1996 HONDA CIVIC ring gap

Forward Clutch
Reassembly {cont'd)
9. Install the disc spring.
NOTE: Installthe disc spring in the direction shown.
- "arr"" o"u*
11.
Soak the clutch discs thoroughly in CW Fluid for a
minimum of 30 minutes.
Starting with a clutch plate. alternately install the
clutch plates and discs. Install the clutch end plate
with flat side toward the disc.
NOTE: Before installing the plates and discs, make
sure the inside of the clutch drum is free of dirt or
other toreign matter.
CLUTCH END PLATEInstall in this dir€ction.
10.
DISC SPRING
14-326
12. Installthe snap ring.
13. Verify that the snap ring end gap is correct.
SNAP RING
CLUTCH
Minimum 7.9 mm (0.31 ini

Transmission Housing Bearings
Driven Pulley Shaft Bearing Replacement
1. To remove the driven pulley shaft b'earing trom the
transmission housing, expand the snap ring with
snap ring pliers, then push the bearing out using
the specialtools and a press as shown.
NOTE: Do not remove the snap ring unless it's nec-
essary to clean the groove in the housing.
07749 - 001(xDo
ATTACHMENT,72x75mm07746 - (x'l05U)
077i() - 001(xrco
14-334
SNAP RING
Expand the snap ring with snap ring pliers, insert
the new bearing part-way into the housing using
the special tools and a press as shown. Install the
bearing with the groove facing outside the housing.
NOTE: Coat all pans with CW Fluid.
Release the pliers, then using the special tools,push the bearing down into the housing until the
snap ring snaps in place.
BEARING
ATTACHMENT,72x75mm07746 - OO1 0600
GROOVE
SNAP RING
After installing the bearing verify the following:
o The snap ring is seated in the bearing and hous-
ing grooves.
. The ring end gap is correct.
END GAP| 0 -9 mm
l0 - 0.35 inl

1.
7.
lnstall the ATF feed pipe in the transmission hous-
ing, and install the three ATF feed pipes with new
O-rings in the transmission housing,
Install the two dowel pins and new transmission hous-
ing gasket on the transmission housing.
Push the control shaft assembly toward the outside
of the transmission housing, then install the inter-
mediate housing assembly (four bolts).
lnstall the manual valve body separator plate and
the two dowel pins on the intermediate housing,
then install the rnanual valve body with the detent
spring (five bolts).
Put the control shaft assembly back, then install the
roller in the intermediate housing.
lnstall the reverse brake piston in the intermediate
housing.
Install the spring retainer/return spring assembly on
the reverse brake Piston.
NOTE: Installthe return springs on the spring guides
of the reverse brake piston securely
tnstall the special tool to compress the return spring
as shown.
REVERSE BRAKESPRING COMPRESSOR07TAE - P4V0110
6.
L
1
CAUTION: lf the spring retainer tab is on the reverse
brakc piston, the spring rstainer may be damaged'
Be sure the spring retainer tab is not on the piston'
rp
SPECIALTOOL REVERSEBRAKE
-^
14-339
10.
9.
14.
Compress the return springs, then install the snap
ring in the intermediate housing above the spring
retainer.
Verify that the snap ring end gap is correct'
Mini
/,,- '-t,,,,.
// \i/ ',r
'1 ,
.r' //'/. .-J?RINGSNAP
mum 15 mm 10.59 in)
Soak the reverse brake discs thoroughly in CVT
Fluid for minimum 30 minutes.
Installthe disc spring on the reverse brake piston'
Starting with a reverse brake plate, alternately
install the reverse brake plates and discs lnstall the
reverse brake end plate, and the snap ring'
Measure the clearance between the reverse brake
end plate and the top disc with a dial indicator' Zero
the dial indicator with a reverse brake end plate
lowered, and lift it up to the snap ring The distance
that the reverse brake and plate moves is the clear-
ance between the reverse end plate, and the top
disc.
NOTE: Take measurements in at least three places'
and use the average as the actual clearance'
STANDARD: 0.45 - 0.75 mm (0.018 - 0'030 in)
{cont'd)
11.
12.
13.

Transmission
Reassembly (cont'd)
35. Verify that the snap ring end gap is correct.
Minimum 18 mm (0.71 in)
,/\,
."or**ol!/'
Install the manual valve body lines A and B wkhnew O-rings on the manual valve body and the inter-mediate housing.
6x1.0mm12 N..n (1.2 kgt m,8.7 rbtft)
8 x 1.25 mm37 N.m 13.8 kgf.m,27 lbf.ftl
flgENDCOVER
37.
ENDCOVER GASKET
DOWEL PINSO-RINGS
MANUAL VALVEBODY LINE A
uaNYuAL VALVE
Install the two dowel pins and new end cover gas_ket on the intermediate housing, then install new O_rings on the ATF feed pipes.
Install the end cover (three 6 mm bolts, eleven g
mm bolts).
NOTE: Install the nine 8 mm bolts in the end cover(two 8 mm bolts remain in the end cover) thentighten the eleven 8 mm bolts.
14-342
39. Install the park pawl, spring, and shaft on the trans-mission housing, then move the control lever to anvgear other than E position.
THBUST SHIM,25x35mm
SNAP RINGCOTTERRETAINER
COTTERS,25.5 mmSelective pan
START CI.UTCHASSEMBLY
O.RINGS
PARKPAWL SPRING
PARK PAWL
,10, Install the secondary gear shaft with setected 25 x35 mm thrust shim (see page ,14-328).
41. Wrap the driven pulley shaft splines with taDe toprevent damage to the O-rings, then install new O_rings.
42, Assemble ths secondary drive goar assembly in thestart clutch assembly, then installthem on the drivenpulley shaft,
43. Pull the handle of the special tool up, then installthe tip of it into the driven pulley shaft hole, and setthe special tool on the stan clutch.
CAUTION: Whib in3trling thc st rt ctutch and rh.3ocondlry driye g.!r a3sombly using lh€ specialtool, bo 3urc nol to sllow du3t or olher foraign par_ticlos to ontq into tho iransmbsion.
I c,rr r,unar".
SECONDARYGEAR SHAFT
START CLUTCHINSTALLER07TAE - P4V0r30
SECONDARYORIVE GEAFASSEMBLY

Ball joint Boot Replacement
'96 - '97 models:
1. Remove the boot set ring and the boot.
CAUTION: Do not contaminate the boot installa.tion section with grsase.
2. Pack the interior of the boot and lip with grease.
3. Wipe the grease off the sliding surface of the ballpin, then pack the lower area with fresh grease.
CAUTION:
. Keep grease off the boot installation seciion andthe tapered s€ction ot the ball pin.
. Do not allow dust, dirt, or oth6r foreign materi-
als to 6nt8r the boot.
LIPEALL PIN TAPEREDSECTIONWipe off the grease.
INSTALLATION
SECTIONWipe off the grease.
Install the boot in the groove of the boot installation
section securely, then bleed the air from the boot.
-6lrBOOTSECTIONWipe off the grease
4.
ADJUSTING BOLTAdjust the depthby turning the bolt.
SET RING
Adjust the special tool with the adjusting bolt untilthe end of the tool aligns with the groove on theboot. Slide the set ring over the tool and into posi-
UOn.
CAUTION: After installing the boot, qhsck the ballpin tapered section for grease contamination andwipe it it necGsary.
17-68
'98 - '00 models:
CAUTION: Do not contaminato the boot installation sec-tion with grease.
1. Remove the boot from the tie-rod end, and wiDe theold grease off the ball pin.
2. Pack the lower area ofthe ball pin with fresh grease.
3. Pack the interior of the new boot and liD with freshgrease.
CAUTION:
. Keop groasc ott tho boot installalion sestion andth. iapored s.ction if th€ ball pin.
. Do not allow dust. dirt, or other foreign materials
to entor tho boot.
BOOT INSTALLASECTIONWipe off the gr€ase,
Install the new boot using the special tool as shownbelow.
NOTE: The boot must not be a gap atthe boot installation sections.
LtP .6r
J_/
ru
CAUTION: Aftor installing the boot, chock the batlpin tapgred section tor grgase cortamination. andwipe it it n€ces3ary.
FRONT HUBDIS/ASSEMBLY TOOL07965 - SA5o500

Troubleshooting
SymptomProbable Cause
Water leaks1. Clogged drain tube.
2. Gap between glass weatherstrjp and roof panel.
3. Defective or improperly installed glass weatherstrip.
4. Gap between drain seal and roof panel.
Wind noise'1. Excessive clearance between glass weatherstrip and roof panel.
Motor noise1. Loose motor.
2. Worn gear or bearing.
3. Cable assembly deformed.
Glass does not move, but motor turns'1. Clutch out of adjustment.
2. Foreign matter stuck between guide rail and slider.
3. lnner cable loose.
4. Cable assembly not attached properly.
Glass does not move and motor does not turn
{glass can be moved with moonroof wrench)
1. Blown fuse,
2. Faulty switch.
3. Battery run down.
4. Defective motor.
5. Faulty relay.
D
Glass Height Adjustment
The roof panel should be even with the glass weather-
strip, to within 1.7 :lr3 mm (0.07 :3:31 in.) all the way
around. lf not, open the giass fully, and:
GLASS WEATHERSTRIP
1. Remove the bracket cover.
Loosen the nuts, and install the shims between the
glass frame and glass bracket as shown.
Shim thickness: Front max.3 mm 10,12 in.l
Rear max. 2 mm 10.08 in.)
Repeat on opposite side i{ necessary.
)
5x1.0mm9.8 N.m 11.0 kgf m,7.2 rbtft)
SRACKETCOVEB
----------1>
6x1.0mm9.8 N.m {1.0 kgtm,7.2 tbf.ft)
1.7 tl.8 mm
{0.07 :3 3i in.}
20-51

Compressor (SANDENI
Replacement
1.lf the compressor is marginally operable, run the
engine at idle speed, and let the air conditioner
work for a few minutes. then shut the engine off.
Disconnect the negative cable from the battery.
Recover the refrigerant with a recovery/recycling/
charging station (see page 22-27l..
Remove the bolts, then disconnect the suction and
discharge lines from the compressor.
NOTE: Plug or cap the lines immediately after dis-
connecting them to avoid moisture and dust con-
tamination.
6xl.0mm
Remove the condenser (see page 22-44).
NOTE: Do not disconnect the discharge hose from
the condenser.
Remove the power steering pump belt (see section
17 t.
22-30
24 N.m l2.ia kgt.m, 17 lbf.ftl
7. Loosen the center nut of the idler pulley and the
adjusting bolt. then remove the A,/C compressor belt
from the pulleys. Remove the two mounting bolts
from the left front mount, then remove the ly'C com-pressor belt by passing it through the gap befiiveen
the bodv and the left front mount.
ADJUSTING BOLT
1.0 x 1.25 mmaa N.m 14.5 kgf,m, 33 bnft)
8. Remove the four mounting bolts and the compressor.
CENTER NUT
COMPRESSOR

Compressor (DENSO)
Replacement
1.lf the compressor is marginally operable, run the
engine at idle speed, and let the air conditioning work
for a few minutes, then shut the engine off
Disconnect the negative cable from the battery'
Recover the refrigerant with a recovery/recycling/
charging station lsee page 22-271
Remove the each bolt, then disconnect the suction
and discharge lines from the compressor' Plug or
cap the lines immediately after disconnecting them
to avoid moisture and dust contaminatlon.
6 x '1.0 mm9.8 N.m (1.0 kgf m,7.2 lbfft)
Remove the condenser, but do not disconnect the dis-
charge hose from the condenser (see page 22-441'
Remove the power steering pump belt (see sectron
17]-.
7. Loosen the pivot bolt of the idler pulley bracket and
the adjusting bolt. then remove the A,/C compressor
belt from the pulleys. lf necessary, remove the mount-
ing bolts from the left front mount. then remove the
fuC compressor belt through the gap between the
bodv and the left front mount.
'10 x 1,25 mm4,0 N.m (,1.5 kgf'm. 33 lbt ftl
Disconnect the compressor clutch connector, then
remove the mounting bolts and the compressor'
PIVOT BOLT10 x 1.25 mm4,1 N.m (4.5 kgt'm,33 lbfft)
COMPRESSOR
24 N.m (2.4 kgf m, 17 lbf ftl
(cont'd)
22-37