lock 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
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ItemMeasurementOualificationStandard or NewService LimirBlock
Piston
I Warpage of deck0.07 mm (0.003 in.) max.foro.. (ulur^^-"1tsore diameterAori
Borll
(3.3858 3.3862 in.)
85.980 85.990 mm (3.3850 3.3854 in.)
l-il?0 €s.980 r"i33846
86.010 86.020 mm
(3.3862 3.3866 in.)
86.000 86.010 mm
86.070 mm (3.3886 in.)
86.070 mm (3.3886 in.)
0.05 mm (0.002 In.J
85.920 mm (3.3827 in.)
0.25 mm (0 0l in.)
85.930 mm (3.383'l in.)
Reboring lrmit
Skirt O.D. at 11 mm (0.4 in.) from
bottom of skirtF" btt"' "' A
Letter B
0.020 0.040 mm (0 0008 0.0016 in.)0.05 mm {0.002 in.)Top1.220 1.230 mm (0.0481 0.0484 in.)1.25 mm 10.049 rn )Second1.220 1.230 mm (0.0481 0 0a84In.)1.25 mm 10.049 in.)
Piston ring
lFis,.€-"'"
",";"*
L-Ring end gap
o.D.
i 2.005 2.025 mm (0.0789 0.0797 in.)
fo.o:s o.oto.rn lo.oora o.ooza i.'.f
EO3t 0 056 rn. {OJ01r OOO2 i")
?.09rrl9.091lt )
0.13 mm (0.005 in )
0.13 mm (0.005 in.)Second (FEDEHAL
I\4OGUL)
Top
0.025 0.060 mm (0.0010 0.0024 in.)0.13 mm (0.005 in )
0.20 0.35 mm (0.008 0.014 in.)0.60 mm (0.024 in.)Second0.40 0.55 mm {0.016 0.022 in.)0.70 mm (0.028 in.)OiI (REKEN)
21.961 21.965 mm {0.8646 0.8648 in.)
0.25 0.65 mm (0.010 0.026 in.)
0 20 0.70 mm i0.008 0.028 in.)
0.75 mm (0.030 in.)OiI(FEDERAL
I\4OG U L)0.80 mm 10.031 in.)
Piston pin21.953 mm l0 8643 inPin'to-piston clearance0.005-*0.002 mm ( 0.00020 +
0.00008 in.)
0.005 mm (0.0002 in.)
Connecting rodPin to-rod clearance0.005 0.015 mm (0.0002 0.0006 in.)0.02 mm lO 0OO8 in ISmall end bore diameler21.970 21.976 mm (0.8650 0.8652 in.)Large-end bore diameter (Normal)48.0 mm (1.89 in.)End play inslalled on crankshaft0.15 0.30 mm (0.006 0.012 in.)0.40 mm (0.016 in.)CrankshaftMain journal diameter
Rod journal diameter
No. l journal
No. 2 journal
No. 4 journal
No. 5 journal
No. 3 journal
s4.e84 s5.008 mm (2.1648=16illl
54.976 55.000 mm (2.1644 2-1654in)
44.976 45.000 mm (1.1707 1.1717 in.lRod/main0.005 mm 10.0002 in.) max.0.010 mm (0.0004 in.)Rod/main iournal out of,round0.005 mm (0.0002 in.) max.0.010 mm (0.0004 in.)End play0.10 0.35 mm (0.004 0.0'14 in.)0.45 mm 10.018 in.)Runout..-'.:--'+0.03 mm (0.0012 in.) max.0.04 mm {0.0016 in.)
Deaflngs
Marn oear,n9-toJournat ott ctearanceNo. l journal
No. 2 journal
No. 4 journal
No.5
No. 3 journa/
0.017 0.041 mm (0.0007 0.0016 in.)
q0rr034, -rn {O'o010 0-o01r|"tl
0.050 mm (0.0020 in.)
0.055 mm (0.0022 in.)Bod bearing clearance0.021 0.049 mm (0.0008 0.0019 in.)0.060 mm (0.0024 in.)
Standards and Service Limits
Enqine Block
_f
c_a
2-4
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L
v
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

cont'
ItemMeasuremeniOualificationSpecilicationSTEERINGTypeElectric, Power assisted rack and pinion
Overall ratio15.1Turns,lock to-lock
Steering wheel diameter360 mm (14.2 in)SUSPENSIONTypeIndependent srrul with stabiliTer. coil springRearDouble wishboneShock absorberFrontTelescopic, hydraulic. nitrogen gas-frlled
RearTelescopic, hydraulic, nitrogen gas,filledWHEEL
ALIGNMENT
CamberFront0"00'
Bear0.45'
CasterFront1'33'TotaltoeFront0 mm (0 in.)
RearIn 2 mm (1/16 in.)BRAKESType of service brakeFrontPowerassisted self-adjusling ventilated disc
BearPower-assisted self-adjusting solid discType of parking brakeMechanical actuating, rear wheelsPad friction surface areaFront45 cm'(7.0 sq in.)x2
Rear28 cm'(4.3 sq in.) x 2TIRESSize offront and reartiresPl95/60 815 88VSize o{ spare tireT125r0 D15 95MAIR
CONDITIONING
CompressorTypeScroll
Number of
cylinders
Capacity85.7 m015.23 cu in.)/rev.
Maximum speed12,000 rpm
Lubricant capacity130 m0 {4 1/3 floz)
LubricanttypeSP-10 (P/N 38897'P13-A01AH or38899-P13 A01)CondenserTypeCorrugated finEvaporatorTvpeCorrugated fin
BlowerTypeSirocco fan
Motor type220 Wl12 V
Speed control4 Speeo
Maximum capacity480 m" 116.900 cu ft)/hTemperature controlAirmixtype
Compressor clutchTvpeDry, single plate, poly-V belt drive
Electricalpower
cons!mptron at
68"F (20.C)
42 W maximum at 12 V
RefrigerantTypeHFC 134a (R-134a)
Capacity500 550 g (17.6 19.4 oz)
Design Specifications
C
aL
2-12
../ a

L
A
I
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.
L
D
E
F
H
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,
3-7

Listed by Maintenance ltem for Severe Conditions
Use this schedule if the vehicle is driven MAINLY in Canada or in anv of the followina conditions.NOTE: it only OCCASIONALLY driven in theseconditions, use the Normal Conditions schedute.Sovere Driving Conditions. Driving less than 5 miles (8 km) per trip or, in lreezing temperatures, driving less than. Driving in extremely hot over 90 "F 132 'C)conditions.10 miles (16 km) per trip.
. Extensive idling, or long periods ot stop-and-go-driving, such as a taxi or a commercial delivery vehicle.. Trailer towing, driving with a cartop carrier, or driving in mountainous conditions.. Driving on muddy, dusty, or de iced roads.
Service at the indicated distance or time,whichever comes first.miles x 1,000102030405060708090100110120
km x 1,0001648648096112128144160176192
months122436486072
Replace engine oilReplace every 5,000 miies 18,000 km)or 6 months
Rotate tires{Checktire intlation and condition at leastonce per monthiaoaaoaaoaaao
Replace engine oil fiher
Inspect front and rear brakes
Lubricate all locks, hinges, and latches
Visually inspect the following items:. Tie rod ends, steering gearbox and boots. Suspension components' Driveshaft boots
Checl parking brale adjuslmentaaOaoa
Visually inspect the following items:. Brake hoses and lines {including ABSi. Allfluid levels and condition oflluids. Exhaust system*. Fuel lines and connections*. Lights and controls, vehicle underbody
Inspect and adjust drive behoaoa
Replace dust and pollen filter"o't'
Replace transmission lluidaa
Service the following items atthe recommended interuals
Replace air cleaner elementEvery 15,000 miies (24,000 km) in dusty conditions, otheMise use normal schedule.
Replace spark plugsEvery 110,000 miles (176,000 km)
Inspect valve clearanceInspect every 110,000 miles (176,000 km), otheMise adiust only if noisy.
Inspect idle speed'Every 160,000 miles (256,000 km)or8 vears
Replace engine coolantAt 120,000 miles (192,000 km) of 10 years,lhen every 60,000 miles (96,000 km)or 5
Replace brake fluidEvery 3 years
* : According to state and federal regulations, failure to do the maintenance items marked with asterisk 1*)will not void customer's emissionswarranties. However, Honda recommends that all maintenance service be done at the recommended interval to ensure long{erm reliabilitv.
NOTE 1: Replace the dust and pollen filter at 15,000 miles/24,000 km if the vehicle is driven mostly in urban areas that have high concentrationsof soot in the air from industrv and diesel-Dowered vehicles.
t,
3-9

\.
Engine Electrical
Engine Electrical
SpecialTools
Starting System
Comoonent Location Index ...............
Circuit Diagram
Starter Circu it Troubleshooting
Clutch Interlock Switch Test
Starter Solenoid Test ..............
Sta rter Performance Test
Starter Reolacement ...............
Starter Overhaul .......................
lgnition System
Component Location Index ...............
Circuit Diagram
lgnition Timing Inspection
lgnition Coil Removal/1nsta11ation .......................
Spark Plug Inspection
Charging System
Component Location Index .................................. 4-2O
Circuit Diagram ........................... 4-21
Charging Circuit Troubleshooting ....................... 4-22
Drive Belt Inspection ................... 4-26
Drive Beft Replacement .............. 4-26
Drive BeftAuto-tensioner Inspection .................. 4-27
Drive Beft Auto-tensioner Replacement .............. 4-28
Alternator Reolacement ............. 4-29
Alternator Overhaul ................ .... 4-30
Cruise Control
Component Location Index .................................. 4-36
Circuit Diagram ........................... 4-37
Symptom Troubleshooting Index ....................... 4-38
Cruise Control Unit lnDut Test ............................. 4-40
Main Switch TesVReolacement ........................... 4-42
SeVResume/Cancel Switch TesVReplacement .. 4-42
Cruise Control Actuator Test ...... 4-43
Cruise Control Actuator/Cable Replacement ...... 4-44
Actuator Cable Adjustment .................................. 4-45
Clutch Pedal Position Switch Test ....................... 4-45
4-2
4-J
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-15
4-16
4-17
4-18
4- 19
-+
ENGINE

\-
Starting System
Component Location Index
UNDER-DASHFUSE/RELAY BOX
CLUTCH INTERLOCK SWITCHTest, page 4-6
STARTERStaner Circuit Troubleshoot,ng, page 4 5Solenoid Test, page 4-7Performance Test, page 4-8Replacement, page 4-9Overhaul, page 4 '10
-l--
ar]]]ll -i I
-. -_- rt_.1
_-- _. /
Itti:
:-lt.i tit-!t:!|- -!t
STARTER CUT RELAYTest, page 22-51
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r\, l,
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4-3

Starting System
Circuit Diagram
- ilo.20lOA) :USA motklNo.2! l50A) : C.nid. model
UiIOEN H@D fUSE/REI.IY BOX
UNDEi OASTIFUST/ifLAY80x
Y.
ST HOT in STA8T illl
cLuTot [{Tr8LocKswtlcH
4-4
a

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