1997 HONDA CIVIC parts

tl
Engine Coolant Refilling and Bleeding
CAUTION: when pouring engine coolant, be sure to
shut the relay box lid and not to lst coolant spill on the
eleqtrical parts or the paint. lf any coolant spills, rinse it
off immediately.
1. Slide the heater temperature control lever to maxl-
mum heat. Make sure the engine and radiator are
cool to the touch.
Remove the radiator caP.
Loosen the drain plug, and drain the coolant'
Remove the drain bolt from the cylinder block'
D16Y5. D16Y7, Dl6Yg sngines:
DRAIN PLUG
0d
I ro
78 N.m {8.0 kgl m.58lbt'ft)
6.
1.
B1642 engin€:
WASHERReplace.
DRAIN BOLT78 N m (8 0 kgf m' 58lbfft)
Apply liquid gasket to the drain bolt threads, then
reinstall the bolt with a new washer and tighten 't
securely.
Tighten the radiator drain plug securely
Remove, drain and reinstall the reservoir' Fill the
tank halfway to the MAX mark with water, then up
to the MAX mark with antitreeze.
(cont'd)
10-7
MAX MARK

Fuel Supply System
Fuel Tank {cont'dl
39 - (xt models:
Replac6ment
o
@ Do not smoke whire working on fuer system. Ke€p open frama away trom your work area.
1. Relievethefuel pressure (see pages 11-230,23'll.
2. Remove the seat cushion lsee section 2O).3, Remove the access panel fromthefloor.
4. Disconnectthe2P (C565) and3P(CS64) connectors and 6p (C569) connecror.5. Disconnect the hose and quick-connect fiftings (see pages 1l-226,22j),6. Jack up the vehicle, and support it with jackstands.
7. Removethefuel hose joint protector and heat shield.8. Removethedrain bolt. and drainthefuel intoan aporoved container.9 Disconnect the hoses (see page 11-226). Slide back the clamps. then twist hoses as you pull, to avoid damagtng rnem.10. Place a jack, or other support, under the tank,11. Remove the strap nuts, and let the straps fallfree,'12. Removethefuel tank. lf itsticks onthe undercoat applied to its mount, carefully pry itoffthe mount.13. Install thedfain boltwith a new washer. then coat the d rain bolt with Noxrust 124B,Allowthe Nox.ust drv for 20 min-utes.
14. Installthe remaining parts in the reverse order of removal,
Replace.
DRAIN BOLT,19 N.m (5.0 kgf.m, 36lbf.ft)
11-242

I
\
\l
(From page 11-292i
Chock the tollowing parts tolleakage to aimosphero, and
ropaii or replaco if necess6.y:. fuel fill cap. fuel tank. fuel v.por pipe. EVAP two way valve. EVAP bypas solonoid valve. tuel tank pre3suae sen3or. EVAP control cankter. EVAP control canisier veni3hut valve. EVAP purge conttol solenoid
. ORVR vent 3hut valve. ORVB vaoor recirculation valve. vacuum hoses tnd connactions
(From page 11 292)
Check toi an opon in the wiro(2wBS linol:1. Turn the ignition switch OFF.2. Reconnect the 2P connectorto the EVAP bypass solenoid
3. Turn the ignition switch ON (ll).
4. Measure voltage betweenECM/PCM connector terminals43 and 82.
Reprir opan in tho wire be(wean
th. EVAP byp.is solonoid valve
rnd rhe EcM/PcM (A31.ls there baftery voltage?
(cont'd)
11-293

lllustrated Index
\
NOTE:
. Whenever the transmission is removed, clean and grease the release bearing sliding surface
. lf the parts marked with an asterisk (*) are removed, the clutch hydraulic system mustbe bled (seepage 12-6)
. Inspect the hoses for damage, leaks, interference, and twisting
'RESERVOIF TANK
ASSIST SPRING
LOCK PIN
5x1,0mm9.8 N.m (1.0 kgf.m,7.2 tbtftl*CLUTCH LINE15 N.m {1.5 kgJ m,11 tbt.ft)
RELEASE BEARINGRemoval/lnspection, page 12-1 1Installation, page 12-'12
*CLUTCH MASTER CYLINDERRemoval/lnstallation, page 12 5
6x1.0mm9.8 N.m (1.0 kgf.m,7.2 tbf.ft)
FLYWHEELInspectaon, page 12IReplacement, Page 12-9
CLUTCH DISCRemoval/lnspection, page 1 2-8
lnstallation, page 12-'10
'12 x 1.0 mm118 N.m {12.0 kgt'm,86.8lbfft)
PBESSURE PLATEBemoval/lnspection, page 12 7Installation, page 12''10
8 x 1.25 mm22 N m (2.2 kgf.m, 16lbf ft)
ISLAVE CYLINDERRemoval/lnstallation, page 12_6
12-3

Transmission Assembly
Removal(cont'd)
17. Remove the three upper transmission mounting
bolts and the lower starter mounting bolt,
STARTERMOUNTINGBOLT10 x 1.25 mm44 N.m (4.5 kgf.m,33 rbnftl
TRANSMISSIONMOUI{TING EOLTS12 x 1.25 mm& N.m (6.5 kgt'm,47 lbl.ftl
18. Remove the rear mount bracket bolts and transmis-
sion mounting bolts.
12 x 1.25 mm64 N.ft 16.5 kgl.m,47 lbl.ftl
SPECIAL BOLTReplace.'ll x 1.5 mm84 N.m (8.5 kgf.m, 61 lbf.ftl
SPECIAL BOLTReplace.14 x 1,5 mln84 N.m (8.5 kgl.m, 61
WASI{ERREARMOUNTBRACKET
rbl.ftt
Pull the transmission away from the engine until it
clears the mainshaft. then lower it on the transmis-
sion jack.
CAUTION: Take caro not to b6nd tho clutch lin€.
1(|
Installation
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 BOLT12 x 1.25 mm29 N'm 13.0 kgt,m,(P/N 08798-90021
22 tbl.ttlR€LEASEBEARING
J
RELEASEFORK8()07
ra
{PiN 08798-9002)
tP/N 08798-900210.3-0.9 g
10.01-0.03 ozl

lllustrated lndex
!
Refer to the drawing below for transmission disassembly/reassembly,
Clean all the parts thoroughly in solvent and dry with compressed air.
I luuricate attthe parts with oil before reassembty.
NOTE:
. This transmission uses no gaskets betvveen the major housings; use liquid gasket (PiN 08718-0001 or08718-0003)
(see page 13-41).
. Always clean the magnet @ whenever the transmission housing is disassembled.
. Inspect all the bearings for wear and operation.
a6_
'%/t'*.
k+-o
-{-g}.-_a
13-10

Mainshaft Assembly
I
lndex
Note the following during reassembly:
. The 3rd/4th and sth svnchro hubs are installed with a press
. Install the angular ball bearing with the thin-edge outer race facing the sth synchro hub
. Install the ball bearing with the ball cage facing up
prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to all contact surfaces the 3rd/4th
and sth svnchro hubs.
Ballcage faces uP.
Thin edge of outerrace laces down.
3RD/4TH SYNCHRO SLEEVE
page 13'27
SYNCHRO SPRINGSYNCHRO RINGInspection,page 13-28
BALL BEARING {*1)ANGULAR BALL BEARING ('2)
Check for wear and operataon.Note the direction ot installation
5TH SYNCHROSLEEVElnspection, page 13-27
SYNCHRO HUB
SYNCHRO RINGInspection, pase 13 28
sTH GEARInspection, page 13-17
3RD GEARlnspection, page 1 3-1 6
34 x 39 x 27.5 mmNEEDLE BEARINGCheck for wearano opetaflon,
MAINSHAFTInspection, page 13-18
CHAMFEB
32 x 37 x 23.5 mmNEEDLE BEARINGCheck for wear andoperation.SPACER COLLABInspection, page 1316
34x39x23mmNEEDLE EEARINGCheck for wearand operation,
4TH GEARrnspeclron,
*1: D16Y7 engine*2: D16Y5, D16Y8 engines
page 13'16RINGInspectaon, page 13 28
SPRING
13-15

Countershaft Assembly
Index
I.r
NOTE:
-re
The 3rd, 4th, and sth gears are installed with a press.
Prior_to reassembling, clean all the parts in solvent, dry them and apply lubricant to all contact surfaces except the3rd, 4th, and 5th gears.
Snap ring groove faces up.
LOCKNUT Replace.108-O- 108 N.m
I 11.0-O-11.0 kst.ml
I 79.6-0- 79.6 lbt.ft I
SYNCHRO SPRING
SYNCHRO RINGInspectaon, page 13-28
FRICTION DAMPER
Thin edge ol outerrace faces down.
Check for wear andoperatron,
/ BALL EEAR|NG t*1)
t NEEDLE BEARTNG (.2)
Check for wearand operatron,
WASHERBEARING
GEAR
4TH GEAR
3RD GEAR2ND GEAR
FRICTION DAMPER
SYNCHRO SPRING
SYNCHRO RINGInspection, page 13-2836 x 41 x 25.5 mmNEEDLE BEARINGCheck for wear and operataon.
Inspection, page 13-23
1ST GEARlnspection, page 13 21, 28lnspection, page 13-21, 2839x44x27mmNEEDLE BEARIfI'GCheck for wear andoperation.
SPACER COLLARInspection, page 13-21
REVERSE GEARlnspection, page 13 27
1ST/2ND SYNCHRO HUB
*1: D'16Y7 engine*2: D16Y5, D16Y8 engines
13-20