2002 HONDA CIVIC lock

Clutch
Slave Cylinder Replacement (cont'd)
11. Bleed the clutch hydraulic system.
. Aftach a hose to the bleeder screw (A), and
suspend the hose in a container of brake fluid.. Make sure there is an adequate supply offluid in
the clutch master cylinder, then slowly pump the
clutch pedal until no more bubbles appear atthe
bleeder hose.. lt may be necessary to llmit the movement of the
release fork (B) with a block of wood to remove
all the air from the system.. Tighten the bleed screw to I N.m (0.8 kgf.m, 6 lbf
ft); do not ovenighten it,. Refill the clutch master cylinder with fluid when
done.. Always use only Honda DOT 3 brake fluid.
Install the intake air duct (see step 36 on page 5-14).
Installthe air cleaner housing (see step 37 on page
5-15).
Install the battery tray.
Install the battery, connect the positive (+) cable
first, then the negative (- ) cable.
Reset the frequencies for the radio station preset
buttons,
12.
13.
14.
t5.
16.
12-8
L

10. Carefully remove the slave cylinder and clutch line
bracket so as not to bend the clutch line. Do not
operate the clutch pedal once the slave cylinder has
been removed,
Remove the engine wire harness cover (A) by
lifting up on the lock tab (B), then slide the harness
forward offthe aircleaner housing mounting
bracket {C).
11.
12. Attach the special tool to the threaded hole in the
cylinder head.
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Installthe engine hanger (A) and the engine support
hanger {B) to the vehicle, then attach the hook to the
sDeciai tool.
tJ.
14.
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Remove the two upper transmission mounting
bolts.
(cont'd)
13-5

Manual Transmission
Transmission Disassembly
Exploded View-Clutch Housing
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.!) DIFFERENTTAL ASSEMBLY
r2l SHIFT FORK ASSEMBLY
a9l 6 mm FLANGE BOLT12 N.m (1.2 kgf m,9lbf ftl
..4] BEARING sET PLATE
G, COUNTERSHAFT ASSEMBLY
O NEEDLE BEARING
3 OIL GUIDE PLATE C
e 14 x 20 mm DOWEL PIN
.9-i MAGNETi.!! MAINSHAFT ASSEMBLY
U 28 mm WASHER
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i[, 28 mm SPRING WASHERiO BALL BEARING(l 28 x 43 x 7 mm OIL SEALReplace.
.D REVERSE GEAR SHAFT
1' REVERSE IDLER GEARf lr 6 mm SPECIAL BOLT15 N.m (1.5 kgt.m, 11 lbf.ft)
(!I REVERSE SHIFT FORK
.4' REVERSE LOCK CAMQ-t 35 x 58 x 8 mm OIL SEALReplace.
n""
?]] BACK-UP LIGHT SWITCH29 N m (3.0 kgf.m,22 lbf ftl.?1 O.RINGReplace.
1!) VEHICLE SPEEo sENsoR (Vss).O 8 mm FLANGE BOLT22 N.m (2.2 kgf m, 16lbf.ftl
.' CLUTCH HOUSINGiI6) TRANSMISSION HANGER
tl 10 mm FLANGE BOLT44 N.m {4.5 kgt.m,33 lbf.ft}
:
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13-14

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Exploded View-Transmission Housing
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{i) 80 mm SHIM
0 8 x 14 mm DOWEL PIN
[A CHANGE LEVER ASSEMBLY
a0 6 mm FLANGE BOLT12 N m {1.2 kgf.m,9 lbf ft}
O DETENT BOLT22 N.m {2.2 kgf.m, 16lbf.ft)
O 12 mm waSHERReDlace.
(D SPRING
[I STEEL BALL(D TRANSMISSION HANGER B(9 CLUTCH LINE CLIP BRACKET
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O TRANSMISSION HOUSING
O 10 mm WASHERReplace.
@ 10 mm FLANGE BOLT44 N.m {4.5 kgf.m,33lbf.ft)
O 8 mm FLANGE BOLT27 N.m 12.8 kgf m,20lbl.ft)
.' TRANSMISSION HANGER A
O INTERLOCK BOLT39N m (4.0ksf.m,29lbf.ft)
O OIL GUIOE PLATE M
€.1 72 mm SHIM
.' OIL GUTTEB PLATE
,-1 _\(g/----------__-
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@) 20 mm WASHERReplace.
q,] FILLER PLUG44 N m {4.5 kgf.m,33 lbf.ft)
@ 40 x 56 x 8 mm OILSEALReplace.
qO 14 mm WASHERReplace.
q' DRAIN PLUG39 N.m (4.0 kgf.m,29 lbf.ftl
@ 32 mm SEALING CAP34 N m (3.5 kgf.m, 25 lbf.ft)
o
(cont'd)
13-15

Manual Transmission
Transmission Disassembly (cont'd)
NOTE: Place the clutch housing on two pieces of wood
thick enough to keep the mainshaft from hitting the
workbench.
1. Remove the detent bolts (A), springs, steel balls,
and back-up light switch (B).
Remove the vehicle speed sensor (VSS) (A) and
O-ring (B).
13-16
3, Remove the interlock bolt (A), the change lever
assembly (B), 8 x 14 mm dowel pins (C), andthe
clutch line clip bracket {D).
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Remove the drain plug (A), filler plug (B), and
10 mm flange bolt (C).

6.
5. Remove the 8 mm flange bolts in a crisscross
Dattern in several steos.
Remove the transmission hanger A, and
transmission hanger B.
Remove the 32 mm sealing cap (A).
Expand the 72 mm snap ring (B) on the
countershaft ball bearing, and remove it from the
groove using a pair of snap ring pliers.
Remove the transmission housing (C) and
14 x 20 mm dowel pins (D).
7.
L
10. Remove the reverse lock cam.
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11.Remove the reverse idler gear {A) and reverse gear
shaft {B).
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(cont'd)
13-17

Manual Transmission
Change Lever Assembly Disassembly/Reassembly
Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surface.
BREATHER CAPTurn the arrow toward the {ronto{ the vehicle, and install it.
SELECT LEVERBe careful not to damage the dust sealwhen installing it.@).1 IlLrl
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DUST COVEB
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(P/N 08798-9002)
ROLLER
6x1.0mm12 N.m(1.2 kgl.m,8.7 lbf.ft)
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,.* (A)tace. ix#,,l
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lV srxSELECT-z:-=:l-': SPRING
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' -, OIL SEAL,/ ReDlace./-r,s
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INTERLOCK
SHIFT ARM
SELECT STOPPLATE
REVERSE LOCK CAMSTRIKER
SHIFT ARM COVER
WASHER
9.8Nm{1.0 kgf.m, 7.2 lbf.ft)
13-20

'10. Measure the thickness ofthe MBS distance collar.
. lf the thickness of MBS distance collar is less
than the standard, replace the MBS distance
collar with a new one.
Standard:23.95 24.05 mm
{0.9(3 0.947 in.)
E-f
Mainshaft Disassembly
1.Remove the angular ball bearing (A) and the
tapered cone ring using a commercially available
bearing separator {B) and a commercially available
bearing puller {C). Be sure the bearing separator is
under the tapered cone ring.
Support 5th gear (A) on steel blocks, and press the
mainshaft out of the sth synchro hub (B). Use of ajaw-type puller can damage the gear teeth.
(cont'd)
13-25