height HONDA CIVIC 2002 7.G Workshop Manual

General Information
Lift and Support Points
NOTE: If you are going to remove heavy componentssuch as suspension or the fuel tank from the rear of thevehicle, first supportthe front ofthe vehicle with tallsafety stands. When substantialweight is removed
from the rear of the vehicle, the center of gravity canchange and cause the vehicle to tip forward on the hoist.
Frame Hoist
1. Position the hoist lift blocks (A), or safety stands,under the vehicle's front support points (B) and rearsupport points (C).
2. Raise the hoist a few inches, and rock the vehiclegently to be sure it is firmly supported.
3. Raise the hoistto full height, and inspectthe liftpoints for solid contact with the lift blocks.
Safety Stands
To support the vehicle on safety stands. use the samesuppon points (B and C) as for a frame hoist, Alwaysuse satety stands when working on or under anyvehicle that is supported only by a jack.
1-8
Floor Jack
1. Set the parking brake.
2. Block the wheels that are not being lifted.
3. When lifting the rear of the vehicle. put thegearshift Iever in reverse.
4. Position the floor jack under the front jacking
bracket (A) or rear jacking bracket (B), center thejacking bracket in the jack lift ptatform (C), and jack
up the vehicle high enough to fit the safety standsunder it.
c
Position the safety stands underthe support points
and adjust them so the vehicle will tevet.
Lower the vehicle onto the stands.
0
Jt

L
vlo
2-3
a
ead
o
nder H
ItemMeasur6mentOualificationStandard or NewService Limit
HeadWarpage0.05 mm {0.002 in.)
Height'103.95 104.05 mm
(4.093 4.096 in.)
CamshaftEnd play0.05 0.20 mm (0.002 0.008 in.)0.4 mm (0.02 in.)
Camshaft to holder oil clearanceNo.l journal0.030 0.069 mm
{0.001 0.003 in.)
0.15 mm {0.006 in.)
No.2,3, 4,5
journals
0.060 0.099 mm
(0.002- 0.004 in.)
0.15 mm (0.006 in.)
Total runout0.03 mrn (0.001 in.) max.0.04 mm {0.002 in.)
Cam lobe heightIntake, primary33.925 mm (1.3356 in.)
Intake,29.638 mm (l.1668 in.)
Exhaust34.092 mm (1.3422 in.)
clearance (cold)lntake0.21 0.2s mm 10.008 0.010 in.)
Exhaust0.28 0.32 mm (0.011 0.013 in.)
Stem O.D-lnlaKe5.475 5.485 mm 10.2156 0.2159 in.)5.445 mm (0.214 in.)
Exhaust5.450 5.460 mm (0.2146 0.2150 in )5.42 mm (0.213 in.)
Stem-to-gLride clearancelntake0.030 0.055 mm (0.0012 0.0022in.|0.08 mm (0.003 in.)
Exhaust0.055 0.080 mm (0.0022 0.0031 in )0.11 mm (0.004 in.)
lntake1.25 1.55 mm (0.049 0.061 in.)2.00 mm {0.079 in.)
Exhaust1.25 1.55 mm (0.049 0.061 in.)2.00 mm {0.079 in.)
stem installed heightlntake40.8- 41.0 mm (1.606 1.614in.)
Exhaust54.6 54.8 mm (2.150 2.157 in.)
Valve springsFree lengthlntake47.61 mm (1.874 in.)
Exhaust49.64 mm (1.954 in.)
Valve guidesLD.Intake5.515 5.530 mm
|.0.2171 0.2117 4n.1
5.55 mm (0.219 in.)
Exhaust5.515 5.530 mm
\0.2111 0.2177 in.l
5.55 mm {0.219 in.)
Installed heightlntaKe15.2 "16.2 mm (0.598 0.638in.)
Exhaust15.5 16.5 mm (0.610 0.650 in.)
Rocker armsArm-to-shaft clearancelntaKe0.025 0.052 mm
(0.00'10 0.0020 in.)
0.08 mm (0.003 in.)
Exhaust0.018 0.056 mm
(0.0007 0.0022 in.)
0.08 mm (0.003 in.)

ItemMeasulementOualificationStandard or New Service LimitFuel pressure
regulator
Pressure with fuel pressure gauge
connected
320-370 kPa 13.3-'3.8 kgtcm', 47 52psi)
FueltankCapacity50 4 (13.2 US galiEngine idleldle speed with headlights and radiator
fan off
Neutral750 50 rpm
Fast idleNeutral1,600150 rpm
Standards and Service Limits
Fuel and Emissionsf
.\
ra
Clutch
ItemMea3urem€nlOualificationSlandard or NewService LimitClutch pedalHeight from the floor193 mm (7.60 in.)Stroke130 140 mm 15.1 5.5in.)
10 16 mm (0.39 0.63 in.)Disengagement height from the floor1'15 mm (4.53 in.) min.Bunout on clutch mating surface0.05 mm 10.002 in.) max.0.15 mm (0.006 in.)Clutch discBivet head depth1.65 2.25 mm (0.065 0.089 in.)0.7 mm {0.03 in.)Ihickness8.3 8.9 mm (0.33 0.35 in.)6.0 mm (0.24 in.)Pressure plateWarpage0.03 mm (0.001 in.)max.0.15 mm (0.001 in.)Height of diaphragm spring fingersMeasured with
specialtool and
feeler gauge
0.6 mm (0.02 in.) max.0.8 mm (0-03 in.)
2-6
\

ItemM€asurementOualificationStandard or NewService LimitParking brake
lever
Distance traveled when lever pulled
with 196 N (20 kgf, 44 lbs) ol force
7 8 clicks
Brake pedalPedal height (carpet removed)184 mm (7 4/16 in.)
Free play0.4 3.0 mm (0 016 0 '118 in.)Master cylinderPiston-to-pushrod clearance0 0.4 mm (0 0.02 in.)Erake discThicknessFront21.0 mm (0.83 in.)19.00 mm (0.75 in.)
Rear9.0 mm {0.35 in.)8-0 mm (0.31 in.iRunoutFront0.10 mm (0.004 in.)
Rear0.10 mm (0.004 in.)ParallelismFront and rear0.015 mm (0.0006 in.)Brake padsThicknessFront10.0 mm (0.39 in.)1.6 mm (0.06 in.)
llear9.0 mm {0.35 in.)1.6 mm (0.06 in.)
Standards and Service Limits
Brakes
a
e-o
Air Gonditionin
ItemMoasurementOualilicationStandard or New Service LimitRefrige.antTvpeHFC 134 a (B-134 a)
Capacity of system500 550 g 117.6 19.4 oz)Refrigerant oilTypeSP 1O
(P/N 38897-P13-A01AH or 38899-P13-A01 )Capacity ofcomponentsCondenser25 m0, 15/6 fl ozl
Evaporator45 mA 11 1/2 fl ozt
Each line and
hose
10 m0 (1/3 fl or)
Compressor130 150 m014 1/3 5floz)CompressorStarter coil resistanceAt 68"F (20"C)3.05 3.35 0Pulley-to-pressure plate clearance0.35 0.6 mm (0.014 0.024 in.)Drive beltAuto tensioner lneeds no adjustment)
2-10
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2-11
Design Specifications
O
o
o
|temMeasurementOualificationSpecilication
DIMENSIONSOveralllength4,210 mm {165.8 in.)
Overallwidth1,695 mm 166.7 in.)
Overallheight1,440 mm (56.7 in.)
2,570 mm (101.2 in.)
Trackrront1,470 mm (57.9 in.)
Rear'1,470 mm (57.9 in.i
Ground clearance152 mm (5.98 in.)
Seating capacityfour {4)
wEtGt-iT {u.s.A.)Gross Vehicle Weight Rating
(GVWR)
3,660 rbs
WEIGHT
(CANADA)
Gross Vehicle Weight Rating
{GVWR)
1,660 kg
ENGIN ETvpeWater cooled. 4 stroke DOHC V-EC engin(
Cylinder arrangementInline 4'cylinder, transverse
Bore and stroke86 x 86 mm (3.39 x 3.39 in.)
Displacement1,998 cm'(122 cu in.)
Compression ratio9.8
Valve trainChain drive. DOHC VTEC 4 valves per cylinder
Lubrication systemForced, wet sump, with trochoid pumP
Oil pump displacementAt 6,000 engine
rpm
54.3 0 (57.4 US qo/minute
Water pump displacementAt 3,400 engine82 0 (87 US qt)/minute
F!el requiredUNLEADED gasoline with 86 pump octane number or higher
STARTERTvpeGear reduction
Normaloutput
Nominalvoltage12V
Hour rating30 seconds
Direction of rotationClockwise as viewecl from gear end
CLUTCHClutch tvpeSinqle plate dry, diaphragm spring
Clutch friction material surface area174 cm'{26.97 sq in.)
I\,1AN UAL
TRANSMISSION
TvpeSvnchronized, s-speed forward, 1 reverse
Primarv reductionDirect 1:1
Gear ratiolst3.062
2nd1.769
3rd1.212
4th0.921
5th0.738
Reverse3.583
FinalreductionTypeSinole helicalgear
Gear ratio4.164

Starting System
Starter Circuit Troubleshooting
(cont'dl
6. Check the following items in the order listed untilyou find the open circuit.
. Check the BLIVWHT wire and connectors
between the under-dash fuse/relay box and theignition switch, and between the under-dash
fuse/relay box and the starter.. Check the ignition switch {see page 22-53).. Check the clutch interlock switch and connector.. Check the starter cut relay (see page 22-51).. Check LT GRN wire between the starter cut relayl
under-dash fuse/relay box and the clutch
interlock switch.. Check the BLK wire between the clutch interlock
switch and G501.
7, Check the cranking voltage and current draw.
ls ctanking voltage greatet than or equal to 8.7 V
and current draw less than or equal to 230 A?
YES-Go to step 8.
NO Replace the starter. or remove and
disassemble it, and check these items until you find
the cause.
. Starter armature dragging. Shorted armatu re winding. Excessive drag in engine
8. Check the engine speed while cranking the engine.
ls the engine speed above 100 tpm?
YES Go to step 9.
NO-Replace the starter, or remove and
disassemble it, and check for the following untilyou find the cause.
. Excessively worn starter brushes. Open circuit in commutator brushes. Open circuit in starter armature commutator
segments. Dirty or damaged helical splines or drive gear. Faulty drive gear clutch
9. Remove the starter, and inspect its drive gear andthe flywheel ring gear for damage. Replace anydamaged pans.I
4-6
Clutch Interlock Switch Test
1. Disconnect the clutch interlock switch 2P connector.
2. Remove the clutch interlock switch (A).
Check for continuity between the terminals
according to the table.
. lf the continuity is not as specified, replace the
clutch interlock switch.. lf OK, install clutch interlock switch and adjust
the pedal height (see page 12-4l..
Terminal
Cl","f ri"t.tf ."tS""*Jrl2
PRESSEDo--- --o
RELEASED

'10. Check continuity between the ECM connector
terminal 810 and body ground.
ECM CONNECTOR S I24PI
23 t4 t567
8I10,/1,/315
118,Nnt,/2123
ACGL (WHT/BLUI
t1'
Wire side ol female terminals
ls there continuity?
YES- Repair short to ground in the wire between
the ECM and the engine wire harness 6P connector.
t
NO-Go to alternator and regulator test.
Alternator and Regulator Circuit Test
1. Be sure the battery is sufficiently charged and in
good condition {see page 22-50), and the
connections at the fuse box and alternator are
clean and tight.
2. Raise the hoist to full height.
3. Hook up the ammeter, 0 400 A, to the starter
sub harness.
Lower the hoist.
Hook up the voltmeter, 0 20 V (accurate within
0.1V),toT101.
(cont'd)
4-23

Gruise Control
Component Location Index
CLUTCH PEDAL POSITIONswtTcHTest, page 4-45Clutch Pedal Adjustment,page 12-4
t.- _,- _
CRUISE CONTROLACTUATORTest, page 4'43Replacement, page 4-44
CRUISE CONTROL UNITlnput Test, page 4-40
BRAKE PEDAL POSITION SWITCHTest, page 22-84Pedal Height Adjustment, page '19-6
CRUISE CONTROL INDICATOR(Built into gaug6 assembly)
ACTUATOR CABLEAdjustment, page 4-45
-ll
4-36
\-a

Actuator Cable Adiustment
1. Check that the actuator cable {A) moves smoothly
with no binding or sticking.
2. Start the engine.
3. Measure the amount of movement of the output
linkage (B) until the engine speed starts to increase.
At first, the output linkage should be located at the
fully closed position (C). The free play (D) should be
3.7510.5 mm (0.1510.02 in,).
4. lf the free play is not within specs, loosenthe
locknut (E). and turn the adjusting nut (F) untilthe
free play is as specified, then retighten the locknut
Clutch Pedal Position Switch Test
1. Disconnect the 2P connector from the clutch pedal
position switch (A),
CLUTCH PEOAL POSITION SWITCH 2P CONNECTOR
Terminalside ofmale terminals
Remove the clutch pedal position switch.
Check for continuity between the terminals
according to the table.. lf the continuity is not as specified, replace the
clutch pedal position switch.. lf OK, install theclutch pedal position switch and
adjust the pedal height (see page 12-4).
Terminal
Cl"t"h P"d"l IPosition Switch
12
PRESSED
RELEASEDoo
4-45

18.
19.
Remove the drive belt (see page 4-26).
Remove the lvC line mounting bolt.
20. Remove the radiator cap.
21. Raise the hoist to full height.
22. Remove the front tires/wheels.
23. Remove the splash shield.
o@
24. Loosen the drain plug in the radiatorto drain the
engine coolant (see page 10-6).
25. Drain the transmission fluid (see page 13'3).
26. Drain the engine oil {see page 8-5).
27. Disconnect the stabilizer links (see page 18-18).
28. Disconnect the suspension lower arm ball joints
(see step 3 on page 18-19).
29. Remove the driveshafts {see page 16-3). Coat all
precision finished surfaces with clean engine oil.
Tie plastic bags over the driveshaft ends.
30. Disconnect the air fuel ratio {4,/F) sensor connector
(A) and secondary heated oxygen sensor
(secondary HO2S) connector (B), then remove the
three way catalytic converter {TWC) assembly {C).
31. Remove the lower hose.
(cont'd)
5-5