2002 HONDA CIVIC valve gasket

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EXHAUST VALVESEAL
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CYLINDER HEADRemoval, page 6'23Inspection, page 6-25Installation, page 6-39
EXHAUST VALVERemoval, page 6-31Installation, page 6-37
INTAKE VALVERemoval, page 6 31Installation, page 6 37
CYLINDER HEADGASKET
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II ^-'-- 9E4LI I U- Replacement, Page 6-31
He,tl E- _-/ |NTAKE VALVEY I 1.- GUIDE
U Replacement, page 6-33
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HEAT SHIELD
6-5

Cylinder Head
Engine Compression Inspection
1. Warm up the engine to normal operating
temperature (cooling fan comes on).
2. Turn the ignition switch OFF.
3. Remove the intake manifold cover (see step 1 onpage 6-22).
4, Disconnect all four injector connectors.
5. Start the engine, and let it run until it stalls.
6. Remove the iour ignition coils (see page 4-18).
7. Remove the four spark plugs.
8. Attach the compression gauge to the spark plug
note.
6-6
V,
\
9.
10.
Open the throttle fully, then crank the engine with
the starter motor and measure the compression.
Compression Pressure
Above 930 kpa (9.5 kgf/cm', 135 psi)
Measure the compression on the remaining
cylinders,
Maximum vadation
Within 200 kPa (2.0 kgf/cm', 28 psi)
lf the compression is not within specifications,
check these items, then remeasure the
compressron.
. Damaged orworn valves and seats. Damaged cylinder head gasket. Damaged or worn piston rings. Damaged orworn piston and cylinder bore
11.
\-

Cylinder Head
Rocker Arm Assembly Installation
:,ean and dry the No. 5 rocker shaft holder mating
surfaces.
eeassemble the rocker arm assembly (see page 6-
21 t.
Apply liquid gasket, P/N 08718-0009, evenly to the
:ylinder head mating surface ofthe No. 5 rocker
shaft holder.
\OTE: Do not lnstall the parts if 5 minutes or more
rave elapsed since applying liquid gasket. Instead,'eapply liquid gasket after removing old residue.
Insert the bolts (A) into the rocker shaft holder, then
install the rocker arm assembly (B) on the cylinder
head.
Apply liquid gasketalong the broken line.
6-38
l-
\
5.
6.
Remove the bolts from the rocker shaft holder.
Make sure the DUnch marks on the variable valve
timing control (VTC) actuator and exhaust camshaft
sprocket are facing up. then set the camshafts (A) in
the holder.
Set the camshaft holders (B) and cam chain guide B
(C) in place.
Tighten the bolts to the specified torque.
Specified torque:
8 mm bolts: 22 N.m (2.2 kgf.m, 16 lbl.ft)
6 mm bolts: 12 N.m {1.2 kgf.m,8.7 lbf.fil
6 mm bolts: @),@.@
lnstall the cam chain (see page 6-15). and adjust the
valve clearance (see page 6-9).
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7.
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14. Installthe water bvpass hose.
15. Installthe air cleaner housing (see step 37 on page
5-15).
16. Installthe intake manifold (see page 9-5).
17. Installthe exhaust manifold (see page 9-7).
'18. Installthe cam chain (see page 6-15).
19. Adjust the valve clearance (seepage6-9).
20. Installthe drive belt (see page 4-26).
21. Clean the battery posts and cable terminals with
sandpaper, then assemble them and apply grease
to prevent corrosion.
22. After installation, checkthatall tubes, hosesand
connectors are installed correctly.
23. Inspectforfuel leaks. Turn the ignition switch ON
{ll) {do not operate the starter) so that the fuel pump
runs for about 2 seconds and pressurizes the fuel
line. Repeat thls operation two or three times, then
check for fuel leakage at any point in the fuel line.
24. Refillthe radiator with engine coolant, and bleed
air from the cooling system with the heater valve
open (see page 10-6).
25. Inspect the idle speed (see page 11-'138).
26. Inspect the ignition timing (see page 4-17).
Gylinder Head Cover lnstallation
1. Thoroughly clean the head cover gasket and the
groove.
2. Installthe head cover gasket (A) in the groove of
the cylinder head cover (B).
Check that the mating surfaces are clean and dry.
Apply liquid gasket. P/N 08718-0009, on the chain
case and the No.5 rocker shaft holder mating areas.
NOTE: Do not install the parts if 5 minutes or more
have elapsed since applying liquid gasket. Instead,
reapply liquid gasket after removing old residue.
(cont'd)
6-41

1.
2.
3.
Exhaust Manifold Removal and Installation
Remove the VTEC solenoid valve (see page 1 '1-128).
Remove the driveshaft heat shield (see page 16-19).
Remove the cover and exhaust manifold bracket, then remove the exhaust manifold.
8x 1.25 mm22 N.m(2.2 kgf.m, 16lbt.ftl
#'-.-
GASKETReplace.
SELF-LOCKING NUT10 x 1.25 mm44 N.m {4.5 ksf.m, 33lbt.ftlBeplace.
10 x 1.25 mm44 N.m(4.5 kgt.m, 33 lbl ftlReplace.
WASHEB8 x 1-25 mm22 N.m (2.2 kgI m, 16lbf.ft)Replace.Tighten the bolts in steps,alternating side to side.10 x 1.25 mm14 N.m{4.5 kgl.rn, 33lbf.ft)
5.
Install the exhaust manifold and tighten the bolts/nuts in a crisscross pattern in two or three steps, beginning withthe inner bolt.
Installthe other parts in the reverse order of removal.
9-7

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

A/C System Tests
Pressure Test
Test resultssvmotom3DGaUSeDischarge (high)pressureabnormally high
After stopping compressor, pressure
drops quickly, and then continues toAir in systemRecover, evacuate (see page 21-54),and recharge with specified amount{see oaoe 21 55).
Beduced or no air flow throughcondenserClogged condenser or radiatorfinsCondenser or radiator fan not
CleanCheck fan voltage and rpm.Check fan direction.
Line to condenser is excessively hot.Restricted flow of refrigerant inReplace restricted lines.
Discharge pressureHigh and low pressures are balancedsoon after stopping compressor, Lowside is hioherthan normal.
. Faulty compressor dischargevalve. Faultv comoressor seal
Beplace the compressor.
Outlet of expansion valve is notfrosted, low pressure gauge indicatesFaulty expansion valveMoisture in system
. Replace the expansion valve.. Recover, evacuate for at least30 minutes, and recharge withsDecified amount.
Suction (low)pressureabnormally low
Expansion valve is not frosted, andlow-pressure line is not cold. Lowpressure gauge indicates vacuum,
' Frozen expansion valve(Moisture in system). Faulty expansion valve
Recover, evacuate for at least30 minutes, and recharge withspecified amount.Beplace the expansion valve.
Discharge temperature is low, and theair flow from vents is restricted.Frozen evaporatorRun the fan with compressor off, thencheck evaooratot temoerature sensor.
Exoansion valve is frosted.ean or reolace,
Receivetdryer outlet is cool, and inletis warm (should be warm duringooeralton),
Clogged receiver/dryerReplace receaver/dryer.
Suction pressureabnormally highLow pressure hose and check joint arecooler than the temperature aroundevaoorator,
Expansion valve open too longBepair or replace.
Suction pressure is lowered when..nrlenser is cooled bv water.Excessive refrigerant in systemRecover, evacuate, and recharge withqnp.ifie.lamo'rnr
High and low pressure are equalizedas soon asthecompressor is stopped,and both gauges fluctuate while
Faulty gasketFaulty high pressure valveForeign panicle stuck in high
Replace the compressor.
Suction anddaschargepressuresabnormallv hioh
Reduced air flow through condenser.. Clogged condenser or radiatorfins' Condenser or radiator fan notworkino orooerlv
CleanCheck voltage and fan rpm.Check fan direction.
Suction anddischarge pressureabnormally low
Low-pressure hose and metalendareas are coolerthan evaoorator,Clogged or kinked low-pressurehose oartsRepair or replace.
Temperature around expansion valveis too low compared with that aroundClogged high-pressure lineRepair or replace,
Fefrigerant leaks:omoressor clulch is dirtv.:omoressor shaft seal leakinqReolace the comDressor,
lomoressor bolt(s) are dirtv.no around bolt(s)Tiohten bolt{s) ot reolace comDressor,
;omDressor oasket is wet with oil.ietnoace the comoressor.
(cont'd)
21-57