1996 HONDA CIVIC torque sequence

INTRODUCTION
How to Use This Manual
This manual contains information for the 1996 - 2000 ClVlC. lt is
divided into 24 sections. The first page of each section is marked
with a black tab that lines up with its corresponding thumb index
tab on this page and the back cover. You can quicklY find the first
page of each section without looking through a tull table ol con_
tents. The symbols printed at the top corner of each page can also
be used as a quick reference system.
Each section includesl
1. A table of contents, or an exploded view index showing:
. Parts disassemblY sequence.
. Bolt torques and thread sizes.
. Page references to descriptaons in text
2. Disassembly/assembly procedures and tools.
3. Inspection.
4. Testing/troubleshooting.
5. Repair.
6. Adjustments.
Special Information
!@ Indicates a sttong possibility of sover. perconal iniurY
or loss ol lite if in3tructions are not follow€d.
GAUTION: Indicaiqs a possibility ot p€lsonal injury or 6quipm.nt
damage il instiuc'tions are not followod
t Noncali-. pu.po.. ot thes6 messages is to help provent demage lo lhe
vehicle, other property, or the €nvironment.
NOTE: Gives helpful information.
CAUTfON: Detaifed descriptions ol standard workshop p.oceduro3.
safoty principles and servico operations are not included. Pleaso
note that this manual contain3 wetnings and cautions against
some sp6cific sGrvic€ methods which could cause PERSONAL
INJURY, damage a vohicle or make il unsafe. Ploase undorstand
that these warnings cannot covsr all conceivable weys in which
service. whelher or not iocommgndod bY HONDA. mighi bo done,
or ol tho possiblG hazardou3 consgquonces of ev€aY conceivablg
way, nor could HONDA invqstigato all 3uch way3. AnYono using
sgrvice procedures or lools, whethei or nol rGcommendod bY
HONDA, must srtisty hifisetf thoroughlylhat nohher pefsonal sefety
nor vehiclc satsty will be reopardi2ed.
All intormation contained in this manual is based on the latest prod
uct information available at the time oI 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 trans'
mitted, in any form by any means, electronic, mechanical, photo
copying, recording, or otherwise, without the prior written permis-
sion of the publisher. This includes text, figures and tables.
*Transaxle
ds
First Edition 8/99 1848 PagesAll Right Reserved
HONOA MOTOR CO., LTD.
Sorvico Publication Offico
As sections with * include SRS components;
sDecial precautions are lequired when servlclng
*Electrical't
*SRSSRS

Engine RemovaUlnstallation
Installation
Brackei Bolts Torque Specifications:
Dl5Y5, Dl6Y7, Dl6Y8 €nginss
D16Y5, D16Y8 engines (M/Tl:
REAR STIFFENER
8 x 1.25 mm2/t N.m 12.4 kgf.m, 17 tbf.ftl
EXCEPT D16Y5, Dl6Yg engines lM/T)jSTIFFENERTighten the bolts on the stiffenerin the numbered sequence as shown
10 x 1.25 mm44 N.m 14.5 kgf.m,33 tbf.frt
O8x1.25mm24 N.m {2.4 kg{.m,17 tbr.ftt
10 x 1.25 mm14 N.m 14.5 kgt m,33 tbf.ft)
10 x 1.25 mm44 N.m {4.5 kgt m,33 tbr.ftl
10 x 1.25 mm54 N.m {5.5 kgf.m,40 rbf.ftl
10 x 1.25 mm44 N.m {4.5 kg'f.m,33 tbtftlALTERNATOFBRACKET
li) o).
l3l 10 x 1.25 mm44 N.m {1.5 kgt.m,33 tbt.ft)8 x 1.25 mm24 N.m (2.4 kgf.m,17 tbf.ft)
o16Ys, D16Y8enginoslM/T):FRONTSTIFFENER
10 x 1.25 mm4,4 N.m {4.5 kg{.m.33 tbf.ftl8 x 1.25 mm2{ N.m (2.t kgtm,17 rbtft)
10 x 1.25 mm14 N.m (4.5 kgf.m,33 lbf.ftl
5-12

I
Cylinder Head
Installation
lnstall the cylinder head in the reverse order of removal:
NOTE:
. Always use a new head and manifold gasket.. The cylinder head gasket is a metal gasket, Take carenot to bend it.
. Rotate the crankshaft, set the No. 1 piston at TDC (seepage 6-63).
. Do not use the middle cover and lower cover forstorang removed items.. Clean the middle cover and lower cover before instal_lation.
o Replace any washers that are damaged or deteriorated.
1. Install the cylinder head gasket, dowel pins and thehead oil control orifice on the cylinder head.
NOTE: Clean the oil control orifice when installing.
DOWEL PIN
6-84
2, Tighten the cylinder head bolts in two steps. In thefirst step, tighten all bolts in sequence to about 29N.m (3.0 kgf.m, 22 tbf.ftl. ln the final step, tighten inthe same sequence to 83 N.m (8.S kgf.m,6t lbf.ft).
NOTE:
. Apply clean engine oil to the bolt threads andunder the bolt head.. We recommend using a beam-type torquewrench. When using a preset-type torque wrench,be sure to tighten slowly and not to overtighten.. lf a bolt makes any noise while you are torquing it,loosen the bolt, and retighten it from the 1st step.
CYLINDER HEAD BOLT TOROUE SEOUENCE
11x 1.5 mm83 N.m 18.5 kgf.m, 61 tbf.ftl
Install the intake manifold and tighten the nuts in acflsscross pattern in two or three steps, beginningwith the inner nuts.. Always use a new intake manifold gasket.
Install the exhaust manifold and tighten the newself-locking nuts in a crisscross pattern in two orthree steps. beginning with the inner nuts.. Always use a new exhaust manifold gasket.
4.

. Torque the mounting bolt and nuts in the sequence
shown.
O 12 x 1.25 mm64 N.m {6.5 kgt.m,47 lbf.fr)
@ 12 x 1.25 mm74 N.m (7.5 kgl'm,54 tbt.fr)
Check that the bushings are not twisted or offset.
Install the clip as shown.
SHIFT ROD
Turn the boot so the hole is facing down.
Make sure the boot is installed on the shift rod.
O) 12 x 'l.25 mm64 N.m 16.5 kgl.m,47 tbt.ft)
I
a
a
a
a
8 x 1.25 mmN.m t2.2 kgt.m, l6 lbl'tt)
6 x 1.0 mm9.8 N.m (1.0 kgl.m.7.2 tbf.tr)
. Apply grease to the slave cylinder push rod.
NOTE: Use only Super High Temp Urea Grease
{P/N 08798 - 9002}.
CLUTCHUNE
a
a
(P/N-6tl
08798-9002)
8 x 1.25 mm22 N.m 12.2 kgl.n.16 tbf.frl
. Turn the breather cap so that the "F" mark points at
the front of the car as shown.
Refill the transmission with the recommended oil
(see page 13-3).
Connect the positive (+) cable first, then the negative
(-) cable to the battery.
Check the clutch oDeration,
Shift the transmission and check for smooth opera-
tion.
Check the front wheel alignment (see section 18).
FRONT
13-9

Transmission Assembly
lnstallation
Install the transmission assembly in the reverse order of
removal.
. Before installing, check that the two dowel pins are
installed in the clutch housing.
. When installing the starter cable. make sure that the
crimped side of the ring terminal is facing out (see
section 23).
. Apply grease to the parts as shown, then install the
release fork and release bearing.
NOTE; Use only Super High Temp Urea Grease(P/N 08798 -9002).
RELEASE FORK BOLT29 N.m 13.0 kgf.m,22 tbllrl
(P/N 08798 - 9rD2l
-R1
tP/N 08798 -
13-52
CLIP
L f ;
Torque the mounting bolt and nuts in the sequence
shown.
Check that the busings are not twisted or offset.
@ t2 x 1.25 mm6,t N.m 16.5 kgtm,47 lbf.ft)O t2 x 1.25 mm6,r N.m (6.s kg{.m,17 tbf.ft)
O 12 x 1.25 mm7ilNm17.5kgf.m,5it lbt ft)
I
Install the alip and the spring pin on the change joint
as snown.
Turn the shift rod boot so the hole is facing down as
snown.
Make sure the shift rod boot is installed on the changerod.
CHANGE ROO
FL.- SPRING PINll heptace,
8 mm PINPUNCH
/ "*,*
lo,iD(
CHANGE ./EXTENSfoN ( ^ st
l?rffi
l\K

17.
18.
19.
lnstall the reverse idler gear and the gear shaft
holder (see page 14-175).
lnstall the differential assembly in the torque con-
verter housing.
Assemble the mainshaft sub-assembly and the
countershaft sub-assembly, then install them
together in the torque converter houslng
MAINSHAFTSUB-ASSEMBLY
20,
COUNTERSHAFTSUB.ASSEMBLY
Turn the shift fork so the large chamfered hole is
tacing the fork bolt hole, then install the shift fork
with the reverse selector, and tighten the lock bolt'
Bend the lock tab against the bolt head
SHIFT FORK
LOCK WASHERReplace.
6 x 1.0 mm4 N.m('l.4 kgl'm, 1O lbt'ft)
Large chamtered hole
21.
22.
lnstall the needle bearing, countershaft reverse gear
and reverse gear collar on the countershaft.
Align the spring pin on the control shaft with the
transmission housing groove by turning the control
shaft.
CONTROL SHAFT
Install the two dowel pins and a new gasket on the
torque converter housing.
Place the transmission housing on the torque con-
verter housing.
CAUTION: Make sure that lhe mainshaft speed
sensor is not installed on the transmission housing
before installing the transmission housing on the
torque conv€rter housing.
lnstall the transmission housing mounting bolts
along with the transmission hanger, then tighten
the bolts in two or more steps in the sequence as
shown.
TOROUE: ,l,t N'm l{.5 kgf'm, 33 lbf'ft}
TRANSMISSIONHANGER
24.
o
(cont'di
SPRING PIN
14-179

Sub-frame
Sub-frame Torque Sequence:
CAUTION: After loos€ning the sub-frame mounting bolts, be sure to replace them with new ones.
BOLTS
10 x 1.25 mm38Nm{3.9kg{.m:
14 x 1.5 mm90 N m (9.1 ks{ m,66 rbf.ft)Replace.
28 tbf.ft)
20-119