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0-1

Introduction
How to Use This Manual

This supplement contains information for the 2001 HONDA General Info
CIVIC 3-door. Refer to following shop manuals for service Specifications
procedures and data on this 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 aaa
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.
Safety Messages - preceded by a safety

alert symbol and one of three signal


words, DANGER, WARNING or CAUTION.
These signal words mean:

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.

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0-1

Service Publication Office


As sections with * include SRS components;
special precautions are required when servicing.

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0-2


A Few Words About Safety
Service Information

The service and repair information contained in this manual is IMPORTANT SAFETY PRECAUTIONS
intended for use by qualified, professional technicians. Make sure you have a clear understanding of all
Attempting service or repairs without the proper training, tools basic shop safety practices and that you are wearing
and equipment could cause injury to you or others. It could appropriate clothing and using safety equipment.
also damage the vehicle or create an unsafe condition. When performing any service task, be especially
This manual describes the proper methods and procedures for careful of the following:
performing service, maintenance and repairs. Some procedures Read all of the instructions before you begin and
require the use of specially designed tools and dedicated make sure you have the tools, the replacement or
equipment. Any person who intends to use a replacement part, repair parts and the skills required to perform the
service procedure or a tool that is not recommended by Honda, tasks safely and completely.
must determine the risks to their personal safety and the safe Protect your eyes by using proper safety glasses,
operation of the vehicle. goggles or face shields any time you hammer,
If you need to replace a part, use genuine Honda parts with drill, grind or work around pressurised air or liquids
the correct part number or an equivalent part. We strongly and springs or other stored-energy components. If
recommend that you do not use replacement parts of inferior there is any doubt, put on eye protection.
quality. Use other protective wear when necessary, for
example gloves or safety shoes. Handling hot or
FOR YOUR CUSTOMER'S SAFETY
sharp parts can cause severe burns or cuts.
Proper service and maintenance are essential to the Before you grab something that looks like it can
customer's safety and the reliability of the vehicle. Any error or hurt you, stop and put on gloves.
oversight while servicing a vehicle can result in faulty Protect yourself and others whenever you have
operation, damage to the vehicle, or injury to others. the vehicle up in the air. Any time you lift the
vehicle, either with a hoist or a jack, make sure
WARNING that it is always securely supported. Use jack
Improper service or repairs can create an stands.
unsafe condition that can cause your
Make sure the engine is off before you begin any
customer or others to be seriously hurt or
servicing procedures, unless the instruction tells you
killed.
to do otherwise. This will help eliminate several
Follow the procedures and precautions in potential hazards:
this manual and other service materials Carbon monoxide poisoning from engine exhaust.
carefully. Be sure there is adequate ventilation whenever
you run the engine.
FOR YOUR SAFETY Burns from hot parts or coolant. Let the engine
Because this manual is intended for the professional service and exhaust system cool before working in those
technician, we do not provide warnings about many basic shop areas.
safety practices (e.g., Hot parts - wear gloves). If you have not Injury from moving parts. If the instruction tells you
received shop safety training or do not feel confident about to run the engine, be sure your hands, fingers and
your knowledge of safe servicing practices, we recommend that clothing are out of the way.
you do not attempt to perform the procedures described in this Gasoline vapours and hydrogen gases from batteries
manual. are explosive. To reduce the possibility of a fire or
explosion, be careful when working around gasoline
WARNING or batteries.
Failure to properly follow instructions and Use only a non-flammable solvent, not gasoline to
precautions can cause you to be seriously clean parts.
hurt or killed. Never drain or store gasoline in an open
Follow the procedures and precautions in container.
this manual carefully. Keep all cigarettes, sparks and flames away from
the battery and all fuel-related parts.
Some of the most important general service safety precautions aaa
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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0-3


Introduction
Supplemental Restraint System (SRS)

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 and some models include side airbags in the front seat-backs.
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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0-4


Introduction
Outline of Model Changes

ITEM DESCRIPTION 2001 2-door 2001 5-door 2001 3-door REFERENCE


(Made-in- (Made-in- SECTION
England) England)
General Coupe model O -
added
D17A8, D17A9
engines added
5-door LHD model added O -
3-door model added O 1,2
Engine Electrical D17A8, D17A9 engines O -
added
D14Z6, D16V1 and D16V3 O -
engines added to suit 5-door
LHD model
Engine D17A8, D17A9 engines O -
added
D14Z6, D16V1 and D16V3 O -
engines added to suit 5-door
LHD model
Fuel and Coupe model added O -
Emissions KG, KS, KY models added O -
Automatic Shift schedule added O -
Transmission 5-door LHD model added, O -
equipped with 7-position
transmission
Shift schedule and stall speed O 14
changed
Driveline/Axle 5-door LHD model added O -
3-door model added O 16
Body Coupe model added O -
5-door LHD model added O -
3-door model added O 20
Body Electrical Coupe model added O -
5-door LHD model added O -
3-door model added O 22
Restraints Coupe model added O -
3-door model added O 23

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1-1


General Information

Chassis and Engine Numbers 1-2


Abbreviations 1-4

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1-2

1-2
General Information
Chassis and Engine Numbers

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1-3

1-3
General Information
Applicable Area Code/VIN/Engine
Number/Transmission Number List

MODEL APPLICABLE GRADE TRANSMISSION VEHICLE ENGINE TRANSMISSION


AREA CODE NAME TYPE IDENTIFICATION NUMBER NUMBER
NUMBER
CIVIC 3- KE 1.4S 5MT SHHEP13401U000001- D14Z6-1100001- HMW-1000001-
door 4AT SHHEP14201U000001- D14Z6-1100001- SLXA-1000001-
1.4B 5MT SHHEP13201U000001- D14Z6-1100001- HMW-1000001-
4AT SHHEP14101U000001- D14Z6-1100001- SLXA-1000001-
1.4SE 5MT SHHEP13601U000001- D14Z6-1100001- HMW-1000001-
4AT SHHEP14601U000001- D14Z6-1100001- SLXA-1000001-
1.6S 5MT SHHEP23201U000001- D16V1-1100001- HMW-1000001-
4AT SHHEP24201U000001- D16V1-1100001- SLXA-1000001-
1.6SE 5MT SHHEP23501U000001- D16V1-1100001- HMW-1000001-
4AT SHHEP24501U000001- D16V1-1100001- SLXA-1000001-
1.6SE 5MT SHHEP23801U000001- D16V1-1100001- HMW-1000001-
Executive 4AT SHHEP24801U000001- D16V1-1100001- SLXA-1000001-
CVT SHHEP24601U000001- D16V1-1100001- SLYA-1000001-
KG 1.4S 5MT SHHEP13401U000001- D14Z6-1100001- HMW-1000001-
4AT SHHEP14201U000001- D14Z6-1100001- SLXA-1000001-
1.4LS 5MT SHHEP13501U000001- D14Z6-1100001- HMW-1000001-
4AT SHHEP14501U000001- D14Z6-1100001- SLXA-1000001-
1.6S 5MT SHHEP23201U000001- D16V1-1100001- HMW-1000001-
4AT SHHEP24201U000001- D16V1-1100001- SLXA-1000001-
1.6LS 5MT SHHEP23401U000001- D16V1-1100001- HMW-1000001-
4AT SHHEP24401U000001- D16V1-1100001- SLXA-1000001-
1.6ES 5MT SHHEP23701U000001- D16V1-1100001- HMW-1000001-
4AT SHHEP24701U000001- D16V1-1100001- SLXA-1000001-
CVT SHHEP24401U000001- D16V1-1100001- SLYA-1000001-
KR 1.4S 5MT SHHEP13401U000001- D14Z6-1100001- HMW-1000001-
4AT SHHEP14201U000001- D14Z6-1100001- SLXA-1000001-
1.4LS 5MT SHHEP13501U000001- D14Z6-1100001- HMW-1000001-
4AT SHHEP14501U000001- D14Z6-1100001- SLXA-1000001-
1.6S 5MT SHHEP23201U000001- D16V1-1100001- HMW-1000001-
4AT SHHEP24201U000001- D16V1-1100001- SLXA-1000001-
1.6LS 5MT SHHEP23401U000001- D16V1-1100001- HMW-1000001-
4AT SHHEP24401U000001- D16V1-1100001- SLXA-1000001-
1.6ES 5MT SHHEP23701U000001- D16V1-1100001- HMW-1000001-
4AT SHHEP24701U000001- D16V1-1100001- SLXA-1000001-
CVT SHHEP24401U000001- D16V1-1100001- SLYA-1000001-
KS 1.4S 5MT SHHEP13401U000001- D14Z6-1100001- HMW-1000001-
4AT SHHEP14201U000001- D14Z6-1100001- SLXA-1000001-
1.4LS 5MT SHHEP13501U000001- D14Z6-1100001- HMW-1000001-
4AT SHHEP14501U000001- D14Z6-1100001- SLXA-1000001-
1.6LS 5MT SHHEP23401U000001- D16V1-1100001- HMW-1000001-
4AT SHHEP24401U000001- D16V1-1100001- SLXA-1000001-

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1-4

1-4
General Information
Abbreviations

List of automotive abbreviations which may be used in shop EPR Evaporator Pressure Regulator
manual.
EPS Electrical Power Steering
ABS Anti-lock Brake System EVAP Evaporative
A/C Air Conditioning, Air Conditioner EX Exhaust
ACL Air Cleaner
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
A/T Automatic Transmission GAL Gallon
ATDC After Top Dead Center GND Ground
ATF Automatic Transmission Fluid GPS Global Positioning System
ATT Attachment
ATTS Active Torque Transfer System H/B Hatchback
AUTO Automatic HC Hydrocarbons
AUX Auxiliary HID High Intensity Discharge
HO2S Heated Oxygen Sensor
BARO Barometric
BAT Battery IAB Intake Air Bypass
BDC Bottom Dead Center IAC Idle Air Control
BTDC Before Top Dead Center IACV Idle Air Control Valve
IAR Intake Air Resonator
CARB Carburetor IAT Intake Air Temperature
CAT or CATA Catalytic Converter ICM Ignition Control Module
CHG Charge ID Identification
CKF Crankshaft Speed Fluctuation ID or I.D. Inside Diameter
CKP Crankshaft Position IG or IGN Ignition
CO Carbon Monoxide IMA Idle Mixture Adjustment
COMP Complete Integrated Motor Assisted
CPB Clutch Pressure Back up IMMOBI. Immobilizer (Immobiliser)
CPC Clutch Pressure Control IN Intake
CPU Central Processing Unit INJ Injection
CVT Continuously Variable Transmission INT Intermittent
CYL Cylinder
CYP Cylinder Position KS Knock Sensor

DI Distributor Ignition L Left
DIFF Differential L/C Lock-up Clutch
DLC Data Link Connector LCD Liquid Crystal Display
DOHC Double Overhead Camshaft LED Light Emitting Diode

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1-4

DPI Dual Point Injection


LEV Low Emission Vehicle
DTC Diagnostic Trouble Code
LF Left Front

LH Left Handle
EBD Electronic Brake Distribution
LHD Left Handle Drive
ECM Engine Control Module
LR Left Rear
ECT Engine Coolant Temperature
LSD Limited Slip Differential
EGR Exhaust Gas Recirculation
L-4 In-line Four Cylinder (engine)
ELD Electrical Load Detector

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14-1


Automatic Transmission

Road Test 14-2


Stall Speed Test 14-4
Driveline/Axle 16-1

Outline of Model Change


Shift schedule and stall speed have been added for 3-door model.

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14-2

14-2
Automatic Transmission
Road Test

1. 1. Warm up the engine to normal operating temperature 1. 5. Remove the PCM and lower it, refer to the '01 Civic
(the radiator fan comes on). Shop Manual on this CD (see page 14-6).
2. Apply the parking brake and block the rear wheels. 6. Connect a digital multitester (A) and tapered tip
Start the engine, then shift to position while probe (B) to check voltage between the A15 (+)
pressing the brake pedal. Press the accelerator terminal and A23 (-) or A24 (-) terminal of the PCM
pedal and release it suddenly. The engine should not (C).
stall.
3. Repeat the same test in position.
4. Connect the Honda PGM Tester (A) and go to the
PGM-FI Data List; then go to step 9. If you do not
have a PGM Tester, go to step 5.

PCM CONNECTOR A (31P)

Wire side of female terminals


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14-3

14-3
Automatic Transmission
Road Test (cont'd)

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 mph 31-37 63-71 96-107 96-107
sensor 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 mph 93-104 85-95 54-61 23-29
sensor voltage: 4.5 V km/h 150-166 136-152 87-98 37-45

1. 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.
2. 9. Test in (Parking) Position.
Park the vehicle on a slope (about 16), apply the parking brake and shift into position. Release the brake; the vehicle
should not move.
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14-4

14-4
Automatic Transmission
Stall Speed Test

1. 1. Set the parking brake, and block the front wheels. 1. 7. If the measurements are out of the service limit,
2. Connect a tachometer to the engine and start the problems and probable causes are listed in the table
engine. below:
3. Make sure the A/C switch is OFF. Problem Probable cause
4. After the engine has warmed up to normal operating Stall speed rpm high in Low fluid level or
temperature (the radiator fan comes on), shift to , , and ATF pump
position. output low
positions
5. Fully press the brake pedal and accelerator for 6 to 8 Clogged ATF
seconds and note engine speed. Do not move the strainer
shift lever while raising engine speed. Pressure
6. Allow 2 minutes for cooling, then repeat the test in regulator valve
, and positions. stuck closed
NOTE: Slipping clutch
Stall speed rpm high in Slippage of 1st clutch
Do not test stall speed for more than 10 seconds
at a time. position
Stall speed tests should be used for diagnostic Stall speed rpm high in Slippage of 2nd clutch
purposes only.
position
Stall speed should be the same in , , Stall speed rpm high in Slippage of 4th clutch
and positions. position
Do not test stall speed with the A/T pressure
Stall speed rpm low in Engine output
gauges installed.
low
Stall Speed rpm: , , and
Torque
D14Z6 engine: positions
converter one-
Specification: way clutch
2,550 rpm (min -1 ) slipping
Service Limit: aaa
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


Honda Multi Matic /Continuously
Variable Transmission (CVT)

Road Test 14-6


Stall Speed Test 14-8

Outline of Model Change


Shift schedule and stall speed have been added for 3 door model.

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14-6

14-6
Honda Multi Matic Transmission/CVT
Road Test

1. 1. Warm up the engine to normal operating temperature 1. 5. Set the digital multitester (A) to check voltage
(the radiator fan comes on). between PCM connector terminals A15 (+) and A23
2. Apply the parking brake and block rear wheels. Start (-) or A24 (-) for throttle position sensor with tapered
the engine, then shift to position while pressing tip probe (B).
the brake pedal. Press the accelerator pedal and
release it suddenly. The engine should not stall.
3. Test in position:
Park the vehicle in a slope about 16, apply parking
brake and shift into position. Release the brake;
the vehicle should not move.
4. Test-drive the vehicle on a flat road in the position
shown in the table. Check that the engine speeds
meet the approximate vehicle speeds shown in the
table.
1. Remove the glove box stop, then open the glove
box.
2. Remove the harness connector clamp (A) from its
bracket.
3. Loosen the mounting nut (B) on the lower right of
the PCM and remove the mounting bolt (C) and
nut (D) on the left of the PCM. PCM CONNECTOR A (31P)
4. Lift the PCM up to clear the mounting nut on the
lower right of the PCM, then pull out the PCM (E).

Wire side of female terminals


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14-7

14-7
Honda Multi Matic Transmission/CVT
Road Test (cont'd)

Position: Engine Speed rpm (min -1 )


Throttle Opening Vehicle Speed
25 mph (40 km/h) 37 mph (60 km/h) 62 mph (100 km/h)
Throttle position sensor voltage: 0.75 V 1,250-1,650 - -
Throttle position sensor voltage: 2.0 V 2,300-2,900 2,300-2,900 2,450-3,050
Throttle position sensor voltage: 4.5 V 3,700-4,300 4,300-4,900 4,700-5,300
Fully-throttle position

Position: Engine Speed rpm (min -1 )


Throttle Opening Vehicle Speed
25 mph (40 km/h) 37 mph (60 km/h) 62 mph (100 km/h)
Throttle position sensor voltage: 0.75 V 1,800-2,400 2,250-2,850 3,300-3,900
Throttle position sensor voltage: 2.0 V 2,600-3,200 3,000-3,600 3,800-4,400
Throttle position sensor voltage: 4.5 V 4,100-4,700 5,100-5,700 5,500-6,100
Fully-throttle position

Position: Engine Speed rpm (min -1 )


Throttle Opening Vehicle Speed
25 mph (40 km/h) 37 mph (60 km/h) 62 mph (100 km/h)
Throttle position sensor voltage: 0.75 V 3,100-3,700 3,650-4,250 4,000-4,600
Throttle position sensor voltage: 2.0 V 3,350-3,950 3,900-4,500 4,700-5,300
Throttle position sensor voltage: 4.5 V 4,100-4,700 5,100-5,700 4,900-6,100
Fully-throttle position

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14-8

14-8
Honda Multi Matic Transmission/CVT
Stall Speed Test

1. 1. Set the parking brake, and block the front wheels. 1. 7. If the measurements are out of the service limit,
2. Connect a tachometer to the engine, and start the problems and probable causes are listed in the table
engine. below.
3. Make sure the A/C switch is OFF. Problem Probable cause
4. After the engine has warmed up to normal operating Stall speed rpm high Low fluid level or
temperature (the radiator fan comes on), shift to in , , ATF pump output
position. low
and positions
5. Fully press the brake pedal and accelerator for 6 to 8 Clogged ATF
seconds and note engine speed. Do not move the strainer
shift lever while raising engine speed. PH regulator valve
6. Allow 2 minutes for cooling, then repeat the test in stuck closed
, and positions. Slipping forward
NOTE: clutch
Faulty start clutch
Do not test stall speed for more than 10 seconds
at a time. Stall speed rpm high Slippage of
Stall speed tests should be used for diagnostic in position reverse clutch
purposes only. Faulty start clutch
Stall speed rpm low Engine output low
Stall speed should be the same in , ,
in , , Faulty start clutch
and positions. Stuck pulley
Do not test stall speed with the A/T pressure and positions
control valve
gauges installed.
Stall Speed rpm in position:
Specification:
2,500 rpm (min -1 )
Service Limit:
2,350-2,650 rpm (min -1 )
Stall Speed rpm in , and positions:
Specification:
2,800 rpm (min -1 )
Service Limit:
2,600-2,900 rpm (min -1 )

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1-5

1-5
General Information
Abbreviations (cont'd)

MAP Manifold Absolute Pressure STD Standard


MAX. Maximum SW Switch
MBS Mainshaft Brake System T Torque
MCK Motor Check TB Throttle Body
MCU Moment Control Unit T/B Timing Belt
MIL Malfunction Indicator Lamp TC Torque Converter
MIN. Minimum TCM Transmission Control Module
MPI Multi Point Injection TCS Traction Control System
M/S Manual Steering TDC Top Dead Center
M/T Manual Transmission TFT Thin Film Transistor
N Neutral T/N Tool Number
NOx Oxides of Nitrogen TP Throttle Position
OBD On-board Diagnostic TWC Three Way Catalytic Converter
O2S Oxygen Sensor VC Viscous Coupling
OD or O.D. Outside Diameter VDP Variable Displacement Pump
P Park VFV Variable Force Control Valve
PAIR Pulsed Secondary Air Injection VGR Variable Gear Ratio
PCM Powertrain Control Module VIN Vehicle Identification Number
PCV Positive Crankcase Ventilation VSS Vehicle Speed Sensor
Proportioning Control Valve VTEC Variable Valve Timing & Valve Lift
Electronic Control
PDU Power Drive Unit
VVIS Variable Volume Intake System
PGM-FI Programmed-fuel Injection
V-6 V-type Six Cylinder (engine)
PGM-IG Programmed Ignition
W With
PH Pressure High
W/O Without
PL Pilot Light or Pressure Low
WOT Wide Open Throttle
PMR Pump Motor Relay
2WD Two Wheel Drive
P/N Part Number
4WD Four Wheel Drive
PRI Primary
2WS Two Wheel Steering
P/S Power Steering
4WS Four Wheel Steering
PSF Power Steering Fluid
4AT 4-speed Automatic Transmission
PSP Power Steering Pressure
5MT 5-speed Manual Transmission
PSW Pressure Switch
6MT 6-speed Manual Transmission
Qty Quantity
Park
R Right
REF Reference Reverse

RGB Red, Green, Black Neutral

RH Right Handle Drive (1st through 4th gear)


RHD Right Handle Drive Drive (1st through 3rd gear)
RL Rear Left Second
RON Research Octane Number First
RR Rear Right Drive
SAE Society of Automotive Engineers Second
SCS Service Check Signal Low
SEC Second O/D Over Drive

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1-5

Secondary
1ST Low (gear)
SOHC Single Overhead Camshaft 2ND Second (gear)
SOL Solenoid 3RD Third (gear)
SPEC Specification 4TH Fourth (gear)
S/R Sun Roof 5TH Fifth (gear)
SRS Supplemental Restraint System 6TH Sixth (gear)

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16-1


Transaxle

Driveline/Axle
Driveshafts Reassembly 16-2

Outline of Model Change


A Honda of the U.K. Manufacturing produced 3-Door model has been added. For related information, refer to the Civic Shop
Manual (P/N 62S5A00), Civic 5-Door Supplement (P/N 62S5A21).

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16-10

16-10
Driveline/Axle
Driveshafts Reassembly (cont'd)

1. 6. Check the alignment of the paint mark (A) with the 1. 8. Fit the boot (A) ends onto the driveshaft (B) and
outboard joint end (B). outboard joint (C).

2. 7. Pack the outboard joint with the joint grease included


in the new joint boot set.
Grease quantity
Outboard joint:
D14Z6 engine model:
80-100 g (2.8-3.5 oz) 2. 9. Close the ear portion (A) of the band with a
D16V1 engine model: commercially available boot band pincers (B).
95-105 g (3.4-3.7 oz)

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16-11

16-11
Driveline/Axle
Driveshafts Reassembly (cont'd)

1. 10. Check the clearance between the closed ear portion


of the bands. If the clearance is not within the
standard, close the ear portion of the bands further.

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16-2

16-2
Driveline/Axle
Driveshafts Reassembly

Exploaded View
D16V1 engine model:
1. SET RING
Replace.
2. INBOARD JOINT
3. CIRCLIP
4. ROLLER
5. SPIDER
6. INBOARD BOOT
Pack cavity with grease.
7. DOUBLE LOOP BAND
Replace.
8. Pack cavity with grease.
9. Left driveshaft
10. LOW PROFILE BAND
Replace.
11. DRIVESHAFT
12. STOP RING
Replace.
13. EAR CLAMP BANDS
Replace.
14. OUTBOARD JOINT
15. Pack cavity with grease.
16. OUTBOARD BOOT (TPE)
17. Right driveshaft
18. DYNAMIC DAMPER
(Undirectional)

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16-3

16-3
Driveline/Axle
Driveshafts Reassembly (cont'd)

D14Z6 engine model:


*: There is a type with dynamic and there is a type without dynamic damper.
1. INBOARD JOINT
2. CIRCLIP
3. (Right driveshaft)
4. ROLLER
5. DOUBLE LOOP BAND
Replace.
(Replacement parts only)
6. INBOARD BOOT
Pack cavity with grease.
7. EAR CLAMP BAND
Replace.
8. LOW PROFILE BAND
Replace.
9. SPIDER
10. Pack cavity with grease.
11. SET RING
Replace.
12. Left driveshaft
13. EAR CLAMP BAND
Replace.
14. DRIVESHAFT
15. STOP RING
Replace.
16. EAR CLAMP BANDS
Replace.
17. OUTBOARD JOINT
18. Pack cavity with grease.
19. OUTBOARD BOOT (TPE)
20. Right driveshaft*
21. DYNAMIC DAMPER
(Undirectional)

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16-4

16-4
Driveline/Axle
Driveshafts Reassembly (cont'd)

Special Tools Required 1. 3. Install the spider (A) onto the driveshaft by aligning
the marks (B) on the spider and the end of the
Boot band tool, KD-3191 or equivalent commercially
driveshaft.
available
Boot band pincers, KENT-MOORE J-35910 or
equivalent commercially available
Boot band pincer, commercially available
NOTE: Refer to the Exploded View as needed during this
procedure.
Inboard Joint Side:
1. 1. Wrap the splines with vinyl tape (A) to prevent
damage to the inboard boot and dynamic damper.

2. 4. Fit the circlip (C) into the driveshaft groove. Always


rotate the circlip in its groove to make sure it is fully
seated.
5. Fit the rollers (A) onto the spider (B) with their high
shoulders facing outward and note these items:
Reinstall the rollers in their original positions on
the spider by aligning the marks (C).
Hold the driveshaft pointed up to prevent the
2. 2. Install the dynamic damper, inboard boot and the ear rollers from falling off.
clamp bands (B) onto the driveshaft, then remove the
vinyl tape. Take care not to damage the inboard boot
and dynamic damper.

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16-5

16-5
Driveline/Axle
Driveshafts Reassembly (cont'd)

1. 6. Pack the inboard joint with the joint grease included 1. 8. Adjust the length of the driveshafts to the figure
in the new driveshaft set. below, then adjust the boots to halfway between full
Grease quantity compression and full extension. Make sure the ends
Inboard joint: of the boots seat in the grooves of the driveshaft and
D14Z6 engine model: joint.
Left driveshaft:
Right driveshaft:
D14Z6 engine model:
108-126 g (3.8-4.4 oz)
775-780 mm (30.5-30.7 in.)
Left driveshaft:
D16V1 engine model:
103.5-121.5 g (3.7-4.3 oz)
M/T: 784-789 mm (30.9-31.1 in.)
D16V1 engine model:
A/T: 787-792 mm (31.0-31.2 in.)
100-110 g (3.5-3.9 oz)
Right driveshaft:
D14Z6 engine model:
486-491 mm (19.1-19.3 in.)
D16V1 engine model:
498-503 mm (19.6-19.8 in.)

2. 9. Position the dynamic damper as shown below.


As for the D14Z6 engine model, there is a type with right
2. 7. Fit the inboard joint onto the driveshaft and note driveshaft dynamic damper and there is a type without right
these items: driveshaft dynamic damper.
Reinstall the inboard joint onto the driveshaft by Left driveshaft:
aligning the marks (A) on the inboard joint and 478-482 mm (18.8-19.0 in.)
the rollers. Right driveshaft:
Hold the driveshaft so the inboard joint points up
258-262 mm (10.2-10.3 in.)
to prevent it from falling off.

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16-6

16-6
Driveline/Axle
Driveshafts Reassembly (cont'd)

1. 10. Install the boot bands. 1. 13. Fit the boot ends onto the driveshaft and the inboard
For the low profile type, go to step 11. joint, then install the band (A) onto the boot.
For the double loop type, go to step 13.
For the ear clamp type, go to step 21.
2. 11. Install the new low profile band (A) onto the boot (B)
and dynamic damper, then hook the tab (C) of the
band.

2. 14. Pull up the slack in the band by hand.


15. Mark a position (A) on the band 10-14 mm (0.4-0.6
in.) from the clip (B).

3. 12. Close the hook portion of the band with a


commercially available boot band pincers (A), then
hook the tabs (B) of the band.

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16-7

16-7
Driveline/Axle
Driveshafts Reassembly (cont'd)

1. 16. Thread the free end of the band through the nose 1. 19. Unwind the boot band tool and cut off the excess
section of the commercially available boot band tool free end of the band to leave a 5-10 mm (0.2-0.4
KD-3191 or equivalent (A) and into the slot on the in.) tail protruding from the clip.
winding mandrel (B).

2. 20. Bend the band end (A) by tapping it down with a


hammer.
NOTE:
Make sure the band and clip do not interfere with
anything and the band does not move.
Remove any grease remaining on the surrounding
surfaces.

2. 17. Place a wrench on the winding mandrel of the boot


band tool and tighten the band until the marked spot
(C) on the band meets the edge of the clip.
18. Lift up the boot band tool to bend the free end of the
band 90 degrees to the clip. Center punch the clip,
then fold over the remaining tail onto the clip.

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16-8

16-8
Driveline/Axle
Driveshafts Reassembly (cont'd)

1. 21. Close the ear portion (A) of the band with a 1. 23. Install the new set ring.
commercially available boot band pincers (B).

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2. 22. Check the clearance between the closed ear portion


of the band. If the clearance is not within the
standard, close the ear portion of the band further.

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16-9

16-9
Driveline/Axle
Driveshafts Reassembly (cont'd)

Outboard Joint Side: 1. 4. Insert the driveshaft (A) into the outboard joint (B)
until the stop ring (C) is close to the joint.
1. 1. Wrap the splines with vinyl tape (A) to prevent
damage to the outboard boot.

2. 2. Install the new ear clamp bands (B) and outboard


boot onto the driveshaft, then remove the vinyl tape.
Take care not to damage the outboard boot.
3. Install the new stop ring into the driveshaft groove
(A).

2. 5. To completely seat the outboard joint, pick up the


driveshaft and joint and drop them from about 10 cm
(4 in.) onto a hard surface. Do not use a hammer as
excessive force may damage the driveshaft.

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20-0


Body

Doors
Component Location Index 20-2
Door Panel Removal/Installation 20-4
Door Outer Handle Replacement 20-6
Door Latch Replacement 20-8

Glass
Component Location Index 20-10
Windshield Replacement 20-12
Rear Window Replacement 20-18
Quarter Glass Replacement 20-22

Interior Trim
Component Location Index 20-28
Trim Removal/Installation-Door Area 20-29
Trim Removal/Installation-Rear Side Area 20-30
Trim Removal/Installation-Trunk Floor Area 20-31
Trim Removal/Installation-Tailgate Area 20-32
Headliner Removal/Installation 20-33
*Carpet Replacement 20-35

Consoles
Consoles, Front and Rear Removal/Installation 20-37
Front Console Disassembly/Reassembly 20-38

Seats
*Front Seat Disassembly/Reassembly-Passenger's 20-39
Rear Seat Removal/Installation 20-40

Exterior Trim
Front Pillar Corner Trim Replacement 20-41
Tailgate Spoiler Replacement 20-42
Emblem Replacement 20-43

Openers
*Fuel Fill Door Opener Cable Replacement 20-45

Frame
*Frame Repair Chart 20-46

NOTE: Refer to the '01 Civic Shop Manual on this CD, P/N 62S5A00 and '01 Civic Shop Manual Supplement on this CD, P/N
62S5A20, P/N 62S5A21, for the items not shown in this section.
Outline of 3-door Model Change
The Civic 3-door model has been added.

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20-1


SRS
Supplemental Restraint System (SRS)

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If body maintenance is required)


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 and some models include side airbags in the front seat-backs.
Information necessary to safely service the SRS is included in the Shop Manual on this CD, 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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20-10

20-10
Glass
Component Location Index

1. PASSENGER'S
AIRBAG CAUTION
LABEL
(For some models)
2. FASTENER, 2
(Self-adhesive-type,
glass side)
3. FASTENER, 2
(Clip-type, body side)
4. WINDSHIELD
MOULDING
5. SIDE RUBBER DAM
6. WINDSHIELD SIDE
TRIM
7. RETAINER, 2
Orange
8. RETAINER, 6
Black
9. CLIP, 2
Grey
10. CLIP, 4
Blue
11. CLIP
12. LOWER RUBBER DAM
13. UPPER RUBBER DAM,
4
14. REAR WINDOW
Replacement, page 20-
18
15. SEAL
16. LOWER RUBBER DAM
17. SIDE LOWER
FASTENER, 2
(Self-adhesive-type,
glass side)
18. SIDE LOWER
FASTENER, 2
(Self-adhesive-type,
tailgate side)
19. SIDE UPPER
FASTENER, 2
(Self-adhesive-type,
glass side)
20. SIDE UPPER
FASTENER, 2
(Self-adhesive-type,
tailgate side)
21. SPOILER FASTENER,
2
(Self-adhesive-type)
22. WINDSHIELD
Replacement, page 20-
12

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20-11

20-11
Glass
Component Location Index (cont'd)

1. OUTER GLASS FRONT


SEAL
2. UPPER CLIP
(Self-adhesive-type)
3. RUBBER DAM
4. REAR CLIP
(Self-adhesive-type)
5. QUARTER GLASS
Replacement, page 20-
22
6. LOWER CLIP
(Self-adhesive-type)

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20-12

20-12
Glass
Windshield Replacement

NOTE: 1. 3. Remove the cowl covers, refer to the '01 Civic Shop
Manual on this CD (see page 20-252).
Put on gloves to protect your hands.
4. Remove the moulding (A) from the upper edge of the
Wear eye protection when removing the glass with
windshield (B). If necessary, cut the moulding with a
piano wire.
utility knife.
Use seat covers to avoid damaging the seat.
Use glass adhesive set P/N. 08C73-X0230N.
1. 1. Remove these items, refer to the '01 Civic Shop
Manual on this CD:
Rearview mirror (see page 20-173)
Windshield wiper arms (see page 22-179)
2. 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.

2. 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

20-13
Glass
Windshield Replacement (cont'd)

1. 8. With a helper on the outside, pull the piano wire (A) 1. 10. With a knife, scrape the old adhesive smooth to a
back and forth in a sawing motion. Hold the piano thickness of about 2 mm (0.08 in.) on the bonding
wire as close to the windshield (B) as possible to surface around the entire windshield opening flange:
prevent damage to the body and dashboard. Do not scrape down to the painted surface of the
Carefully cut through the rubber dam and adhesive body; damaged paint will interfere with proper
(C) around the entire windshield. bonding.
Remove the rubber dam and fasteners from the
body.
2. 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.
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Cutting portions:

2. 9. Carefully remove the windshield.

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20-14

20-14
Glass
Windshield Replacement (cont'd)

1. 13. Glue the side rubber dams (A), lower rubber dam (B) 1. 14. Glue the moulding (A) with adhesive tape (B) to the
and fasteners (C) to the inside face of the windshield upper edge of the windshield (C):
(D) as shown: Be sure the alignment mark (D) of the moulding
Be sure the rubber dams and fasteners line up lines up with the alignment mark (E) of the
with the alignment marks (E). windshield.
Be careful not to touch the windshield where Be careful not to touch the windshield where
adhesive will be applied. adhesive will be applied.

2. 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

20-15
Glass
Windshield Replacement (cont'd)

1. 16. Set the windshield in the opening and centre it. Make 1. 18. With a sponge, apply a light coat of glass primer
alignment marks (A) across the windshield and body around the edge of the windshield (A) between the
with a grease pencil at the four points shown. Be dams (B) and moulding (C) as shown, then lightly
careful not to touch the windshield where adhesive wipe it off with gauze or cheesecloth:
will be applied. Apply glass primer to the moulding.
Do not apply body primer to the windshield and
do not get body and glass primer sponges mixed
up.
Never touch the primed surfaces with your hands.
If you do, the adhesive may 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.
Cross hatched area: Apply glass primer here.

2. 17. Remove the windshield.

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20-16

20-16
Glass
Windshield Replacement (cont'd)

1. 19. With a sponge, apply a light coat of body primer to 1. 21. Pack adhesive into the cartridge without air pockets
the original adhesive remaining around the to ensure continuous delivery. Put the cartridge in a
windshield opening flange. Let the body primer dry caulking gun and run a bead of adhesive (A) around
for at least 10 minutes: the edge of the windshield (B) between the dams (C)
Do not apply glass primer to the body and be and moulding (D) as shown. Apply the adhesive
careful not to mix up glass and body primer within 30 minutes after applying the glass primer.
sponges. Make a slightly thicker bead at each corner.
Never touch the primed surfaces with your hands.
Mask off the dashboard before painting the
flange.
Cross hatched area: Apply body primer here.

2. 20. Before filling a cartridge, cut a ''V'' in the end of the


nozzle (A) as shown.

2. 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

20-17
Glass
Windshield Replacement (cont'd)

1. 23. Scrape or wipe the excess adhesive off with a putty 1. 27. On both sides of the windshield, install the trim to
knife or towel. To remove adhesive from a painted the clip (C), then set the bottom edge of the side trim
surface or the windshield, wipe with a soft shop towel (A) over the cowl cover (B) and align the clips (D)
dampened with alcohol. with the retainers (E) and push on the clip portions
24. Let the adhesive dry for at least 1 hour, then spray of the trim until the trim is fully seated on the
water over the windshield and check for leaks. Mark windshield.
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 has to be
used within the first 4 hours, it must be driven
slowly.
Keep the windshield dry for the first hour after
installation.
2. 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

2. 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 angle or driving
over rough, uneven roads).
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20-18

20-18
Glass
Rear Window Replacement

NOTE: 1. 6. With a helper on the outside, pull the piano wire (A)
back and forth in a sawing motion. Hold the piano
Put on gloves to protect your hands.
wire as close to the rear window (B) as possible to
Wear eye protection when removing the glass with
prevent damage to the tailgate and carefully cut
piano wire.
through the adhesive (C) around the entire rear
Use seat covers to avoid damaging any surfaces.
window.
Do not damage the rear window defogger grid lines
and terminals.
Use glass adhesive set P/N. 08C73-X0230N.
1. 1. Remove these items:
Tailgate lower trim panel (see page 20-32)
Tailgate spoiler (see page 20-42)
2. 2. Remove these items, refer to the '01 Civic Shop
Manual on this CD:
High mount brake light (see page 22-120)
Rear window wiper motor (see page 22-181)
3. 3. Disconnect the rear window defogger connectors (A).

Cutting positions:

4. 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 2. 7. Carefully remove the rear window.
through the adhesive from inside the vehicle at the
aaa
corner portion of the rear window. Push the piano
wire through the hole and wrap each end around a
piece of wood.

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20-19

20-19
Glass
Rear Window Replacement (cont'd)

1. 8. With a putty knife, scrape the old adhesive smooth to 1. 11. Glue the side upper fasteners (A), side lower
a thickness of about 2 mm (0.08 in.) on the bonding fasteners (B), upper rubber dams (C) and lower
surface around the entire rear window opening rubber dam (D) to the inside face of the rear window
flange: (E) as shown. Before installing the lower rubber dam,
Do not scrape down to the painted surface of the apply primer (3M M200, or equivalent) to the areas
body; damaged paint will interfere with proper between the alignment marks (F), then glue the
bonding rubber dam on. If necessary, glue the spoiler
Remove the fasteners from the tailgate. fasteners (G) to the outside face of the rear window:
2. 9. Clean the tailgate bonding surface with a sponge Be sure the side upper fasteners and upper
dampened in alcohol. After cleaning, keep oil, grease rubber dams line up with alignment marks (H, I).
and water from getting on the surface. Be sure both ends of the lower rubber dam line
10. If the old rear window is to be reinstalled, use a putty up with the edge of the glass.
knife to scrape off all of the old adhesive, the Be sure the spoiler fasteners line up with
fasteners and the rubber dams from the rear window. alignment marks (J).
Clean the inside face and the edge of the rear Be careful not to touch the rear window where
window with alcohol where new adhesive is to be adhesive will be applied.
applied. Make sure the bonding surface is kept free Cross hatched area: Apply primer here.
of water, oil and grease.

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20-2

20-2
Doors
Component Location Index

1. PLASTIC COVER
2. DOOR WEATHERSTRIP
3. REFLECTOR TAPE
4. DOOR OUTER CHANNEL
TAPE
5. DOOR SASH TRIM
6. DOOR GLASS OUTER
WEATHERSTRIP
7. DOOR
8. HINGE
9. DETENT ROD
10. HINGE
11. SPEAKER
12. DOOR GLASS INNER
WEATHERSTRIP
13. INNER HANDLE
14. POWER DOOR LOCK
SWITCH
(Driver's for some models)
15. DOOR PANEL
Removal/installation, page 20-
4
16. DOOR GRIP BASE
17. ARMREST COVER
18. DOOR GRIP COVER
19. POWER WINDOW SWITCH
(For some models)
20. SWITCH PANEL

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20-20

20-20
Glass
Rear Window Replacement (cont'd)

1. 12. Glue the side upper fasteners (A) and side lower 1. 15. With a sponge, apply a light coat of glass primer
fasteners (B) to the tailgate as shown. along the edge of the rear window (A), upper rubber
Fastener Locations dams (B) and lower rubber dam (C) as shown, then
A : Fastener, 2 B : Fastener, 2 lightly wipe it off with gauze or cheesecloth:
With the printed dots (D) on the rear window as a
guide, apply the glass primer to both side portions
of the rear window.
Do not apply body primer to the rear window and
do not get tailgate and glass primer sponges
mixed up.
Never touch the primed surfaces with your hands.
If you do, the adhesive may 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.
Cross hatched area: Apply glass primer here.

2. 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.

aaa

3. 14. Remove the rear window.

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20-21

20-21
Glass
Rear Window Replacement (cont'd)

1. 16. With a sponge, apply a light coat of body primer to 1. 18. Pack adhesive into the cartridge without air pockets
the original adhesive remaining around the rear to ensure continuous delivery. Put the cartridge in a
window opening flange. Let the body primer dry for caulking gun and run a bead of adhesive (A) around
at least 10 minutes: the edge of the rear window (B) as shown.
Do not apply glass primer to the body and be With the glass primer (C) you applied in step 15 as a guide,
careful not to mix up glass and body primer apply the adhesive to both side portions of the rear window.
sponges. Apply the adhesive within 30 minutes after applying the
Never touch the primed surfaces with your hands. glass primer. Make a slightly thicker bead at each corner.
Cross hatched area: Apply body primer here.

aaa

2. 17. Before filling a cartridge, cut a ''V'' in the end of the


nozzle (A) as shown.

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20-22

Quarter Glass Replacement


20-22
Glass
Rear Window Replacement (cont'd)

1. 19. Use suction cups to hold the rear window over the NOTE:
opening, align it with the alignment marks you made
Put on gloves to protect your hands.
in step 13 and set it down on the adhesive. Lightly
Wear eye protection when removing the glass with
push on the rear window until its edges are fully
piano wire.
seated on the adhesive all the way around. Do not
Use seat covers to avoid damaging any surfaces.
open or close the doors until the adhesive is dry.
Use glass adhesive set P/N. 08C73-X0230N.
20. Scrape or wipe the excess adhesive off with a putty
1. 1. Remove the rear pillar trim (see page 20-30).
knife or towel. To remove adhesive from a painted
If necessary, remove the rear side trim panel (see
surface or the rear window, use a soft shop towel
page 20-30) and centre pillar upper trim (see page
dampened with alcohol.
20-29).
21. Let the adhesive dry for at least 1 hour, then spray
2. Remove the front seal (A) from the front edge of the
water over the rear window and check for leaks.
glass (B). If necessary, cut the seal with a utility
Mark the leaking areas, let the rear window dry, then
knife.
seal with sealant. Let the vehicle stand for at least 4
hours after rear window installation. If the vehicle has
to be used within the first 4 hours, it must be driven
slowly.
22. Reinstall all remaining removed parts. 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 angle or driving over
rough, uneven roads).

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20-23

20-23
Glass
Quarter Glass Replacement (cont'd)

1. 3. Apply protective tape along the inside and outside 1. 6. With a putty knife, scrape the old adhesive smooth
edges of the body. Using an awl, make a hole to a thickness of about 2 mm (0.08 in.) on the
through the adhesive from inside the vehicle. Push a bonding surface around the entire quarter glass
piece of piano wire through the hole and wrap each opening flange:
end around a piece of wood. Do not scrape down to the painted surface of the
4. With a helper on the outside, pull the piano wire (A) body; damaged paint will interfere with proper
back and forth in a sawing motion. Hold the piano bonding.
wire as close to the quarter glass (B) as possible to Remove the clips from the body.
prevent damage to the body and carefully cut 2. 7. Clean the body bonding surface with a sponge
through the adhesive (C) around the entire quarter dampened in alcohol. After cleaning, keep oil, grease
glass. and water from getting on the surface.
8. If the old quarter glass is to be reinstalled, use a
putty knife to scrape off all of the old adhesive and
the rubber dam from the glass. Clean the inside face
and the edge of the glass with alcohol where new
adhesive is to be applied. Make sure the bonding
surface is kept free of water, oil and grease.
aaa

Cutting positions:

2. 5. Carefully remove the quarter glass.

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20-24

20-24
Glass
Quarter Glass Replacement (cont'd)

1. 9. Set the quarter glass (A) in the opening and centre 1. 11. Align the upper clip (A) and lower clip (B) with the
it. From inside the vehicle, make alignment mark (B) edge of the quarter glass (C), then glue them to the
to the quarter glass where the rear clip will be inside face of the quarter glass and align the centre
installed with a grease pencil. Be careful not to touch of the rear clip (D) with the alignment mark (E) you
the glass where adhesive will be applied. made in step 9 and glue it to the inside face of the
quarter glass as shown. Be careful not to touch the
glass where adhesive will be applied.

2. 10. Remove the quarter glass.

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20-25

20-25
Glass
Quarter Glass Replacement (cont'd)

1. 12. First glue the front seal (A) and glue the rubber dam 1. 13. With a sponge, apply a light coat of glass primer
(B) to the inside face of the quarter glass (C) as along the edge of the rubber dam (A) and front seal
shown. Before installing the front seal and rubber (B) as shown, then lightly wipe it off with gauze or
dam, apply primer (3M N-200, or equivalent) to the cheesecloth:
inside face of the glass, then glue the seal on: With the printed dots (C) on the quarter glass (D)
Be sure the front seal lines up with the bottom and as a guide, apply the glass primer to the upper
front edges of the glass. and lower corner portions of the quarter glass.
Be careful not to touch the glass where adhesive Do not apply body primer to the quarter glass
will be applied. and do not get body and glass primer sponges
Cross hatched area: Apply primer here. mixed up.
Never touch the primed surfaces with your hands
. If you do, the adhesive may not bond to the
quarter glass properly, causing a leak after the
quarter glass is installed.
Keep water, dust and abrasive materials away
from the primed surface.
Cross hatched area: Apply primer here.

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20-26

20-26
Glass
Quarter Glass Replacement (cont'd)

1. 14. With a sponge, apply a light coat of body primer to 1. 16. Pack adhesive into the cartridge without air pockets
the original adhesive remaining around the quarter to ensure continuous delivery. Put the cartridge in a
glass opening flange. Let the body primer dry for at caulking gun and run a bead of adhesive (A) around
least 10 minutes: the edge of the rubber dam (B) as shown. With the
Do not apply glass primer to the body and be glass primer (C) you applied in step 13 on the
careful not to mix up glass and body primer quarter glass (D) as a guide, apply the adhesive to
sponges. the upper and lower corner portions of the quarter
Never touch the primed surfaces with your hands. glass. Apply the adhesive within 30 minutes after
Cross hatched area: Apply body primer here. applying the glass primer. Make a slightly thicker
bead at each corner.

2. 15. Before filling a cartridge, cut a ''V'' in the end of the


nozzle (A) as shown.

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20-27

20-27
Glass
Quarter Glass Replacement (cont'd)

1. 17. Use suction cups (A) to hold the quarter glass over aaa
the opening, align it with the clips (B) and set it down
on the adhesive. Lightly push on the quarter glass
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.

2. 18. Scrape or wipe the excess adhesive off with a putty


knife or towel. To remove adhesive from a painted
surface or the quarter glass, use a soft shop towel
dampened with alcohol.
19. Let the adhesive dry for at least 1 hour, then spray
water over the quarter glass and check for leaks.
Mark the leaking areas, let the quarter glass dry,
then seal with sealant. Let the vehicle stand for at
least 4 hours after quarter glass installation. If the
vehicle has to be used within the first 4 hours, it
must be driven slowly.
20. Reinstall all remaining removed parts. 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 angle or driving over
rough, uneven roads).

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20-28

20-28
Interior Trim
Component Location Index

1. TAILGATE LOWER TRIM


PANEL
page 20-32
2. TAILGATE SIDE TRIM
page 20-32
3. REAR PILLAR TRIM
page 20-30
4. TAILGATE UPPER TRIM
PANEL
page 20-32
5. CENTRE PILLAR UPPER
TRIM
page 20-29
6. DOOR OPENING TRIM
page 20-29
7. FRONT PILLAR TRIM
page 20-29
8. HEADLINER
Removal/Installation, page
20-33
9. KICK PANEL
page 20-29
10. CARPET
Replacement, page 20-35
11. DOOR SILL TRIM
page 20-29
12. TRUNK SIDE FRONT
SPACER
page 20-31
13. SPARE TYRE LID
page 20-31
14. TRUNK SIDE REAR
SPACER
page 20-31
15. REAR CENTRE SHELF
page 20-30
16. TRUNK FLOOR MAT
page 20-31
17. REAR TRIM PANEL
page 20-31
18. REAR SIDE TRIM PANEL
page 20-30
19. REAR SIDE SHELF
page 20-30

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20-29

20-29
Interior Trim
Trim Removal/Installation - Door Area

NOTE:
Put on gloves to protect your hands.
When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage.
Take care not to bend or scratch the trim and panels.
LHD is shown, RHD is symmetrical.
Remove the trim as shown. To remove the door sill trim and centre-pillar upper trim, remove the rear side trim panel as necessary
(see page 20-30).
Install the trim in the reverse order of removal and note these items:
Replace any damaged clips.
Before installing the anchor bolts, make sure there are no twists or kinks in the belts.
Fastener Locations
A : Clip, 2 B : Clip, 3 C : Clip, 7
(Black)(White)
1. CENTRE PILLAR UPPER
TRIM
2. FRONT SEAT BELT
UPPER ANCHOR BOLT
7/16-20 UNF
32 Nm (3.3 kgf/m, 24 lbf/ft)
3. FRONT PILLAR TRIM
4. DOOR OPENING TRIM
5. UPPER ANCHOR COVER
6. FRONT SIDE CAP
7. KICK PANEL
8. DOOR SILL TRIM
9. FRONT SEAT BELT
LOWER ANCHOR BOLTS
7/16-20 UNF
32 Nm (3.3 kgf/m, 24 lbf/ft)
10. REAR SIDE TRIM PANEL
11. To body.

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20-3

20-3
Doors
Component Location Index (cont'd)

1. CENTRE LOWER CHANNEL


2. IMMOBILISER LABEL
3. GLASS
4. GLASS RUN CHANNEL
5. FRONT LOWER CHANNEL
6. OUTER HANDLE
Replacement, page 20-6
7. OUTER HANDLE
PROTECTOR
8. RETAINER CLIP
9. LOCK CYLINDER
(Driver's and some
passenger's)
10. INNER HANDLE CABLE
11. LATCH PROTECTOR
(KE model)
12. POWER DOOR LOCK
ACTUATOR
(Except KE model)
13. POWER DOOR LOCK
ACTUATOR
(KE model)
14. LATCH
Replacement, page 20-8
15. STRIKER
16. CYLINDER ROD PROTECTOR
(KE model)
17. LOCK KNOB
18. CYLINDER SWITCH
(For some models)
19. REGULATOR HANDLE
(Manual window)
20. REGULATOR

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20-30

20-30
Interior Trim
Trim Removal/Installation - Rear Side Area

NOTE:
Put on gloves to protect your hands.
When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage.
Take care not to bend or scratch the trim and panels.
To remove the rear side trim panel, remove these items:
Rear seat cushion and rear seat-back (see page 20-40)
Trunk floor mat and spare tyre lid (see page 20-31)
Trunk side spacers, for some models (see page 20-31)
Rear trim panel (see page 20-31)
Remove the trim as shown. On the right side, disconnect the trunk compartment light connector.
Install the trim in the reverse order of removal and note these items:
Replace any damaged clips.
Make sure the trunk compartment light connector is plugged in properly.
If the threads on the rear side trim panel mounting self-tapping ET screws are worn out, use an oversized self-tapping
ET screw made specifically for this application.
When installing the rear side shelf, slip the rear seat belt through the slit in the trim.
Before installing the anchor bolts, make sure there are no twists or kinks in the belt.
Fastener Locations
A : Clip, 11 B : Clip, 1 C : Clip, 1
(White)
1. LID
2. REAR CENTRE SHELF
3. REAR PILLAR TRIM
4. REAR SIDE SHELF
5. REAR SEAT BELT
6. SLIT
7. REAR SIDE TRIM PANEL
8. REAR SEAT STRIKER CAP
9. CENTRE PILLAR UPPER
TRIM
10. REAR SPEAKER
CONNECTOR
11. DOOR SILL TRIM
12. FRONT SEAT BELT
LOWER ANCHOR BOLTS
7/16-20 UNF
32 Nm (3.3 kgf/m, 24 lbf/ft)
13. REAR SPEAKER
(For some models)
14. REAR SPEAKER LID
15. Without trunk side spacers
model.
16. REAR BULKHEAD COVER
17. SELF-TAPPING ET
SCREWS
5 x 0.8 mm
4 Nm (0.4 kgf/m, 3 lbf/ft)

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20-31

20-31
Interior Trim
Trim Removal/Installation - Trunk Floor Area

NOTE:
Put on gloves to protect your hands.
When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage.
Take care not to bend or scratch the trim and panels.
Remove the trim as shown.
Install the trim in the reverse order of removal, and note these items:
Replace any damaged clips.
Make sure the trunk compartment light connector is plugged in properly.
Fastener Locations
A : Clip, 3 B : Clip, 4 C : Clip, 2
(White)
1. TRUNK FLOOR MAT
(With spare tyre)
2. HOOK
3. TRUCK FLOOR MAT
4. SPARE TYRE LID
5. HOLE
6. TRUNK FLOOR MAT
(With normal tyre)
7. SPARE TYRE LID
8. RIGHT TRUNK SIDE
FRONT SPACER
(With normal tyre)
9. RIGHT TRUNK SIDE
REAR SPACER
(With normal tyre)
10. REAR SIDE TRIM PANEL
11. To rear side trim panel.
12. REAR TRIM PANEL
13. HOOK
14. To rear side trim panel.
15. To rear side trim panel.
16. LEFT TRUCK SIDE
REAR SPACER
(With normal tyre)
17. LEFT TRUNK SIDE
FRONT SPACER
(With normal tyre)
18. REAR SEAT-BACK
COVER

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Body - 20-34

20-32
Interior Trim
Trim Removal/Installation - Tailgate Area

NOTE:
Put on gloves to protect your hands.
When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage.
Take care not to bend or scratch the trim and panels.
Remove the trim as shown.
Install the trim in the reverse order of removal and replace any damaged clips.
Fastener Locations
A : Clip, 4 B : Clip, 2 C : Clip, 12 D : Clip, 1 E : Clip, 2
(White) (Black)
a. a. TAILGATE LOWER
TRIM PANEL
b. TAILGATE LOWER
TRIM PANEL
c. RIGHT TAILGATE
SIDE TRIM
d. TAILGATE UPPER
TRIM PANEL
e. TAILGATE UPPER
TRIM PANEL
f. TAILGATE SIDE TRIM
g. LEFT TAILGATE SIDE
TRIM
h. TAILGATE SIDE TRIM

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20-33

20-33
Interior Trim
Headliner Removal/Installation

NOTE: 1. 3. From both rear passenger's, remove the cap (A) and
remove the self-tapping ET screws and washers (B),
When prying with a flat-tip screwdriver, wrap it with
then remove the grab handles (C).
protective tape to prevent damage.
Fastener Locations
Take care not to bend and scratch the headliner.
Be careful not to damage the dashboard and other : Screw, 4
interior trim.
1. 1. Remove these items:
Front pillar trim, both sides (see page 20-29)
Centre pillar upper trim, both sides (see page 20-
29)
Rear pillar trim, both sides (see page 20-30)
Sunroof switch, for some models, refer to the '01
Civic Shop Manual on this CD (see page 22-157)
Spotlights, for some models, refer to the '01 Civic
Shop Manual on this CD (see page 22-138)
Ceiling light, refer to the '01 Civic Shop Manual on
this CD (see page 22-138)
2. 2. From both sides, remove the caps (A) and remove
the screws, then remove the sunvisor (B) and holder
(C).
Fastener Locations
: Screw, 4
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Body - 20-34

20-34
Interior Trim
Headliner Removal/Installation (cont'd)

1. 4. Remove the headliner. 1. 5. Remove the headliner.


With sunroof: Without sunroof:
1. Remove the socket plug (A). 1. Remove the remaining door opening trim (A) from
2. Remove the remaining door opening trim (B) from each roof portion.
each roof portion. 2. With the help of an assistant, release the
3. Detach the clips (C) and release the fasteners (D) headliner (B) from the clips (C) by sliding the
by pulling the front portion of the headliner (E) headliner forward and lowering the headliner.
down. 3. Remove the cushion tape (D), then remove the
4. With the help of an assistant, release the clips (F) roof harness (E) from the headliner.
of the headliner from the sunroof frame (G) and 4. Remove the headliner through the tailgate
release the headliner from the clips (H) by sliding opening.
the headliner forward and lowering the headliner. Fastener Locations
5. Remove the headliner through the tailgate
opening. C : Clip, 2 D : Cushion tape, 5

Fastener Locations
C : Clip, 3 F : Clip, 2 H : Clip, 2

2. 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 bend it. Also, be
careful not to scratch the body.
Check that both sides of the headliner are
securely attached to the trim.
If the threads on the grab handle mounting self-
tapping ET screws are worn out, use on oversized
self-tapping ET screw made specifically for this
application.
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20-35

20-35
Interior Trim
Carpet Replacement

SRS components are located in this area. Review the SRS 1. 4. RHD: Detach the clips, then remove the footrest (A).
component locations (see page 23-24) and the precautions Fastener Locations
and procedures (see page 23-25) in the SRS section before : Clip, 2
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 damage, wrinkle or twist the carpet.
Be careful not to damage the dashboard or other
interior trim pieces.
1. 1. Remove these items, refer to the '01 Civic Shop
Manual on this CD:
Front seats, both sides (see page 20-229)
Driver's dashboard under cover (see page 20-
216)
Passenger's dashboard lower cover (see page
20-220)
2. 2. Remove these items:
Rear seat cushion (see page 20-40) 2. 5. Using a utility knife, cut the carpet (A) under the
Kick panels, both sides (see page 20-29) heater areas (B) and cut out the parking brake lever
Door sill trim, both sides (see page 20-29) area (C) as shown, then pull back the carpet. LHD is
Consoles, front and rear (see page 20-37) shown, RHD is symmetrical.
3. 3. LHD: Remove the nut (A) and using a hex wrench,
release the clip (B), then remove the footrest (C).
Fastener Locations
A : Nut, 1 B : Clip, 1

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20-36

20-36
Interior Trim
Carpet Replacement (cont'd)

1. 6. Remove the clip (A) and release the fasteners (B). 1. 7. Install the carpet in the reverse order of removal and
Pull the carpet out from both rear side trim panels note these items:
(D), then remove the carpet (C). LHD is shown, RHD Take care not to damage, wrinkle or twist the
is symmetrical. carpet.
Fastener Locations Make sure the seat harnesses are routed
A : Clip, 1 correctly.
Slip the carpet under the rear side trim panel on
each side properly.
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

20-37
Consoles
Consoles, Front and Rear Removal/Installation

NOTE: Take care not to scratch the front seat, dashboard and 1. 2. Remove the rear console (A).
related parts. 1. Remove the ashtray (B).
1. 1. Remove the front console (A). 2. Remove the console box mat (C).
3. Remove the bolts (D), screws (E) and clips (F).
1. Slide the front seat forward fully on each side.
4. Gently pull out the rear console to release the
2. Remove the screws (B) from the rear portion of
hooks (G) and pins (H).
the rear console.
3. Slide the front seat rearward fully on each side. Fastener Location
4. Pull the front position of the rear console up to D : Bolt, 2 E : Screw, 2 F : Clip, 2
detach the clips (C) and hooks (D), then release
the rear console from the front console (E).
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

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

20-38
Consoles
Front Console Disassembly/Reassembly

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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20-38

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20-39

20-39
Seats
Front Seat Disassembly/Reassembly -
Passenger's

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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20-4

20-4
Doors
Door Panel Removal/Installation

Special Tools Required 1. 4. Remove the armrest cover (A). Take care not to
scratch the door panel.
Trim pad remover, Snap-on A 177 or equivalent, commercially
available. 1. Pry out the front edge of the cover to release the
hooks (B).
NOTE: When prying with a flat-tip screwdriver, wrap it with
2. Pry out the bottom and rear edge of the cover to
protective tape and apply protective tape around the related
release the hooks (C).
parts, to prevent damage.
3. Pry out along the top to release the tabs (D).
1. 1. Remove the mirror mount cover, refer to the '01 Civic
Shop Manual on this CD (see step 2 on page 20-
170).
2. If applicable, remove the regulator handle (A) by
pulling the clip (B) out with a wire hook (C).

2. 5. Remove the screws (A, B) and release the tabs (C),


then remove the grip base (D). Remove the screw
2. 3. Insert a hex wrench through the hole (A) in the grip (A) securing the door panel from the armrest portion.
base (B). Push the grip cover (C) out to release the Fastener Locations
hook (D) and tab (E), and pull out the cover to
release the tabs (F) and hook (G) by hand, then A : Screw, 3 B : Screw, 5
remove the cover.

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20-40

20-40
Seats
Rear Seat Removal/Installation

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

20-41
Exterior Trim
Front Pillar Corner Trim Replacement

1. 1. Open the door. 1. 5. Replace any damaged clips.


2. Wrap a flat-tip screwdriver with protective tape and 6. Hold the trim up and fit the upper clip and lower clips
apply protective tape around the body to prevent into the holes in the body, then push on the trim until
damage. Carefully insert a flat-tip screwdriver next to the clips snap into place.
the upper clip and detach the clip by prying on the aaa
front pillar corner trim (A). Take care not to scratch
the body and related parts.
Fastener Locations
: Clip, 1

2. 3. Close the door half-way.


4. Pull the front pillar corner trim (A) out to detach the
lower clips, then remove the trim.
Fastener Locations
: Clip, 2

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20-42

20-42
Exterior Trim
Tailgate Spoiler Replacement

NOTE: Put on gloves to protect your hands. 1. 4. From inside the tailgate, release the clips, while
pulling the tailgate spoiler (A) away and release the
1. 1. Remove the tailgate upper trim (see page 20-32).
fasteners (B), then remove the spoiler. Take care not
2. Remove the high mount brake light, refer to the '01
to scratch the body.
Civic Shop Manual on this CD (see page 22-120).
Fastener Locations
3. From inside the tailgate, remove the bolts (A) and
nuts (B). : Clip, 2
Fastener Locations
A : Bolt, 2 B : Nut, 2

2. 5. Install the spoiler in the reverse order of removal and


replace any damaged clips.
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20-43

20-43
Exterior Trim
Emblem Replacement

NOTE: When removing the emblem, take care not to scratch the body.
1. 1. To remove the front ''H'' emblem and rear ''H'' emblem, remove these items. Refer to the '01 Civic Shop Manual on this
CD:
Front bumper (see page 20-243)
Rear license trim (see page 20-255)
2. 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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20-43

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20-44

20-44
Exterior Trim
Emblem Replacement (cont'd)

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20-45

20-45
Openers
Fuel Fill Door Opener Cable Replacement

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. 1. Remove these items:
Door sill trim (see page 20-29)
Rear side trim panel, left side (see page 20-30)
2. 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, 5E : Cushion TapeF : Clip, 1G : Clip, 2
LHD, 1 (LHD) LHD, 2
RHD, 3 RHD, 3

LHD:RHD:

3. 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

20-46
Frame
Frame Repair Chart

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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20-47

20-47
Frame
Frame Repair Chart (cont'd)

l Locate hole 25 (0.98) t For upper arm bracket centre 15 (0.59)


m For trailing arm 13 (0.51) u1, u2 Locate hole 13 (0.51)
n Locate hole 25 (0.98) v For upper arm 13 (0.51)
o Locate hole 20 (0.79) w Locate hole 25 (0.98)
p Trailing arm centre x For rear lower arm centre
q Rear damper centre 73 x 68 (Slot) y Locate hole 50 (1.97)
r For upper arm 13 (0.51) z Locate hole 20 (0.79)
s For trailing arm 13 (0.51)

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20-48

20-48
Frame
Frame Repair Chart (cont'd)

Side 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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20-49

20-49
Frame
Frame Repair Chart (cont'd)

l Locate hole 25 (0.98) t For upper arm bracket centre 15 (0.59)


m For trailing arm 13 (0.51) u1, u2 Locate hole 13 (0.51)
n Locate hole 25 (0.98) v For upper arm 13 (0.51)
o Locate hole 20 (0.79) w Locate hole 25 (0.98)
p Trailing arm centre x For rear lower arm centre
q Rear damper centre 73 x 68 (Slot) y Locate hole 50 (1.97)
r For upper arm 13 (0.51) z Locate hole 20 (0.79)
s For trailing arm 13 (0.51)

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20-5

20-5
Doors
Door panel removal/Installation (cont'd)

1. 6. Pull out the switch panel (A) to release the hook (B), 1. 8. Disconnect the inner handle cable (A) from the inner
then remove the panel from the door panel. handle (B) and if equipped, disconnect the power
Disconnect the power window switch connector (C) door lock switch connector (C). Take care not to
(except manual window). bend the cable.

2. 9. Detach the harness clip (A) from the door panel (B).

2. 7. Release the clips that hold the door panel (A) with a
commercially available trim pad remover (B), then
remove the door panel by pulling it upward. Remove
the door panel with as little bending as possible to
avoid creasing or breaking it.
Fastener Locations
: Clip, 9

3. 10. Install the door panel in the reverse order of removal


and note these items:
Replace any damaged clips.
Make sure the cable is connected securely and
the connector is plugged in properly.
Install the regulator handle so it points forward
with the glass fully closed.

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20-6

20-6
Doors
Door Outer Handle Replacement

NOTE: Put on gloves to protect your hands. 1. 4. On driver's and some passenger's: Release the
retainer clip (A), then remove the lock cylinder (B).
1. 1. Raise the glass fully.
Disconnect the cylinder rod (C).
2. Remove these items:
Door panel (see page 20-4)
Plastic cover, as necessary (see page 20-2)
2. 3. Pull the glass run channel (A) away as necessary
and remove the bolt, then remove the centre lower
channel (B) by pulling it downward.
Fastener Locations
: Bolt, 1

2. 5. With cylinder switch: Remove the screw, then


separate the lock cylinder (A) and cylinder switch (B).
Fastener Locations
: Screw, 1

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20-7

20-7
Doors
Door Outer Handle Replacement (cont'd)

1. 6. With cylinder switch: Disconnect the cylinder switch 1. 8. Disconnect the outer handle rod (A).
connector (A) and detach the harness clips (B), then Fastener Locations
remove the cylinder switch (C). : Bolt, 2

2. 7. On driver's and some passenger's: Release the


cylinder rod protector (A) from the latch (B).

2. 9. Remove the maintenance cap (B) and remove the


bolts securing the outer handle (C). Release the
hook (D), then remove the outer handle protector (E)
with the cylinder rod protector (F).
10. Pull out the outer handle (A), then remove it.

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20-8

Door 20-8
Latch Replacement
Doors
Door Outer Handle Replacement (cont'd)

1. 11. If necessary, remove the cylinder rod protector (A) NOTE: Put on gloves to protect your hands.
from the outer handle protector (B) by releasing the
1. 1. Raise the glass fully.
hook (C).
2. Remove these items:
Door panel (see page 20-4)
Plastic cover, as necessary (see page 20-2)
Centre lower channel (see step 3 on page 20-6)
2. 3. On driver's and some passenger's, disconnect the
cylinder rod (see step 4 on page 20-6).
4. If equipped, release the cylinder rod protector from
the latch (see step 7 on page 20-7).
5. Disconnect the outer handle rod (see step 8 on page
20-7).
6. Disconnect the actuator connector(s) (A) and for
some models, detach the harness clip (B) and
actuator connector. Release the inner handle cable
2. 12. Install the handle in the reverse order of removal and (C) from the door by detaching the cable clip (D).
note these items: KE model:
Make sure the cylinder switch harness is routed
properly (for some models).
Make sure the cylinder switch connector is
plugged in properly (for some models) and each
rod is connected securely.
Make sure the door locks and opens properly.
When installing the lock cylinder, leave the outer
door handle bolts loose so the inner protector
does not interfere with the lock cylinder, then
tighten the handle bolts.
Install the lock cylinder retaining clip on the
handle, then install the lock cylinder. Be sure the
clip is fully seated in the slot on the lock cylinder.

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20-9

20-9
Doors
Door Latch Replacement (cont'd)

Except KE model: aaa

1. 7. Remove the screws, then remove the latch (A)


through the hole in the door. Take care not to
bend the outer handle rod (B), cylinder rod (C),
lock rod (D) and inner handle cable (E).
Fastener Locations
: Screw, 3

2. 8. Install the latch in the reverse order of removal


and note these items:
Make sure the actuator connector(s) is/are
plugged in properly, and each rod is
connected securely.
Make sure the door locks and opens
properly.

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2-1


Specifications

Standards and Service Limits


Engine Electrical 2-2
Engine Assembly 2-2
Cylinder Head 2-3
Engine Block 2-4
Engine Lubrication 2-5
Cooling 2-5
Fuel and Emissions 2-6
Clutch 2-6
Manual Transmission and Differential 2-7
Automatic Transmission and Differential 2-9
CVT and Differential 2-15
Steering 2-20
Suspension 2-20
Brakes 2-21
Air Conditioning 2-21

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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2-10

2-10
Standards and Service Limits
Automatic Transmission and Differential
(cont'd)

Item Measurement Qualification Standard or New Service Limit


Clutch Clutch end plate-to-top 1st and 2nd 0.65-0.85 mm
disc clearance (0.026-0.033 in.)
3rd and 4th 0.4-0.6 mm
(0.016-0.024 in.)
1st-hold 0.5-0.8 mm
(0.020-0.031 in.)
Clutch return spring free 1st, 2nd, 3rd and 30.5 mm (1.20 in.) 28.5 mm (1.12 in.)
length 4th
1st-hold 34.6 mm (1.36 in.) 32.6 mm (1.28 in.)
Clutch disc thickness 1.94 mm (0.076 in.) -
Clutch plate thickness 1st, 1st-hold 1.6 mm (0.06 in.) When discoloured
2nd, 3rd and 4th 2.0 mm (0.079 in.) When discoloured
1st, 2nd, 3rd and 4th clutch Mark 1 2.1 mm (0.083 in.) When discoloured
end plate thickness Mark 2 2.2 mm (0.087 in.) When discoloured
Mark 3 2.3 mm (0.091 in.) When discoloured
Mark 4 2.4 mm (0.094 in.) When discoloured
Mark 5 2.5 mm (0.098 in.) When discoloured
Mark 6 2.6 mm (0.102 in.) When discoloured
Mark 7 2.7 mm (0.106 in.) When discoloured
Mark 8 2.8 mm (0.110 in.) When discoloured
Mark 9 2.9 mm (0.114 in.) When discoloured
1st-hold clutch end plate Mark 1 2.1 mm (0.083 in.) When discoloured
thickness Mark 2 2.2 mm (0.087 in.) When discoloured
Mark 3 2.3 mm (0.091 in.) When discoloured
Mark 4 2.4 mm (0.094 in.) When discoloured
No Mark 2.5 mm (0.098 in.) When discoloured
Mark 6 2.6 mm (0.102 in.) When discoloured
Mark 7 2.7 mm (0.106 in.) When discoloured

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2-11

2-11
Standards and Service Limits
Automatic Transmission and Differential
(cont'd)

Item Measurement Qualification Standard or New Service Limit


Mainshaft Diameter of needle bearing at stator shaft 22.980-22.993 mm (0.9047-0.9052 in.) When worn or damaged
contact area at 2nd gear 35.975-35.991 mm (1.4163-1.4169 in.) When worn or damaged
at 4th gear collar 31.975-31.991 mm (1.2589-1.2595 in.) When worn or damaged
at 1st gear collar 30.975-30.991 mm (1.2195-1.2201 in.) When worn or damaged
I.D. of gears 1st gear 35.000-35.016 mm (1.3780-1.3786 in.) When worn or damaged
2nd gear 41.000-41.016 mm (1.6142-1.6148 in.) When worn or damaged
4th gear 38.000-38.016 mm (1.4961-1.4967 in.) When worn or damaged
End play of gears 1st gear 0.08-0.19 mm (0.003-0.007 in.) -
2nd gear 0.05-0.13 mm (0.002-0.005 in.) -
4th gear 0.075-0.185 mm (0.003-0.007 in.) -
4th gear collar length 49.50-49.55 mm (1.9488-1.9508 in.) -
4th gear collar flange 4.435-4.525 mm (0.1746-0.1781 in.) -
thickness
1st gear collar length 27.00-27.05 mm (1.063-1.065 in.) -
36.5 x 55 mm thrust No. 1 4.00 mm (0.157 in.) When worn or damaged
washer thickness No. 2 4.05 mm (0.159 in.) When worn or damaged
No. 3 4.10 mm (0.161 in.) When worn or damaged
No. 4 4.15 mm (0.163 in.) When worn or damaged
No. 5 4.20 mm (0.165 in.) When worn or damaged
No. 6 4.25 mm (0.167 in.) When worn or damaged
No. 7 4.30 mm (0.169 in.) When worn or damaged
No. 8 4.35 mm (0.171 in.) When worn or damaged
No. 9 4.40 mm (0.173 in.) When worn or damaged
No. 10 4.45 mm (0.175 in.) When worn or damaged
Thrust washer thickness 26 x 45 x 3 mm 2.95-3.05 mm (0.116-0.120 in.) When worn or damaged
1st gear, 26 mm 2.43-2.50 mm (0.096-0.098 in.) When worn or damaged
Clutch feed pipe O.D. 1st clutch feed pipe 8.97-8.98 mm (0.535-0.354 in.) 8.95 mm (0.352 in.)
at 15 mm (0.6 in.)
from end
4th clutch feed pipe 5.97-5.98 mm (0.2350-0.2354 in.) 5.95 mm (0.234 in.)
at 30 mm (1.2 in.)
from end
Sealing ring thickness 35 mm sealing ring 1.87-1.97 mm (0.074-0.078 in.) 1.8 mm (0.071 in.)
29 mm sealing ring 1.87-1.97 mm (0.074-0.078 in.) 1.8 mm (0.071 in.)
Clutch feed pipe bushing 1st clutch 9.000-9.015 mm (0.3543-0.3549 in.) 9.03 mm (0.356 in.)
I.D. 4th clutch 6.018-6.030 mm (0.2369-0.2374 in.) 6.045 mm (0.2380 in.)
Width of sealing ring 2.025-2.075 mm (0.0797-0.0811 in.) 2.095 mm (0.082 in.)
groove

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2-12

2-12
Standards and Service Limits
Automatic Transmission and Differential
(cont'd)

Item Measurement Qualification Standard or New Service Limit


Countershaft Diameter of needle bearing at left end 36.004-36.017 mm When worn or damaged
contact area (1.4175-1.4180 in.)
at 3rd gear 35.980-35.996 mm When worn or damaged
(1.4165-1.4172 in.)
at 4th gear 27.980-27.993 mm When worn or damaged
(1.1016-1.1021 in.)
at reverse gear 31.975-31.991 mm When worn or damaged
collar (1.2589-1.2595 in.)
at 1st gear collar 31.975-31.991 mm When worn or damaged
(1.2589-1.2595 in.)
I.D. of gears 1st gear 38.000-38.016 mm When worn or damaged
(1.4961-1.4967 in.)
3rd gear 41.000-41.016 mm When worn or damaged
(1.6142-1.6148 in.)
4th gear 33.000-33.016 mm When worn or damaged
(1.2992-1.2998 in.)
Reverse gear 38.000-38.016 mm When worn or damaged
(1.4961-1.4967 in.)
End play of gears 1st gear 0.1-0.5 mm (0.004-0.020 in.) -
3rd gear 0.05-0.17 mm (0.002-0.007 in.) -
4th gear 0.10-0.18 mm (0.004-0.007 in.) -
Reverse gear 0.10-0.25 mm (0.004-0.010 in.) -
28 mm distance collar No. 1 39.00 mm (1.535 in.) -
length No. 2 39.10 mm (1.539 in.) -
No. 3 39.20 mm (1.543 in.) -
No. 4 39.30 mm (1.547 in.) -
No. 5 39.05 mm (1.537 in.) -
No. 6 39.15 mm (1.541 in.) -
No. 7 39.25 mm (1.545 in.) -
No. 8 38.90 mm (1.531 in.) -
No. 9 38.95 mm (1.533 in.) -
3rd gear collar length 20.65-20.70 mm (0.8130-0.8150 in.) -
Reverse gear collar length 14.5-14.6 mm (0.571-0.575 in.) -
Reverse gear collar flange 2.4-2.6 mm (0.094-0.102 in.) When worn or damaged
thickness
1st gear collar length 14.5-14.6 mm (0.571-0.575 in.) -
1st gear collar flange 2.4-2.6 mm (0.094-0.102 in.) When worn or damaged
thickness
3rd gear splined washer 4.95-5.00 mm (0.195-0.197 in.) When worn or damaged
thickness
3rd clutch feed pipe O.D. At 15 mm (0.6 in.) 7.97-7.98 mm (0.3138-0.3142 in.) 7.95 mm (0.313 in.)
from end
3rd clutch feed pipe 8.000-8.022 mm (0.3150-0.3158 in.) 8.03 mm (0.316 in.)
bushing I.D.
Reverse selector hub O.D. 51.87-51.90 mm (2.042-2.043 in.) When worn or damaged
1st gear I.D. of one-way 83.339-83.365 mm (3.2810-3.2821 in.) When worn or damaged
clutch contact area
Park gear diameter of one- 66.685-66.698 mm (2.6254-2.6259 in.) When worn or damaged
way clutch contact area

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2-12

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2-13

2-13
Standards and Service Limits
Automatic Transmission and Differential
(cont'd)

Item Measurement Qualification Standard or New Service Limit


Reverse idler gear Reverse idler gear shaft 13.990-14.000 mm When worn or damaged
diameter at needle bearing (0.5508-0.5512 in.)
contact area
I.D. 18.007-18.020 mm When worn or damaged
(0.7089-0.7094 in.)
End play 0.05-0.18 mm (0.002-0.007 in.) -
I.D. of reverse idler gear 14.416-14.434 mm When worn or damaged
shaft holder (0.5676-0.5683 in.)
Sub-shaft Diameter of needle bearing at transmission 25.991-26.000 mm When worn or damaged
contact area housing (1.023-1.024 in.)
at 4th gear collar 23.9935-23.0065 mm When worn or damaged
(0.9446-0.9058 in.)
4th gear I.D. 32.000-32.016 mm When worn or damaged
(1.2600-1.2605 in.)
4th gear and play 0.05-0.17 mm -
(0.002-0.007 in.)
4th gear collar length 24.0-24.1 mm -
(0.945-0.949 in.)
4th gear collar flange 2.95-3.10 mm When worn or damaged
thickness (0.116-0.122 in.)
4th gear thrust washer 2.93-3.00 mm When worn or damaged
thickness (0.115-0.118 in.)
1st-clutch feed pipe O.D. at 15 mm (0.6 in.) 7.97-7.98 mm 7.95 mm (0.313 in.)
from end (0.3138-0.3142 in.)

Item Measurement Qualification Standard or New


Wire Diameter O.D. Free Length No. of Coil
Main valve body Relief valve spring 1.1 mm 8.6 mm 37.1 mm 13.4
springs, refer to the (0.043 in.) (0.339 in.) (1.416 in.)
'01 Civic Shop
Modulator valve spring 1.4 mm 9.4 mm 33.8 mm 10.9
Manual on this CD
(see page 14-183) (0.055 in.) (0.370 in.) (1.331 in.)
CPB valve spring 1.0 mm 8.1 mm 40.9 mm 16.2
(0.039 in.) (0.319 in.) (1.610 in.)
1-2 shift valve spring 0.9 mm 7.6 mm 41.3 mm 16.3
(0.035 in.) (0.299 in.) (1.626 in.)
2nd orifice control valve 0.7 mm 6.6 mm 34.8 mm 22.0
spring (0.028 in.) (0.260 in.) (1.370 in.)
Servo control valve spring 1.0 m 8.1 mm 52.1 mm 20.8
(0.039 in.) (0.319 in.) (2.051 in.)
Regulator valve Stator reaction spring 4.5 mm 35.4 mm 30.3 mm 1.9
body springs, refer (0.177 in.) (1.394 in.) (1.193 in.)
to the '01 Civic
Regulator valve spring A 1.9 mm 14.7 mm 77.4 mm 15.2
Shop Manual on
this CD (see page (0.075 in.) (0.579 in.) (3.047 in.)
14-186) Regulator valve spring B 1.8 mm 9.6 mm 44.0 mm 12.6
(0.071 in.) (0.378 in.) (1.732 in.)
Cooler relief valve spring 1.0 mm 8.4 mm 33.8 mm 8.2
(0.039 in.) (0.331 in.) (1.331 in.)
Torque converter check 1.0 mm 8.4 mm 33.8 mm 8.2
valve spring (0.039 in.) (0.331 in.) (1.331 in.)

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2-13

Lock-up control valve 0.8 mm 6.0 mm 38.4 mm 30.3


spring (0.031 in.) (0.236 in.) (1.512 in.)

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2-14

2-14
Standards and Service Limits
Automatic Transmission and Differential
(cont'd)

Item Measurement Qualification Standard or New


Wire Diameter O.D. Free Length No. of Coil
Secondary valve 3-4 shift valve spring 0.9 mm 7.6 mm 57.0 mm 26.8
body springs, refer (0.035 in.) (0.299 in.) (2.244 in.)
to the '01 Civic
2-3 shift valve spring 0.9 mm 7.6 mm 57.0 mm 26.8
Shop Manual on
this CD (see page (0.035 in.) (0.299 in.) (2.244 in.)
14-187) 4th exhaust valve spring 0.9 mm 6.1 mm 36.4 mm 19.5
(0.035 in.) (0.240 in.) (1.433 in.)
3-4 orifice control valve 0.7 mm 6.6 mm 37.5 mm 24.6
spring (0.028 in.) (0.260 in.) (1.476 in.)
Servo body springs, 1st accumulator spring 2.1 mm 16.0 mm 89.1 mm 16.2
refer to the '01 Civic (0.083 in.) (0.630 in.) (3.508 in.)
5-door Shop
4th accumulator spring A 2.6 mm 17.0 mm 88.4 mm 14.2
Manual on this CD
(see page 14-94) (0.102 in.) (0.669 in.) (3.480 in.)
4th accumulator spring B 2.3 mm 10.2 mm 51.6 mm 13.8
(0.091 in.) (0.402 in.) (2.031 in.)
3rd accumulator spring A 2.8 mm 17.5 mm 94.3 mm 15.6
(0.110 in.) (0.689 in.) (3.713 in.)
3rd accumulator spring B 2.1 mm 31.0 mm 38.2 mm 2.4
(0.083 in.) (1.220 in.) (1.504 in.)
2nd accumulator spring C 2.2 mm 14.5 mm 68.0 mm 13.9
(0.087 in.) (0.571 in.) (2.677 in.)
2nd accumulator spring A 2.4 mm 29.0 mm 39.0 mm 2.9
(0.094 in.) (1.142 in.) (1.535 in.)
Lock-up valve body Lock-up shift valve spring 0.9 mm 7.6 mm 73.7 mm 32.0
springs, refer to the (0.035 in.) (0.299 in.) (2.902 in.)
'01 Civic Shop
Lock-up timing valve 0.9 mm 8.1 mm 80.7 mm 54.2
Manual on this CD
spring (0.035 in.) (0.319 in.) (3.177 in.)
(see page 14-189)

Item Measurement Qualification Standard or New Service Limit


A/T differential Pinion shaft contact area 18.010-18.028 mm -
carrier I.D. (0.709-0.710 in.)
Carrier-to-pinion shaft 0.023-0.057 mm 0.1 mm (0.004 in.)
clearance (0.001-0.002 in.)
Driveshaft contact area 26.025-26.045 mm -
I.D. (1.0246-1.0254 in.)
Carrier-to-driveshaft 0.045-0.086 mm 0.12 mm
clearance (0.002-0.003 in.) (0.005 in.)
Set ring-to-carrier bearing 0-0.15 mm Adjust
outer race clearance (0-0.006 in)
A/T differential Backlash 0.05-0.15 mm -
pinion gear (0.002-0.006 in.)
I.D. 18.042-18.066 mm -
(0.7103-0.7113 in.)
Pinion gear-to-pinion shaft 0.055-0.095 mm 0.15 mm (0.006 in.)
clearance (0.0022-0.0037 in.)

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2-15

2-15
Standards and Service Limits
CVT and Differential

Item Measurement Qualification Standard or New Service Limit


CVT Fluid Capacity Use genuine Honda For fluid change: 3.1 l (3.3 US qt, 2.7 lmp qt)
ATF-Z1 For overhaul: 5.6 l (5.9 US qt, 4.9 lmp qt)
Hydraulic pressure Forward clutch pressure At 1,500 rpm (min - 1.4-1.75 MPa
1) in position (14.3-17.8 kgf/cm 2 , 203-253 psi)
Reverse brake pressure At 1,500 rpm (min - 1.4-1.75 MPa
1) in position (14.3-17.8 kgf/cm 2 , 203-253 psi)
Drive pulley pressure At 1,500 rpm (min - 0.2-0.7 MPa
1) in position (2.0-7.1 kgf/cm 2 , 28-101 psi)
Driven pulley pressure At 1,500 rpm (min - 1.5-2.3 MPa
1) in position (15.3-23.5 kgf/cm 2 , 218-334 psi)
Lubrication pressure At 3,000 rpm (min - Above 0.2 MPa
1) in position (Above 0.2 kgf/cm 2 , 30 psi)
Torque converter Stall speed
In position 2,500 rpm (min -1 ) 2,350-2,650 rpm (min -1 )
Check with vehicle on
In , and 2,800 rpm (min -1 ) 2,600-2,900 rpm (min -1 )
level ground
positions
ATF pump ATF pump drive gear shaft 9.98-9.99 mm (0.3929-0.3933 in.) When worn or damaged
O.D.
ATF pump driven gear 9.98-9.99 mm (0.3929-0.3933 in.) When worn or damaged
shaft O.D.
ATF pump body bushing Drive gear shaft 10.0-10.015 mm (0.3937-0.3944 in.) When worn or damaged
I.D. Driven gear shaft 10.0-10.015 mm (0.3937-0.3944 in.) When worn or damaged
ATF pump gear side 0.015-0.035 mm (0.0006-0.0014 in.) -
clearance
ATF pump gear-to-body Drive gear 0.035-0.0505 mm (0.0014-0.0020 in.) -
clearance Driven gear 0.035-0.0505 mm (0.0014-0.0020 in.) -

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2-16

2-16
Standards and Service Limits
CVT and Differential (cont'd)

Item Measurement Qualification Standard or New Service Limit


Clutch Clutch end plate-to-top Forward clutch 0.6-0.8 mm -
disc clearance (0.024-0.031 in.)
Start clutch 0.5-0.7 mm -
(0.020-0.028 in.)
Reverse brake 0.45-0.75 mm -
(0.018-0.030 in.)
Clutch return spring free Forward clutch 30.5 mm (1.20 in.) 28.5 mm (1.12 in.)
length Start clutch 40.9 mm (1.61 in.) 38.9 mm (1.53 in.)
Reverse brake 29.4 mm (1.16 in.) 27.4 mm (1.08 in.)
Clutch disc thickness Forward clutch 1.94 mm (0.076 in.) -
Start clutch 1.94 mm (0.076 in.) -
Reverse brake 2.00 mm (0.79 in.) -
Clutch plate thickness Forward clutch 2.00 mm (0.079 in.) When discoloured
Start clutch 2.3 mm (0.091 in.) When discoloured
Reverse brake 1.35 mm (0.053 in.) When discoloured
Forward clutch end plate Mark 14 3.4 mm (0.134 in.) When discoloured
Mark 15 3.5 mm (0.138 in.) When discoloured
Mark 16 3.6 mm (0.142 in.) When discoloured
Mark 17 3.7 mm (0.146 in.) When discoloured
Mark 18 3.8 mm (0.150 in.) When discoloured
Mark 19 3.9 mm (0.154 in.) When discoloured
Mark 20 4.0 mm (0.157 in.) When discoloured
Mark 21 4.1 mm (0.161 in.) When discoloured
Mark 22 4.2 mm (0.165 in.) When discoloured
Mark 23 4.3 mm (0.169 in.) When discoloured
Mark 24 4.4 mm (0.173 in.) When discoloured
Mark 25 4.5 mm (0.177 in.) When discoloured
Mark 26 4.6 mm (0.181 in.) When discoloured
Mark 27 4.7 mm (0.185 in.) When discoloured
Reverse brake end plate Mark 1 3.6 mm (0.142 in.) When discoloured
Mark 2 3.8 mm (0.150 in.) When discoloured
Mark 3 4.0 mm (0.157 in.) When discoloured
Mark 4 4.2 mm (0.165 in.) When discoloured
Mark 5 4.4 mm (0.173 in.) When discoloured
Mark 6 4.6 mm (0.181 in.) When discoloured
Mark 7 4.8 mm (0.189 in.) When discoloured
Mark 8 5.0 mm (0.197 in.) When discoloured

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2-17

2-17
Standards and Service Limits
CVT and Differential (cont'd)

Item Measurement Qualification Standard or New Service Limit


Input shaft Diameter of needle bearing Flywheel side 19.987-20.000 mm When worn or damaged
contact area (0.7869-0.7874 in.)
Forward clutch side 19.987-20.000 mm When worn or damaged
(0.7869-0.7874 in.)
Thrust clearance ATF pump driven 0.37-0.65 mm -
sprocket hub (0.015-0.026 in.)
Planetary carrier 0.05-0.11 mm -
(0.002-0.0043 in.)
Feed pipe O.D. Drive pulley feed 6.97-6.98 mm 6.95 mm (0.274)
pipe (0.274-0.275 in.)
Forward clutch feed 11.47-11.48 mm 11.45 mm (0.451 in.)
pipe (0.4516-0.4520 in.)
Feed pipe bushing I.D. Drive pulley feed 7.00-7.015 mm 7.030 mm (0.277 in.)
pipe (0.2756-0.2762 in.)
Forward clutch feed 11.5-11.518 mm 11.533 mm (0.454 in.)
pipe (0.4528-0.4535 in.)
Sealing ring groove width 2.00-2.10 mm 2.105 mm (0.083 in.)
(0.079-0.083 in.)
Thrust shim, 22 x 28 mm C 1.15 mm (0.045 in.) When worn or damaged
thickness (ATF pump D 1.40 mm (0.055 in.) When worn or damaged
driven sprocket hub)
E 1.65 mm (0.065 in.) When worn or damaged
F 1.90 mm (0.075 in.) When worn or damaged
G 2.15 mm (0.085 in.) When worn or damaged
H 2.40 mm (0.095 in.) When worn or damaged
Thrust shim, 25 x 31 mm A 1.050 mm (0.041 in.) When worn or damaged
thickness (Planetary B 1.12 mm (0.044 in.) When worn or damaged
carrier)
C 1.19 mm (0.047 in.) When worn or damaged
D 1.26 mm (0.050 in.) When worn or damaged
E 1.33 mm (0.052 in.) When worn or damaged
F 1.40 mm (0.055 in.) When worn or damaged
G 1.47 mm (0.058 in.) When worn or damaged
H 1.54 mm (0.061 in.) When worn or damaged
I 1.61 mm (0.063 in.) When worn or damaged
J 1.68 mm (0.066 in.) When worn or damaged
K 1.75 mm (0.069 in.) When worn or damaged
L 1.82 mm (0.072 in.) When worn or damaged
M 1.085 mm (0.0427 in.) When worn or damaged
N 1.155 mm (0.0454 in.) When worn or damaged
O 1.225 mm (0.0482 in.) When worn or damaged
P 1.295 mm (0.0510 in.) When worn or damaged
Q 1.365 mm (0.0537 in.) When worn or damaged
R 1.435 mm (0.0565 in.) When worn or damaged
S 1.505 mm (0.0593 in.) When worn or damaged
T 1.575 mm (0.0620 in.) When worn or damaged
U 1.645 mm (0.0648 in.) When worn or damaged
V 1.715 mm (0.0675 in.) When worn or damaged
W 1.785 mm (0.0703 in.) When worn or damaged

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2-18

2-18
Standards and Service Limits
CVT and Differential (cont'd)

Item Measurement Qualification Standard or New Service Limit


Drive pulley shaft Diameter of needle bearing Flywheel side 24.007-24.020 mm (0.945-0.946 in.) When worn or damaged
contact area Forward clutch side 24.007-24.020 mm (0.945-0.946 in.) When worn or damaged
I.D. at sealing ring 24.007-24.020 mm (0.945-0.946 in.) When worn or damaged
Driven pulley shaft Diameter of needle bearing Start clutch side 43.981-43.991 mm (1.7315-1.7319 in.) When worn or damaged
contact area
Thrust clearance Start clutch side 0-0.13 mm (0-0.005 in.) -
Cotter, 25.5 mm thickness A 2.90 mm (0.114 in.) When worn or damaged
(Start clutch hub) B 3.00 mm (0.118 in.) When worn or damaged
C 3.10 mm (0.122 in.) When worn or damaged
D 3.20 mm (0.126 in.) When worn or damaged
Start clutch feed pipe O.D. End cover side 6.97-6.98 mm (0.274-0.275 in.) 6.95 mm (0.274 in.)
Flywheel housing 8.97-8.98 mm (0.353-0.354 in.) 8.95 mm (0.352 in.)
side
Driven pulley shaft feed 11.47-11.48 mm (0.4516-0.4520 in.) 11.45 mm (0.451 in.)
pipe O.D.
Start clutch feed pipe End cover side 7.00-7.015 mm (0.2756-0.2762 in.) 7.030 mm (0.277 in.)
bushing I.D. Flywheel housing 9.0-9.015 mm (0.354-0.355 in.) 9.03 mm (0.356 in.)
side
Driven pulley shaft feed 11.50-11.518 mm (0.4528-0.4535 in.) 11.533 mm (0.454 in.)
pipe bushing I.D.
Start clutch end plate I.D. 88.90-88.935 mm (3.500-3.501 in.) When worn or damaged
Secondary gear Thrust clearance 0-0.15 mm (0-0.006 in.) -
shaft Thrust shim, 25 x 35 mm A 2.80 mm (0.110 in.) When worn or damaged
thickness B 2.90 mm (0.114 in.) When worn or damaged
C 3.00 mm (0.118 in.) When worn or damaged
D 3.10 mm (0.122 in.) When worn or damaged
E 3.20 mm (0.126 in.) When worn or damaged
F 3.30 mm (0.130 in.) When worn or damaged
G 3.40 mm (0.134 in.) When worn or damaged
H 3.50 mm (0.138 in.) When worn or damaged
I 3.60 mm (0.142 in.) When worn or damaged
J 3.70 mm (0.146 in.) When worn or damaged
K 3.80 mm (0.150 in.) When worn or damaged
Sealing ring groove width 2.50-2.65 mm (0.098-0.104 in.) 2.655 mm (0.105 in.)
Park gear and pawl When worn or damaged

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2-19

2-19
Standards and Service Limits
CVT and Differential (cont'd)

Item Measurement Qualification Standard or New Service Limit


CVT differential Pinion shaft contact area 18.010-18.028 mm -
carrier I.D. (0.709-0.710 in.)
Carrier-to-pinion shaft 0.023-0.057 mm 0.1 mm (0.004 in.)
clearance (0.001-0.002 in.)
Driveshaft contact area 26.025-26.045 mm -
I.D. (1.0246-1.0254 in.)
Carrier-to-driveshaft 0.045-0.086 mm 0.12 mm (0.005 in.)
clearance (0.002-0.003 in.)
Set ring-to-carrier bearing 0-0.15 mm Adjust
outer race clearance (0-0.006 in.)
CVT differential Backlash 0.08-0.15 mm -
pinion gear (0.003-0.006 in.)
I.D. 18.042-18.066 mm -
(0.7103-0.7113 in.)
Pinion gear-to-pinion shaft 0.055-0.095 mm 0.15 mm (0.006 in.)
clearance (0.0022-0.0037 in.)

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2-2

2-2
Standards and Service Limits
Engine Electrical

Item Measurement Qualification Standard or New Service Limit


Ignition coil Rated voltage 12 V
Firing order 1-3-4-2
Spark plug Type NGK: ZFR5J-11,
ZFR6J-11
DENSO: KJ16CR-L11,
KJ20CR-L11
Gap 1.0-1.1 mm (0.039-0.043 in.) -
Ignition timing At idle (check the red M/T (in neutral): 8 2 BTDC at 700 50 rpm (min -1 )
mark)
A/T (in or ): 8 2 BTDC at 700 50 rpm (min -1 )
Alternator belt Deflection with 98 N (10 Without A/C (with A/C, Used belt: 8.5-11.0 mm (0.33-0.43 in.)
NOTE: Adjust a kgf, 22 lbs) applied midway see ''Compressor belt'' New belt: 6.5-8.5 mm (0.26-0.33 in.)
new belt to the new between pulleys in the A/C table)
belt spec., run the Tension (measured with Without A/C (with A/C, Used belt: 340-490 N (35-55 kgf, 77-110 lbs)
engine for 5 belt tension gauge) see ''Compressor belt'' New belt: 540-740 N (55-75 kgf, 120-170 lbs)
minutes, then in the A/C table)
readjust it to the
used belt spec.
Alternator Output At 13.5 V and normal 70 A
engine 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, Output 0.8 kW
D16V1 (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 Output 1.0 kW
(KG, KR, KS Commutator mica depth 0.50-0.75 mm (0.020-0.030 in.) 0.2 mm (0.008 in.)
models) engine with
Commutator runout 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.)
A/T (DENSO)
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 Output 1.0 kW
(KG, KR, KS Commutator mica depth 0.50-0.90 mm (0.020-0.035 in.) 0.2 mm (0.008 in.)
models) engine with
Commutator runout 0.01 mm (0.0004 in.) max. 0.015 mm (0.0006 in.)
M/T (VALEO)
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 Minimum 930 kPa (9.5 kgf/cm 2 , 135 psi) -
(min -1 ) with wide open Maximum variation 200 kPa (2.0 kgf/cm 2 , 28 psi) -
throttle. (See Design
Specs for ratio.)

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22-0


Body Electrical

Wire Harness and Ground Locations 22-2

Ground Distribution
Ground Identification 22-3

Exterior Lights
Taillight Replacement 22-4
High Mount Brake Light Replacement 22-4

Power Windows
Circuit Diagram 22-5
Master Switch Input Test 22-6
Master Switch Test 22-8
Master Switch Replacement 22-9
Passenger's Switch Replacement 22-9

Power Mirrors
Power Mirror Switch Test 22-10
Power Mirror Actuator Replacement 22-11

Wipers/Washers
Washer Motor Test 22-13
Headlight Washer Nozzle Replacement 22-13

Outline of Model Changes


3-door model has been added; related information is included.
The information in which differ from the '01 Civic Shop Manual on this CD has been included.

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2-20

2-20
Standards and Service Limits
Steering

Item Measurement Qualification Standard or New Service Limit


Steering wheel Rotational play measured With engine running 0-10 mm (0-0.39 in.) -
at outside edge
Starting load measured at With engine running 29 N (3.0 kgf, 6.6 lbs) -
outside edge
Gearbox Angle of rack guide screw 20 Max.
loosened from locked
position
Pump Output pressure with shut- Engine speed at 7,600-8,300 kPa (78-85 kgf/cm 2 , 1,110-1,210 psi)
off valve closed 3,000 rpm (min -1 ) 290-1,100 kPa (3-11 kgf/cm 2 , 43-156 psi)
Power steering fluid Capacity Use Genuine Honda For reservoir capacity: 0.3 l (0.32 US qt, 0.26 lmp qt)
power steering fluid For system capacity: 1.0 l (1.06 US qt, 0.88 lmp qt)
Power steering Deflection with 98 N (10 Used belt: 13.0-16.5 mm (0.51-0.65 in.)
pump belt kgf, 22 lbs) applied mid- New belt: 9.0-11.0 mm (0.35-0.43 in.)
NOTE: Adjust a way between pulleys
new belt to the Tension (measured with Used belt: 390-540 N (40-55 kgf, 88-121 lbs)
new belt spec, run belt tension gauge) New belt: 740-880 N (75-90 kgf, 165-198 lbs)
the engine for 5
minutes, then
readjust it to the
used belt spec.

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.)
Front wheel turning angle Inside wheel 4000' 2
Outside wheel 3100' (Reference)
Aluminium wheel Runout Axial 0-0.7 mm (0-0.03 in.) 2.0 mm (0.08 in.)
Radial 0-0.7 mm (0-0.03 in.) 1.5 mm (0.06 in.)
Steel wheel Runout Axial 0-1.0 mm (0-0.04 in.) 2.0 mm (0.08 in.)
Radial 0-1.0 mm (0-0.04 in.) 1.5 mm (0.06 in.)
Wheel bearings End play Front 0-0.05 mm (0-0.002 in.)
Rear 0-0.05 mm (0-0.002 in.)

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22-1


SRS
Supplemental Restraint System (SRS)

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If electrical maintenance is required)


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 and some models include side airbags in the front seat-backs.
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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2-21

2-21
Standards and Service Limits
Brakes

Item Measurement Qualification Standard or New Service Limit


Parking brake lever Distance travelled when 8-9 clicks
pulled with 196 N (20 kgf,
44 lbs) of force
Brake pedal Pedal height (Carpet M/T 180 mm (7.09 in.)
removed) A/T 184 mm (7.24 in.)
Free play 0.4-3.0 mm (0.016-0.118 in.)
Master cylinder Piston-to-pushrod 0-0.4 mm (0-0.02 in.)
clearance
Brake disc Thickness Front 20.9-21.1 mm (0.82-0.83 in.) 19.0 mm (0.75 in.)
Rear 9.9-10.1 mm (0.390-0.398 in.) 8.0 mm (0.31 in.)
Runout - 0.10 mm (0.004 in.)
Parallelism - 0.015 mm (0.0006 in.)
Brake pads Thickness Front 11.0-11.7 mm (0.43-0.46 in.) 1.6 mm (0.06 in.)
Thickness Rear 8.3-9.0 mm (0.33-0.35 in.) 1.6 mm (0.06 in.)
Brake drum I.D. 219.9-220.0 mm (8.657-8.661 in.) 221 mm (8.701 in.)
Brake shoes Lining thickness 4.5 mm (0.18 in.) 2.0 mm (0.08 in.)
Brake booster Characteristics at 196 N Vacuum N (kgf, lbf) kPa (kgf/cm 2 , psi)
Vehicle with ABS (20 kgf, 44 lbf) pedal kPa (mmHg, inHg)
force
0 (0, 0) 98 (10, 22) 0 (0, 0)
294 (30, 66) 1700 (17, 240)
66.7 (500, 19.7) 98 (10, 22) 4600 (47, 670)
294 (30, 66) 10500 (107, 1500)
Brake booster Characteristics at 196 N Vacuum N (kgf, lbf) kPa (kgf/cm 2 , psi)
Vehicle without ABS (20 kgf, 44 lbf) pedal kPa (mmHg, inHg)
force
0 (0, 0) 98 (10, 22) 0 (0, 0)
294 (30, 66) 1700 (17, 240)
66.7 (500, 19.7) 98 (10, 22) 4400 (45, 640)
294 (30, 66) 10500 (107, 1500)

Air Conditioning
Item Measurement Qualification Standard or New
Refrigerant Type HFC-134 a (R-134 a)
Capacity or system 500-550 g (17.6-19.4 oz)
Refrigerant oil Type SANDEN: SP-10 (P/N 38897-P13-003 or 38899-P13-A01)
Capacity of components Condenser 25 mI (5/6 fl oz, 0.9 lmp oz)
Evaporator 45 ml (1 1/2 fl oz, 1.3 lmp oz)
Each line and hose 10 ml (1/3 fl oz, 0.4 lmp oz)
Receiver 10 ml (1/3 fl oz, 0.4 lmp oz)
Compressor 130-150 ml (4 1/3 fl oz, 3.7 lmp oz-5 fl oz, 4.5 lmp oz)
Compressor Starter coil resistance at 68F (20C) 3.05-3.35 ohms
Pulley-to-pressure plate 0.5 0.15 mm (0.02 0.006 in.)
clearance
Compressor belt Deflection with 98 N (10 Used belt: 8.5-11.0 mm (0.33-0.43 in.)
NOTE: Adjust a kgf, 22 lbs) applied mid- New belt: 5.0-6.5 mm (0.20-0.26 in.)
new belt to the way between pulleys
new belt spec., run Tension (measured with Used belt: 440-590 N (45-60 kgf, 100-130 lbs)
the engine for 5 belt tension gauge) New belt: 930-1,125 N (95-115 kgf, 210-255 lbs)
minutes, then
readjust it to the
used belt spec.

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22-10

22-10
Power Mirrors
Power Mirror Switch Test

1. 1. Carefully push out the power mirror switch (A) from 1. 3. Check for continuity between the terminals in each
behind the dashboard. switch position according to the table.

2. 2. Disconnect the 13P connector (B) from the switch.

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22-11

22-11
Power Mirrors
Power Mirror Actuator Replacement

1. 1. Remove the mirror holder and disconnect the mirror 1. 6. Remove the three Torx screws using a Torx T10 bit,
defogger connectors*, refer to the '01 Civic Shop then remove the actuator (A).
Manual on this CD, P/N 62S5A00 (see page 20-35).
*: With defogger
2. Remove the power mirror, refer to the '01 Civic Shop
Manual on this CD, P/N 62S5A00 (see page 20-170).
3. Disconnect the 6P connector (A) from the mirror and
record the terminal locations and wire colours.

Installation:
2. 7. Route the wire harness (A) of the new actuator
through the hole in the bracket.

2. 4. Cut the wire harness with wire cutters, and remove


the gasket.
5. Remove the three screws from under the mirror.

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22-12

22-12
Power Mirrors
Power Mirror Actuator Replacement (cont'd)

1. 8. Insert the terminal into the connector as shown aaa


below:

2. 9. Seal the intersection of wire harness with tape.


10. Reassemble in the reverse order of disassembly. Be
careful not to break the mirror when reinstalling into
the actuator.
11. Reinstall the mirror assembly onto the door.
12. Operate the power mirror to ensure smooth
operation.

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22-13

Headlight
22-13 Washer Nozzle Replacement
Wipers/Washers
Washer Motor Test

1. 1. Remove the left inner fender, refer to the '01 Civic 1. 1. Remove the front bumper, refer to the '01 Civic Shop
Shop Manual on this CD (see page 20-121). Manual on this CD (see page 20-104).
2. Disconnect each 2P connector from the washer 2. Disconnect the tube (A) from the washer nozzle (B).
motor.

2. 3. Pull the washer nozzle lid (A) out and remove it from
the nozzle (B).

2. 3. Test the motor by connecting battery power to the


No.1 terminal and ground the No.2 terminal of the
washer motor. The motor should run.
If the motor does not run or fails to run smoothly,
replace it.
If the motor runs smoothly, but little or no washer
fluid is pumped, check for a disconnected or
blocked washer hose, or a clogged pump outlet in
the motor.

3. 4. Remove the two screws and the washer nozzle.


5. Install in the reverse order of removal.
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22-2

22-2
Wire Harness and Ground Locations
Engine Compartment

NOTE: LHD type is shown, RHD is similar


1. BATTERY GROUND CABLE
2. EPS MOTOR GROUND CABLE
3. ENGINE GROUND CABLE

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2-22

2-22
Design Specifications

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 1,440 mm (56.7 in.)
with roof antenna 1,565 mm (61.6 in.)
Wheelbase 2,575 mm (101.4 in.)
(MPW condition)
Track Front 1,472 mm (58.0 in.)
(MPW condition) Rear 1,490 mm (58.7 in.)
Ground clearance 140 mm (5.5 in.)
Seating capacity Five (5)
WEIGHT Curb weight M/T 1,096-1,182 kg (2,416-2,606 lbs)
A/T 1,123-1,208 kg (2,476-2,663 lbs)
CVT 1,167-1,208 kg (2,573-2,663 lbs)
Max. permissible weight European models 1,575-1,635 kg (3,472-3,605 lbs)
ENGINE Type D14Z6 engine Water-cooled, 4-stroke SOHC engine
D16V1 engine Water-cooled, 4-stroke SOHC VTEC engine
Cylinder arrangement Inline 4-cylinder, transverse
Bore and stroke D14Z6 engine 75 x 79 mm (2.95 x 3.11 in.)
D16V1 engine 75 x 90 mm (2.95 x 3.54 in.)
Displacement D14Z6 engine 1,396 cm3 (85 cu in.)
D16V1 engine 1,590 cm3 (97 cu in.)
Compression ratio D14Z6 engine 10.4
D16V1 engine 9.4
Valve train D14Z6 engine Belt driven, SOHC 4 valves per cylinder
D16V1 engine Belt driven, SOHC VTEC 4 valves per cylinder
Lubrication system Forced wet sump, with trochoid pump
Oil pump displacement at 6,000 engine rpm 36.4 litre (38.5 US qt, 32.0 Imp qt) per minute
(min -1 )
Water pump at 6,000 engine rpm 130 litre (137 US qt, 114 Imp qt) per minute
displacement (min -1 )
Fuel required UNLEADED gasoline with 95 research octane number or higher

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22-3

22-3
Ground Distribution
Circuit Identification

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2-23

2-23
Design Specifications
(cont'd)

Item Measurement Qualification Specification


STARTER Type Gear reduction
Normal output 0.8 kW, 1.0 kW
Hour rating 30 seconds
Direction of rotation Clockwise as viewed from gear end
CLUTCH Clutch M/T Single plate dry, diaphragm spring
A/T Torque converter
CVT Hydraulically-actuated friction multi-discs and steel plates
Clutch friction material M/T 176 cm 2 (102 sq in.)
surface area
MANUAL Type Synchronised, 5-speed forward, 1 reverse
TRANSMISSION Primary reduction Direct 1:1
Gear ratio for D14Z6 1st 3.461
engine 1.4S and 1.4B 2nd 1.869
models
3rd 1.241
4th 0.969
5th 0.805
Reverse 3.230
Gear ratio for D14Z6 1st 3.142
engine 1.4SE and 1.4LS 2nd 1.750
models
3rd 1.241
4th 0.969
5th 0.805
Reverse 3.230
Gear ratio for D16V1 1st 3.142
engine models 2nd 1.869
3rd 1.241
4th 0.969
5th 0.805
Reverse 3.230
Final reduction Type Single helical gear
Gear ratio 4.411
AUTOMATIC Type Electronically controlled automatic, 4-speed forward, 1 reverse
TRANSMISSION Primary reduction Direct 1:1
Gear ratio 1st 2.722
2nd 1.468
3rd 0.975
4th 0.673
Reverse 1.954
Final reduction Type Single helical gear
Gear ratio 4.357
CVT Type Electronically controlled continuously variable transmission
Primary reduction Direct 1:1
Gear ratio Low-High 2.466-0.449
Reverse 2.466
Final reduction Type Single helical gear
Gear ratio 4.562
STEERING Type Rack and pinion, with electrical power assistance
Over ratio 14.49
Turns, lock-to-lock 2.83
Steering wheel diameter 380 mm (15.0 in.)
SUSPENSION Type Strut

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2-23

Rear Double wishbone


Shock absorber Front and rear Telescopic, hydraulic, nitrogen gas-filled

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22-4

High 22-4
Mount Brake Light Replacement
Exterior Lights
Taillight Replacement

1. 1. Remove the rear bumper (see page 20-244). 1. 1. Remove the maintenance lids (A).
2. Open the tailgate and disconnect the connectors (A) 2. Remove the bolts and the high mount brake light (B).
from the taillight (B).
Brake/Taillight: 21/5 W
Turn Signal Light: 21 W
Back-up Light (or Rear Fog Light): 21 W

2. 3. Disconnect the connectors (C) from the light.


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2. 3. Remove the mounting nuts and bolts, then remove


the taillight.
4. Turn the bulb socket 45 counterclockwise to remove
the bulb socket.
5. When installing the taillight, check for the gasket; if it
is distorted or stays compressed, replace it.
6. After installing the taillight, run water over the taillight
to make sure they do not leak.

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2-24

2-24
Design Specifications
(cont'd)

Item Measurement Qualification Specification


WHEEL Camber Front 0
ALIGNMENT Rear -045'
Caster Front 133'
Total toe Front 0 mm (0 in.)
Rear In 2 mm (1/16 in.)
BRAKE Type of service brake Front Power-assisted self-adjusting ventilated disc
Rear Power-assisted self-adjusting solid disc or drum
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 cm 2 x 2 (4.3 sq in. x 2)
Shoe friction surface area Rear 68 cm 2 x 2 (10.4 sq in. x 2)
TYRES Size of front, rear and 1.4S, 1.4SE 185/70R14 88H
spare for KE model 1.4SE Executive, 195/60R15 88H
1.6S, 1.6SE, 1.6SE
Executive
Size of front and rear for 1.4S, 1.4LS 185/70R14 88H
KG, KR, KS models 1.6S, 1.6LS 1.6ES 195/60R15 88H
Size of spare for KG, KR, T125/70D15 95M
KS models
AIR Cooling capacity 3,870 kcal/h (15,400 BTU/h)
CONDITIONING Compressor Type/manufacturer Scroll/SANDEN
Number of cylinders -
Capacity 85.7 ml /rev. (5.23 cu in./rev.)
Maximum speed 12,000 rpm
Lubricant capacity 130 ml (4 1/3 fl oz)
Lubricant type SP-10 (P/N 38897-P13-003, 38898-P13-003 or 38899-P13-A01)
Condenser Type Corrugated fin
Evaporator Type Corrugated fin
Blower Type Radial fan
Motor type 190 W/12 V
Speed control 9-speed
Maximum capacity 480 m 3 /h (16,900 cu ft/h)
Temperature clutch Air-mix type
Compressor clutch Type Dry, single plate, poly-V belt drive
Electrical power 42 W maximum at 12 V
consumption at 20C
(68F)
Refrigerant Type HFC-134a (R-134a)
Quantity 500-550 g (17.5-19.5 oz)

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22-5

22-5
Power Windows
Circuit Diagram

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2-25

2-25
Design Specifications
(cont'd)

Item Measurement Qualification Specification


ELECTRICAL Battery 12 V-36 AH/5 hours
RATINGS 12 V-45 AH/20 hours
Starter 12 V-0.8 kW, 1.0 kW
Alternator 12 V-70 A
Fuses Under-hood 80 A, 40 A, 30 A, 20 A, 15 A, 7.5 A
fuse/relay box
Under-dash 20 A, 15 A, 10 A, 7.5 A
fuse/relay box
Light bulbs Headlight high beam 12 V-60 W
Headlight low beam 12 V-55 W
Front turn 12 V-21 W/5 W
signal/Front 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 12 V-21W/5 W
side marker light
Rear fog light 12 V-21 W
Taillights 12 V-5 W
High mount brake 12 V-21 W
light
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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22-6

22-6
Power Windows
Master Switch Input Test

NOTE: The power window control unit is built into the power window master switch and it only controls the driver's window
operations.
1. 1. Remove the power window master switch (A) (see page 22-9).
2. Disconnect the 14P connector (B) from the master switch.

2. 3. Inspect the connector and socket terminals to be sure they are all making good contact.
If the terminals are bent, loose or corroded, repair them as necessary and recheck the system.
If the terminals look OK, make the following input tests at the connector.
If a test indicates a problem, find and correct the cause, then recheck the system.
If all the input tests prove OK, go to step 4.
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2-26

2-26
Body Specifications

Unit: mm (in.)

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22-7

22-7
Power Windows
Master Switch Input Test (cont'd)

1. 4. With the connector still disconnected, make these input tests at the connector.
If any test indicates a problem, find and correct the cause, then recheck the system.
If all the input tests prove OK, go to step 5.
Cavity Wire Test condition Test: Desired result Possible cause if result is not
obtained
10 [10] BLK Under all conditions Check for continuity to ground: Poor ground (G501)
14 [14] There should be continuity. An open in the wire
11 [11] GRN/WHT Ignition switch ON (II) Check for voltage to ground: Blown No. 6 (7.5A) fuse in
2 [2] GRN/BLK There should be battery the under-dash fuse/relay
voltage. box
Blown No. 22, 23 (20A)
fuse in the under-dash
fuse/relay box
Faulty power window relay
An open in the wire
7 [3] RED/YEL Connect the No. 11 and No. Check for driver's window Faulty driver's window
4 [1] RED/BLK 7 [No. 3] terminals and the motor operation: motor
No. 4 [No. 1]and No. 14 It should run (the driver's An open in the wire
terminals and turn the window moves down).
ignition switch ON (II).
3 [4] BLU/RED Connect the No. 2 and No. 1 Check for passenger's window Faulty passenger's window
1 [7] BLU/WHT [No. 7] terminals and the No. motor operation: motor
3 [No. 4] and No. 10 It should run (the passenger's Faulty passenger's window
terminals and turn the window moves down). switch
ignition switch ON (II). An open in the wire
2. 5. Reconnect the 14P connector to the switch and perform the following input tests.
If any test indicates a problem, find and correct the cause, then recheck the system.
If all the input tests prove OK, the control unit must be faulty; replace the power window master switch.
Cavity Wire Test condition Test: Desired result Possible cause if result is not
obtained
13 [13] ORN Connect the No. 11 and No. Check for voltage between the Faulty driver's window
7 [No. 3] terminals and the No. 13 and No. 14 terminals: motor
No. 4 [No. 1] and No. 14 About 6 V should be indicated An open in the wire
terminals and turn the while the driver's window
ignition switch ON (II). motor running.
[ ]: RHD type
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22-8

22-8
Power Windows
Master Switch Test

1. 1. Remove the power window master switch. (see page 1. 3. Check for continuity between the terminals in each
22-9). switch position according to the table.
2. Disconnect the 14P connector from the switch (A). Driver's Switch:
The driver's switch is combined with the control unit so you
cannot isolate the switch to test it. Instead, run the master
switch input test procedures on page 22-6. If the tests are
normal, the driver's switch must be faulty.
Passenger's Switch:

[ ]: RHD type
2. 4. If the switch is faulty, replace the switch.
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22-9

Passenger's
22-9 Switch Replacement
Power Windows
Master Switch Replacement

1. 1. Remove the door grip (see page 20-4). 1. 1. Remove the door grip (see page 20-4).
2. Remove the power window master switch (A) from 2. Remove the power window switch (A) from the door
the door lining. lining.

2. 3. Disconnect the 14P connector (B) from the switch.


4. Remove the three screws and switch from the switch
panel.
2. 3. Disconnect the 5P connector (B) from the switch.
4. Remove the two screws and switch from the switch
panel.
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2-3

2-3
Standards and Service Limits
Cylinder Head

Item Measurement Qualification Standard or New Service Limit


Head Warpage - 0.05 mm (0.002 in.)
Height 92.95-93.05 mm -
(3.659-3.663 in.)
Camshaft End play 0.05-0.15 mm 0.5 mm (0.02 in.)
(0.002-0.006 in.)
Camshaft-to-holder oil 0.050-0.089 mm 0.15 mm (0.006 in.)
clearance (0.0020-0.0035 in.)
Total runout 0.03 mm (0.001 in.) max. 0.04 mm (0.002 in.)
Cam lobe height D14Z6 Intake 34.158 mm (1.3448 in.) -
engine Exhaust 36.488 mm (1.4365 in.) -
Cam lobe height D16V1 VTEC intake, primary 38.427 mm (1.5129 in.) -
engine VTEC intake, 32.848 mm (1.2932 in.) -
secondary
VTEC exhaust 38.784 mm (1.5269 in.) -
Valves Clearance (cold) Intake 0.18-0.22 mm (0.007-0.009 in.) -
Exhaust 0.23-0.27 mm (0.009-0.01 in.) -
Stem O.D. Intake 5.48-5.49 mm 5.45 mm (0.215 in.)
(0.2157-0.2161 in.)
Exhaust 5.45-5.46 mm 5.42 mm (0.213 in.)
(0.2146-0.2150 in.)
Stem-to-guide clearance Intake 0.02-0.05 mm 0.08 mm (0.003 in.)
(0.0008-0.0020 in.)
Exhaust 0.05-0.08 mm 0.11 mm (0.004 in.)
(0.0020-0.0031 in.)
Valve seats Width Intake 0.85-1.15 mm 1.60 mm (0.063 in.)
(0.033-0.045 in.)
Exhaust 1.25-1.55 mm 2.00 mm (0.079 in.)
(0.049-0.061 in.)
Stem installed height Intake 53.17-53.64 mm 53.89 mm (2.122 in.)
(2.093-2.112 in.)
Exhaust 53.17-53.64 mm 53.89 mm (2.122 in.)
(2.093-2.112 in.)
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 5.51-5.53 mm 5.55 mm (0.219 in.)
(0.217-0.218 in.)
Installed height Intake 17.85-18.35 mm -
(0.703-0.722 in.)
Exhaust 18.65-19.15 mm -
(0.734-0.754 in.)
Rocker arms Arm-to-shaft clearance Intake 0.017-0.050 mm 0.08 mm (0.003 in.)
(0.0007-0.0020 in.)
Exhaust 0.018-0.054 mm 0.08 mm (0.003 in.)
(0.0007-0.0021 in.)

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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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23-2

23-2
Seat Belts
Front Seat Belt Replacement

SRS components are located in this area. Review the SRS 1. 5. Remove the upper anchor cover (A), and remove the
component location, precautions and procedures in the SRS upper anchor bolt (B).
section before performing repairs or service. Refer to the '01
Civic Shop Manual on this CD, P/N 62S5A00.
NOTE: Check the front seat belts for damage and replace them
if necessary. Be careful not to damage them during removal
and installation.
Front Seat Belt
1. 1. Disconnect the negative battery cable and wait at
least 3 minutes before beginning work.
2. Slide the front seat forward fully.
3. Remove the lower anchor bolts, then remove the
slide bar (A).

2. 6. Disconnect the seat belt tensioner connector (A).


Remove the retractor mounting self-tapping ET
screw (B) and the retractor bolt (C), then remove the
front seat belt (D) and retractor (E).

2. 4. Remove the rear side trim panel (see page 20-30).

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23-3

23-3
Seat Belts
Front Seat Belt Replacement (cont'd)

1. 7. Remove the center pillar upper trim (see page 20- Upper anchor bolt construction:
29)
8. Remove the shoulder anchor adjuster (A).

1. 1. UPPER ANCHOR BOLT


2. UPPER ANCHOR
3. COLLAR
4. TOOTHED LOCK WASHER
5. BUSHING
Lower anchor bolt construction:

2. 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 an oversized
self-tapping ET screw made specifically for this
application. 2. 1. LOWER ANCHOR BOLT
Check that the retractor locking mechanism 2. TOOTHED LOCK WASHER
functions (see page 23-5). 3. COLLAR
4. LOWER ANCHOR
Assemble the washers, collars and bushing on
5. SPRING WASHER
the upper and lower anchor bolts as shown.
Before installing the anchor bolts, make sure
there are no twists or kinks in the front seat belt.
Make sure the seat belt tensioner connector is
plugged in properly.
Reconnect the negative cable to the battery.

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23-4

23-4
Seat Belts
Rear Seat Belt Replacement

NOTE: Check the rear seat belts for damage and replace them 1. 4. Install the seat belt in the reverse order of removal
if necessary. Be careful not to damage them during removal and note these items:
and installation. If the threads on the retractor mounting self-
tapping ET screw are worn out, use an oversized
Rear Seat Belt
self-tapping ET screw made specifically for this
1. 1. Remove the rear side trim panel (see page 20-30). application.
2. Remove the lower anchor bolt (A). Check that the retractor locking mechanism
functions as described, refer to the '01 Civic Shop
Manual on this CD (see page 23-20).
Before installing the anchor bolt, make sure there
are no twists or kinks in the rear seat belt.

2. 3. Remove the retractor mounting self-tapping ET screw


(A) and the retractor bolt (B), then remove the rear
seat belt (C) and retractor (D).

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23-5

23-5
Seat Belts
Inspection

For front seat belt retractor with seat belt tensioner, review the
SRS component locations, precautions and procedures in the
SRS section before performing repairs or service. Refer to the
'01 M Civic Shop Manual on this CD, P/N 62S5A00.
Retractor
1. 1. Before installing the retractor, check that the seat belt
can be pulled out freely.
2. Make sure that the seat belt does not lock when the
retractor (A) is leaned slowly up to 15 from the
mounted position. The seat belt should lock when the
retractor is leaned over 40. Do not attempt to
disassemble the retractor.
Front:

2. 3. Replace the seat belt with a new assembly if there is


any abnormality. Do not disassemble any part of the
seat belt for any reason.

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2-4

2-4
Standards and Service Limits
Engine Block

Item Measurement Qualification Standard or New Service Limit


Block Warpage of deck 0.07 mm (0.003 in.) max. 0.10 mm (0.004 in.)
Bore diameter 75.00-75.02 mm 75.07 mm (2.9555 in.)
(2.9528-2.9535 in.)
Bore taper - 0.05 mm (0.002 in.)
Reboring limit - 0.5 mm (0.02 in.)
Piston Skirt O.D. at 13 mm (0.5 74.98-74.99 mm 74.97 mm (2.9516 in.)
in.) from bottom of skirt (2.9520-2.9524 in.)
Clearance in cylinder 0.010-0.040 mm (0.0004-0.0016 in.) 0.05 mm (0.002 in.)
Ring groove width Top 1.020-1.030 mm (0.0402-0.0406 in.) 1.05 mm (0.041 in.)
Second 1.220-1.230 mm (0.0481-0.0484 in.) 1.25 mm (0.049 in)
Oil 2.005-2.020 mm (0.0789-0.0795 in) 2.05 mm (0.08 in.)
Piston rings Ring-to-groove clearance Top 0.035-0.060 mm (0.0014-0.0024 in.) 0.13 mm (0.005 in.)
Second 0.030-0.055 mm (0.0012-0.0022 in.) 0.13 mm (0.005 in.)
Ring end gap Top 0.15-0.30 mm (0.006-0.012 in.) 0.60 mm (0.024 in.)
Second 0.30-0.45 mm (0.012-0.018 in.) 0.60 mm (0.024 in.)
Oil 0.20-0.70 mm (0.008-0.028 in.) 0.80 mm (0.031 in.)
Piston pin O.D. 18.996-19.000 mm (0.7479-0.7480 in.) -
Pin-to-piston clearance 0.010-0.020 mm (0.0004-0.0008 in.) -
Connecting rod Pin-to-rod interference 0.016-0.036 mm (0.0006-0.0014 in.) -
Small-end bore diameter 18.96-18.98 mm (0.746-0.747 in.) -
Large-end bore diameter D14Z6 engine 43.0 mm (1.69 in.) -
(Nominal) D16V1 engine 48.0 mm (1.89 in.) -
End play installed on 0.15-0.30 mm (0.006-0.012 in.) 0.40 mm (0.016 in.)
crankshaft
Crankshaft Main journal diameter D14Z6 engine 44.976-45.000 mm (1.7707-1.7717 in.) -
D16V1 engine 54.976-55.000 mm (2.1644-2.1654 in.) -
Rod journal diameter D14Z6 engine 39.976-40.000 mm (1.5739-1.5748 in.) -
D16V1 engine 44.976-45.000 mm (1.7707-1.7717 in.) -
Rod/main journal taper 0.0025 mm (0.0001 in.) 0.005 mm (0.0002 in.)
Rod/main journal out-of- 0.0025 mm (0.0001 in.) 0.005 mm (0.0002 in.)
round
End play 0.10-0.35 mm (0.004-0.014 in.) 0.45 mm (0.018 in.)
Runout 0.03 mm (0.001 in.) max. 0.04 mm (0.002 in.)
Crankshaft bearings Main bearing-to-journal oil No. 1 journal 0.018-0.036 mm (0.0007-0.0014 in.) 0.05 mm (0.002 in.)
clearance for D14Z6 No. 5 journal
engine No. 2 journal 0.020-0.038 mm (0.0008-0.0015 in.) 0.05 mm (0.002 in.)
No. 3 journal
No. 4 journal
Main bearing-to-journal oil No. 1 journal 0.018-0.036 mm (0.0007-0.0014 in.) 0.05 mm (0.002 in.)
clearance for D16V1 No. 5 journal
engine No. 2 journal 0.024-0.042 mm (0.0009-0.0017 in.) 0.05 mm (0.002 in.)
No. 3 journal
No. 4 journal
Rod bearing clearance 0.024-0.042 mm (0.0009-0.0017 in.) 0.05 mm (0.002 in.)

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2-5

2-5
Standards and Service Limits
Engine Lubrication

Item Measurement Qualification Standard or New Service Limit


Engine oil Capacity 4.2 l (4.4 US qt, 3.7 lmp qt) for engine overhaul
3.5 l (3.7 US qt, 3.1 lmp qt) for oil change, including filter
3.3 l (3.5 US qt, 2.9 lmp qt) for oil change, without filter
Oil pump Inner-to-outer rotor 0.06-0.18 mm (0.002-0.007 in.) 0.20 mm (0.008 in.)
clearance
Pump housing-to-outer 0.10-0.18 mm (0.004-0.007 in.) 0.20 mm (0.008 in.)
rotor clearance
Pump housing-to-rotor 0.02-0.07 mm (0.001-0.003 in.) 0.15 mm (0.006 in.)
axial clearance
Oil pressure with oil At idle 70 kPa (0.7 kgf/cm 2 , 10 psi) min.
temperature at 80C at 3,000 rpm (min -1 ) 340 kPa (3.5 kgf/cm 2 , 50 psi) min.
(176F)

Cooling
Item Measurement Qualification Standard or New Service Limit
Radiator Coolant capacity (Includes M/T: engine overhaul 5.1 l (5.4 US qt, 4.5 lmp qt)
engine, heater, hoses, and M/T: coolant change 4.0 l (4.2 US qt, 3.5 lmp qt)
reservoir)
A/T, CVT: engine 5.0 l (5.3 US qt, 4.4 lmp qt)
overhaul
A/T, CVT: coolant 3.9 l (4.1 US qt, 3.4 lmp qt)
change
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/cm 2 , 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'' 91-95C (196-203F)
temperature
Thermoswitch ''OFF'' Subtract 3-8C (5-15F) from actual ''ON'' temperature
temperature

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2-6

2-6
Standards and Service Limits
Fuel and Emissions

Item Measurement Qualification Standard or New Service Limit


Fuel pressure Pressure with fuel pressure 270-320 kPa (2.8-3.3 kgf/cm 2 , 40-47 psi)
gauge connected
Fuel tank Capacity 50 l (13.2 US gal, 11.0 lmp gal)
Engine idle Idle speed with headlights M/T in neutral 700 50 rpm
and radiator fan off 700 50 rpm
A/T in or
Fast idle M/T in neutral 1,250 50 rpm
1,250 50 rpm
A/T in or
Idle CO % 0.1 max.

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 0.06 mm (0.002 in.) max. 0.15 mm (0.006 in.)
surface
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 Measure with feeler 0.6 mm (0.02 in.) max. 1.0 mm (0.04 in.)
fingers gauge and special tool

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2-7

2-7
Standards and Service Limits
Manual Transmission and Differential

Item Measurement Qualification Standard or New Service Limit


Transmission oil Capacity For fluid change: 1.5 l
(1.6 US qt, 1.3 lmp qt)
For overhaul: 1.6 l (1.7 US qt, 1.4 lmp
qt)
Mainshaft End play 0.11-0.18 mm Adjust
(0.004-0.007 in.)
Diameter of ball bearing 25.977-25.990 mm 25.92 mm
contact area (clutch (1.0227-1.0232 in.) (1.021 in.)
housing side)
Diameter of spacer collar 28.980-28.993 mm 28.930 mm
contact area (1.1409-1.1415 in.) (1.1390 in.)
Diameter of needle bearing 34.984-35.000 mm 34.93 mm
contact area (1.3773-1.3780 in.) (1.375 in.)
Diameter of ball bearing 25.987-26.000 mm 25.93 mm
contact area (transmission (1.0231-1.0236 in.) (1.020 in.)
housing side)
Run out 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.)
Mainshaft 3rd and I.D. 39.009-39.025 mm 39.070 mm
4th gears (1.5358-1.5364 in.) (1.5382 in.)
End play 3rd gear 0.06-0.21 mm 0.33 mm
(0.002-0.008 in.) (0.013 in.)
4th gear 0.06-0.19 mm 0.31 mm
(0.002-0.007 in.) (0.012 in.)
Thickness 3rd gear 27.92-27.97 mm 27.85 mm
(1.099-1.101 in.) (1.096 in.)
4th gear 27.02-27.07 mm 26.95 mm
(1.064-1.066 in.) (1.061 in.)
Mainshaft 5th gear I.D. 39.009-39.025 mm 39.070 mm
(1.5358-1.5364 in.) (1.5382 in.)
End play 0.06-0.19 mm 0.31 mm
(0.002-0.007 in.) (0.012 in.)
Thickness 28.92-28.97 mm 28.85 mm
(1.139-1.141 in.) (1.136 in.)
Countershaft Diameter of needle bearing 34.000-34.015 mm 33.95 mm
contact area (clutch (1.3386-1.3392 in.) (1.337 in.)
housing side)
Diameter of ball bearing 24.980-24.993 mm 24.93 mm
contact area (transmission (0.9835-0.9840 in.) (0.981 in.)
housing side)
Diameter of 1st gear 37.984-38.000 mm 37.934 mm
contact area (1.4954-1.4961 in.) (1.493 in.)
Run out 0.02 mm 0.05 mm
(0.001 in.) max. (0.002 in.)
Countershaft 1st I.D. 43.009-43.025 mm 43.070 mm
gear (1.6932-1.6939 in.) (1.6957 in.)
End play 0.03-0.10 mm 0.22 mm
(0.001-0.039 in.) (0.009 in.)
Thickness 26.91-26.94 mm (1.059-1.061 in.) -
Countershaft 2nd I.D. 45.009-45.025 mm 45.070 mm
gear (1.7720-1.7726 in.) (1.7744 in.)
End play 0.04-0.12 mm (0.002-0.005 in.) 0.24 mm
(0.009 in.)

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2-7

Thickness 27.41-27.46 mm (1.079-1.081 in.) 27.36 mm (1.077 in.)


Countershaft 2nd I.D. 34.000-34.010 mm 34.040 mm
gear spacer collar (1.3386-1.3390 in.) (1.3402 in.)
O.D. 39.989-40.000 mm 39.930 mm
(1.5744-1.5748 in.) (1.5720 in.)
Length 27.53-27.56 mm 27.51 mm
(1.084-1.085 in.) (1.083 in.)

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2-8

2-8
Standards and Service Limits
Manual Transmission and Differential (cont'd)

Item Measurement Qualification Standard or New Service


Limit
Mainshaft 4th I.D. 29.002-29.012 mm 29.060 mm
and 5th gears (1.1418-1.1422 in.) (1.1441 in.)
spacer collar
O.D. 34.989-35.000 mm 34.930 mm
(1.3775-1.3780 in.) (1.3752 in.)
Length A 51.97-52.03 mm -
(2.046-2.048 in.)
B 24.03-24.06 mm -
(0.946-0.947 in.)

Reverse idler I.D. 15.016-15.043 mm 15.080 mm


gear (0.5912-0.5922 in.) (0.5937 in.)
Gear-to-reverse gear shaft clearance 0.032-0.077 mm 0.140 mm
(0.0012-0.0030 in.) (0.0055 in.)
Synchro ring Ring-to-gear clearance Ring pushed 0.85-1.10 mm 0.4 mm
against gear (0.033-0.043 in.) (0.016 in.)
Dual cone Outer synchro ring-to-synchro cone clearance Ring pushed 0.5-1.0 mm 0.3 mm
synchro against gear (0.02-0.04 in.) (0.01 in.)
Synchro cone-to-gear clearance Ring pushed 0.5-1.0 mm 0.3 mm
against gear (0.02-0.04 in.) (0.01 in.)
Outer synchro ring-to-gear cone clearance Ring pushed 0.95-1.68 mm 0.6 mm
against gear (0.037-0.066 in.) (0.02 in.)
Shift fork Finger thickness 1st-2nd and 3rd- 7.4-7.6 mm -
4th forks (0.29-0.30 in.)
5th fork 6.7-6.9 mm -
(0.26-0.27 in.)
Fork-to-synchro sleeve clearance 0.35-0.65 mm 1.00 mm
(0.014-0.026 in.) (0.039 in.)
Reverse shift Pawl groove width 13.8-14.1 mm 15.5 mm
fork (0.543-0.555 in.) (0.610 in.)
Fork-to-reverse idler gear clearance 1.6-2.2 mm 2.8 mm
(0.06-0.09 in.) (0.11 in.)
Shift arm I.D. 13.973-14.000 mm -
(0.5501-0.5512 in.)
Shift fork diameter at contact area 12.9-13.0 mm (0.508- -
0.512 in.)
Shift arm-to-shift lever clearance 0.2-0.5 mm 0.62 mm
(0.008-0.020 in.) (0.024 in.)
Select lever Finger width 14.75-14.95 mm (0.581- -
0.589 in.)
Shift lever Shaft-to-select lever clearance 0.05-0.40 mm 0.6 mm
(0.002-0.016 in.) (0.024 in.)
Groove (to select lever) 15.00-15.15 mm -
(0.591-0.596 in.)
Shaft-to-shift arm clearance 0.013-0.07 mm 0.1 mm
(0.0005-0.003 in.) (0.004 in.)

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2-8

M/T differential Pinion shaft contact area I.D. 18.010-18.028 mm -


carrier (0.7091-0.7098 in.)
Carrier-to-pinion shaft clearance 0.023-0.057 mm 0.100 mm
(0.0009-0.0022 in.) (0.0039 in.)
Driveshaft contact area I.D. 26.025-26.045 mm -
(1.0246-1.0254 in.)
M/T differential Backlash 0.05-0.15 mm -
pinion gear (0.002-0.006 in.)
I.D. 18.042-18.066 mm -
(0.7103-0.7113 in.)
Pinion gear-to-pinion shaft clearance 0.059-0.095 mm 0.150 mm
(0.0023-0.0037 in.) (0.0059 in.)

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2-9

2-9
Standards and Service Limits
Automatic Transmission and Differential

Item Measurement Qualification Standard or New Service Limit


ATF (Automatic Capacity Use genuine Honda For fluid change: 2.7 l (2.9 US qt, 2.4 lmp qt)
Transmission Fluid) ATF-Z1 For overhaul: 6.0 l (6.3 US qt, 5.3 lmp qt)
ATF pressure Line pressure At 2,000 rpm (min - 880-930 kPa 830 kPa
1)in or (9.0-9.5 kgf/cm 2 , 120-130 psi) (8.5 kgf/cm 2 , 120 psi)
position
4th clutch pressure At 2,000 rpm (min - 850-900 kPa 800 kPa
1) in position (8.7-9.2 kgf/cm 2 , 120-130 psi) (8.2 kgf/cm 2 120 psi)
3rd clutch pressure At 2,000 rpm (min - 850-900 kPa 800 kPa
1) in position (8.7-9.2 kgf/cm 2 , 120-130 psi) (8.2 kgf/cm 2 , 120 psi)

2nd clutch pressure At 2,000 rpm (min - 850-900 kPa 800 kPa
1) in position (8.7-9.2 kgf/cm 2 , 120-130 psi) (8.2 kgf/cm 2 , 120 psi)
1st clutch pressure At 2,000 rpm (min - 880-930 kPa 830 kPa
1) in position (9.0-9.5 kgf/cm 2 , 120-130 psi) (8.5 kgf/cm 2 , 120 psi)
1st-hold clutch pressure At 2,000 rpm (min - 880-930 kPa 830 kPa
1) in position (9.0-9.5 kgf/cm 2 , 120-130 psi) (8.5 kgf/cm 2 , 120 psi)
Torque converter Stall speed D14Z6 engine 2,550 rpm (min -1 ) 2,400-2,700 rpm (min -1 )
Check with vehicle on D16V1 engine 2,800 rpm (min -1 ) 2,650-2,950 rpm (min -1 )
level ground
Valve body Stator shaft needle bearing Torque converter 27.000-27.021 mm (1.063-1.064 in.) When worn or damaged
contact I.D. side
ATF pump side 29.000-29.013 mm (1.1417-1.1422 in.) When worn or damaged
ATF pump gear thrust 0.03-0.06 mm (0.001-0.002 in.) 0.07 mm (0.003 in.)
clearance
ATF pump gear-to-body Drive gear 0.105-0.1325 mm (0.004-0.005 in.) -
clearance Driven gear 0.0350-0.0625 mm (0.001-0.002 in.) -
ATF pump driven gear I.D. 14.016-14.034 mm (0.5518-0.5525 in.) When worn or damaged
ATF pump driven gear 13.980-13.990 mm (0.5504-0.5508 in.) When worn or damaged
shaft O.D.
Reverse shift fork Fork finger thickness 5.90-6.00 mm (0.232-0.236 in.) 5.4 mm (0.213 in.)
Park gear and pawl When worn or damaged
Servo body Shift fork shaft bore I.D. 14.000-14.010 mm (0.5512-0.5516 in.) -
Shift fork shaft valve bore 37.000-37.039 mm (1.4567-1.4582 in.) 37.045 mm (1.4585 in.)
I.D.
Regulator valve Sealing ring contact I.D. 35.000-35.025 mm (1.3780-1.3782 in.) 35.050 mm (1.3799 in.)
body
Stator shaft Diameter of needle bearing ATF pump side 29.000-29.013 mm (1.1417-1.1422 in.) When worn or damaged
contact area Torque converter 27.000-27.021 mm (1.0630-1.0638 in.) When worn or damaged
side

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3-1


Maintenance

Lubricants and Fluids 3-2


Maintenance Schedule for Normal Conditions (European Model) 3-4
Maintenance Schedule for Severe Conditions (European Model) 3-6
Maintenance Schedule (Except European Model) 3-8

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3-2

3-2
Lubricants and Fluids

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.
2 Transmission Manual Genuine Honda Manual Transmission Fluid (MTF) *1
Automatic Genuine Honda ATF-Z1 (ATF) *2
Honda Multi Matic
3 Brake system (includes ABS line) Brake fluid DOT 3 or DOT 4 *3
4 Clutch line Brake fluid DOT 3 or DOT 4 *3
5 Power steering gearbox Steering grease P/N 08733-B070E
6 Release fork (manual transmission) Super High Temp Urea Grease (P/N 08798-9002)
7 Shift and select cable ends (Manual transmission)
8 Throttle cable end (dashboard lower panel hole) Silicon grease
9 Throttle cable end (throttle link) Multi-purpose grease
10 Brake master cylinder pushrod
11 Clutch master cylinder pushrod
12 Shift lever
13 Pedal linkage
14 Battery terminals
15 Fuel fill lid
16 Rear brake shoe linkage Honda White Lithium Grease
17 Hood hinges and latch
18 Tailgate hinges and latch
19 Door hinges, upper and lower
20 Door opening detent
21 Caliper piston boot, caliper pins and boots Silicon grease
22 Brake line joints (front and rear wheelhouse) Rust preventives
23 Power steering system Honda Power Steering Fluid *4
24 Air conditioning compressor Compressor oil: SANDEN: SP-10 (P/N 38897-P13-003 or
38899-P13-A01)
For refrigerant: HFC-134a (R-134a)

Recommended Engine Oil


Engine oil viscosity for ambient temperature ranges

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3-2

CAUTION
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged
periods. Although this is unlikely unless you handle used oil on a daily basis, it is still 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: Always use genuine Honda ATF-Z1 (ATF). Using a non-Honda ATF can affect shift quality.
*3: We recommend Genuine Honda Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system.
*4: Always use Honda Power Steering Fluid. Using any other type of power steering fluid or automatic transmission fluid can cause increased
wear and poor steering in cold weather.
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3-3

3-3
Lubrication and Fluids

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3-4

3-4
Maintenance Schedule for Normal
Conditions (European Model)

Listed by Distance/Time
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 km x 1,000 20 40 60 80 100 120 140 160 180 200
time 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
Replace timing belt, and inspect auto-tensioner, water pump Every 120,000 km (72,000 miles) or 96 months
Inspect and adjust drive belts
Inspect idle speed
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 120,000 km (72,000 miles) or 96 months
Automatic Transmission At 120,000 km (72,000 miles) or 96 months, then replace every 80,000
km (48,000 miles) or 48 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
Replace brake fluid Every 36 months
Check parking brake adjustment
Replace air conditioning filter Every 30,000 km (18,000 miles) or 12 months
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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3-5

3-5
Maintenance Schedule for Normal
Conditions (European Model) (cont'd)

NOTES REFERENCE MANUAL, SECTION and


PAGE
Refer to the 2001 Civic shop manuals on this
CD (see page 8-5)
Refer to the 2001 Civic shop manuals on this
CD (see page 8-6)
Refer to the 2001 Civic shop manuals on this
CD (see page 11-147) (see page 11-447)
Check the valve clearance. Refer to the 2001 Civic shop manuals on this
CD (see page 6-14)
Refer to the 2001 Civic shop manuals on this
CD (see page 11-138) (see page 11-296)
Refer to the 2001 Civic shop manuals on this
CD (see page 11-438) (see page 11-571)
Refer to the 2001 Civic shop manuals on this
CD (see page 4-25)
Check water pump for signs of seal leakage. (see page 6-2)
Refer to the 2001 Civic shop manuals on this
CD (see page 6-18) (see page 6-22)
Refer to the 2001 Civic shop manuals on this
CD (see page 10-7)
Check for cracks and damage. Refer to the 2001 Civic shop manuals on this
Check deflection and tension. CD (see 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 Refer to the 2001 Civic shop manuals on this
cracks. CD (see page 19-3)
Check the wheel cylinder for leaks.
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
Check that brake fluid level is between the upper and lower marks on the CD (see page 19-7)
reservoir.
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.

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3-5

Check tightness of screws, nuts and joints. If necessary,


retighten.
Check rack grease and steering linkage. Check the boot for Refer to the 2001 Civic shop manuals on this
damage and leaking grease. CD (see page 17-5)
Check the fluid line for damage and leaks.
Check the bolts for tightness. Refer to the 2001 Civic shop manuals on this
Check all dust covers for deterioration and damage. CD (see page 18-3)
Check the boot and boot band for cracks Refer to the 2001 Civic shop manuals on this
Check rack grease. CD (see page 16-3)
Check the master cylinder, proportioning control valve and ABS modulator and Refer to the 2001 Civic shop manuals on this
leakage. CD (see page 19-48)
Check for leaks. -
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, Refer to the 2001 Civic shop manuals on this
leaks and tightness. CD (see page 9-5)
Check fuel lines for loose connections, cracks and deterioration. Retighten loose Refer to the 2001 Civic shop manuals on this
connections and replace any damaged parts. CD (see 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)
Check for pressure, puncture or cuts and irregular tread wear. -

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3-6

3-6
(European Model)

Listed by Distance/Time
Service at the indicated distance or km x 1,000 20 40 60 80 100 120 140 160 180 200
time 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
Replace fuel filter
Replace spark plugs
Replace timing belt, and inspect auto-tensioner, water pump
Inspect and adjust drive belts
Inspect idle speed
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
Replace air conditioning filter Every 30,000 km (18,000 miles) or 12 months
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 conditions over 35C (95F).
Extensive idling or long periods of stop-and-go-driving.
Trailer towing, driving with a car-top carrier or driving in mountainous conditions.
Driving on muddy, dusty or de-iced roads.
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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3-7

3-7
(European Model) (cont'd)

NOTES REFERENCE MANUAL, SECTION and


PAGE
Refer to the 2001 Civic shop manuals on this
CD (see page 8-5)
Refer to the 2001 Civic shop manuals on this
CD (see page 8-6)
Refer to the 2001 Civic shop manuals on this
CD (see page 11-147) (see page 11-447)
Check the valve clearance. Refer to the 2001 Civic shop manuals on this
CD (see page 6-14)
Refer to the 2001 Civic shop manuals on this
CD (see page 11-138) (see page 11-296)
Refer to the 2001 Civic shop manuals on this
CD (see page 11-438) (see page 11-571)
Refer to the 2001 Civic shop manuals on this
CD (see page 4-25)
Check water pump for signs of seal leakage. (see page 6-2)
Refer to the 2001 Civic shop manuals on this
CD (see page 6-18) (see page 6-22)
Refer to the 2001 Civic shop manuals on this
CD (see page 10-7)
Check for cracks and damage. Refer to the 2001 Civic shop manuals on this
Check deflection and tension. CD (see 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 Refer to the 2001 Civic shop manuals on this
cracks. CD (see page 19-3)
Check the wheel cylinder for leaks.
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
Check that brake fluid level is between the upper and lower marks on the CD (see page 19-7)
reservoir.
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,

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3-7

retighten.
Check rack grease and steering linkage. Check the boot for Refer to the 2001 Civic shop manuals on this
damage and leaking grease. CD (see page 17-5)
Check the fluid line for damage and leaks
Check the bolts for tightness. Refer to the 2001 Civic shop manuals on this
Check all dust cover for deterioration and damage CD (see page 18-3)
Check the boot and boot band for cracks Refer to the 2001 Civic shop manuals on this
Check rack grease. CD (see page 16-3)
Check the master cylinder, proportioning control valve and ABS modulator and Refer to the 2001 Civic shop manuals on this
leakage. CD (see page 19-48)
Check for leaks. -
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, Refer to the 2001 Civic shop manuals on this
leaks and tightness. CD (see page 9-5)
Check fuel lines for loose connections, cracks and deterioration. Retighten loose Refer to the 2001 Civic shop manuals on this
connections and replace any damaged parts. CD (see 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)
Check for pressure, puncture or cuts and irregular tread wear. -

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3-8

3-8
(Except European Model)

Listed by Maintenance Item


This maintenance schedule outlines the minimum required maintenance that you should perform to ensure the trouble-free
operation of the customer's vehicle. Due to the regional and climatic differences, some additional servicing may be required. Please
consult the warranty handbook for a more detailed description.
Service at the indicated distance or km x 1,000 20 40 60 80 100 120 140 160 180 200
time 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 Normal Condition Every 10,000 km (6,000 miles) or 12 months
Severe Condition Every 5,000 km (3,000 miles) or 6 months
Replace engine oil filter Normal Condition Every 20,000 km (12,000 miles) or 12 months
Severe Condition Every 10,000 km (6,000 miles) or 6 months
Clean or replace air cleaner element Every 20,000 km (12,000 miles)
Inspect valve clearance Every 40,000 km (24,000 miles),
Replace fuel filter
Replace spark plugs Every 40,000 km (24,000 miles)
Replace timing belt, and inspect auto-tensioner, water pump
Inspect and adjust drive belts
Inspect idle speed
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 Manual Transmission Normal Condition
transmission Severe Condition
fluid
Automatic Transmission Normal Condition
Severe Condition
CVT Normal 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 Every 10,000 km (6,000 miles)
per month)
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.
Trailer towing, driving with a car-top carrier or driving in mountainous conditions.
Driving on muddy, dusty or de-iced roads.
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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3-9

3-9
(Except European Model) (cont'd)

NOTES REFERENCE MANUAL, SECTION and


PAGE
Refer to the 2001 Civic shop manuals on this
CD (see page 8-5)
Refer to the 2001 Civic shop manuals on this
CD (see page 8-6)
Refer to the 2001 Civic shop manuals on this
CD (see page 11-147) (see page 11-447)
Check the valve clearance. Refer to the 2001 Civic shop manuals on this
CD (see page 6-14)
Refer to the 2001 Civic shop manuals on this
CD (see page 11-138) (see page 11-296)
Refer to the 2001 Civic shop manuals on this
CD (see page 11-438) (see page 11-571)
Refer to the 2001 Civic shop manuals on this
CD (see page 4-25)
Check water pump for signs of seal leakage. (see page 6-2)
Refer to the 2001 Civic shop manuals on this
CD (see page 6-18) (see page 6-22)
Refer to the 2001 Civic shop manuals on this
CD (see page 10-7)
Check for cracks and damage. Refer to the 2001 Civic shop manuals on this
Check deflection and tension. CD (see 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 Refer to the 2001 Civic shop manuals on this
cracks. CD (see page 19-3)
Check the wheel cylinder for leaks.
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
Check that brake fluid level is between the upper and lower marks on the CD (see page 19-7)
reservoir.
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.

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3-9

Check rack grease and steering linkage. Check the boot for Refer to the 2001 Civic shop manuals on this
damage and leaking grease. CD (see page 17-5)
Check the fluid line for damage and leaks.
Check the bolts for tightness. Refer to the 2001 Civic shop manuals on this
Check all dust cover for deterioration and damage. CD (see page 18-3)
Check the boot and boot band for cracks Refer to the 2001 Civic shop manuals on this
Check rack grease. CD (see page 16-3)
Check the master cylinder, proportioning control valve and ABS modulator and Refer to the 2001 Civic shop manuals on this
leakage. CD (see page 19-48)
Check for leaks. -
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, Refer to the 2001 Civic shop manuals on this
leaks and tightness. CD (see page 9-5)
Check fuel lines for loose connections, cracks and deterioration. Retighten loose Refer to the 2001 Civic shop manuals on this
connections and replace any damaged parts. CD (see 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)

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6-0


Engine Mechanical

Cylinder Head 6-1

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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6-1


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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6-2

6-2
Cylinder Head
Auto-Tensioner Inspection

1. 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. 2. Put the auto-tensioner on the surface plate.
3. Measure the height at point A (A) and point B (B).

3. 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.)
4. 5. Inspect the spring grommet (A). Replace the
grommet if damaged or deteriorated.

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Service Manual Civic - Civic 4/5D Maintenance, Repair & Construction 01

SERVICE
MANUAL
CIVIC
CIVIC 3D
MAINTENANCE, REPAIR &
CONSTRUCTION 01

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