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Introduction
Safety Messages
Your safety and the safety of others, is very important. To help you make
informed decisions, we have provided safety messages and other safety
information throughout this manual. Of course, it is not practical or
possible to warn you about all the hazards associated with servicing this
vehicle. You must use your own good judgement.
You will find important safety information in a variety of forms including:
Safety Labels - on the vehicle.
DANGER
You WILL be KILLED or SERIOUSLY HURT if you
do not follow instructions.
WARNING
You CAN be KILLED or SERIOUSLY HURT if you
do not follow instructions.
CAUTION
You CAN be HURT if you do not follow
instructions.
Instructions - how to service this vehicle correctly and safely.
Introduction
Supplemental Restraint System (SRS)
This model has an SRS which includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above the glove box, seat belt tensioners in the front
seat belt retractors. Information necessary to safely service the SRS is included in the Shop Manual, P/N 62S5A00. Items marked with an asterisk (*) on the contents page
include, or are located near, SRS components. Servicing, disassembling or replacing these items will require special precautions and tools and should therefore be done by an
authorised Honda dealer.
WARNING
To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe
frontal collision, all SRS service work must be performed by an authorised Honda dealer.
Improper service procedures, including incorrect removal and installation of the SRS, could lead to personal
injury caused by unintentional deployment of the airbags.
Do not bump the SRS unit. Otherwise, the system may fail in a collision, or airbags may deploy when the ignition
switch is ON (II).
SRS electrical wiring connectors are identified by yellow colour coding. Related components are located in the
steering column, front console, dashboard, dashboard lower panel and in the dashboard above the glove box. Do
not use electrical test equipment on these circuits.
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The service and repair information contained in this manual is intended for Make sure you have a clear understanding of all basic shop safety
use by qualified, professional technicians. Attempting service or repairs practices and that you are wearing appropriate clothing and using
without the proper training, tools and equipment could cause injury to you safety equipment. When performing any service task, be especially
or others. It could also damage the vehicle or create an unsafe condition. careful of the following:
Read all of the instructions before you begin and make sure you
This manual describes the proper methods and procedures for performing
service, maintenance and repairs. Some procedures require the use of have the tools, the replacement or repair parts and the skills
specially designed tools and dedicated equipment. Any person who intends required to perform the tasks safely and completely.
Protect your eyes by using proper safety glasses, goggles or face
to use a replacement part, service procedure or a tool that is not
recommended by Honda, must determine the risks to their personal safety shields any time you hammer, drill, grind, or work around
and the safe operation of the vehicle. pressurised air or liquids and springs or other stored-energy
components. If there is any doubt, put on eye protection.
If you need to replace a part, use genuine Honda parts with the correct part Use other protective wear when necessary, for example gloves or
number or an equivalent part. We strongly recommend that you do not use safety shoes. Handling hot or sharp parts can cause severe burns
replacement parts of inferior quality. or cuts. Before you grab something that looks like it can hurt you,
FOR YOUR CUSTOMER'S SAFETY stop and put on gloves.
Protect yourself and others whenever you have the vehicle up in the
Proper service and maintenance are essential to the customer's safety and
the reliability of the vehicle. Any error or oversight while servicing a vehicle air. Any time you lift the vehicle, either with a hoist or a jack, make
can result in faulty operation, damage to the vehicle, or injury to others. sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing
WARNING procedures, unless the instruction tells you to do otherwise. This will
Improper service or repairs can create an help eliminate several potential hazards:
Carbon monoxide poisoning from engine exhaust. Be sure there is
unsafe condition that can cause your
customer or others to be seriously hurt or adequate ventilation whenever you run the engine.
Burns from hot parts or coolant. Let the engine and exhaust system
killed.
cool before working in those areas.
Follow the procedures and precautions in this Injury from moving parts. If the instruction tells you to run the
manual and other service materials carefully. engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapours and hydrogen gases from batteries are explosive.
FOR YOUR SAFETY To reduce the possibility of a fire or explosion, be careful when
Because this manual is intended for the professional service technician, we working around gasoline or batteries.
do not provide warnings about many basic shop safety practices (e.g., Hot Use only a non-flammable solvent, not gasoline to clean parts.
parts - wear gloves). If you have not received shop safety training or do not Never drain or store gasoline in an open container.
feel confident about your knowledge of safe servicing practices, we Keep all cigarettes, sparks and flames away from the battery and all
recommend that you do not attempt to perform the procedures described in fuel-related parts.
this manual.
WARNING
Failure to properly follow instructions and
precautions can cause you to be seriously
hurt or killed.
Follow the procedures and precautions in this
manual carefully.
Some of the most important general service safety precautions are given
below. However, we cannot warn you of every conceivable hazard that can
arise in performing service and repair procedures. Only you can decide
whether or not you should perform a given task.
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Introduction
Outline of Model Changes
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General Information
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General Information 1-
Identification Number Locations
3
1. Vehicle Identification Number (VIN)
2. Built Date and Vehicle Type
3. Transmission Number (Manual)
4. Engine Number
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General Information 1-
Warning/Caution Label Locations
4
1. SRS WARNING
2. ENGINE COOLANT INFORMATION and SERVICE
INFORMATION
3. BATTERY CAUTION
4. RADIATOR CAP CAUTION
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List of automotive abbreviations which may be used in shop manual. EPR Evaporator Pressure Regulator
ABS Anti-lock Brake System EPS Electrical Power Steering
A/C Air Conditioning, Air Conditioner EVAP Evaporative
ACL Air Cleaner EX Exhaust
A/F Air Fuel Ratio F Front
ALR Automatic Locking Retractor FIA Fuel Injection Air
ALT Alternator FL Front Left
AMP Ampere(s) FP Fuel Pump
ANT Antenna FR Front Right
API American Petroleum Institute FSR Fail Safe Relay
APPROX. Approximately FWD Front Wheel Drive
ASSY Assembly GAL Gallon
A/T Automatic Transmission GND Ground
ATDC After Top Dead Centre GPS Global Positioning System
ATF Automatic Transmission Fluid H/B Hatchback
ATT Attachment HC Hydrocarbons
ATTS Active Torque Transfer System HID High Intensity Discharge
AUTO Automatic HO2S Heated Oxygen Sensor
AUX Auxiliary IAB Intake Air Bypass
BARO Barometric IAC Idle Air Control
BAT Battery IACV Idle Air Control Valve
BDC Bottom Dead Centre IAR Intake Air Resonator
BTDC Before Top Dead Centre IAT Intake Air Temperature
CARB Carburettor ICM Ignition Control Module
CAT Catalytic Converter ID Identification
or CATA ID or I.D. Inside Diameter
CHG Charge IG or IGN Ignition
CKF Crankshaft Speed Fluctuation IMA Idle Mixture Adjustment
CKP Crankshaft Position Integrated Motor Assisted
CO Carbon Monoxide IMMOBI. Immobilizer (Immobiliser)
COMP Complete IN Intake
CPB Clutch Pressure Back up INJ Injection
CPC Clutch Pressure Control INT Intermittent
CPU Central Processing Unit KS Knock Sensor
CVT Continuously Variable Transmission L Left
CYL Cylinder L/C Lock-up Clutch
CYP Cylinder Position LCD Liquid Crystal Display
DI Distributor Ignition LED Light Emitting Diode
DIFF Differential LEV Low Emission Vehicle
DLC Data Link Connector LF Left Front
DOHC Double Overhead Camshaft LH Left Handle
DPI Dual Point Injection LHD Left Handle Drive
DTC Diagnostic Trouble Code LR Left Rear
EBD Electronic Brake Distribution LSD Limited Slip Differential
Secondary Low
SOHC Single Overhead Camshaft O/D Over Drive
SOL Solenoid 1ST Low (gear)
SPEC Specification 2ND Second (gear)
S/R Sun Roof 3RD Third (gear)
SRS Supplemental Restraint System 4TH Fourth (gear)
5TH Fifth (gear)
6TH Sixth (gear)
Specifications
Design Specifications
Dimensions 2-11
Weight 2-11
Engine 2-11
Starter 2-12
Clutch 2-12
Manual Transmission 2-12
Steering 2-12
Suspension 2-12
Wheel Alignment 2-12
Brakes 2-12
Tyres 2-12
Electrical Ratings 2-13
Body Specifications
Illustration 2-14
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Engine Assembly
Item Measurement Qualification Standard or New Service Limit
Compression Pressure check at 250 rpm (min- Minimum 930 kPa (9.5 kgf/cm2, 135 psi) -
1) with wide open throttle. (See
Design Specs for ratio) Maximum variation 200 kPa (2.0 kgf/cm2, 28 psi) -
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Oil pump Inner-to-outer rotor clearance 0.02-0.15 mm (0.001-0.006 in.) 0.20 mm (0.008 in.)
Pump housing-to-outer rotor 0.15-0.21 mm (0.006-0.008 in.) 0.23 mm (0.009 in.)
clearance
Pump housing-to-rotor axial 0.02-0.07 mm (0.001-0.003 in.) 0.12 mm (0.005 in.)
clearance
Relief valve, oil pressure with oil At idle 70 kPa (0.7 kgf/cm2, 10 psi) min.
temperature at 80C (176F)
at 3,000 rpm (min-1) 300 kPa (3.1 kgf/cm2, 44 psi) min.
Cooling
Item Measurement Qualification Standard or New Service Limit
Radiator Coolant capacity (Includes Engine overhaul 6.8 l (7.2 US qt, 6.0 lmp qt)
engine, heater, hoses and
reservoir) Coolant change 5.3 l (5.6 US qt, 4.7 lmp qt)
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B 24.03-24.08 mm (0.946-0.947 -
in.)
Suspension
Item Measurement Qualification Standard or New Service Limit
Wheel alignment Camber Front 000' + 45'
Rear -045' + 45'
Caster Front 133' + 1
Total Toe Front 0 +3 mm (0 +0.12 in.)
Rear Adjust: IN 2+2 -1 mm (0.08+0.08 -0.04 in.)
Inspect: IN 2 + 3 mm (0.08 + 0.12 in.)
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Design Specifications 2-
11
Item Measurement Qualification Specification
DIMENSIONS Overall length 4,410 mm (163.0 in.)
Overall width 1,695 mm (66.7 in.)
Overall height without roof antenna 1,425 mm (56.1 in.)
with roof antenna 1,550 mm (61.0 in.)
Wheelbase 2,570 mm (101.2 in.)
(MPW condition)
Water pump displacement at 6,000 engine rpm (min- 82 litre (87 US qt, 72 Imp qt) per minute
1)
Fuel required Premium UNLEADED gasoline with 95 research octane number or higher
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Design Specifications 2-
12
Item Measurement Qualification Specification
STARTER Type Gear reduction
Normal output 1.1 kW
Hour rating 30 seconds
Direction of rotation Clockwise as viewed from gear end
CLUTCH Clutch Single plate dry, diaphragm spring
Clutch friction material surface 174 cm2 (26.97 sq in.)
area
MANUAL Type Synchronised, 6-speed forward, 1 reverse
TRANSMISSION
Primary reduction Direct 1:1
Gear ratio 1st 3.266
2nd 2.130
3rd 1.517
4th 1.147
5th 0.921
6th 0.738
Reverse 3.583
Final reduction Type Single helical gear
Gear ratio 4.764
STEERING Type Rack and pinion, with electrical power assistance
Overall ratio 14.49
Turns, lock-to-lock 2.83
Steering wheel diameter 380 mm (15.0 in.)
SUSPENSION Type Front Strut
Rear Double wishbone
Shock absorber Front and rear Telescopic, hydraulic, nitrogen gas-filled
WHEEL ALIGNMENT Camber Front 0
Rear - 045'
Caster Front 133'
Total toe Front 0 mm (0 in.)
Rear In 2 mm (1/16 in.)
BRAKES Type of service brake Front Power-assisted self-adjusting ventilated disc
Rear Power-assisted self-adjusting solid disc
Type of parking brake Mechanical actuating, rear wheels
Pad friction surface area Front 49 cm2 x 2 (7.6 sq in. x 2)
Rear 28 cm2 x 2 (4.3 sq in. x 2)
TYRES Size of front and rear 205/45R17 84W
Size of spare T135/70D15 99M
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Design Specifications 2-
13
Item Measurement Qualification Specification
ELECTRICAL Battery 12 V-45 AH/20 hours
RATINGS
Starter 12 V-1.1 kW
Alternator 12 V-80 A
Fuses Under-hood fuse/relay box 80 A, 40 A, 30 A, 20 A, 15 A, 7.5 A
Under-dash fuse/relay box 20 A, 15 A, 10 A, 7.5 A
Light bulbs Headlight high beam 12 V-60 W
Headlight low beam 12 V-55 W
Front turn signal/Front 12 V-21 W/5 W
side marker lights
Front position lights 12 V-5 W/3 CP (candlepower)
Side turn signal lights 12 V-5 W
Rear turn signal lights 12 V-21 W
Brake/Taillights/Rear side 12 V-21W/5 W
marker light
Rear fog light 12 V-21 W
Taillights 12 V-5 W
High mount brake light 12 V-21 W
Back-up light 12 V-21 W
License plate light 12 V-3 CP
Ceiling light 12 V-8 W, 5 W
Luggage area light 12 V-5 W
Individual map light 12 V-8 W
Spotlights 14 V-8 W
Gauge light 14 V-1.4 W
Indicator light 12 V-1.12 W
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Body Specifications 2-
14
Unit: mm (in.)
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Maintenance
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For the details of lubrication points and type of lubricants to be applied, refer to the illustrated index and various work procedures (such as Assembly/Reassembly, Replacement,
Overhaul, Installation, etc.) contained in each section.
NO. LUBRICATION POINTS LUBRICANT
1 Engine Always use fuel-efficient is that says "API service SG, SH or SJ"
SAE Viscosity See chart below.
CAUTION
Used engine oil may cause skin cancer if repeatedly left in contact with skin for prolonged periods. Although this is
unlikely unless you handle used oil on a daily basis, it is sill advisable to thoroughly wash your hands with soap and
water as soon as possible after handling used oil.
*1: Always use genuine Honda Manual Transmission Fluid (MTF). Using motor oil can cause stiffer shifting because it does not contain the proper
additives.
*2: We recommend Genuine Honda Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system.
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Follow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe Conditions Maintenance Schedule on 3-6 and 3-7 do not apply.
Service at the indicated distance or time km x 1,000 20 40 60 80 100 120 140 160 180 200
whichever comes first.
miles x 1,000 12 24 36 48 60 72 84 96 108 120
months 12 24 36 48 60 72 84 96 108 120
Replace engine oil
Replace engine oil filter
Replace air cleaner element
Inspect valve clearance
Replace fuel filter
Replace spark plugs Every 120,000 km (72,000 miles)
Inspect and adjust drive belts
Inspect idle speed
Replace engine coolant At 200,000 km (120,000 miles) or 10 years, then replace every 100,000 km (60,000 miles) or
5 years
Replace transmission fluid Every 120,000 km (72,000 miles) or 8 years
Inspect front and rear brakes
Replace brake fluid Every 3 years
Check parking brake adjustment
Check light alignment
Test drive (noise, stability, dashboard operation)
Visually inspect the following items:
Tie rod ends, steering gearbox and boots
Suspension components
Driveshaft boots
Brake hoses and lines (including ABS)
All fluid levels and condition of fluid
Exhaust system
Fuel line and connections
Tyre condition
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Check for cracks and damage. Refer to the 2001 Civic shop manuals (see page 17-23)
Check deflection and tension.
(see page 11-125) (see page 11-285)
Refer to the 2001 Civic shop manuals (see page 11-425) (see page 11-
560)
Use genuine Honda All Season Antifreeze/Coolant Type 2. (see page 10-8)
Use genuine Honda MTF (Manual Transmission Fluid). (see page 13-3)
Check the brake pad and disc thickness. Check for damage or cracks. Refer to the 2001 Civic shop manuals (see page 19-3)
Check the wheel cylinder for leaks.
Check the brake linings for cracking, glazing, wear, or contamination.
Check the calipers for damage, leaks, and tightness.
Use only DOT 3 or DOT 4 brake fluid. (We recommend Genuine Honda Brake Fluid.) Refer to the 2001 Civic shop manuals (see page 19-7)
Check that brake fluid level is between the upper and lower marks on the reservoir.
Check the parking brake operation. Refer to the 2001 Civic shop manuals (see page 19-6)
Check the position of the headlight. Refer to the 2001 Civic shop manuals (see page 22-114)
Check for road stability, noise, vibrations and dashboard operation. -
Check for correct installation and position, check for cracks, deterioration rust -
and leaks.
Check tightness of screws, nuts and joints. If necessary, retighten.
Check rack grease and steering linkage. Check the boot for damage and Refer to the 2001 Civic shop manuals (see page 17-5)
leaking grease.
Check the fluid line for damage and leaks.
Check the bolts for tightness. Refer to the 2001 Civic shop manuals (see page 18-3)
Check all dust cover for deterioration and damage.
Check the boot and boot band for cracks Refer to the 2001 Civic shop manuals (see page 16-3)
Check rack grease.
Check the master cylinder, proportioning control valve and ABS modulator and leakage. Refer to the 2001 Civic shop manuals (see page 19-48)
-
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, leaks and (see page 9-5)
tightness.
Check fuel lines for loose connections, cracks and deterioration. Retighten loose Refer to the 2001 Civic shop manuals (see page 11-132) (see page 11-
connections and replace any damaged parts. 290)
Refer to the 2001 Civic shop manuals (see page 11-432) (see page 11-
565)
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Service at the indicated distance or time km x 1,000 20 40 60 80 100 120 140 160 180 200
whichever comes first.
miles x 1,000 12 24 36 48 60 72 84 96 108 120
months 12 24 36 48 60 72 84 96 108 120
Replace engine oil Every 10,000 km (6,000 miles) or 6 months
Replace engine oil filter
Replace air cleaner element
Inspect valve clearance Every 40,000 km (24,000 miles)
Replace fuel filter
Replace spark plugs Every 120,000 km (72,000 miles)
Inspect and adjust drive belts
Inspect idle speed
Replace engine coolant At 200,000 km (120,000 miles) or 10 years, then replace every 100,000 km (60,000 miles) or
5 years
Replace transmission fluid Every 60,000 km (36,000 miles) or 4 years
Inspect front and rear brakes Every 10,000 km (6,000 miles) or 6 months
Replace brake fluid Every 3 years
Check parking brake adjustment
Check light alignment
Test drive (noise, stability, dashboard operation)
Visually inspect the following items:
Tie rod ends, steering gearbox and boots Every 10,000 km (6,000 miles) or 6 months
Suspension components
Driveshaft boots
Brake hoses and lines (including ABS)
All fluid levels and condition of fluid
Exhaust system
Fuel line and connections
Tyre condition
Follow the Severe Conditions Maintenance Schedule if the customer's vehicle is driven MAINLY under one or more of the following conditions:
Driving less than 8 km (5 miles) per trip or, in freezing temperatures, driving less than 16 km (10 miles) per trip.
Driving in extremely hot over 35C (95F) conditions.
Extensive idling or long periods of stop-and-go-driving.
NOTE: If the customer's vehicle is driven OCCASIONALLY under severe condition, you should follow the Normal Condition Maintenance Schedule on pages 3-4 and 3-5
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Use genuine Honda All Season Antifreeze/Coolant Type 2. (see page 10-8)
Use genuine Honda MTF (Manual Transmission Fluid). (see page 13-3)
Check the brake pad and disc thickness. Check for damage or cracks. Refer to the 2001 Civic shop manuals (see page 19-3)
Check the wheel cylinder for leaks.
Check the brake linings for cracking, glazing, wear, or contamination.
Check the calipers for damage, leaks and tightness.
Use only DOT 3 or DOT 4 brake fluid. (We recommend Genuine Honda Brake Refer to the 2001 Civic shop manuals (see page 19-7)
Fluid.)
Check that brake fluid level is between the upper and lower marks on the reservoir.
Check the parking brake operation. Refer to the 2001 Civic shop manuals (see page 19-6)
Check the position of the headlight. Refer to the 2001 Civic shop manuals (see page 22-114)
Check for road stability, noise, vibrations and dashboard operation. -
Check for correct installation and position, check for cracks, deterioration rust -
and leaks.
Check tightness of screws, nuts and joints. If necessary, retighten.
Check rack grease and steering linkage. Check the boot for damage and Refer to the 2001 Civic shop manuals (see page 17-5)
leaking grease.
Check the fluid line for damage and leaks.
Check the bolts for tightness. Refer to the 2001 Civic shop manuals (see page 18-3)
Check all dust cover for deterioration and damage.
Check the boot and boot band for cracks Refer to the 2001 Civic shop manuals (see page 16-3)
Check rack grease.
Check the master cylinder, proportioning control valve and ABS modulator and Refer to the 2001 Civic shop manuals (see page 19-48)
leakage.
Check for leaks. -
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, (see page 9-5)
leaks and tightness.
Check fuel lines for loose connections, cracks and deterioration. Retighten loose Refer to the 2001 Civic shop manuals (see page 11-132) (see
connections and replace any damaged parts. page 11-290)
Refer to the 2001 Civic shop manuals (see page 11-432) (see
page 11-565)
Engine Electrical
Engine Electrical
Special Tools 4-2
Starting System
Component Location Index 4-3
Circuit Diagram 4-4
Starter Circuit Troubleshooting 4-5
Starter Solenoid Test 4-6
Starter Performance Test 4-7
Starter Replacement 4-8
Starter Overhaul 4-9
Ignition System
Component Location Index 4-14
Circuit Diagram 4-15
Ignition Timing Inspection 4-16
Ignition Coil Removal/Installation 4-17
Spark Plug Inspection 4-18
Charging System
Component Location Index 4-19
Circuit Diagram 4-20
Charging Circuit Troubleshooting 4-21
Drive Belt Inspection 4-25
Drive Belt Replacement 4-25
Drive Belt Auto-tensioner Inspection 4-26
Drive Belt Auto-tensioner Replacement 4-27
Alternator Replacement 4-28
Alternator Overhaul 4-29
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1. STARTER
Starter Circuit Troubleshooting, page 4-5
Solenoid Test, page 4-6
Performance Test, page 4-7
Replacement, page 4-8
Overhaul, page 4-9
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6. Check the following items in the order listed until you find the open 1. Check the hold-in coil for continuity between the S terminal (A) and the
circuit. armature housing (ground). There should be continuity.
Check the BLK/WHT wire and connectors between the under-dash If there is continuity, go to step 2.
fuse/relay box and the ignition switch and between the under-dash If there is no continuity, replace the solenoid.
page 22-131).
7. Check the engine speed while cranking the engine.
Is the engine speed above 100 rpm (min-1)?
YES - Go to step 8.
NO - Replace the starter, or remove and disassemble it and check for
the following until you find the cause.
Excessively worn starter brushes
Open circuit in commutator brushes
Dirty or damaged helical splines or drive gear
8. Check the cranking voltage and current draw. 2. Check the pull-in coil for continuity between the S terminal (A) and M
Is cranking voltage greater than or equal to 8.7 V and terminal (B). There should be continuity.
If there is continuity, the solenoid is OK.
current draw less than or equal to 230 A?
YES - Go to step 9. If there is no continuity, replace the solenoid.
9. Remove the starter, and inspect its drive gear and the flywheel ring
gear for damage. Replace any damaged parts.
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Starter System 4-
Starter Overhaul (cont'd)
11
7. Check the mica depth (A). If the mica is too high (B), undercut the 9. Place the armature (A) on an armature tester (B). Hold a hacksaw
mica with a hacksaw blade to the proper depth. Cut away all the mica blade (C) on the armature core. If the blade is attracted to the core or
(C) between the commutator segments. The undercut should not be vibrates while the core is turned, the armature is shorted. Replace the
too shallow, too narrow, or V-shaped (D). armature.
Commutator Mica Depth
Standard (New):
0.50-0.80 mm (0.020-0.031 in.)
Service Limit:
0.20 mm (0.008 in.)
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Ignition System 4-
Spark Plug Inspection
18
1. Inspect the electrodes and ceramic insulator. 3. Replace the plug at the specified interval, or if the centre electrode is
Burned or worn electrodes may be caused by: rounded (A). Use only the spark plugs listed below.
Advanced ignition timing Spark Plugs:
Loose spark plug IFR7G-11K (NGK)
Plug heat range too hot SK22PR-M11 (DENSO)
Insufficient cooling
2. 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 - 0.043 in.)
Service Limit:
1.3 mm (0.051 in.)
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Charging System 4-
Component Location Index
19
1. CHARGING SYSTEM INDICATOR
(In the gauge assembly)
2. UNDER-HOOD FUSE/RELAY BOX (Has built-in
ELECTRICAL LOAD DETECTOR (ELD) UNIT)
ELD Troubleshooting, page 11-72
3. BATTERY
Test, page 22-79 in the 2001 CIVIC Shop Manual
4. ALTERNATOR
Troubleshooting, page 4-21
Replacement, page 4-28
Overhaul, page 4-29
5. DRIVE BELT
Inspection, page 4-25
Replacement, page 4-25
6. AUTO-TENSIONER
Inspection, page 4-26
Replacement, page 4-27
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Charging System 4-
Circuit Diagram
20
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Charging System 4-
Charging Circuit Troubleshooting
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If the charging system indicator does not come on or does not go off, or 6. Measure the voltage at the No. 3 terminal of the engine wire harness
the battery is dead or low, test the following items in the order listed below: 6P connector with the ignition switch ON (II).
Battery, refer to the 2001 Civic Shop Manual (see page 22-79) ENGINE WIRE HARNESS 6P CONNECTOR
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Charging System 4-
Charging Circuit Troubleshooting (cont'd)
22
10. Check continuity between the ECM connector terminal B10 and body Alternator and Regulator Circuit Test
ground.
1. Be sure the battery is sufficiently charged, refer to the 2001 Civic Shop
ECM CONNECTOR B (24P)
Manual (see page 22-79).
2. Raise the hoist to full height.
3. Hook up the ammeter, 0 - 400 A, to the starter sub-harness.
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Charging System 4-
Charging Circuit Troubleshooting (cont'd)
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6. Start the engine. Hold the engine at 3,000 rpm (min-1) with no load (in Alternator Control System Test
Neutral) until the radiator fan comes on then let it idle.
1. Check for proper operation of the ELD by checking the MIL (see page
7. Raise the engine speed to 2,000 rpm (min-1) and hold it there. 11-3).
8. Turn the headlights (high beam) on, and measure voltage at the under-
2. Disconnect the engine wire harness 6P connector from the starter sub-
hood fuse/relay box terminal.
harness 6P connector.
Is the voltage between 13.9 and 15.1 V?
3. Start the engine, and turn the headlights (high beam) ON.
YES - Go to step 9. 4. Measure voltage between the engine wire harness 6P connector
NO - Repair the alternator components (see page 4-29). terminal No. 2 and the positive terminal of the battery.
BATTERY
9. Read the amperage at 13.5 V.
NOTE: Adjust the voltage by turning the blower motor, rear window
defogger, brake lights, etc. ON.
Is the amperage 60A or more?
YES - Alternator/regulator operation is OK.
NO - Repair the alternator components (see page 4-29).
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Charging System 4-
Charging Circuit Troubleshooting (cont'd)
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7. Check for continuity between ECM connector terminal B18 and body 10. Check for continuity between ECM connector terminal B18 and
ground. engine wire harness 6P connector terminal No. 2.
ECM CONNECTOR B (24P) ECM CONNECTOR B (24P)
If prescribed voltage is now available, replace the original ECM. YES - Repair the alternator (see page 4-29).
8. Turn the headlights and ignition switch OFF. NO - Repair open in the wire between the alternator and ECM.
9. Disconnect ECM connector B (24P).
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Charging System 4-
Drive Belt Auto-tensioner Inspection
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1. Check whether there is a change in the position of the auto-tensioner 5. Remove the auto-tensioner (see page 4-27).
indicator before starting the engine and after starting the engine. If 6. Install the tensioner pulley.
there is a change in the position, replace the auto-tensioner. 7. Clamp the auto-tensioner (A) by using two 8 mm bolts (B) and a vice
(C) as shown. Do not clamp the auto-tensioner itself.
2. Check for abnormal noise from the tensioner pulley. If abnormal noise
is heard, replace the tensioner pulley.
3. Remove the drive belt (see page 4-25).
4. Move the auto-tensioner within its limit with the belt tension release 8. Set the torque wrench (D) on the pulley bolt.
tool in the direction shown. Check that the tensioner moves smoothly 9. Align the indicator (E) on the tensioner base with centre mark (F) on
and without any abnormal noise. If the tensioner does not move the tensioner arm by using the torque wrench, and measure the
smoothly or there is abnormal noise, replace the auto-tensioner. torque. If the torque value is out of specification, replace the auto-
tensioner.
NOTE: If the indicator exceeds the centre mark, recheck the torque.
26.5 - 36.3 Nm (2.7 - 3.7 kg/m, 19.5 - 26.8 lbf/ft)
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Charging System 4-
Drive Belt Auto-tensioner Replacement
27
1. Remove the drive belt (see page 4-25). 4. Remove the auto-tensioner.
2. Remove the idler pulley.
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Charging System 4-
Alternator Replacement
28
1. Make sure you have the anti-theft code for the radio, then write down 8. Disconnect the alternator connector (A) and BLK wire (B) from the
the frequencies for the radio's preset buttons. alternator.
2. Disconnect the battery negative cable, then disconnect the positive
cable.
3. Remove the front bumper, refer to the 2001 Civic Shop Manual
Supplement, P/N 62S5A21 (see page 20-8).
4. Remove the right side head light, refer to the 2001 Civic Shop Manual
(see page 22-114).
5. Remove the reserve tank.
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Charging System 4-
Alternator Overhaul
29
Exploded View
1. WAVE WASHER
2. BEARING COVER
3. REAR BEARING
4. ROTOR
5. BEARING RETAINER
6. FRONT BEARING
7. STATOR THROUGH BOLT
8. DRIVE-END HOUSING
9. PULLEY
10. PULLEY LOCKNUT
11. SEAL RING
12. REAR HOUSING ASSEMBLY
13. INSULATOR BUSHING
14. END COVER
15. TERMINAL PLATE
16. TERMINAL INSULATOR
17. RECTIFIER ASSEMBLY
18. BRUSH HOLDER INSULATOR
19. BRUSH HOLDER
20. VOLTAGE REGULATOR
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Charging System 4-
Alternator Overhaul (cont'd)
30
Special Tools Required 5. Remove the end cover (A) and dust seal (B).
Handle driver, 07749-0010000
Driver attachment, 52 x 55 mm, 07746-0010400
NOTE: Refer to the Exploded View as needed during this procedure.
1. Test the alternator and regulator before you remove them (see page 4-
21).
2. Remove the alternator (see page 4-28).
3. If the front bearing needs replacing, remove the pulley locknut with a
10 mm wrench (A) and a 22 mm wrench (B). If necessary, use an
impact wrench.
6. Remove the brush holder (A), voltage regulator (B) and the rubber seal
(C).
4. Remove the harness bracket (A), insulator (B), three flange nuts (C)
and the screw (D), then remove the plate terminal (E).
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16. Remove the shift cable (A) and select cable (B). 22. Loosen the drain plug in the radiator to drain the engine coolant (see
page 10-6).
23. Drain the transmission fluid (see page 13-4).
24. Drain the engine oil (see page 8-5).
25. Disconnect the primary Heated Oxygen Sensor (primary HO2S)
connector (A) and secondary Heated Oxygen Sensor (secondary
HO2S) connector (B).
17. If the A/C compressor is equipped, remove the drive belt (see page 4-
25).
18. Remove the radiator cap. 26. Remove the Three Way Catalytic Converter (TWC) assembly (C).
19. Raise the hoist to full height. 27. Disconnect the stabiliser links (see step 9 on page 18-5) and
20. Remove the front tyres/wheels. suspension lower arm ball joints (see step 10 on page 18-5).
21. Remove the splash shield. 28. Remove the driveshafts (see page 16-3). Coat all precision finished
surfaces with clean engine oil. Tie plastic bags over the driveshaft
ends.
39. Use a marker to make alignment marks on the reference lines (A) 41. Disconnect the compressor clutch connector (A), then remove the A/
that align with the centres of the rear sub-frame mounting bolts (B). C compressor (B) without disconnecting the A/C hoses.
1. Install the accessory brackets, and tighten their bolts and nuts to the specified torques.
1. ENGINE MOUNT BRACKET
2. A/C COMPRESSOR BRACKET
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2. Position the engine under the vehicle. Attach the chain hoist to the 4. Install the sub-frame (A). Align the reference lines (B) on the sub-
engine, then lift the engine into position in the vehicle. frame with the bolt head centre, then tighten the bolts.
6. Tighten the rear mount mounting bolts. 9. Tighten the support bolt and nuts.
14. Install the TWC assembly (A); use new gaskets (B) and new self 17. Install the lower radiator hose.
locking nuts (C).
15. Connect the primary HO2S connector (D) and secondary HO2S
connector (E).
16. Install the radiator (see page 10-10).
18. Install the splash shield. 21. Push the ECM connectors through the bulkhead, then install the
grommet (A).
LHD models:
RHD models:
23. Connect the ECM connectors (A) and main wire harness connector 25. Install the brake booster vacuum hose (A) and the EVAP canister
(B). hose (B).
LHD models:
RHD models:
26. Install the fuel feed hose (see page 11-121).
27. Install the select cable (A) and shift cable (B) using the plastic
washers (C), washers (D), and new cotter pins (E).
24. Install the throttle cable (see page 11-128), then adjust the cable (see
page 11-127).
28. Install the clutch slave cylinder (A) and clutch line bracket mounting 31. Install the intake air duct.
bolt (B).
32. Install the air cleaner housing (A) and connect the IAT sensor
connector (B).
29. Install the battery cables (A) on the under-hood fuse/relay box, then
install the harness clamp (B).
35. Clean the battery posts and cable terminals with sandpaper, then
assemble them and apply grease to prevent corrosion.
36. Check that the transmission shifts into gear smoothly.
37. Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate
the starter) so that the fuel pump runs for approximately 2 seconds
and pressurises the fuel line. Repeat this operation two or three times,
then check for fuel leakage at any point in the fuel line.
38. Refill the engine with engine oil (see page 8-5).
39. Refill the transmission with fluid. (see page 13-4).
40. Refill the radiator with engine coolant, and bleed air from the cooling
system with the heater valve open (see page 10-6).
41. Inspect the idle speed (see page 11-110).
42. Inspect the ignition timing (see page 4-16).
43. Check the wheel alignment (see page 18-3).
44. Enter the anti-theft code for the radio, then enter the customer's radio
station presets.
Engine Mechanical
Cylinder Head
Special Tools 6-2
Component Location Index 6-3
Engine Compression Inspection 6-6
VTEC Rocker Arm Test 6-7
VTC Actuator Inspection 6-9
Valve Clearance Adjustment 6-10
Crankshaft Pulley Removal and Installation 6-12
Cam Chain Removal 6-13
Cam Chain Installation 6-16
Auto-Tensioner Removal/Installation 6-21
Chain Case Oil Seal Installation 6-23
Cylinder Head Cover Removal 6-24
Cylinder Head Removal 6-25
VTC Actuator, Exhaust Camshaft Sprocket Replacement 6-26
Cylinder Head Inspection for Warpage 6-27
Rocker Arm Assembly Removal 6-28
Rocker Arms and Shafts Disassembly/Reassembly 6-29
Rocker Arms and Shafts Inspection 6-30
Camshaft Inspection 6-31
Valves, Springs, and Valve Seals Removal 6-34
Valve Inspection 6-34
Valve Stem-to-Guide Clearance Inspection 6-35
Valve Guide Replacement 6-36
Valve Seat Reconditioning 6-38
Valves, Springs, and Valve Seals Installation 6-40
Rocker Arm Assembly Installation 6-41
Cylinder Head Installation 6-42
Cylinder Head Cover Installation 6-44
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Cylinder Head 6-
Cam Chain Installation (cont'd)
19
15. Install the new O-ring (A) on the chain case. Set the edge of the 16. Install the side engine mount bracket.
chain case (B) to the edge of the oil pan (C), then install the chain
case on the cylinder block (D).
NOTE: When installing the chain case, do not slide the bottom surface
on the oil pan mounting surface.
17. Install the upper bracket (A), then tighten the bolt/nuts in the
numbered sequence shown.
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2. Measure the distance between the chain case surface and oil seal.
6. Install the chain case cover.
Oil Seal Installed Height:
33.0 - 33.7 mm (1.30 - 1.33 in.)
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Cylinder Head 6-
Cylinder Head Cover Removal
24
1. Remove the intake manifold cover. 4. Remove the cylinder head cover.
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Cylinder Head 6-
Camshaft Inspection (cont'd)
32
3. Seat the camshaft by pushing it away from the camshaft pulley end of 5. Unscrew the camshaft holder bolts two turns at a time, in a crisscross
the cylinder head. pattern. Then remove the camshaft holders from the cylinder head.
4. Zero the dial indicator against the end of the camshaft, then push the 6. Lift the camshafts out of the cylinder head, wipe them clean, then
camshaft back and forth and read the end play. If the end play is inspect the lift ramps. Replace the camshaft if any lobes are pitted,
beyond the service limit, replace the cylinder head and recheck. If it is scored, or excessively worn.
still beyond the service limit, replace the camshaft. 7. Clean the camshaft journal surfaces in the cylinder head, then set the
Camshaft End Play: camshafts back in place. Place a plastigage strip across each journal.
Standard (New): 8. Install the camshaft holders, then tighten the bolts to the specified
torque as shown in step 2.
0.05 - 0.20 mm
9. Remove the camshaft holders. Measure the widest portion of
(0.002 - 0.008 in.) plastigage on each journal.
Service Limit: If the camshaft-to-holder clearance is within limits, go to step 11.
0.4 mm (0.02 in.) If the camshaft-to-holder clearance is beyond the service limit and
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Cylinder Head 6-
Camshaft Inspection (cont'd)
33
10. Check the total runout with the camshaft supported on V-blocks. 11. Measure cam lobe height.
If the total runout of the camshaft is within the service limit, replace Cam Lobe Height Standard (New):
the cylinder head.
INTAKE EXHAUST
If the total runout is beyond the service limit, replace the camshaft
and recheck the camshaft-to-holder oil clearance. If the oil PRI 32.791 mm 32.772 mm
clearance is still beyond the service limit, replace the cylinder head. (1.2910 in.) (1.2902 in.)
Camshaft Total Runout:
MID 35.534 mm 34.768 mm
Standard (New):
(1.3990 in.) (1.3688 in.)
0.03 mm (0.001 in.) max.
SEC 32.678 mm 32.661 mm
Service Limit:
(1.2865 in.) (1.2859 in.)
0.04 mm (0.002 in.)
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Cylinder Head 6-
Valve Stem-to-Guide Clearance Inspection
35
1. Remove the valves (see page 6-34). The difference between the largest guide measurement and the
2. Slide the valve out of its guide about 10 mm, then measure the guide- smallest stem measurement should not exceed the service limit.
to-stem clearance with a dial indicator while rocking the stem in the Intake Valve Stem-to-Guide Clearance:
direction of normal thrust (wobble method). Standard (New):
If the measurement exceeds the service limit, recheck it using a
0.030 - 0.055 mm
new valve.
If the measurement is now within the service limit, reassemble
(0.0012 - 0.0022 in.)
using a new valve. Service Limit:
If the measurement with a new valve still exceeds the service limit, 0.08 mm (0.003 in.)
go to step 3. Exhaust Valve Stem-to-Guide Clearance:
Intake Valve Stem-to-Guide Clearance:
Standard (New):
Standard (New):
0.055 - 0.080 mm
0.06 - 0.11 mm
(0.0022 - 0.0031 in.)
(0.002 - 0.004 in.)
Service Limit:
Service Limit:
0.11 mm (0.004 in.)
0.16 mm (0.006 in.)
Exhaust Valve Stem-to-Guide Clearance:
Standard (New):
0.11 - 0.16 mm
(0.004 - 0.006 in.)
Service Limit:
0.22 mm (0.009 in.)
3. Subtract the O.D. of the valve stem, measured with a micrometer, from
the I.D. of the valve guide, measured with an inside micrometer or ball
gauge.
Take the measurements in three places along the valve stem and
three places inside the valve guide.
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Cylinder Head 6-
Valve Guide Replacement
36
Special Tools Required 5. Working from the camshaft side, use the driver and an air hammer to
Valve guide driver, 5.5 mm, 07742-0010100 drive the guide about 2 mm (0.1 in.) towards the combustion chamber.
Valve guide reamer, 5.525 mm, 07HAH-PJ70100 This will knock off some of the carbon and make removal easier. Hold
the air hammer directly in line with the valve guide to prevent
1. Inspect valve stem-to-guide clearance (see page 6-35). damaging the driver.
2. As illustrated below, use a commercially available air-impact valve 6. Turn the head over and drive the guide out toward the camshaft side
guide driver (A) modified to fit the diameter of the valve guides. In most of the head.
cases, the same procedure can be done using the special tool and a
conventional hammer.
3. Select the proper replacement guides and chill them in the freezer
section of a refrigerator for about an hour.
4. Use a hot plate or oven to evenly heat the cylinder head to 150C
(300F). Monitor the temperature with a cooking thermometer. Do not
get the head hotter than 150C (300F); excessive heat may loosen
the valve seats.
7. If a valve guide will not move, drill it out with a 8 mm (5/16 inch) bit,
then try again. Drill guides only in extreme cases; you could damage
the cylinder head if the guide breaks.
8. Remove the new guide(s) from the freezer, one at a time, as you need
them.
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Cylinder Head 6-
Valve Guide Replacement (cont'd)
37
9. Apply a thin coat of clean engine oil to the outside of the new valve 10. Coat both reamer and valve guide with cutting oil.
guide. Install the guide from the camshaft side of the head; use the 11. Rotate the reamer clockwise the full length of the valve guide bore.
special tool to drive the guide in to the specified installed height (A) of
the guide (B). If you have all 16 guides to do, you may have to reheat
the head.
Valve Guide Installed Height:
Intake:
15.2 - 16.2 mm (0.598 - 0.638 in.)
Exhaust:
15.5 - 16.5 mm (0.610 - 0.650 in.)
12. Continue to rotate the reamer clockwise while removing it from the
bore.
13. Thoroughly wash the guide in detergent and water to remove any
cutting residue.
14. Check the clearances with a valve (see page 6-35). Verify that a
valve slides in the intake and exhaust valve guides without exerting
pressure.
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6-38
Cylinder Head 6-
Valve Seat Reconditioning
38
1. Inspect valve stem-to-guide clearance (see page 6-35). If the valve 5. Make one more very light pass with the 45 cutter to remove any
guides are worn, replace them (see page 6-36) before cutting the possible burrs caused by the other cutters.
valve seats. Valve Seat Width:
2. Renew the valve seats in the cylinder head using a valve seat cutter. Standard (New):
1.25 - 1.55 mm (0.049 - 0.061 in.)
Service Limit:
2.00 mm (0.079 in.)
6. After resurfacing the seat, inspect for even valve seating: Apply
Prussian Blue compound (A) to the valve face. Insert the valve in its
original location in the head, then lift it and snap it closed against the
seat several times.
7. The actual valve seating surface (B), as shown by the blue compound,
should be centred on the seat.
If it is too high (closer to the valve stem), you must make a second
cut with the 67.5 cutter to move it down, then one more cut with
the 45 cutter to restore seat width.
If it is too low (close to the valve edge), you must make a second
cut with the 35 cutter (intake side) or the 30 cutter (exhaust side)
to move it up, then make one more cut with the 45 cutter to restore
seat width.
NOTE: The final cut should always be made with the 45 cutter.
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6-39
Cylinder Head 6-
Valve Seat Reconditioning (cont'd)
39
8. Insert the intake and exhaust valves in the head and measure valve
stem installed height (A).
Intake Valve Stem Installed Height:
Standard (New):
40.8 - 41.0 mm
(1.606 - 1.614 in.)
Exhaust Valve Stem Installed Height:
Standard (New):
54.6 - 54.8 mm
(2.150 - 2.157 in.)
9. If valve stem installed height is over the standard, replace the valve
and recheck. If it is still over the standard, replace the cylinder head;
the valve seat in the head is too deep.
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6-40
Cylinder Head 6-
Valves, Springs and Valve Seals Installation
40
Special Tools Required 5. Install the inner and outer valve springs. Place the end of the valve
Stem seal driver, 07PAD-0010000 spring with closely wound coils toward the cylinder head.
Valve spring compressor attachment, 07757-PJ10100 6. Install the valve retainer.
Valve spring compressor, 07757-0010000 7. Install the valve spring compressor. Compress the spring, and install
the valve keepers.
1. Coat the valve stems with engine oil. Install the valves in the valve
guides.
2. Check that the valves move up and down smoothly.
3. Install the spring seats on the cylinder head.
4. Install the new valve seals (A) using the valve guide seal installer (B).
NOTE: The exhaust valve seal (C) has a black spring (D) and the
intake valve seal (E) has a white spring (F). They are not
interchangeable.
8. Lightly tap the end of each valve stem two or three times with a plastic
mallet (A) to ensure proper seating of the valve and valve keepers.
Tap the valve stem only along its axis so you do not bend the stem.
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6-41
Cylinder Head 6-
Rocker Arm Assembly Installation
41
1. Clean and dry the No. 5 rocker shaft holder mating surface. 5. Remove the bolts from the rocker shaft holder.
2. Apply liquid gasket, P/N 08C70-K0234M, 08C70-K0334M or 08C70- 6. Make sure the punch marks on the VTC actuator and exhaust
X0331S, evenly to the cylinder head mating surface of the No. 5 rocker camshaft sprocket are facing up, then set the camshafts (A) in the
shaft holder. holder.
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.
7. Set the camshaft holders (B) and cam chain guide B (C) in place.
8. Tighten the bolts to the specified torque.
Specified torque:
8 mm bolts: 22 Nm (2.2 kgf/m, 16 lbf/ft)
6 mm bolts: 12 Nm (1.2 kgf/m, 8.7 lbf/ft)
6 mm bolts: (21), (22), (23)
9. Install the cam chain (see page 6-16) and adjust the valve clearance
(see page 6-10).
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7-13
Engine Block 7-
Crankshaft and Piston Removal
13
1. Remove the engine assembly (see page 5-3). 8. Remove the bearing cap bolts. To prevent warpage, unscrew the bolts
2. Remove the transmission (see page 13-5). in sequence 1/3 turn at a time: repeat the sequence until all bolts are
3. Remove the oil pan (see page 7-12). loosened.
4. Remove the oil pump (see page 8-11).
5. Remove the cylinder head (see page 6-25).
6. Remove the baffle plate.
7. Remove the 8 mm bolts. 9. Remove the lower block and bearings. Keep all bearings in order.
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7-16
Engine Block 7-
Block and Piston Inspection
16
1. Remove the crankshaft and pistons (see page 7-13). 4. Measure wear and taper in direction X and Y at three levels in each
2. Check the piston for distortion or cracks. cylinder as shown. If measurements in any cylinder are beyond the
3. Measure the piston diameter at a point 11 mm (0.4 in.) from the bottom Oversize Bore Service Limit, replace the block. If the block is to be
of the skirt. There are two standard-size pistons (No Letter or A, and rebored, refer to step 7 after reboring.
B). The letter is stamped on the top of the piston. Letters are also Cylinder Bore Size:
stamped on the block as cylinder bore sizes. Standard (New):
Piston Diameter: A or I:
Standard (New): 86.010 - 86.020 mm
No Letter (or A): (3.3862 - 3.3866 in.)
85.980 - 85.990 mm B or II:
(3.3850 - 3.3854 in.) 86.000 - 86.010 mm
B: (3.3858 - 3.3862 in.)
85.970 - 85.980 mm Service Limit:
(3.3846 - 3.3850 in.) 86.070 mm (3.3886 in.)
Service Limit: Oversize:
No Letter (or A): 0.25: 86.250 - 86.260 mm (3.3957 - 3.3961 in.)
85.930 mm (3.3831 in.) Reboring limit: 0.25 mm (0.01 in.) max.
B: Bore Taper:
85.920 mm (3.3827 in.) Limit:
(Difference between first and third
measurement) 0.05 mm (0.002 in.)
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7-17
Engine Block 7-
Block and Piston Inspection (cont'd)
17
5. Scored or scratched cylinder bores must be honed. 7. Calculate the difference between the cylinder bore diameter and the
6. Check the top of the block for warpage. Measure along the edges and piston diameter. If the clearance is near or exceeds the service limit,
across the centre as shown. inspect the piston and cylinder block for excessive wear.
Engine Block Warpage: Piston-to-Cylinder Clearance:
Standard (New): Standard (New):
0.07 mm (0.003 in.) max. 0.020 - 0.040 mm
Service Limit: (0.0008 - 0.0016 in.)
0.10 mm (0.004 in.) Service Limit:
0.05 mm (0.002 in.)
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7-18
Engine Block 7-
Cylinder Honing
18
Only a scored or scratched cylinder bore must be honed.
1. Measure the cylinder bores (see page 7-16).
If the block is to be reused, hone the cylinders and remeasure the
bores.
2. Hone the cylinder bores with honing oil and a fine (400 grit) stone in a
60 degree cross-hatch pattern (A). Use only a rigid hone with 400 grit
or finer stone such as Sunnen, Ammco, or equivalent. Do not use
stones that are worn or broken.
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7-19
Engine Block 7-
Piston, Pin and Connecting Rod Replacement
19
Disassembly 4. Heat the piston and connecting rod assembly to approximately 70C
1. Remove the piston from the cylinder block (see page 7-13). (158F), then remove the piston pin.
2. Apply engine oil to the piston pin snap rings (A), and turn them in the
ring grooves until the end gaps are lined up with the cut-outs in the
piston pin bores (B).
NOTE: Take care not to damage the ring grooves.
3. Remove both snap rings (A). Start at the cut-out in the piston pin bore.
Remove the snap rings carefully so they do not go flying or get lost.
Wear eye protection.
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7-20
Engine Block 7-
Piston, Pin and Connecting Rod Replacement
(cont'd)
20
Inspection 3. Check the difference between the piston pin diameter and piston pin
NOTE: Inspect the piston, piston pin, and connecting rod when they are at hole diameter in the piston.
room temperature. Piston Pin-to-Piston Clearance:
1. Measure the diameter of the piston pin. Standard (New):
Piston Pin Diameter: -0.005 to +0.002 mm
Standard (New): (-0.00020 to +0.00008 in.)
21.961 - 21.965 mm Service Limit:
(0.8646 - 0.8648 in.) 0.005 mm (0.0002 in.)
Service Limit:
21.953 mm (0.8643 in.)
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7-21
Engine Block 7-
Piston, Pin and Connecting Rod Replacement
(cont'd)
21
Reassembly 4. Install the piston pin (A). Assemble the piston (B) and connecting rod
1. Install a piston pin snap ring (A). (C) with the arrow (D) and the embossed mark (E) on the same side.
2. Coat the piston pin bore in the piston, the bore in the connecting rod,
and the piston pin with engine oil.
3. Heat the piston to approximately 70C (158F).
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7-22
Engine Block 7-
Piston Ring Replacement
22
1. Remove the piston from the cylinder block (see page 7-13). 4. Using a piston, push a new ring (A) into the cylinder bore 15 - 20 mm
2. Using a ring expander (A), remove the old piston rings (B). (0.6 - 0.8 in.) from the bottom.
3. Clean all ring grooves thoroughly with a squared-off broken ring or ring
groove cleaner with a blade to fit the piston grooves. 5. Measure the piston ring end-gap (B) with a feeler gauge:
The top and 2nd ring grooves are 1.2 mm (0.05 in.) wide. The oil ring If the gap is too small, check to see if you have the proper rings for
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7-25
2. Check the connecting rod bearing clearance with plastigage (see page
7-9).
3. Check the main bearing clearance with plastigage (see page 7-7).
4. Inspect the connecting rod bolts (see page 7-25).
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7-26
Engine Block 7-
Crankshaft Installation (cont'd)
26
5. Install the bearing halves in the cylinder block and connecting rods. 12. Tighten the connecting rod bolts to 29 Nm (3.0 kgf/m, 22 lbf/ft).
6. Apply a coat of engine oil to the main bearings and rod bearings. 13. Tighten the connecting rod bolts an additional 90.
7. Hold the crankshaft so rod journal No. 2 and rod journal No. 3 are 14. Remove old liquid gasket from the lower block mating surfaces, bolts
straight up, and lower the crankshaft into the block. and bolt holes.
8. Install the thrust washers (A) in the No. 4 journal of the cylinder block. 15. Clean and dry the lower block mating surfaces.
16. Apply liquid gasket, P/N 08C70-K0234M, 08C70-K0334M or 08C70-
X0331S, evenly to the cylinder block mating surface of the lower block
and to the inner threads of the bolt holes.
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.
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7-27
Engine Block 7-
Crankshaft Installation (cont'd)
27
17. Put the lower block on the cylinder block. 21. Use the special tools to drive a new oil seal squarely into the block to
18. Tighten the bearing cap bolts in sequence to 29 Nm (3.0 kgf/m, 22 lbf/ the specified installed height.
ft).
22. Measure the distance between the crankshaft (A) and oil seal (B).
Oil Seal Installed Height:
5.5 - 6.5 mm (0.22 - 0.26 in.)
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7-28
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7-29
Engine Block 7-
Oil Pan Installation (cont'd)
29
6. Install the clutch cover (A), and tighten the two bolts (B) securing the
transmission.
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8-1
Engine Mechanical
Engine Lubrication
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8-2
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8-3
1. OIL PAN
Removal, page 7-12
Installation, page 7-28
2. WASHER
3. DRAIN BOLT
4. BAFFLE PLATE
5. OIL PUMP
Overhaul, page 8-10
6. SEALING BOLT
7. WASHER
8. O-RING
9. OIL COOLER
Replacement, page 8-9
10. OIL COOLER CENTRE BOLT
11. OIL FILTER
Replacement, page 8-6
12. OIL PRESSURE SWITCH
Circuit Diagram, page 22-88 in the 2001
Civic Shop Manuals
Switch test, page 8-4
Oil pressure test, page 8-4
Replacement, page 8-13
13. OIL PUMP CHAIN GUIDE
14. CRANKSHAFT SPROCKET
15. OIL JET
Inspection, page 8-9
16. OIL JET BOLT
Inspection, page 8-9
17. OIL PUMP CHAIN TENSIONER
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8-4
1. Remove the YEL/RED wire (A) from the engine oil pressure switch (B). Special Tools Required
Oil pressure gauge attachment, 07406-0030000
Oil pressure gauge, 07506-3000001
If the low oil pressure indicator stays on with the engine running, check
the engine oil level. If the oil level is correct:
1. Connect a tachometer or a Honda PGM Tester.
2. Remove the engine oil pressure switch and install the special tools.
2. Check for continuity between the positive terminal (C) and the engine
(ground). There should be continuity with the engine stopped. There
should be no continuity with the engine running.
3. If the switch fails to operate, check the engine oil level. If the engine oil
level is OK, check the engine oil pressure. If the oil pressure is OK,
replace the oil pressure switch.
3. Start the engine. Shut it off immediately if the gauge registers no oil
pressure. Repair the problem before continuing.
4. Allow the engine to reach operating temperature (fan comes on at
least twice). The pressure should be:
Engine Oil Temperature:
80C (176F)
Engine Oil Pressure:
At Idle:
70 kPa (0.7 kgf/cm2, 10 psi) minimum
At 3,000 rpm (min-1):
300 kPa (3.1 kgf/cm2, 44 psi) minimum
5. If the oil pressure is NOT within specification, inspect the following
items.
Check the oil strainer for clogging.
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8-5
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8-6
1. Remove the oil filter with the special oil filter wrench. the one you noted. For example, if number 2 is at the bottom when
2. Inspect the threads (A) and rubber seal (B) on the new filter. Wipe off the seal is seated, tighten the filter until the number 1 comes
the seat on the engine block, then apply a light coat of oil to the filter around the bottom.
rubber seal. Use only filters with a built-in bypass system.
6. After installation, fill the engine with oil up to the specified level, run the
engine for more than 3 minutes, then check for oil leakage.
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8-7
Japan-Made Oil Filter 5. If 8 numbers (1 to 8) are printed around the outside of the filter, use
(7/8-turn type) the following procedure to tighten the filter.
Spin the filter on until its seats lightly seats against the oil cooler
1. Remove the oil filter with the special oil filter wrench. and note which number is at the bottom.
2. Inspect the threads (A) and rubber seal (B) on the new filter. Wipe off Tighten the filter by turning it clockwise 7 numbers from the one you
the seat on the engine block, then apply a light coat of oil to the filter noted. For example, if number 2 is at the bottom when the seal is
rubber seal. Use only filters with a built-in bypass system. seated, tighten the filter until the number 1 comes around the
bottom.
6. After installation, fill the engine with oil up to the specified level, run the
engine for more than 3 minutes, then check for oil leakage.
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8-8
France-Made Oil Filter 5. If 4 numbers (1 to 4) are printed around the outside of the filter, use
(3/4-turn type) the following procedure to tighten the filter.
Spin the filter on until its seal lightly seats against the oil cooler and
1. Remove the oil filter with the commercially available oil filter wrench note which number is at the bottom.
(LABINAL-Purflux 76). Tighten the filter by turning it clockwise 3 numbers from the one you
2. Inspect the threads (A) and rubber seal (B) on the new filter. Wipe off noted. For example, if number 2 is at the bottom when the seal is
the seat on the engine block, then apply a light coat of oil to the filter seated, tighten the filter until the number 1 comes around the
rubber seal. Use only filters with a built-in bypass system. bottom.
6. After installation, fill the engine with oil up to the specified level, run the
engine for more than 3 minutes, then check for oil leakage.
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10-13
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10-14
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10-15
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10-16
Is there continuity?
YES - Repair short in the wire between the radiator fan switch 2P
connector terminal No. 2 and under-hood fuse/relay box.
NO - Replace the under-hood fuse/relay box.
Is there continuity?
YES - Replace the radiator fan switch.
NO - Check for an open in the wire between the radiator fan switch
2P connector terminal No. 1 and body ground. If the wire is OK, check
for a poor ground at G301.
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10-17
3. Heat the water, and check the temperature with a thermometer. Do not
let the thermometer (B) touch the bottom of the hot container.
4. Measure the continuity between terminal No.1 and terminal No.2
according to the table.
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11-1
PGM-FI System
Component Location Index 11-53
DTC Troubleshooting 11-56
MIL Circuit Troubleshooting 11-77
DLC Circuit Troubleshooting 11-88
Injector Replacement 11-90
Primary HO2S Replacement 11-92
CKP Sensor Replacement 11-92
ECT Sensor Replacement 11-93
TDC Sensor Replacement 11-93
IAT Sensor Replacement 11-94
Knock Sensor Replacement 11-94
Secondary HO2S Replacement 11-95
VTEC/VTC
Component Location Index 11-96
DTC Troubleshooting 11-97
VTC Oil Control Solenoid Valve Test 11-107
VTEC Solenoid Valve Removal/Inspection 11-108
CMP Sensor Replacement 11-108
PCV System
PCV Valve Inspection and Test 11-132
PCV Valve Replacement 11-132
EVAP System
Component Location Index 11-133
Refer to the '01 Civic Shop Manual P/N 62S5A00, for items not shown in this section.
Outline of Civic (3-door) Model Change
K20A2 engine have been added.
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11-4
How to Reset the ECM How to Remove the ECM for Testing
You can reset the ECM in either of 2 ways: If the inspection for a trouble code requires voltage or resistance checks
Use the scan tool or Honda PGM Tester to clear the ECM's memory. at the ECM connectors, remove the ECM and test it:
See the scan tool or Honda PGM Tester user's manuals for specific 1. Remove the passenger's dashboard lower cover, refer to the 2001
instructions. Civic Shop Manual (see page 20-78), the passenger's kick panel, refer
Turn the ignition switch OFF and remove the No. 6 ECU (ECM) (15A) to the 2001 Civic Shop Manual (see page 20-64), and the glove box,
fuse (A) from the under-hood fuse/relay box (B) for 10 seconds. refer to the 2001 Civic Shop Manual (see page 20-79).
2. Remove the ECM mounting bolt (A) and the bracket.
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11-20
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11-21
VTEC system
The VTEC system changes the cam profile to correspond to the engine speed. It maximises torque at low engine speeds and output at high engine speed.
The low lift cam is used at low engine speeds, and the high lift cam is used at high engine speeds.
The K20A2 engine changes both the intake and exhaust camshaft. Only the intake camshaft side has a VTEC mechanism on the K20A3 engine.
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NOTE: Connector with male terminals (double outline): View from terminal side
Connector with female terminals (single outline): View from wire side
O: Related to ECM control
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11-39
NOTE: Connector with male terminals (double outline): View from terminal side
Connector with female terminals (single outline): View from wire side
O: Related to ECM control
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11-41
NOTE: Connector with male terminals (double outline): View from terminal side
Connector with female terminals (single outline): View from wire side
O: Related to ECM control
*: Terminal side of female terminals
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NOTE: Connector with male terminals (double outline): View from terminal side
Connector with female terminals (single outline): View from wire side
O: Related to ECM control
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NO - Repair short in the wire between No. 10 METER (7.5A) fuse and YES - Substitute a known-good ECM and recheck (see page 11-5). If
the gauge assembly. Also replace the No. 10 METER (7.5A) fuse. symptom/indication goes away, replace the original ECM.
NO - Check for an open in the wire between the ECM (E31) and the
gauge assembly. Also check for a blown MIL bulb. If the wires and the
bulb are OK, replace the gauge assembly.
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Is there continuity?
YES - Repair short in the wire between the No. 6 ECU (ECM) (15A)
fuse and the PGM-FI main relay 1. Also replace the No. 6 ECU (ECM)
(15A) fuse.
NO - Go to step 26.
26. Disconnect each of the components or the connectors below, one at
a time, and check for continuity between the PGM-FI main relay 1 4P
connector terminal No. 1 and body ground.
RHD model: PGM-FI main relay 2
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28. Check for continuity between the PGM-FI main relay 1 4P connector
terminal No. 1 and body ground.
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34. Check for continuity between ECM connector terminal E9 and body
ground.
ECM CONNECTOR E (31P)
RHD model:
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YES - Go to step 56. YES - Repair open in the wire(s) between that had more than 1.0 V
between G101 and the ECM (A4, A5, A23, A24).
NO - Repair open in the wire between the No. 6 ECU (ECM) (15A)
fuse and the PGM-FI main relay 1. NO - Go to step 59.
56. Turn the ignition switch OFF. 59. Measure voltage between body ground and ECM connector terminal
57. Check for continuity between the PGM-FI main relay 1 4P connector A21.
terminal No. 1 and ECM connector terminals A2 and A3 individually. ECM CONNECTOR A (31P)
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Wire side of female terminals YES - Repair short in the wire between the ECM (A20) and the TP
sensor.
Is there about 5 V?
NO - Substitute a known-good ECM and recheck (see page 11-5). If
YES - Replace the TP sensor.
symptom/indication goes away, replace the original ECM.
NO - Go to step 72.
72. Turn the ignition switch OFF.
73. Disconnect ECM connector A (31P).
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3. Install the part in the reverse order of removal with a new O-ring (B).
2. Install the primary HO2S in the reverse order of removal.
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4. Install the part in the reverse order of removal with a new O-ring (B). 4. Install the part in the reverse order of removal with a new O-ring (B).
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2. At idle, make sure there is a clicking sound from the PCV valve when 3. Install the parts in the reverse order of removal with a new O-ring (B).
the hose between the PCV valve and intake manifold is lightly pinched
(A) with your fingers or pliers.
If there is no clicking sound, check the PCV valve grommet for cracks
or damage. If the grommet is OK, replace the PCV valve and recheck.
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12-4
Clutch 12-4
Clutch Pedal and Clutch Pedal Position Switch
Adjustment
NOTE: 5. Turn the clutch pedal position switch (B) in an additional 3/4 to 1 turn.
To check the clutch pedal position switch, refer to the 2001 Civic Shop 6. Tighten locknut (A).
Manual (see page 4-49).
Remove the driver's side floor mat before adjusting the clutch pedal.
The clutch is self-adjusting to compensate for wear.
If there is no clearance between the master cylinder piston and push
rod, the release bearing will be held against the diaphragm spring,
which can result in clutch slippage or other clutch problems.
1. Loosen locknut (A), and back off the clutch pedal position switch (B)
(or adjusting bolt) until it no longer touches the clutch pedal (C).
NOTE: RHD type is shown, LHD type is similar.
2. Loosen locknut (D), and turn the push rod (E) in or out to get the
specified height (F) and stroke (G) at the clutch pedal.
Clutch Pedal Stroke:
130 - 140 mm (5.1 - 5.5 in.)
Clutch Pedal Height:
200 mm (7.87 in.)
3. Tighten locknut (D).
4. With the clutch pedal released, turn the clutch pedal position switch (B)
in until it contacts the clutch pedal (C).
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12-5
Clutch 12-5
Clutch Master Cylinder Replacement
NOTE: Do not spill brake fluid on the vehicle; it may damage the paint; if 5. Remove the clutch master cylinder (A).
brake fluid does contact the paint, wash it off immediately with water.
1. Remove the brake fluid from the clutch master cylinder reservoir with a
syringe.
2. Remove the retaining clip (A). Disconnect the clutch line (B). Plug the
end of the clutch line with a shop towel to prevent brake fluid from
coming out.
6. Remove the O-ring (B) and the clutch master cylinder seal (C) from the
master cylinder.
7. Install the clutch master cylinder in the reverse order of removal. Install
a new O-ring. Tighten the master cylinder mounting nuts to 13 Nm (1.3
kgf/m, 9.4 lbf/ft). Make sure the tabs on the master cylinder hose
clamps are pointed in the directions shown.
3. Disconnect the reservoir hose (C) from the clutch master cylinder 8. To prevent the retaining clip (A) from coming off, pry to open the tip of
reservoir. Plug the end of the reservoir hose with a shop towel to the retaining clip (B) with a screwdriver.
prevent brake fluid from coming out.
4. Pry out the lock pin (A), and pull the pedal pin (B) out of the yoke.
Remove the master cylinder mounting nuts (C).
9. Bleed the clutch master hydraulic system (see step 11 on page 12-9).
NOTE: The reservoir filling is covered in the bleeding procedure.
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12-6
Clutch 12-6
Clutch Master Cylinder Overhaul
Exploded View
NOTE:
RHD type is shown, LHD type is similar.
When attaching the reservoir hose, align the yellow mark on the hose to the rib on reservoir connection area.
When attaching the reservoir hose, align the blue mark on the hose to the rib on clutch master cylinder connection area.
1. Clip catches should be on
the arrow marked side
2. CONNECTOR
3. O-RING
Replace
4. O-RING
Replace
5. CLUTCH LINE
CONNECTOR
6. RESERVOIR HOSE
Inspect for damage, leaks,
interference and twisting
7. Clip catches should be on
the arrow marked side
8. RESERVOIR
9. RETAINING CLIP
Replace
10. PISTON ASSEMBLY
Check for scoring and wear.
11. (Brake Assembly Lube)
12. PUSH ROD
13. CIRCLIP
14. LOCK PIN
Replace
15. YOKE
16. PEDAL PIN
17. STOPPER
Check for damage and
bending.
18. CLUTCH MASTER
CYLINDER SEAL
19. MASTER CYLINDER BODY
Check the cylinder wall for
scoring and wear.
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12-7
Clutch 12-7
Clutch Master Cylinder Overhaul (cont'd)
NOTE: 3. Slide the piston assembly into the clutch master cylinder.
Refer to the Exploded View, as needed during this procedure.
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.
Clean all parts in brake fluid and air dry; blow out all passages with
compressed air.
Before reassembling, check that all parts are free of dust and other
foreign particles.
Replace parts with new ones whenever specified to do so.
Make sure no dirt or other foreign matter is allowed to contaminate the
brake fluid.
Do not mix different brands of brake fluid as they may not be
compatible.
Do not reuse the drained fluid. Use only clean DOT 3 or 4 brake fluid.
1. Pry the circlip off the clutch master cylinder.
2. Carefully remove the piston by applying air pressure through the clutch
line hole.
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12-8
Clutch 12-8
Slave Cylinder Replacement
NOTE: 6. Remove the mounting bolts (A) and the slave cylinder (B).
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.
7. 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 from coming out.
8. Install the slave cylinder in the reverse order of removal. Install a new
O-ring (A).
9. Pull the boot (B) back, and apply brake assembly lube to the boot and
slave cylinder rod (C). Reinstall the boot.
10. Apply Urea Grease UM264 (P/N 41211-PY5-305) to the push rod of
the slave cylinder. Tighten the slave cylinder mounting bolts to 22 Nm
(2.2 kgf/m, 16 lbf/ft).
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12-9
Clutch 12-9
Slave Cylinder Replacement (cont'd)
cylinder, then slowly pump the clutch pedal until no more bubbles
appear at the bleeder hose.
Tighten the bleed screw to 8 Nm (0.8 kgf/m, 6 lbf/ft); do not
overtighten it.
Refill the clutch master cylinder with fluid when done.
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12-10
Clutch 12-
Slave Cylinder Overhaul
10
1. ROLL PINS
Replace
2. BLEEDER SCREW CAP
3. BLEEDER SCREW
8 Nm (0.8 kgf/m, 5.8 lbf/ft)
4. O-RING
Replace
5. SLAVE CYLINDER BODY
Check the cylinder wall for scoring and
wear
6. (Brake Assembly Lube)
7. PISTON CLIP
Replace
8. SLAVE CYLINDER PISTON
Check for wear and damage.
9. SLAVE CYLINDER SPRING
Install with small end facing piston.
10. BOOT
Check that it is fitted securely over the
cylinder body.
11. PUSH ROD
12. Urea Grease UM 264
(P/N 41211-PY-5-305)
13. (Brake Assembly Lube)
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12-11
Clutch 12-
Clutch Replacement
11
Special Tools Required 2. Install the special tools.
Clutch alignment tool set, 07PAF-0020000
Ring gear holder, 07LAB-PV00100 or 07924-PD20003
Pressure Plate and Clutch Disc Removal
1. Check the diaphragm spring fingers for height using the dial indicator
(A). If the height is more than the service limit, replace the pressure
plate.
Standard (New):
0.6 mm (0.02 in.) max.
Service Limit:
0.8 mm (0.03 in.)
5. Inspect the fingers of the diaphragm spring (B) for wear at the release
bearing contact area.
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12-12
Clutch 12-
Clutch Replacement (cont'd)
12
6. Inspect for warpage using a straight edge (A) and feeler gauge (B). 9. Measure the clutch disc thickness. If the thickness is less than the
Measure across the pressure plate (C). If the warpage is more than service limit, replace the clutch disc.
the service limit, replace the pressure plate. Standard (New):
Standard (New): 8.3 - 8.9 mm
0.03 mm (0.001 in.) max. (0.33 - 0.35 in.) max.
Service Limit: Service Limit:
0.15 mm (0.006 in.) 6.0 mm (0.24 in.)
8. Inspect the lining of the clutch disc for signs of slipping or oil. If the
clutch disc is burned black or oil soaked, replace it.
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12-13
Clutch 12-
Clutch Replacement (cont'd)
13
Flywheel Inspection Flywheel Replacement
1. Inspect the ring gear teeth for wear and damage. 1. Install the special tool.
2. Inspect the clutch disc mating surface on the flywheel for wear, cracks
and burning.
3. Measure the flywheel (A) runout using a dial indicator (B) through at
least two full turns with the engine installed. Push against the flywheel
each time you turn it to take up the crankshaft thrust washer
clearance. If the runout is more than the service limit, replace the
flywheel and recheck the runout. Resurfacing the flywheel is not
recommended.
Standard (New):
0.05 mm (0.002 in.) max.
Service Limit:
0.15 mm (0.006 in.)
2. Remove the flywheel mounting bolts in a criss-cross pattern in several
steps, then remove the flywheel.
3. Install the flywheel on the crankshaft, and install the mounting bolts
finger-tight.
4. Install the special tool, then torque the flywheel mounting bolts in a
criss-cross pattern in several steps.
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12-14
Clutch 12-
Clutch Replacement (cont'd)
14
Clutch Disc and Pressure Plate Installation 4. Torque the mounting bolts in a criss-cross pattern. Tighten the bolts in
1. Install the ring gear holder. several steps to prevent warping the diaphragm spring.
PRESSURE PLATE MOUNTING BOLT TORQUE:
25 Nm (2.6 kgf/m, 19 lbf/ft)
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13-5
NOTE: Use fender covers to avoid damaging painted surfaces. 8. First remove the cable bracket (A), then disconnect the cables (B) from
1. Write down the frequencies for the radio's preset buttons. Disconnect the top of the transmission housing. Carefully remove both cables and
the negative (-) cable first, then the positive (+) cable from the battery. the bracket together so as not to bend the cables.
Remove the battery.
2. Remove the intake manifold cover (see step 5 on page 5-3).
3. Remove the air cleaner (see page 11-126).
4. Remove the intake air duct (see step 7 on page 5-3).
5. Remove the battery tray (A).
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13-10
3. Install the transmission rear mount bracket (A) and the transmission
rear mount (B).
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13-11
6. Install the intake manifold bracket (A), then install the harness bracket
(B).
8. Install the front engine mount.
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13-13
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13-14
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13-15
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13-16
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13-17
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13-18
4. Remove the drain plug (A), filler plug (B) and 10 mm flange bolt (C).
2. Remove the vehicle speed sensor (VSS) (A) and O-ring (B).
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13-19
6. Remove the harness bracket (A), the transmission hanger A (B) and
the transmission hanger B (C).
7. Remove the 32 mm sealing cap (A).
8. Expand the 72 mm snap ring (B) on the countershaft ball bearing and
remove it from the groove using a pair of snap ring pliers.
9. Remove the transmission housing (C) and 14 x 20 mm dowel pins (D).
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13-20
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13-21
If distance is not within the standard, replace the reverse shift fork new one.
with a new one. If distance is within the standard, replace the select lever with a
If distance is within the standard, replace the reverse gear with a new one.
new one. Standard:
Standard: 15.00 - 15.10 mm (0.591 - 0.594 in.)
13.4 - 13.7 mm (0.527 - 0.539 in.)
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13-22
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13-23
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13-24
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13-51
9. Place the transmission housing over the clutch housing, being careful
to line up the shafts.
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13-59
1. Remove the reverse lockout solenoid (see page 13-22). 1. Remove the reverse lockout solenoid (see page 13-22).
2. Connect battery positive terminal to the No. 2 terminal of the reverse 2. Remove the roller (A), the select lock return spring (C), and the select
lockout solenoid 2P connector, and connect the battery negative lock cam B.
terminal to the No. 1 terminal.
REVERSE LOCKOUT SOLENOID 2P CONNECTOR
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13-60
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13-61
2. Measure the backlash of both pinion gears (B) with a dial indicator (C).
If the backlash is not within the standard, replace the differential
carrier. 2. Install the final driven gear with the chamfer on the inside diameter
Standard (New): facing the carrier. Tighten the bolts in a criss-cross pattern in several
steps.
0.05 - 0.15 mm (0.002 - 0.006 in.)
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13-62
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13-63
5. Install the new oil seal in the clutch housing with the special tools.
3. Remove the oil seal (A) from the clutch housing (B).
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13-64
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13-65
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16-1
Driveline/Axle
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16-2
Driveline/Axle 16-2
Special Tools
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16-3
1. Check the inboard boot (A) and the outboard boot (B) on the driveshaft Special Tool Required
(C) for cracks, damage, leaking grease and loose boot bands (D). If Ball joint remover, 28 mm, 07MAC-SL00200
any damage is found, replace the boot and boot bands.
1. Loosen the wheel nuts slightly.
2. Raise the front of the vehicle, and support it with safety stands in the
proper locations, refer to the 2001 Civic Shop Manual (see page 1-15).
3. Remove the wheel nuts and front wheels.
2. Turn the driveshaft by hand and make sure the splines (E) and joint
are not excessively loose.
3. Make sure the driveshaft is not twisted or cracked; if it is, replace it.
4. Lift up the locking tab (A) on the spindle nut (B), then remove the nut.
5. If the driveshaft is removed, drain the transmission fluid. Reinstall the
drain plug using a new washer:
Manual transmission (see page 13-4)
6. Hold the stabiliser ball joint pin (A) with a hex wrench (B) and remove
the flange nut (C). Separate the front stabiliser link (D) from the lower
arm.
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16-4
Driveline/Axle 16-4
Driveshafts Removal (cont'd)
7. Remove the cotter pin (A) from the lower arm ball joint castle nut (B) 10. Pry/tap the inboard joint (A) with a prybar and remove the driveshaft
and remove the nut. from the differential case or bearing support as an assembly. Do not
pull on the driveshaft (B) because the inboard joint may come apart.
Draw the driveshaft straight out to avoid damaging the differential oil
seal.
Left driveshaft:
8. Separate the ball joint from the lower arm (C) with the special tool,
refer to the 2001 Civic Shop Manual (see page 18-9). Be careful not to
dislodge the lower ball joint from the knuckle.
9. Pull the knuckle outward and remove the driveshaft outboard joint from
the front wheel hub using a plastic hammer.
Right driveshaft:
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16-5
Driveline/Axle 16-5
Driveshafts Disassembly
2. Remove the boot bands. Take care not to damage the boot and
dynamic damper.
If the boot band is welded type (A), cut the boot band (B).
If the boot band is a double loop type (C), lift up the band bend (D)
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18-1
Suspension
Front Suspension
Special Tools 18-2
Knuckle/Hub/Wheel Bearing Replacement 18-3
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18-2
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18-4
Special Tools Required 5. Raise the stake (A) and remove the spindle nut (B).
Hub disassembly/assembly tool, 07GAF-SD40100
Ball joint remover, 28 mm, 07MAC-SL00200
Attachment 62 x 68 mm, 07746-0010500
Driver, 07749-0010000
Support base, 07965-SD90100
1. Raise the front of the vehicle and make sure it is securely supported.
2. Remove the wheel cap, wheel nuts and front wheel.
7. Screw two 8 x 1.25 mm bolts (B) into the disc to push it away from the
hub. Turn each bolt two turns at a time to prevent cocking the disc
4. Remove the caliper bracket mounting bolts (B) and remove the caliper excessively.
assembly (C) from the knuckle. To prevent damage to the caliper
assembly or brake hose, use a short piece of wire to hang the caliper
assembly from the undercarriage. Do not twist the brake hose with
force.
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18-5
8. Remove the flange bolt (A) and wheel sensor (B) from the knuckle. Do 10. Remove the clip (A) from the lower arm ball joint and remove the
not disconnect the wheel sensor connector. castle nut (B).
NOTE: During installation, insert the clip into the ball joint pin from the
inside to the outside of the vehicle. The closed end of the clip must be
in the range shown.
9. Remove the flange nut (A) while holding the joint pin (B) with a hex
wrench (C), and disconnect the stabiliser link (D) from the lower arm
(E).
11. Disconnect the lower arm from the knuckle using the special tool.
12. Loosen the damper pinch bolts (A) while holding the nuts (B) and
remove the bolts and nuts.
13. Remove the driveshaft outboard joint (C) from the knuckle (D) by
tapping the driveshaft end (E) with a plastic hammer while drawing the
knuckle outward, then remove the knuckle.
NOTE: Do not pull the driveshaft end outward. The driveshaft joint may
come off.
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18-6
14. Separate the hub (A) from the knuckle (B) using the special tool and 16. Remove the snap ring (A) and the splash guard (B) from the knuckle
a hydraulic press. Take care not to deform the splash guard. Hold onto (C).
the hub to keep it from falling when pressed clear.
17. Press the wheel bearing (A) out of the knuckle (B) using the special
tool and a press.
15. Press the wheel bearing inner race (A) off of the hub (B) using the
special tool, a commercially available bearing separator (C), and a
press.
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18-7
18. Wash the knuckle and hub thoroughly in high flash point solvent 22. Press a new hub bearing unit (A) onto the hub (B) using the special
before reassembly. tools and a press.
19. Press a new wheel bearing (A) into the knuckle (B) using the old
bearing (C), a steel plate (D), the special tool and a press. Place the
wheel bearing on the knuckle with the pack seal side facing (metal
colour) toward the inside. Be careful not to damage the sleeve of the
pack seal.
20. Install the snap ring (A) securely in the knuckle (B). knuckle.
Tighten all mounting hardware to the specified torque values.
Torque the castle nut to the lower torque specification, then tighten
it only far enough to align the slot with the clip hole. Do not align the
castle nut by loosening it.
Install a new clip on the castle nut after torquing.
Before installing the spindle nut, apply a small amount of engine oil
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19-1
Brakes
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19-2
Replacement
CAUTION 1. Remove the brake hose mounting bolt (A).
Frequent inhalation of brake pad dust,
regardless of material composition, could
be hazardous to your health.
Avoid breathing dust particles.
Never use an air hose or brush to clean
brake assemblies. Use an appropriate
vacuum cleaner.
Inspection
1. Raise the front of the vehicle and make sure it is securely supported.
Remove the front wheels.
2. Check the thickness of the inner pad (A) and outer pad (B). Do not
include the thickness of the backing plate.
Brake pad thickness:
Standard:
9.5 - 10.5 mm (0.37 - 0.41 in.)
Service limit: 2. Remove the bolt (B), and pivot the caliper (C) up out of the way. Check
1.6 mm (0.06 in.) the hose and pin boots for damage and deterioration.
3. Remove the pad shim (A) and pads (B).
3. If the brake pad thickness is less than the service limit, replace all the
pads as a set.
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19-3
4. Remove the pad retainers (A). 9. Apply Dow Corning Molykote M77 grease to both sides of the pad
shim (A), the back of the pads (B), and the other areas indicated by
the arrows.
Wipe excess grease off the shim. Contaminated brake discs and pads
reduce stopping ability. Keep grease off the discs and pads.
5. Clean the caliper thoroughly; remove any rust and check for grooves
and cracks.
6. Check the brake disc for damage and cracks.
7. Apply Dow Corning Molykote M77 grease to the retainers on their
mating surfaces against the caliper bracket.
8. Install the pad retainers. Wipe excess grease off the retainers.
Contaminated brake discs and pads reduce stopping ability. Keep
grease off the discs and pads.
10. Install the brake pads and pad shim correctly. Install the pads with
the wear indicators (C) on the inside.
If you are reusing the pads, always reinstall the brake pads in their
original positions to prevent a momentary loss of braking efficiency.
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19-4
11. Push in the piston (A) so the caliper will fit over the pads. Make sure
the piston boot is in position to prevent damaging it when pivoting the
caliper down.
12. Pivot the caliper down into position. Being careful not to damage the
pin boots, install the bolt (B) and tighten it to the specified torque.
13. Install the brake house bracket onto the dampers.
14. Press the brake pedal several times to make sure the brake works,
then test-drive.
NOTE: Engagement of the brake may require a greater pedal stroke
immediately after the brake pads have been replaced as a set. Several
applications of the brake pedal will restore the normal pedal stroke.
15. After installation, check for leaks at hose and line joints or
connections, and retighten if necessary.
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19-5
CAUTION
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to
your health.
Avoid breathing dust particles.
Never use an air hose or brush to clean brake assemblies. Use an appropriate vacuum cleaner.
Remove, disassemble, inspect, reassemble and install the caliper and note the following items:
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water.
To prevent dripping, cover disconnected hose joints with rags or shop towels.
Clean all parts in brake fluid and air dry; blow out all passages with compressed air.
Before reassembling, check that all parts are free of dust and other foreign particles.
Replace parts with new ones as specified in the illustration.
Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency.
Do not reuse drained brake fluid.
Use only clean Genuine Honda DOT 4 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the system.
Do not mix different brands of brake fluid as they may not be compatible.
Coat the piston, piston seal groove, and caliper bore with clean brake fluid.
Make sure no grease or oil gets on the brake discs or pads.
Replace all rubber parts with new ones whenever disassembled.
After installing the caliper, check the brake hose and line for leaks, interference, and twisting.
1. Rubber grease
2. Silicone grease
3. CALIPER PIN
4. CALIPER BRACKET
5. PIN BOOT, Replace.
6. BANJO BOLT
34 Nm (3.5 kgf/m, 25 lbf/ft)
7. BRAKE HOSE
8. CALIPER BOLTS
32 Nm (3.3 kgf/m, 24 lbf/ft)
9. BLEED SCREW
9 Nm (0.9 kgf/m, 7 lbf/ft)
10. CALIPER BODY
11. PISTON BOOT, Replace.
12. PISTON
13. PISTON SEAL, Replace.
14. BRAKE PADS
15. SEALING WASHERS,
Replace.
16. OUTER PAD SHIM
17. WEAR INDICATOR
Install inner pad with its wear
indicator downward.
18. INNER PAD SHIM B
19. INNER PAD SHIM A
20. PIN BOOTS, Replace.
21. CALIPER PIN
22. CALIPER BRACKET
23. PAD RETAINERS
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20-11
5. Install the spoiler in the reverse order of removal and make sure the
high mount brake light connector is plugged in properly.
3. Remove the bolts (B) and nuts (C) securing the tailgate spoiler (D).
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22-1
Body Electrical
Power Distribution
Fuse to Components Index 22-8
Ground Distribution
Circuit Identification 22-10
Exterior Lights
Circuit Diagram-Brake Light 22-15
Wipers/Washers
Washer Reservoir Replacement 22-16
Washer Tubes Replacement 22-17
WARNING
To avoid rendering the SRS inoperative, which could lead to personal injury or death in the
event of a severe frontal collision, all SRS service work must be performed by an authorised
Honda dealer.
Improper service procedures, including incorrect removal and installation of the SRS, could lead
to personal injury caused by unintentional deployment of the airbags.
Do not bump the SRS unit. Otherwise, the system may fail in a collision, or airbags may deploy
when the ignition switch is ON (II).
SRS electrical wiring connectors are identified by yellow colour coding. Related components
are located in the steering column, front console, dashboard, dashboard lower panel, and in the
dashboard above the glove box. Do not use electrical test equipment on these circuits.
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22-2
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22-3
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22-4
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22-5
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22-6
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22-7
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22-8
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22-9
*: Not used
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22-10
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22-11
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22-16
Wipers/Washers 22-
Washer Reservoir Replacement
16
1. Remove the right inner fender, refer to the '01 Civic Shop Manual (see
page 20-121).
2. Disconnect the 2P connectors (A) and washer tube (B) from the
motors.
4. Install the reservoir in the reverse order of removal. Check the washer
motor operation.
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0-1
Introduction
How to Use This Manual
This supplement contains information for the 2001 HONDA CIVIC 3-door. General Info
Refer to following shop manuals for service procedures and data on this Specifications
CD.
Maintenance
HONDA CIVIC MAINTENANCE, Engine
REPAIR and CONSTRUCTION 2001 *Transaxle
HONDA Civic 5-door SUPPLEMENT
*Body
*Body Electrical
Safety Messages *Restraints
Your safety and the safety of others, is very important. To help you make
informed decisions, we have provided safety messages and other safety
information throughout this manual. Of course, it is not practical or possible
to warn you about all the hazards associated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
Safety Labels - on the vehicle.
DANGER
You WILL be KILLED or SERIOUSLY HURT if
you do not follow instructions.
WARNING
You CAN be KILLED or SERIOUSLY HURT if
you do not follow instructions.
CAUTION
You CAN be HURT if you do not follow
instructions.
Instructions - how to service this vehicle correctly and safely.
All information contained in this manual is based on the latest product information
available at the time of printing. We reserve the right to make changes at any time
without notice. No part of this publication may be reproduced, stored in retrieval
system, or transmitted, in any form by any means, electronic, mechanical,
photocopying, recording or otherwise, without the prior written permission of the
publisher. This includes text, figures and tables.
As you read this manual, you will find information that is preceded by a
symbol. The purpose of this message is to help prevent damage to
your vehicle, other property or the environment.
First Edition 4/2000 150 pages
All Rights Reserved
HONDA MOTOR CO., LTD.
Service Publication Office
As sections with * include SRS components;
special precautions are required when servicing.
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0-2
The service and repair information contained in this manual is intended for use by IMPORTANT SAFETY PRECAUTIONS
qualified, professional technicians. Attempting service or repairs without the proper Make sure you have a clear understanding of all basic shop safety practices and
training, tools and equipment could cause injury to you or others. It could also that you are wearing appropriate clothing and using safety equipment. When
damage the vehicle or create an unsafe condition. performing any service task, be especially careful of the following:
This manual describes the proper methods and procedures for performing service, Read all of the instructions before you begin and make sure you have the
maintenance and repairs. Some procedures require the use of specially designed tools, the replacement or repair parts and the skills required to perform the
tools and dedicated equipment. Any person who intends to use a replacement part, tasks safely and completely.
service procedure or a tool that is not recommended by Honda, must determine the Protect your eyes by using proper safety glasses, goggles or face shields any
risks to their personal safety and the safe operation of the vehicle. time you hammer, drill, grind or work around pressurised air or liquids and
If you need to replace a part, use genuine Honda parts with the correct part number springs or other stored-energy components. If there is any doubt, put on eye
or an equivalent part. We strongly recommend that you do not use replacement protection.
Use other protective wear when necessary, for example gloves or safety
parts of inferior quality.
shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you
FOR YOUR CUSTOMER'S SAFETY grab something that looks like it can hurt you, stop and put on gloves.
Proper service and maintenance are essential to the customer's safety and the Protect yourself and others whenever you have the vehicle up in the air. Any
reliability of the vehicle. Any error or oversight while servicing a vehicle can result in time you lift the vehicle, either with a hoist or a jack, make sure that it is always
faulty operation, damage to the vehicle, or injury to others. securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless
WARNING the instruction tells you to do otherwise. This will help eliminate several potential
Improper service or repairs can create an hazards:
unsafe condition that can cause your Carbon monoxide poisoning from engine exhaust. Be sure there is adequate
customer or others to be seriously hurt or ventilation whenever you run the engine.
killed. Burns from hot parts or coolant. Let the engine and exhaust system cool
WARNING
Failure to properly follow instructions and
precautions can cause you to be seriously
hurt or killed.
Follow the procedures and precautions in
this manual carefully.
Some of the most important general service safety precautions are given below.
However, we cannot warn you of every conceivable hazard that can arise in
performing service and repair procedures. Only you can decide whether or not you
should perform a given task.
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General Information
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List of automotive abbreviations which may be used in shop manual. EPR Evaporator Pressure Regulator
ABS Anti-lock Brake System EPS Electrical Power Steering
A/C Air Conditioning, Air Conditioner EVAP Evaporative
ACL Air Cleaner EX Exhaust
A/F Air Fuel Ratio
ALR Automatic Locking Retractor F Front
ALT Alternator FIA Fuel Injection Air
AMP Ampere(s) FL Front Left
ANT Antenna FP Fuel Pump
API American Petroleum Institute FR Front Right
APPROX. Approximately FSR Fail Safe Relay
ASSY Assembly FWD Front Wheel Drive
A/T Automatic Transmission
ATDC After Top Dead Center GAL Gallon
ATF Automatic Transmission Fluid GND Ground
ATT Attachment GPS Global Positioning System
ATTS Active Torque Transfer System
AUTO Automatic H/B Hatchback
AUX Auxiliary HC Hydrocarbons
HID High Intensity Discharge
BARO Barometric HO2S Heated Oxygen Sensor
BAT Battery
BDC Bottom Dead Center IAB Intake Air Bypass
BTDC Before Top Dead Center IAC Idle Air Control
IACV Idle Air Control Valve
CARB Carburetor IAR Intake Air Resonator
CAT or CATA Catalytic Converter IAT Intake Air Temperature
CHG Charge ICM Ignition Control Module
CKF Crankshaft Speed Fluctuation ID Identification
CKP Crankshaft Position ID or I.D. Inside Diameter
CO Carbon Monoxide IG or IGN Ignition
COMP Complete IMA Idle Mixture Adjustment
CPB Clutch Pressure Back up Integrated Motor Assisted
CPC Clutch Pressure Control IMMOBI. Immobilizer (Immobiliser)
CPU Central Processing Unit IN Intake
CVT Continuously Variable Transmission INJ Injection
CYL Cylinder INT Intermittent
CYP Cylinder Position
KS Knock Sensor
DI Distributor Ignition
DIFF Differential L Left
DLC Data Link Connector L/C Lock-up Clutch
DOHC Double Overhead Camshaft LCD Liquid Crystal Display
DPI Dual Point Injection LED Light Emitting Diode
DTC Diagnostic Trouble Code LEV Low Emission Vehicle
LF Left Front
EBD Electronic Brake Distribution LH Left Handle
ECM Engine Control Module LHD Left Handle Drive
ECT Engine Coolant Temperature LR Left Rear
EGR Exhaust Gas Recirculation LSD Limited Slip Differential
ELD Electrical Load Detector L-4 In-line Four Cylinder (engine)
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Specifications
Design Specifications
Dimensions 2-22
Weight 2-22
Engine 2-22
Starter 2-23
Clutch 2-23
Manual Transmission 2-23
Automatic Transmission 2-23
CVT 2-23
Steering 2-23
Suspension 2-23
Wheel Alignment 2-24
Brakes 2-24
Tyres 2-24
Air Conditioning 2-24
Electrical Ratings 2-25
Body Specifications
Illustration 2-26
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Alternator belt NOTE: Deflection with 98 N (10 kgf, 22 Without A/C (with A/C, see Used belt: 8.5-11.0 mm (0.33-0.43 in.)
Adjust a new belt to the lbs) applied midway between ''Compressor belt'' in the A/C
new belt spec., run the pulleys table) New belt: 6.5-8.5 mm (0.26-0.33 in.)
engine for 5 minutes, then
Tension (measured with belt Without A/C (with A/C, see Used belt: 340-490 N (35-55 kgf, 77-110 lbs)
readjust it to the used
tension gauge) ''Compressor belt'' in the A/C
belt spec. New belt: 540-740 N (55-75 kgf, 120-170 lbs)
table)
Alternator Output At 13.5 V and normal engine 70 A
temperature
Coil (rotor) resistance at 68F (20C) 1.84-2.10 ohms
Slip ring O.D. 22.7 mm (0.89 in.) 21.7 mm (0.85 in.)
Brush length 19.0 mm (0.75 in.) 5 mm (0.20 in.)
Brush spring tension 3.3-4.1 N (1.6-1.8 kgf, 3.5-4.0 lbs)
Starter for D14Z6, D16V1 Output 0.8 kW
(KE model)
Commutator mica depth 0.50-0.75 mm (0.020-0.030 in.) 0.2 mm (0.008 in.)
Commutator runout 0.05 mm (0.002 in.) max. 0.4 mm (0.02 in.)
Commutator O.D. 27.9-28.0 mm (1.098-1.102 in.) 27.0 mm (1.063 in.)
Brush length 9.7-10.3 mm (0.38-0.41 in.) 6.0 mm (0.24 in.)
Starter for D16V1 (KG, Output 1.0 kW
KR, KS models) engine
Commutator mica depth 0.50-0.75 mm (0.020-0.030 in.) 0.2 mm (0.008 in.)
with A/T (DENSO)
Commutator runout 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.)
Commutator O.D. 27.9-28.0 mm (1.098-1.102 in.) 27.0 mm (1.063 in.)
Brush length 14.0-14.5 mm (0.55-0.57 in.) 9.0 mm (0.35 in.)
Brush spring tension 13.7-17.7 N (1.40-1.80 kgf, 3.09-3.97 lbf)
Starter for D16V1 (KG, Output 1.0 kW
KR, KS models) engine
Commutator mica depth 0.50-0.90 mm (0.020-0.035 in.) 0.2 mm (0.008 in.)
with M/T (VALEO)
Commutator runout 0.01 mm (0.0004 in.) max. 0.015 mm (0.0006 in.)
Brush length 18 mm (0.7 in.) 5 mm (0.2 in.)
Brush spring tension 15.3-19.2 N (1.56-1.96 kgf, 3.44-4.32 lbf)
Engine Assembly
Item Measurement Qualification Standard or New Service Limit
Compression Pressure check at 250 rpm (min-1) Minimum 930 kPa (9.5 kgf/cm2, 135 psi) -
with wide open throttle. (See
Design Specs for ratio.) Maximum variation 200 kPa (2.0 kgf/cm2, 28 psi) -
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Valve springs Free length D14Z6 engine Intake 58.70 mm (2.311 in.) -
Exhaust 58.70 mm (2.311 in.) -
Free length D16V1 engine VTEC intake 56.49 mm (2.224 in.) -
VTEC exhaust 58.70 mm (2.31 in.) -
Valve guides I.D. Intake 5.51-5.53 mm 5.55 mm (0.219 in.)
(0.217-0.218 in.)
Exhaust 18.65-19.15 mm -
(0.734-0.754 in.)
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Oil pump Inner-to-outer rotor clearance 0.06-0.18 mm (0.002-0.007 in.) 0.20 mm (0.008 in.)
Pump housing-to-outer rotor 0.10-0.18 mm (0.004-0.007 in.) 0.20 mm (0.008 in.)
clearance
Pump housing-to-rotor axial 0.02-0.07 mm (0.001-0.003 in.) 0.15 mm (0.006 in.)
clearance
Oil pressure with oil temperature at At idle 70 kPa (0.7 kgf/cm2, 10 psi) min.
80C (176F)
at 3,000 rpm (min-1) 340 kPa (3.5 kgf/cm2, 50 psi) min.
Cooling
Item Measurement Qualification Standard or New Service Limit
Radiator Coolant capacity (Includes engine, M/T: engine overhaul 5.1 l (5.4 US qt, 4.5 lmp qt)
heater, hoses, and reservoir)
M/T: coolant change 4.0 l (4.2 US qt, 3.5 lmp qt)
A/T, CVT: engine overhaul 5.0 l (5.3 US qt, 4.4 lmp qt)
A/T, CVT: coolant change 3.9 l (4.1 US qt, 3.4 lmp qt)
Reservoir Coolant capacity 0.4 l (0.4 US qt, 0.4 lmp qt)
Radiator cap Opening pressure 93-123 kPa (0.95-1.25 kgf/cm2, 14-18 psi)
Thermostat Opening temperature Begins to open 76-80C (169-176F)
Fully open 90C (194F)
Valve lift at fully open 8.0 mm (0.31 in.) min.
Radiator fan switch Thermoswitch ''ON'' temperature 91-95C (196-203F)
Thermoswitch ''OFF'' temperature Subtract 3-8C (5-15F) from actual ''ON'' temperature
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Clutch
Item Measurement Qualification Standard or New Service Limit
Clutch pedal Height from the floor 198 mm (7.8 in.) -
Stroke 130-140 mm (5.1-5.5 in.) -
Play 8-18 mm (0.3-0.7 in.) -
Disengagement height from the floor 113 mm (4.4 in.) min. -
Flywheel Runout on clutch mating surface 0.06 mm (0.002 in.) max. 0.15 mm (0.006 in.)
Clutch disc Rivet head depth 1.2-1.7 mm (0.047-0.067 in.) 0.2 mm (0.01 in.)
Thickness 8.3-9.0 mm (0.33-0.35 in.) 5.7 mm (0.22 in.)
Pressure plate Warpage 0.03 mm (0.001 in.) max. 0.15 mm (0.006 in.)
Height of diaphragm spring fingers Measure with feeler gauge 0.6 mm (0.02 in.) max. 1.0 mm (0.04 in.)
and special tool
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Length A 51.97-52.03 mm -
(2.046-2.048 in.)
B 24.03-24.06 mm -
(0.946-0.947 in.)
Dual cone Outer synchro ring-to-synchro cone clearance Ring pushed against 0.5-1.0 mm 0.3 mm
synchro gear (0.02-0.04 in.) (0.01 in.)
Outer synchro ring-to-gear cone clearance Ring pushed against 0.95-1.68 mm 0.6 mm
gear (0.037-0.066 in.) (0.02 in.)
I.D. 18.042-18.066 mm -
(0.7103-0.7113 in.)
Check for cracks and damage. Refer to the 2001 Civic shop manuals on this CD (see
Check deflection and tension. page 17-23)
Check specific gravity for freezing point. Refer to the 2001 Civic shop manuals on this CD (see
page 10-8)
Use genuine Honda MTF (Manual Transmission Fluid). Refer to the 2001 Civic shop manuals on this CD (see
page 13-3)
Use genuine Honda AFT-Z1 (ATF). Refer to the 2001 Civic shop manuals on this CD (see
page 14-122)
Check the brake pad and disc thickness. Check for damage or cracks. Refer to the 2001 Civic shop manuals on this CD (see
Check the wheel cylinder for leaks. page 19-3)
Check the brake linings for cracking, glazing, wear or contamination.
Check the callipers for damage, leaks and tightness.
Use only DOT 3 brake fluid. (We recommend Genuine Honda Brake Fluid.) Refer to the 2001 Civic shop manuals on this CD (see
Check that brake fluid level is between the upper and lower marks on the reservoir. page 19-7)
Check the parking brake operation. Refer to the 2001 Civic shop manuals on this CD (see
page 19-6)
-
Check the position of the headlight. Refer to the 2001 Civic shop manuals on this CD (see
page 22-114)
Check for road stability, noise, vibrations and dashboard operation. -
Check for correct installation and position, check for cracks, deterioration rust and leaks. -
Check tightness of screws, nuts and joints. If necessary, retighten.
Check rack grease and steering linkage. Check the boot for damage and leaking grease. Refer to the 2001 Civic shop manuals on this CD (see
Check the fluid line for damage and leaks. page 17-5)
Check the bolts for tightness. Refer to the 2001 Civic shop manuals on this CD (see
Check all dust covers for deterioration and damage. page 18-3)
Check the boot and boot band for cracks Refer to the 2001 Civic shop manuals on this CD (see
Check rack grease. page 16-3)
Check the master cylinder, proportioning control valve and ABS modulator and leakage. Refer to the 2001 Civic shop manuals on this CD (see
page 19-48)
Check for leaks. -
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, leaks and tightness. Refer to the 2001 Civic shop manuals on this CD (see
page 9-5)
Check fuel lines for loose connections, cracks and deterioration. Retighten loose connections and Refer to the 2001 Civic shop manuals on this CD (see
replace any damaged parts. page 11-132) (see page 11-290)
Refer to the 2001 Civic shop manuals on this CD (see
page 11-432) (see page 11-565)
Replace engine coolant At 200,000 km (120,000 miles) or 120 months, then replace every 100,000 km (60,000 miles) or 60
months
Replace transmission fluid Manual Transmission Every 60,000 km (36,000 miles) or 48 months
Automatic Transmission At 60,000 km (36,000 miles) or 48 months, then replace every 40,000 km (24,000 miles) or 24 months
CVT At 80,000 km (48,000 miles) or 60 months, then replace every 60,000 km (36,000 miles) or 48 months
Inspect front and rear brakes Every 10,000 km (6,000 miles) or 6 months
Replace brake fluid Every 36 months
Check parking brake adjustment
Follow the Severe Conditions Maintenance Schedule if the customer's vehicle is driven MAINLY under one or more of the following conditions:
Driving less than 8 km (5 miles) per trip or, in freezing temperatures, driving less than 16 km (10 miles) per trip.
Driving in extremely hot conditions over 35C (95F).
Extensive idling or long periods of stop-and-go-driving.
NOTE: If the customer's vehicle is driven OCCASIONALLY under severe conditions, you should follow the Normal Condition Maintenance Schedule on pages 3-4 and 3-5
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Check for cracks and damage. Refer to the 2001 Civic shop manuals on this CD (see
Check deflection and tension. page 17-23)
Refer to the 2001 Civic shop manuals on this CD (see
page 11-125) (see page 11-285)
Refer to the 2001 Civic shop manuals on this CD (see
page 11-425) (see page 11-560)
Check specific gravity for freezing point. Refer to the 2001 Civic shop manuals on this CD (see
page 10-8)
Use genuine Honda MTF (Manual Transmission Fluid). Refer to the 2001 Civic shop manuals on this CD (see
page 13-3)
Use genuine Honda AFT-Z1 (ATF). Refer to the 2001 Civic shop manuals on this CD (see
page 14-122)
Check the brake pad and disc thickness. Check for damage or cracks. Refer to the 2001 Civic shop manuals on this CD (see
Check the wheel cylinder for leaks. page 19-3)
Check the brake linings for cracking, glazing, wear or contamination.
Check the callipers for damage, leaks and tightness.
Use only DOT 3 brake fluid. (We recommend Genuine Honda Brake Fluid.) Refer to the 2001 Civic shop manuals on this CD (see
Check that brake fluid level is between the upper and lower marks on the reservoir. page 19-7)
Check the parking brake operation. Refer to the 2001 Civic shop manuals on this CD (see
page 19-6)
-
Check the position of the headlight. Refer to the 2001 Civic shop manuals on this CD (see
page 22-114)
Check for road stability, noise, vibrations and dashboard operation. -
Check for correct installation and position, check for cracks, deterioration rust and leaks. -
Check tightness of screws, nuts and joints. If necessary, retighten.
Check rack grease and steering linkage. Check the boot for damage and leaking grease. Refer to the 2001 Civic shop manuals on this CD (see
Check the fluid line for damage and leaks page 17-5)
Check the bolts for tightness. Refer to the 2001 Civic shop manuals on this CD (see
Check all dust cover for deterioration and damage page 18-3)
Check the boot and boot band for cracks Refer to the 2001 Civic shop manuals on this CD (see
Check rack grease. page 16-3)
Check the master cylinder, proportioning control valve and ABS modulator and leakage. Refer to the 2001 Civic shop manuals on this CD (see
page 19-48)
Check for leaks. -
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, leaks and tightness. Refer to the 2001 Civic shop manuals on this CD (see
page 9-5)
Check fuel lines for loose connections, cracks and deterioration. Retighten loose connections and Refer to the 2001 Civic shop manuals on this CD (see
replace any damaged parts. page 11-132) (see page 11-290)
Refer to the 2001 Civic shop manuals on this CD (see
page 11-432) (see page 11-565)
Replace engine coolant At 200,000 km (120,000 miles) or 120 months, then replace every 100,000 km (60,000 miles) or 60 months
Replace transmission Manual Transmission Normal Condition
fluid
Severe Condition
Severe Condition
Severe Condition
Inspect front and rear brakes Every 10,000 km (6,000 miles) or 6 months
Replace brake fluid Every 36 months
Check parking brake adjustment
Rotate tyre (Check tyre inflation and condition at least once per month) Every 10,000 km (6,000 miles)
Visually inspect the following items:
Tie rod ends, steering gearbox and boots Every 10,000 km (6,000 miles) or 6 months
Suspension components
Driveshaft boots
Brake hoses and lines (including ABS)
All fluid levels and condition of fluid
Exhaust system
Fuel line and connections
Replace engine oil and oil filter according to the Severe Condition Schedule, if the vehicle is driven under one or more of the following conditions:
Driving less than 8 km (5 miles) per trip or, in freezing temperatures, driving less than 16 km (10 miles) per trip.
Driving in extremely hot conditions over 35C (95F).
Extensive idling or long periods of stop-and-go-driving.
Replace manual and automatic transmission fluid according to the Severe Condition Schedule, if the vehicle is driven in extremely hot conditions over 35C (95F) with extensive
idling or long periods of stop-and-go driving.
Replace CVT fluid according to the Severe Condition Schedule, if the vehicle is driven at high speed in high temperatures over 35C (95F).
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Check for cracks and damage. Refer to the 2001 Civic shop manuals on this CD (see
Check deflection and tension. page 17-23)
Refer to the 2001 Civic shop manuals on this CD (see
page 11-125) (see page 11-285)
Refer to the 2001 Civic shop manuals on this CD (see
page 11-425) (see page 11-560)
Check specific gravity for freezing point. Refer to the 2001 Civic shop manuals on this CD (see
page 10-8)
Use genuine Honda MTF (Manual Transmission Fluid). Refer to the 2001 Civic shop manuals on this CD (see
page 13-3)
Use genuine Honda AFT-Z1 (ATF). Refer to the 2001 Civic shop manuals on this CD (see
page 14-122)
Use genuine Honda AFT-Z1 (ATF). Refer to the 2001 Civic shop manuals on this CD (see
page 14-320)
Check the brake pad and disc thickness. Check for damage or cracks. Refer to the 2001 Civic shop manuals on this CD (see
Check the wheel cylinder for leaks. page 19-3)
Check the brake linings for cracking, glazing, wear or contamination.
Check the callipers for damage, leaks and tightness.
Use only DOT 3 brake fluid. (We recommend Genuine Honda Brake Fluid.) Refer to the 2001 Civic shop manuals on this CD (see
Check that brake fluid level is between the upper and lower marks on the reservoir. page 19-7)
Check the parking brake operation. Refer to the 2001 Civic shop manuals on this CD (see
page 19-6)
The suggested rotation method is shown in the diagram of the Owner's Manual. -
Check for correct installation and position, check for cracks, deterioration rust and leaks. -
Check tightness of screws, nuts and joints. If necessary, retighten.
Check rack grease and steering linkage. Check the boot for damage and leaking grease. Refer to the 2001 Civic shop manuals on this CD (see
Check the fluid line for damage and leaks. page 17-5)
Check the bolts for tightness. Refer to the 2001 Civic shop manuals on this CD (see
Check all dust cover for deterioration and damage. page 18-3)
Check the boot and boot band for cracks Refer to the 2001 Civic shop manuals on this CD (see
Check rack grease. page 16-3)
Check the master cylinder, proportioning control valve and ABS modulator and leakage. Refer to the 2001 Civic shop manuals on this CD (see
page 19-48)
Check for leaks. -
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, leaks and tightness. Refer to the 2001 Civic shop manuals on this CD (see
page 9-5)
Check fuel lines for loose connections, cracks and deterioration. Retighten loose connections and Refer to the 2001 Civic shop manuals on this CD (see
replace any damaged parts. page 11-132) (see page 11-290)
Refer to the 2001 Civic shop manuals on this CD (see
page 11-432) (see page 11-565)
Engine Mechanical
NOTE: Refer to the 'CIVIC 4/5 D MAINTENANCE, REPAIR and CONSTRUCTION 01'the other part of this CD for the items not shown in this section.
Outline of Model Change
Auto-tensioner inspection has been added in the maintenance schedule.
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Engine Mechanical
Cylinder Head
Auto Tensioner Inspection 6-2
NOTE: Refer to the '01 Civic Shop Manual on this CD, P/N 62S5A00, for items not shown in this section.
Outline of Model Change
Auto-tensioner inspection has been added in the maintenance schedule.
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1. Remove the auto-tensioner, refer to the '01 Civic Shop Manual on this CD (see
page 6-26).
NOTE: Do not apply a force on the tensioner pulley.
2. Put the auto-tensioner on the surface plate.
3. Measure the height at point A (A) and point B (B).
4. Calculate the difference in height between point A and point B. If the difference in
height is out of tolerance, replace the auto-tensioner.
Difference in height:
Specification:
0.75 mm (0.030 in.)
5. Inspect the spring grommet (A). Replace the grommet if damaged or deteriorated.
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Automatic Transmission
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1. Warm up the engine to normal operating temperature (the radiator fan comes on). 5. Remove the PCM and lower it, refer to the '01 Civic Shop Manual on this CD (see
2. Apply the parking brake and block the rear wheels. Start the engine, then shift to page 14-6).
position while pressing the brake pedal. Press the accelerator pedal and 6. Connect a digital multitester (A) and tapered tip probe (B) to check voltage between
release it suddenly. The engine should not stall. the A15 (+) terminal and A23 (-) or A24 (-) terminal of the PCM (C).
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14-3
position
Upshift
Throttle Opening Unit of Speed 1st to 2nd 2nd to 3rd 3rd to 4th Lock-up ON
Throttle position sensor voltage: 0.75 V mph 9-12 19-22 29-34 14-18
km/h 15-19 30-35 47-54 23-28
Throttle position sensor voltage: 2.25 V mph 22-26 42-48 60-66 68-74
km/h 36-42 68-76 96-105 110-119
Fully-opened throttle, Throttle position sensor mph 31-37 63-71 96-107 96-107
voltage: 4.5 V
km/h 50-58 101-114 155-172 155-172
Downshift
Throttle Opening Unit of Speed Lock-up OFF 4th to 3rd 3rd to 2nd 2nd to 1st
Throttle position sensor voltage: 0.5 V mph 13-17 17-20 6-10 (3rd to 1st)
km/h 21-26 27-32 10-15 (3rd to 1st)
Fully-opened throttle, Throttle position sensor mph 93-104 85-95 54-61 23-29
voltage: 4.5 V
km/h 150-166 136-152 87-98 37-45
7. Accelerate to about 35 mph (57 km/h) so the transmission is in 4th, then shift from position to position. The vehicle should immediately begin slowing down from engine
braking.
8. Check for abnormal noise and clutch slippage in the following positions.
(1st Gear) Position
Accelerate from a stop at full throttle. Check that there is no abnormal noise or clutch slippage.
Upshifts should not occur with the shift lever in this position.
(2nd Gear) Position
Accelerate from a stop at full throttle. Check that there is no abnormal noise or clutch slippage.
Upshifts and downshifts should not occur with the shift lever in this position.
(Reverse) Position
Accelerate from a stop at full throttle and check for abnormal noise and clutch slippage.
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14-4
1. Set the parking brake, and block the front wheels. 7. If the measurements are out of the service limit, problems and probable causes are
2. Connect a tachometer to the engine and start the engine. listed in the table below:
3. Make sure the A/C switch is OFF. Problem Probable cause
4. After the engine has warmed up to normal operating temperature (the radiator fan
Stall speed rpm high in Low fluid level or ATF pump
comes on), shift to position. , , and output low
5. Fully press the brake pedal and accelerator for 6 to 8 seconds and note engine positions Clogged ATF strainer
speed. Do not move the shift lever while raising engine speed. Pressure regulator valve
6. Allow 2 minutes for cooling, then repeat the test in , and positions. stuck closed
NOTE: Slipping clutch
Do not test stall speed for more than 10 seconds at a time. Stall speed rpm high in Slippage of 1st clutch
Stall speed tests should be used for diagnostic purposes only. position
Stall speed should be the same in , , and positions. Stall speed rpm high in Slippage of 2nd clutch
Do not test stall speed with the A/T pressure gauges installed. position
Stall Speed rpm:
Stall speed rpm high in Slippage of 4th clutch
D14Z6 engine:
position
Specification:
Stall speed rpm low in , Engine output low
2,550 rpm (min-1) Torque converter one-way
, and
Service Limit: clutch slipping
positions
2,400-2,700 rpm (min-1)
D16V1 engine:
Specification:
2,800 rpm (min-1)
Service Limit:
2,650-2,950 rpm (min-1)
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14-5
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20-12
Glass 20-
Windshield Replacement
12
NOTE: 3. Remove the cowl covers, refer to the '01 Civic Shop Manual on this CD (see page
Put on gloves to protect your hands. 20-252).
Wear eye protection when removing the glass with piano wire. 4. Remove the moulding (A) from the upper edge of the windshield (B). If necessary,
Use seat covers to avoid damaging the seat. cut the moulding with a utility knife.
Use glass adhesive set P/N. 08C73-X0230N.
1. Remove these items, refer to the '01 Civic Shop Manual on this CD:
Rearview mirror (see page 20-173)
2. Pull up the side trim (A) to release the clips (B) from the retainers (C) and pull the
trim rearward to release it from the clip (D) then remove the trim from each side of
the windshield.
5. If the old windshield is to be reinstalled, make alignment marks across the glass and
body with a grease pencil.
6. Pull down the front portion of the headliner (see page 20-33). Take care not to bend
the headliner excessively or you may crease or break it.
7. Apply protective tape along the edge of the dashboard and body. Using an awl,
make a hole through the rubber dam, adhesive and dashboard seal from inside the
vehicle at the corner portion of the windshield. Push a piece of piano wire through
the hole and wrap each end around a piece of wood.
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20-13
Glass 20-
Windshield Replacement (cont'd)
13
8. With a helper on the outside, pull the piano wire (A) back and forth in a sawing 10. With a knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08
motion. Hold the piano wire as close to the windshield (B) as possible to prevent in.) on the bonding surface around the entire windshield opening flange:
damage to the body and dashboard. Carefully cut through the rubber dam and Do not scrape down to the painted surface of the body; damaged paint will
adhesive (C) around the entire windshield. interfere with proper bonding.
Remove the rubber dam and fasteners from the body.
11. Clean the body bonding surface with a sponge dampened in alcohol. After
cleaning, keep oil, grease and water from getting on the clean surface.
12. If the old windshield is to be reinstalled, use a putty knife to scrape off all of the old
adhesive, the fasteners and the rubber dam from the windshield. Clean the inside
face and the edge of the windshield with alcohol where new adhesive is to be
applied. Make sure the bonding surface is kept free of water, oil and grease.
Cutting portions:
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20-14
Glass 20-
Windshield Replacement (cont'd)
14
13. Glue the side rubber dams (A), lower rubber dam (B) and fasteners (C) to the 14. Glue the moulding (A) with adhesive tape (B) to the upper edge of the windshield
inside face of the windshield (D) as shown: (C):
Be sure the rubber dams and fasteners line up with the alignment marks (E). Be sure the alignment mark (D) of the moulding lines up with the alignment mark
Be careful not to touch the windshield where adhesive will be applied. (E) of the windshield.
Be careful not to touch the windshield where adhesive will be applied.
15. Install the fasteners (A), retainers (B, C) and clips (D) to the body.
A : Fastener, 2 B : Retainer, 2
C : Retainer,6 D : Clip, 2
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20-15
Glass 20-
Windshield Replacement (cont'd)
15
16. Set the windshield in the opening and centre it. Make alignment marks (A) across 18. With a sponge, apply a light coat of glass primer around the edge of the windshield
the windshield and body with a grease pencil at the four points shown. Be careful not (A) between the dams (B) and moulding (C) as shown, then lightly wipe it off with
to touch the windshield where adhesive will be applied. gauze or cheesecloth:
Apply glass primer to the moulding.
Do not apply body primer to the windshield and do not get body and glass primer
not bond to the windshield properly, causing a leak after the windshield is
installed.
Keep water, dust and abrasive materials away from the primed surface.
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20-16
Glass 20-
Windshield Replacement (cont'd)
16
19. With a sponge, apply a light coat of body primer to the original adhesive remaining 21. Pack adhesive into the cartridge without air pockets to ensure continuous delivery.
around the windshield opening flange. Let the body primer dry for at least 10 minutes: Put the cartridge in a caulking gun and run a bead of adhesive (A) around the edge
Do not apply glass primer to the body and be careful not to mix up glass and of the windshield (B) between the dams (C) and moulding (D) as shown. Apply the
body primer sponges. adhesive within 30 minutes after applying the glass primer. Make a slightly thicker
Never touch the primed surfaces with your hands. bead at each corner.
Mask off the dashboard before painting the flange.
20. Before filling a cartridge, cut a ''V'' in the end of the nozzle (A) as shown.
22. Use suction cups to hold the windshield over the opening, align it with the
alignment marks made in step 16 and set it down on the adhesive. Lightly push on
the windshield until its edges are fully seated on the adhesive all the way around. Do
not open or close the doors until the adhesive is dry.
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20-17
Glass 20-
Windshield Replacement (cont'd)
17
23. Scrape or wipe the excess adhesive off with a putty knife or towel. To remove 27. On both sides of the windshield, install the trim to the clip (C), then set the bottom
adhesive from a painted surface or the windshield, wipe with a soft shop towel edge of the side trim (A) over the cowl cover (B) and align the clips (D) with the
dampened with alcohol. retainers (E) and push on the clip portions of the trim until the trim is fully seated on
24. Let the adhesive dry for at least 1 hour, then spray water over the windshield and the windshield.
check for leaks. Mark leaking areas and let the windshield dry, then seal with sealant:
Let the vehicle stand for at least 4 hours after windshield installation. If the vehicle
25. Reinstall the cowl covers, refer to the '01 Civic Shop Manual on this CD (see page
20-252).
26. Install the clips (A, B) on both side trim (D). If the clips (E, F) are damaged, replace
the side trim and clips as an assembly.
A: Grey
B: Blue
28. Reinstall all remaining removed parts. Install the rearview mirror after the adhesive
has dried thoroughly. Advise the customer not to do the following things for 2 to 3
days:
Slam the doors with all the windows rolled up.
Twist the body excessively (such as when going in and out of driveways at an
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20-18
Glass 20-
Rear Window Replacement
18
NOTE: 6. With a helper on the outside, pull the piano wire (A) back and forth in a sawing
Put on gloves to protect your hands. motion. Hold the piano wire as close to the rear window (B) as possible to prevent
Wear eye protection when removing the glass with piano wire. damage to the tailgate and carefully cut through the adhesive (C) around the entire
Use seat covers to avoid damaging any surfaces.
rear window.
Do not damage the rear window defogger grid lines and terminals.
2. Remove these items, refer to the '01 Civic Shop Manual on this CD:
High mount brake light (see page 22-120)
Cutting positions:
4. If the old rear window is to be reinstalled, make alignment marks across the glass
and body with a grease pencil.
5. Apply protective tape along the inside and outside edges of the tailgate. Using an
awl, make a hole through the adhesive from inside the vehicle at the corner portion
of the rear window. Push the piano wire through the hole and wrap each end around
a piece of wood.
7. Carefully remove the rear window.
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20-19
Glass 20-
Rear Window Replacement (cont'd)
19
8. With a putty knife, scrape the old adhesive smooth to a thickness of about 2 mm 11. Glue the side upper fasteners (A), side lower fasteners (B), upper rubber dams (C)
(0.08 in.) on the bonding surface around the entire rear window opening flange: and lower rubber dam (D) to the inside face of the rear window (E) as shown. Before
Do not scrape down to the painted surface of the body; damaged paint will installing the lower rubber dam, apply primer (3M M200, or equivalent) to the areas
interfere with proper bonding between the alignment marks (F), then glue the rubber dam on. If necessary, glue
Remove the fasteners from the tailgate. the spoiler fasteners (G) to the outside face of the rear window:
9. Clean the tailgate bonding surface with a sponge dampened in alcohol. After Be sure the side upper fasteners and upper rubber dams line up with alignment
cleaning, keep oil, grease and water from getting on the surface. marks (H, I).
10. If the old rear window is to be reinstalled, use a putty knife to scrape off all of the Be sure both ends of the lower rubber dam line up with the edge of the glass.
old adhesive, the fasteners and the rubber dams from the rear window. Clean the Be sure the spoiler fasteners line up with alignment marks (J).
inside face and the edge of the rear window with alcohol where new adhesive is to Be careful not to touch the rear window where adhesive will be applied.
be applied. Make sure the bonding surface is kept free of water, oil and grease. Cross hatched area: Apply primer here.
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20-20
Glass 20-
Rear Window Replacement (cont'd)
20
12. Glue the side upper fasteners (A) and side lower fasteners (B) to the tailgate as 15. With a sponge, apply a light coat of glass primer along the edge of the rear window
shown. (A), upper rubber dams (B) and lower rubber dam (C) as shown, then lightly wipe it
Fastener Locations off with gauze or cheesecloth:
With the printed dots (D) on the rear window as a guide, apply the glass primer to
A : Fastener, 2 B : Fastener, 2
both side portions of the rear window.
Do not apply body primer to the rear window and do not get tailgate and glass
not bond to the rear window properly, causing a leak after the rear window is
installed.
Keep water, dust and abrasive materials away from the primed surface.
13. Set the rear window in the opening and centre it. Align the clips (A) of the rear
window with the holes in the opening flange. Make alignment marks (B) across the
rear window, tailgate and body with a grease pencil at the four points shown. Be
careful not to touch the rear window where adhesive will be applied.
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Body - 20-34
6. Install the headliner in the reverse order of removal and note these items:
When reinstalling the headliner through the door opening, be careful not to fold or
If the threads on the grab handle mounting self-tapping ET screws are worn out,
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20-36
Fastener Locations Make sure the seat harnesses are routed correctly.
Slip the carpet under the rear side trim panel on each side properly.
A : Clip, 1
Replace the clip if it is damaged.
Reattach the cut areas under the heater around the parking brake lever with a
wire tie.
When installing new carpet, cut the carpet (A) under the heater areas (B) and
around the parking brake lever (C). After installing the new carpet, slip the carpet
from the driver's and passenger's side through the space between the heater unit
and body and reattach the cut area (C) around the parking brake lever with wire
ties.
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20-37
Consoles 20-
Consoles, Front and Rear Removal/Installation
37
NOTE: Take care not to scratch the front seat, dashboard and related parts. 2. Remove the rear console (A).
1. Remove the front console (A). 1. Remove the ashtray (B).
1. Slide the front seat forward fully on each side. 2. Remove the console box mat (C).
2. Remove the screws (B) from the rear portion of the rear console. 3. Remove the bolts (D), screws (E) and clips (F).
3. Slide the front seat rearward fully on each side. 4. Gently pull out the rear console to release the hooks (G) and pins (H).
4. Pull the front position of the rear console up to detach the clips (C) and hooks (D), Fastener Location
then release the rear console from the front console (E).
D : Bolt, 2 E : Screw, 2 F : Clip, 2
5. If equipped, disconnect the seat heater switch connector (F).
6. Starting at the rear, pull the rear console up, then remove it.
Fastener Locations
B : Screw, 2 C : Clip, 2
3. Install the console in the reverse order of removal and note these items:
Replace any damaged clips.
Make sure the seat heater switch connector is plugged in properly (for some
models).
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20-38
Consoles 20-
Front Console Disassembly/Reassembly
38
NOTE: Take care not to scratch the console and related parts.
Disassemble the front console as shown.
Reassemble the console in the reverse order of disassembly.
Fastener Locations
: Screw, 8
1. FRONT CONSOLE
2. BEVERAGE HOLDER ASSEMBLY
3. CONSOLE BOX
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20-39
Seats 20-
Front Seat Disassembly/Reassembly -
Passenger's
39
SRS components are located in this area. Review the SRS component locations (see page 23-24) and the precautions and procedures (see page 23-25) in the SRS section before
performing repairs or service. Refer to the '01 Civic Shop Manual on this CD.
NOTE:
Take care not to tear the seams or damage the seat covers.
Put on gloves to protect your hands.
When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage.
Disassemble the seat as shown. To remove the rear seat access cable from the rear seat access lever, remove the seat-back cover and pad from the seat-back frame, refer to the '01
Civic Shop Manual on this CD (see page 20-234).
Reassemble the seat in the reverse order of disassembly and note these items:
Apply multipurpose grease to the moving portion of the seat track.
To prevent wrinkles in the seat cushion cover, stretch the material evenly over the pad.
Adjust the rear seat access cable.
Make sure the rear seat access cables are connected properly.
Replace any damaged clips and replace the wire ties with new ones.
1. REAR SEAT ACCESS LEVER
2. SCREW
3. REAR SEAT ACCESS KNOB
4. REAR SEAT ACCESS TRIM
5. HEADSET
6. CLIP
7. SIDE AIRBAG HARNESS
8. HOOKS
9. Release the seat cushion cover
from the cushion frame spring.
10. HOOKS
11. HOOKS
(Five places)
12. HANGER SPRING
13. CLIP
14. CLIP
15. CENTRE COVER
16. CLIPS
17. SEAT CUSHION FRAME/SEAT
TRACKS
18. SLIDE LEVER
19. CLIP
20. CLIP
21. HOOK
22. RECLINE COVER
23. HOOK
24. RECLINE KNOB
25. REAR SEAT ACCESS CABLE
26. REAR SEAT ACCESS CABLE
(Slide adjuster side)
27. WIRE TIE
28. 10 x 1.25 mm
47 Nm (4.8 kgf/m, 35 lbf/ft)
29. REAR SEAT ACCESS CABLE
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20-40
Seats 20-
Rear Seat Removal/Installation
40
NOTE: Take care not to scratch the body or tear the seat covers.
Remove the rear seat as shown. To remove the seat-back, remove the front portion of the trunk floor mat (see page 20-31).
Install the seat in the reverse order of removal, and note these items:
Before installing the centre anchor bolts on the seat-back with the centre shoulder belt, make sure there are no twists or kinks in the belt.
Make sure the seat-backs lock securely.
Fastener Locations
A : Bolt, 2 B : Bolt, 1 C : Bolt, 1 D : Clip, 2
1. PIVOT BUSHING
2. CENTRE BELT
(For some models)
3. RIGHT SEAT-BACK
4. CENTRE PIVOT BOLT
8 x 1.25 mm
22 Nm (2.2 kgf/m, 16 lbf/ft)
5. 8 x 1.25 mm
22 Nm (2.2 kgf/m, 16 lbf/ft)
6. HINGE COVER
7. SEAT-BACK CENTRE
HINGE
8. BUSHING
9. LEFT SEAT-BACK
10. HOOK
11. CLIP
12. PIVOT BUSHING
13. 6 x 1.0 mm
9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
14. SLITS
15. HOOK
16. SEAT CUSHION
17. SEAT BELT BUCKLE
18. CLIP
19. CENTRE ANCHOR BOLT
7/16-20 UNF
32 Nm (3.3 kgf/m, 24 lbf/ft)
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20-41
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20-42
5. Install the spoiler in the reverse order of removal and replace any damaged clips.
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20-43
2. Clean the body surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water off the surface.
3. Apply the emblem where shown.
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20-44
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20-45
Openers 20-
Fuel Fill Door Opener Cable Replacement
45
SRS components are located in this area. Review the SRS component locations (see page 23-24) and the precautions and procedures (see page 23-25) in the SRS section before
performing repairs or service. Refer to the '01 Civic Shop Manual on this CD.
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the body and related parts.
1. Remove these items:
Door sill trim (see page 20-29)
2. Pull the carpet back as necessary, refer to the '01 Civic Shop Manual on this CD (see page 20-212).
3. Disconnect the fuel fill door opener cable (A) from the opener (B), refer to the '01 Civic Shop Manual on this CD (see step 3 on page 20-267).
Fastener Locations
C : Bolt, 5 E : Cushion Tape F : Clip, 1 G : Clip, 2
LHD, 1 (LHD) LHD, 2
RHD, 3 RHD, 3
LHD: RHD:
4. RHD: Remove the bolts (C), then remove the left middle floor cross-member gusset (D).
5. Remove the cushion tape (E) and release the cable from the clips (F, G).
6. Remove the fuel fill door latch (H) from the body by turning it 90.
7. Remove the fuel fill door opener cable from the vehicle. Take care not to bend the cable.
8. Install the opener cable in the reverse order of removal and replace the cushion tape and replace the clip if it is damaged.
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20-46
Frame 20-
Frame Repair Chart
46
Top View
Unit: mm (in.) a For sub-frame 15 (0.59) e Damper centre 78 (3.07)
: Inner diameter b1 For engine mount 13 (0.51) f For damper mount 11.5 (0.45)
b2 For engine mount 13 (0.51) g For damper mount 11.5 (0.45)
b3 For engine mount 13 (0.51) h For sub-frame 11 (0.43)
c1 For transmission mount 15 (0.59) I For sub-frame 15 (0.59)
c2 For transmission mount 15 (0.59) j Locate hole 25 (0.98)
c3 For transmission mount 13 (0.51) k Locate hole 50 (1.97)
d For damper mount 11.5 (0.45)
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23-1
Restraints
Seat Belts
Front Seat Belt Replacement 23-2
Rear Seat Belt Replacement 23-4
Inspection 23-5
NOTE: Refer to the 'CIVIC 4/5 D MAINTENANCE, REPAIR and CONSTRUCTION 01'the other part of this CD for the items not shown in this section.
Outline of 3-door Model Changes
The Civic 3-door model has been added.
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23-3
7. Remove the center pillar upper trim (see page 20-29) Upper anchor bolt construction:
8. Remove the shoulder anchor adjuster (A).
9. Install the belt in the reverse order of removal and note these items:
If the threads on the retractor mounting self-tapping ET screw are worn out, use
Assemble the washers, collars and bushing on the upper and lower anchor bolts
as shown.
Before installing the anchor bolts, make sure there are no twists or kinks in the
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