Honda Civic Service Manual: Water Passage Removal and Installation (K24Z7)

Honda Civic Service Manual / Powertrain / Engine / Engine Cooling / Water Passage Removal and Installation (K24Z7)

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1.	Radiator Cap

Wait until the engine is cool, then carefully remove the radiator cap.

2.	Vehicle Lift

Raise the vehicle on a lift, and make sure it is securely supported.

3.	Radiator Coolant - Replacement

Loosen the drain plug (A), and drain the coolant.

4.	Engine Cover

Remove the engine cover.

5.	Fuel Filler Cap

Remove the fuel fill cap to relieve the pressure in the fuel tank.

6.	HDS DLC - Connection

NOTE: For specific operations, refer to the user's manual that came with the Honda Diagnostic System (HDS). Make sure the HDS is loaded with the latest software.

Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.

Turn the ignition switch to ON (II).

Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.

7.	Fuel Pump Off

Turn the ignition switch to ON (II).

From the INSPECTION MENU of the HDS, select Fuel Pump OFF, then start the engine, and let it idle until it stalls.

NOTE:

Do not allow the engine to idle above 1,000 rpm or the ECM/PCM will continue to operate the fuel pump.

Pending or Confirmed DTC may be set during this procedure. Check for DTCs, and clear them as needed.

Turn the ignition switch to LOCK (0).

8.	Battery Terminal - Disconnection

Make sure the ignition switch is in LOCK (0), or the vehicle ignition in the OFF mode.

Disconnect and isolate the negative cable with the battery sensor (A) from the battery.

NOTE:

Always disconnect the negative side first.

To protect the battery sensor connector (B) from damage, do not hold it when removing the negative terminal.

Do not disconnect the battery sensor from the negative terminal (C).

Disconnect the positive cable (D) from the battery.

9.	Fuel Pressure - Relieving

Remove the bracket (A).

Remove the quick-connect fitting cover (A).

Check the fuel quick-connect fitting for dirt, and clean it if needed.

Place a rag or shop towel over the quick-connect fitting (A).

Disconnect the quick-connect fitting: Hold the connector (A) with one hand, and squeeze the retainer tabs (B) with the other hand to release them from the locking tabs (C). Pull the connector off.

NOTE:

Be careful not to damage the line (D) or other parts.

Do not use tools.

If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily.

Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one.

10.	Intake Air Duct

Remove the intake air duct.

11.	Intake Manifold Assembly

Remove the intake manifold bracket.

Remove the intake manifold (A).

Disconnect the PCV hose (A).

12.	Splash Shield

Remove the splash shield (A).

13.	Drive Belt

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Move the auto-tensioner (A) using the belt tension release tool in the direction of the arrow to relieve tension from the drive belt, then remove the drive belt.

14.	Idler Pulley Base Assembly

Remove the idler pulley base.

15.	Auto-Tensioner Assembly

Remove the auto-tensioner.

16.	Front Grille Cover

Remove the front grille cover (A).

If necessary, remove the front bumper upper duct (A).

17.	Bulkhead - Removal

Disconnect the connectors (A).

Remove the harness clamps (B).

Remove the bulkhead (A).

18.	A/C Condenser Fan Shroud Assembly

Remove the A/C condenser fan shroud assembly (A).

19.	Alternator

Remove the three bolts securing the alternator.

Disconnect the connector and the cable.

Remove the alternator.

20.	Compressor Assembly - Move

	1.	Remove the A/C compressor without disconnecting the A/C hoses. Do not bend the A/C hoses excessively.
		NOTE: Hang the A/C compressor with a wire tie.

21.	Radiator Connecting Pipe

Disconnect the heater hose (A) and the water bypass hose (B).

Remove the harness clamp (C) and the connecting pipe mounting bolt (D).

Remove the harness clamps (A) and the connecting pipe (B).

22.	Water Passage Assembly

Disconnect the PCV hose (A) and water bypass hose (B).

Remove the water passage (C).

23.	Thermostat Housing

Remove the thermostat housing

24.	WATER PUMP ASSEMBLY

Remove the water pump.

1.	WATER PUMP ASSEMBLY

Install the water pump (A) with a new O-ring (B)

2.	Thermostat Housing

Install the thermostat housing (A) with a new O-ring (B).

3.	Water Passage Assembly

Clean and dry the water passage mating surfaces.

Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the engine block mating surface of the water passage, and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A).

If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

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Install the water passage (A) with a new O-ring (B).

NOTE:

Wait at least 30 minutes before filling the engine with coolant.

Do not run the engine for at least 3 hours after installing the water passage.

Connect the PCV hose (C) and the water bypass hose (D).

4.	Radiator Connecting Pipe

Install the connecting pipe (A) with a new O-ring (B).

Install the harness clamps (C).

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Install the connecting pipe mounting bolt (A) and the harness clamp (B).

Connect the heater hose (C) and the water bypass hose (D).

5.	Compressor Assembly - Move

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Install the A/C compressor.

6.	Alternator

Connect the connector and the cable.

Install the alternator.

7.	A/C Condenser Fan Shroud Assembly

Install the A/C condenser fan shroud assembly (A).

8.	Bulkhead - Installation

Install the bulkhead (A).

Install the harness clamps (A).

Connect the connectors (B).

9.	Front Grille Cover

Install the front bumper upper duct (A).

Install the front grille cover (A).

10.	Auto-Tensioner Assembly

Install the auto-tensioner.

11.	Idler Pulley Base Assembly

Install the idler pulley base.

12.	Drive Belt

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Install the drive belt.

13.	Splash Shield

Install the splash shield (A).

14.	Intake Manifold Assembly

Connect the PCV hose (A).

Install the intake manifold (A) with new gaskets (B).

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Install the intake manifold bracket.

15.	Intake Air Duct

Install the intake air duct.

16.	Engine Cover

Install the engine cover.

17.	Fuel Filler Cap

Install the fuel fill cap.

18.	Battery Terminal - Reconnection

NOTE: If the battery performs abnormally, test the battery.

Clean the battery terminals.

	2.	Connect the positive cable (A) to the battery.
		NOTE: Always connect the positive side first.

	3.	Connect the negative cable and the battery sensor (B) to the battery.
		NOTE: To protect the battery sensor connector (C) from damage, do not hold it when installing the negative terminal.

Apply multipurpose grease to the terminals to prevent corrosion.

19.	HDS DLC - Connection

Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.

Turn the ignition switch to ON (II).

Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.

20.	Fuel Pump On

	1.	From the INSPECTION MENU of the HDS, select Fuel Pump ON.
		NOTE: Pending or Confirmed DTC may be set during this procedure. Check for DTCs, and clear them as needed.

Turn the ignition switch to LOCK (0).

21.	Fuel Line Leak Check

Turn the ignition switch to ON (II) (but do not operate the starter motor). The fuel pump runs for about 2 seconds, and fuel pressure rises. Repeat this two or three times, then make sure there are no fuel leaks.

22.	Intake Manifold After Install - Check

After installation, check that all tubes, hoses, and connectors are installed correctly.

23.	Radiator Coolant - Replacement

Follow the chart and pour coolant into the radiator up to the base of the filler neck.

NOTE:

Use Honda Long Life Antifreeze/Coolant Type 2, and if necessary add Honda Extreme Cold Weather Antifreeze/Coolant Type 2 (concentrate). Using a non-Honda coolant can result in corrosion, causing the cooling system to malfunction or fail.

Honda Long Life Antifreeze/Coolant Type 2 is a mixture of 50 % antifreeze and 50 % water. Honda Extreme Cold Weather Antifreeze/Coolant Type 2 is a 100 % concentration coolant. Do not add water to either coolant.

If the vehicle is regularly driven in very low temperatures (below -22 °F ( -30 °C)), a 60 % concentration of coolant should be used.

Operation	Vehicle Usage (Desired Mixture)	Current Mixture	Coolant Drain	Add Amount of Honda Extreme Cold Weather Antifreeze/Coolant Type 2 (100 % concentrate)	Then add Honda Long Life Antifreeze/Coolant Type 2 (50/50)
Coolant Change	Normal Area (50/50)	50/50 60/40 unknown	Drain radiator, engine block, and reservoir	None	Top off the cooling system
	Very Cold Area (60/40)	50/50 unknown	Drain radiator, engine block, and reservoir	About 1.3 L (44 fl oz)
	Very Cold Area (60/40)	60/40	Drain radiator, engine block, and reservoir	About 1.2 L (41 fl oz)
Engine Overhaul	Normal Area (50/50)	-	-	None
Engine Overhaul	Very Cold Area (60/40)	-	-	About 1.2 L (41 fl oz)
Coolant Winterizing	Very Cold Area (60/40)	50/50	Drain about 2.0 L (68 fl oz) from radiator	About 1.2 L (41 fl oz)
Coolant Winterizing	Very Cold Area (60/40)	unknown*	Drain radiator, engine block, and reservoir	About 1.2 L (41 fl oz)

*: When you want to winterize the coolant with the minimum amount of coolant change but the current coolant concentration in the vehicle is unknown, you must drain all coolant from the cooling system.

Engine Coolant Capacities (Including the coolant reservoir capacity of 0.475 L (0.1255 US gal))

Except K24Z7 engine
	Manufacturer	Capacity
At Coolant Change	DENSO	5.59 L (1.477 US gal)
At Coolant Change	TRAD	5.50 L (1.453 US gal)
After Engine Overhaul (M/T)	DENSO	6.42 L (1.696 US gal)
After Engine Overhaul (M/T)	TRAD	6.33 L (1.672 US gal)
After Engine Overhaul (A/T)	DENSO	6.56 L (1.732 US gal)
After Engine Overhaul (A/T)	TRAD	6.47 L (1.709 US gal)
After Engine Overhaul (CVT)	DENSO	6.52 L (1.722 US gal)
After Engine Overhaul (CVT)	TRAD	6.43 L (1.699 US gal)

Engine Coolant Capacities (Including the coolant reservoir capacity of 0.475 L (0.1255 US gal))

K24Z7 engine
	Capacity
At Coolant Change	5.5 L (1.45 US gal)
After Engine Overhaul	6.7 L (1.78 US gal)

24.	Maintenance Minder Reset

After doing all procedures, select the individual maintenance item you wish to reset with the HDS..

Coolant Replacement (R18A9)

1. Radiator Cap 1. Wait until the engine is cool, then carefully remove the radiator cap. ...

Thermostat

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Honda Civic Service Manual: Water Passage Removal and Installation (K24Z7)

Coolant Replacement (R18A9)

Thermostat

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