2002 HONDA CIVIC Gasket

Water Passage Installation
1.Clean and dry the water passage mating surfaces.
Apply liquid gasket P/N 08718-0009, evenly to the
cylinder block mating surface ofthewater passage
and to the inner threads of the bolt holes.
NOTE: Do not installthe parts if 5 minutes or more
have elapsed since applying liquid gasket. Instead,
reapply liquid gasket after removing old residue.
3. Installthe water passage (A)with a new O-ring (B).
10 x 1.25 mm44 N m {4.5 kgt m.33 lbf.ft}
4. After assembly, wait at least 30 minutes before
filling the engine with oil.
.t':.:
Water Outlet lnstallation
Installthe water outlet (A)with a new O-ring {B),
12 N m (1.2 kgt m,8,7lbf ft)
10-9

Fuel Supply System
{Fuel Pressure Regulator
Replacement
Remove the fuel pump (see page 1 1-153).
Remove the fuel pressure regulator (A).
Installthe part in the reverse order of removal witha new o-ring (B).
1.
2.
11-152
Fuel Filter Replacement
The fuel filter should be replaced whenever the fuelpressure drops belowthe specified value {270 320 kpa,2.8 3.3 kgf lcm', 40 47 psi), after making sure that thefuel pump and the fuel pressure regulator are OK.
1. Remove the fuel pump(seepagell-'153).
2. Remove the
Install in the reverse order of removalwith a new
base gasket (B) and a new o-ring (C), then check
these items:
' When connecting the wire harness, make sure
the connection is secure and the terminal (D) is
firmly locked into place.. When installing the fuel gauge sending unit iE),make sure the connection is secure and the
connector is firmly locked into place. Be carefulnot to bend or twist it excessively.
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fuel filter (A).
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Fuel Pump/Fuel Gauge Sending Unit Replacement
SpecialTools Required
Fuel sender wrench 07XAA-001010A
1.Relieve the fuel pressure (see page 11-144).
Remove the fuel fill cap.
Remove the seat cushion (see page 20-80).
Remove the access panel (A)from the floor.
5.
7.
Disconnect the fuel pump 5P connector (B).
Disconnect the quick-connect fitting {C) from the
fuel tank unit.
Using the special tool, loosen the fuel tank unit
locknut (A).
93 N.m19.5 kgf.m,69 lbf.ftl
11-153
8. Remove the locknut (A) andthefuel tankunit.
9. Remove the stopper {O). Release the hook (P) and
remove the fuel filter (B), the fuel gauge sending
unit (C). the case (D), the wire harness (E), and the
fuel pressure regulator (F).
10. When connecting the fuel tank unit, make sure the
connection is secure and the suction filter (G) is
firmly connected to the f uel pump (H).
11. Install the fuel tank unit in the reverse order of
removal with a new base gasket (l)and new o-rings
(J), then check these items:
. When connecting the wire harness, make sure
the connection is secure and the connector (K) is
firmly locked into the place.
. When installing the f uel gauge sending unit,
make sure the connection is secure and the
connector is firmly locked into place. Be careful
not to bend or twist the connector excessively.. When installing the fueltank unit, align the marks
(L) on the fuel tank (M) and the fuel tank unit (Ni

PCV Valve Inspection and Test
2.
1. Check the PCV valve (A), hoses {B), and
connections for leaks or restrictions.
At idle, make sure there is a clicking sound from the
PCV valve when the hose between the PCV valve
and intake manifold is lightly pinched {A)with your
fingers or pliers.
lf there is no clicking sound, check the PCV valve
grommet for cracks or damage. lf the grommet is
OK. reDlace the PCV valve and recheck.
PCV Valve Replacement
'LDisconnect the PCV hose.
Remove the PCV valve (A).
3. Install
with a
(4.5 kgf.m,33 lbf.ft)
the parts in the reverse order of removal
new gasket (B).
11-169

Transmission Fluid Inspection and
Replacement
'1. Park the vehicle on level ground, and turn the
engine OFF.
2. Remove the oilfiller plug (A) and washer (B), check
the condition of the fluid, and make sure the fluid is
at the proper level (C).
lf the transmission fluid is diny, remove the drain
plug (D) and drain the fluid.
A44 N.m{4.5 kgt.m,33 rbr.ftl
Reinstall the drain plug with a new washer, and
refill the transmission fluid to the proper level.
Oil Capacity
1.5 0 (1.6 US (F) at tluid change
1.7 0 {1.8 US qt) at overhaul
Always use Honda Manual Transmission Fluid
(MTF). Using motor oil can cause stiffer shifting
and noise because it does not contain the proper
additives.
Reinstall the oil filler plug with a new washer.5.
13-3
Back-Up Light Switch Test
1. Disconnectthe back-up light switch (A) connector.
Check for continuity between the back up light
swilch 2P connector No. 1 and No.2 terminals.
There should be continuity when the shift lever is in
reverse.
lf necessary, replace the back-up light switch.
Apply liquid gasket (P/N 08718-0001), and install it
on the transmission housing.
2.
3.

-26 x 1,0 mmz/ / 15 N.m--' / {1 5 kgf m,€t I 11 tbf.ft)
Fl g
E
6, lnstallthe reverse lock cam.
Select the proper size 72 mm shim (A) according to
the measurements made during the Mainshaft
Thrust Clearance Adjustment (see page '13-43),
Installthe oil gutter plate (B), oilguide plate l\4, and
72 mm shim into the transmission housing (C).
7.
8. Remove the dirt and oil f rom the tramsmission
housing sealing surface. Apply liquid gasket (P/N
08718-0001) to the sealing surface. Be sure to seai
the entire circumference of the bolt holes to
prevent oil leakage.
NOTE: lf 5 minutes have passed after applying
liquid gasket, reapply it and assemble the housings.
Allow it to cure at least 20 minutes after assembly
before filling the transmission with oil.
- - -Liquid gasket
{cont'd)
13-47

Manual Transmission
Transmission Reassembly (cont'dl
9. Install the 14 x 20 mm dowel pins (A).
34 N.m(3.5 kgf.m,25 rbf.ft)
Set the tapered cone ring (B) as shown. Place the
transmission housing over the clutch housing,
being careful to line up the shafts.
10.
13-48
11. Lower the transmission housing the rest of the wayas you expand the 72 mm snap ring {C). Release
the snap ring so it seats in the groove of the
countershaft bearing.
12. Check that the 52 mm snap ring is securely seatedin the groove of the countershaft bearing.
Dimension O as instalted: 3.3 6.0 mm
{0.13 0.24 in.l
Apply liquid gasket (P/N 08718-0001) to the threads
of the 32 mm sealing cap {D), and install it on thetransmission housing,
Install the transmission hangers A. and B, and the
8 mm flange bolts finger-tight.
13.
't4.
15.
8 x 1.25 mm27 N.m(2.8 kgf.m.20 rbf.ft)
(t
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e././
Tighten the 8 mm flange bolts in a crisscross
Pattern In several steDs.
(

16. Remove the dirt and oil from the shift iever cover
sealing surface. Apply liquid gasket (P/N 08718-
0001) to the sealing surface.
NOTE: lf 5 minutes have passed after applylng
liquid gasket. reapply it and assemble the housings.
Allow it to cure at least 20 minutes after assembly
before filling the transmission with oil.
- - -Liquid gasket
17. Installthe 8 x 14 mm dowel pins (A). clutch line clip
bracket (B), and change lever assembly (C).
12 N.m (1.2 kgf.m,9lbt ft)
18. Apply liquid gasket (Pi N 08718-0001) to the threads
of the interlock bolt (D), and install it on the
transmission housing.
6x1.0mm
19. Installthe drain plug (A), filler plug (B), and 10 mm
flange bolt (C) with new washers.
A39Nm(4.0 kgf m,33 tbl.ft)
20.
/..l-.=,'-Bg ^ 44N.m
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-.-t ?0, ,.ru ^44 N m {4.5 kgt m,33lbf.ft}
Installthe detent bolts (A), spring, and steel balls
with new washers.
{3.0 kgf.m.22lbf.ft)
Apply liquid gasket {P/N 08718-0001}to the threads
oithe back-up light switch (B), and install it in the
transmission housing.
(cont'd)
21.
13-49