition coils (see page 4-18).
7. Remove the four spark plugs.
8. Attach the compression gauge to the spark plug
note.
6-6
V,
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9.
10.
Open the throttle fully, then crank the engine with
the starter motor and measure the compression.
Compression Pressure
Above 930 kpa (9.5 kgf/cm', 135 psi)
Measure the compression on the remaining
cylinders,
Maximum vadation
Within 200 kPa (2.0 kgf/cm', 28 psi)
lf the compression is not within specifications,
check these items, then remeasure the
compressron.
. Damaged orworn valves and seats. Damaged cylinder head gasket. Damaged or worn piston rings. Damaged orworn piston and cylinder bore
11.
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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

lntake Manifold and Exhaust System
Intake Manifold Removal and Installation (cont'd)
9. lnstallthe air cleaner housing cover (A), and
connect the IAT sensor connector (B).
BC
Installthe breather hose (C).
lnstallthe EVAP canister hose (A), brake booster
vacuum hose (B), and vacuum hoses {C).
10.
11.
9-6
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12. Installthe intake manifold cover.
6x1.0mm12 N.ml.1.2k91.m,8.7 tbf.ftl
Clean up any spilled engine coolant.
After installation, check that all tubes, hoses, and
connectors are installed correctly.
Inspect for fuel 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 this operation two or three times, then
check for fuel leakage at any point in the fuel line.
Refill the radiator with engine coolant, and bleed
air from the cooling system with the heater valve
open (see page 10-6).
to.
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Engine Cooling
Cooling System
Component Location Index ......................................... 10-2
Radiator Cap Test ..................... .......... 10-3
RadiatorTest ............. 10-3
Fan Motor Test .......... l0-4
Thermostat Test ...................... ........... 10-4
Water Pump Inspection ..................... 10-5
Water Pump Replacement ................. 10-5
Coolant Check .............. ....................... 10-6
Coolant Replacement ......................... 10-6
Thermostat Replacement .................. 10-8
Water Passage Installation ................ 10-9
Water Outlet Installation .................... 10-9
Radiator and Fan Replacement ................................... 10-10
Fan Controls
Component Location Index ......................................... 10-11
Symptom Troubleshooting Index ............................... 10-12
Circuit Diagram ......... 10-13
Radiator Fan CircuitTroubleshooting ........................ 10-14
Radiator Fan Switch Circuit Troubleshooting
(Open) ............ ........ 10-16
Radiator Fan Switch Circuit Troubleshooting
(Short) ............ ........ 10-16
Radiator Fan Switch Test ................... 10-17
Radiator Fan Switch Reolacement .............................. 10-17

Cooling System
Component Location Index
WATER PUMPInspection, page 10-5Replacement. page 10-5
RESERVETANK
RADIATORCAP
RAOIATOR FAN SWITCHTest, page 10-17Replacement, page 10'17
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WATER OUTLET,Installation, page'10-g
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CONNECTING PIPE
WATER PASSAGEInstallation, page 10-9
THERMOSTATTest, page 10 4Replacement, page 10 8
RADIATORReplacement, page 10-'l0
RADIATOR FANASSEMgLYReplacement, page 10-10Fan MotorTest, page 10 4A/C CONDENSERFAN ASSEMBLYReplacement, page 10 10Fan Motor Test, page '10-4
10-2
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Cooling System
Fan Motor Test
1. Disconnect the 2P connectors from the radiator fan
motor and condenser fan motor.
Test the motor by connecting battery power to the
B terminal and ground to the A terminal.
lf the motor fails to run or does not run smoothly,
reptace rL
10-4
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Thermostat Test
Replace the thermostat if it is open at room
remperalure.
To test a closed thermostatl
1. Suspend the thermostat (A) in a container of water.
Do not let the thermometer {B) touch the bottom of
the hot container.
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2.
3.
Heat the water, and check the temDerature with a
thermometer. Check the temperature at which the
thermostat first opens, and at which it is fully open.
Measure the lift height of the thermostat when it is
fullv ooen.
STANDARD THERMOSTAT
Lift height; above 8.0 mm (0.31 in.)
Starts opening: 169 176"F(76 80"C)
Fully open: 194"F {90'Cl
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1.
2.
Water Pump Inspection
Remove the drive belt (see page 4-26),
Turn the water pump pulley counterclockwise.
Check that it turns freely.
Check for signs of seal leakage. A small amount of"weeping" from the bleed holes (A) is normal.
Water Pump Replacement
1. Remove the drive belt (see page 4-26).
2. Drain the engine coolant {see page 10-6).
3. Remove the crankshaft pulley (see page 6-11).
4. Remove the six bolts securing the water pump,
then remove the water pump (A).
6x1.0mm12 N m {1.2 kgt m,8.7 rbf.ft)
Inspect and clean the O-ring groove and mating
surface with the water passage.
Installthe water pump with new O rings in the
reverse order of removal.
7. Clean up any spilled engine coolant.
8. Installthe crankshaft pulley (see page 6-12).
L Refill the radiator with engine coolant, and bleed
air from the cooling system with the heater valve
open {see page 10-6}.
10-5