2003 HONDA CIVIC Workshop Manual

25. Support the subframe with the subframe adapter
and a jack.
---
26.
EOS02C000011
Make reference marks (A) on the front suspension
subframe (B) and mounting bolts (C). then remove
the front suspension subframe.
27. Remove the clutch cover.
28. Remove the front engine mount.
Place the transmission iack under the transmission,
and remove the transmission mounting bolts.
29.
(cont'd)
13-7

Manual Transmission
\
12 x 1.25 mm64 N.m{6.5 ksf.m,47 tbf.ft)
30.
Transmission Removal (cont'd)
Pull the transmission away from the engine until
the transmission mainshaft clears the clutchpressure plate, then lower the transmission on the
transmission jack.
Remove the transmission rear mount (A) and the
transmission rear mount bracket {B).
Remove the boot (A), the release fork {B). and the
release bearing (C) from the transmission (D).
32.
13-8
Transmission Installation
Special Tools Required. Engine hanger adapter, 2.0 to 2.4 liter VS802C000015. E ngine hanger VS802C000018. Engine support hanger, A & Reds AAR-T-12566". subframe adaDter EoS02c000011* Available through the Honda Tool and Equipment
Program 888-424-6857
1. Check the two dowel pins are installed in the clutch
housr ng.
Apply super high temp urea grease (P/N 08798-
9002) to the release fork (A) and the release bearing(B). Installthe release fork and the release bearing.
0.4 1.0 g {0.01 0.04 ozl
3. Installthe transmission rear mount bracket (A)and
the transmission rear mount (B).
x 1.25 mmN m {6.5 kgf.m,
Place the transmission on the transmission iack.
and raise it to the engine level.
't2
6447
1.0 '1.6 g{0.04 0.06 oz)

5. Install the transmission mounting
12 x 1.25 mm64 N.m 16.5 kgf m.47 lbt ft)
12 x 1.25 mm64 N.m (6.5 kgf.m,47 lbf.ft)
6. Installthe front engine mount.
12 x 1.25 ftrn64 N.m(6.5 kgf m. 47 lbf.ft)
bolts.
12x 1.25 mm64 N.m(6.5 kst.m,47 lbf ft)
7. lnstallthe clutch cover.
6x1.0mm12 N.m {1.2 kgI.m, 9 lbf ftl
8. Supportthe subframe with the subframe adapter
and a jack.
Installthe front suspension subframe (A) in its
original position by aligning the marks (B) you
made in the removal procedure,
9.
14 x 1.5 mm
(cont'd)
13-9

Manual Transmission
Transmission Installation (cont'dl
'10. Installthe three rear mounting bolls for the
transmission rear mount.
59 N.m (6.0 kgf.m,43 tbf.ft)
Loosely tighten the front engine mount bracket
mounting bolt.
11.
12.
t5.
14.
Install the intermediate shaft (see page 16-24).
Installthe drivershafts (see page 16-17).
lnstall the three way catalytic converter (TWC)
assembly (see step 17 on page 5-12).
10 x 1.25 mm
13-10
6x1.0mm12Nm
15.Install the transmission mount bracket (A) and the
transmission mounting bolt {B).
12 x 1.25 mm54 N.m {5.5 ksf.m, 40lbf.ft)
12x 1.25 nn54 N.m(5.5 kgf.m,40 tbt.ft)
16.
17.
/t':::= 12 x 1.25 mm-) 54 N.m(5.5 kgf.m,40 tbf.ftl
Install the air cleaner bracket (C).
Install the two upper transmission mounting bolts.
12 x 1.25 mrn64 N.m (6.5 kgt.m,47 lbf.ftl
18. Remove the engine hanger and special tool from
engrne.

19. Tighten the front engine mount bracket mounting
bolt.
'12 x 1.25 mm64 N.m 16.5 kgf.m,il7 lbf.ft)
20. Install the splash shield.
21. lnstallthe brake booster and EVAP line bracket
mounting bolts (A). and air cleaner housing bracket
mounting bolt (B). Tighten the air cleaner housing
bracket mounting bolt (C), and install the water
pipe mounting bolt (D).
A9.8 N.m(1,0 kqf
%,
'B
22 N.ml2.2kgl m,16 rbt.ft)
9.8Nm(1.0 kgf m.7.2 tbl{rl
22.
22Nm{2.2 kgf m, 16 lbf ft)
Installthe engine harness cover.
(cont'd)
13-11

Manual Transmission
Transmission Installation (cont'dl
Apply super high temp urea grease (P/N 08798-
9002) to the end of the slave cylinder rod. Install the
slave cylinder and the clutch line bracket. Take care
not to bend the clutch line.
8 x 1.25 mm22 N.m (2.2 kgf.m, 16 lbf ft)6x1.0mm9.8 N.m(1.0 kgf.m,7.2 tbt.ftla^_#._gEEa9En(P/N 08798-9002)
24. Installthe harness clip.
13-12
25. Installthe cable bracket (A) and cables (B).
BWZ[i:i'u'T!'*n'-'
lPlN 08798-9002)
Apply a light coat of super high temp urea grease(P/N 08798 - 9002)to the cable ends.
Connect the back-up light switch connector (A) and
the vehicle speed sensor {VSS)connector (B).
26.
t1

28. Connect the transmission ground cable (A).
8 x 1.25 mm
B
22 N.m (2.2 kgf.m, 16lbf.ft)
[---.-.---e
e
6x1,0mm9.8 N.m{1.0 kgl m. 7 lbf ftl
29.
30.
8x125mm22Nm12.2 kgt m, 16 lbf ft)
lnstall the battery tray (B).
Installthe intake air duct (see step 36 on page 5-14).
Installthe air cleaner housing (see step 39 on page
5-15).
Installthe intake manifold cover (see step 41 on
page 5-15).
Install the battery. Connectthe positive (+) cable
first, then the negative (-)cable to the battery.
Reflllthe transmission fluid (see page 13-3).
Test-drive the vehicle.
Check the clutch operation.
Check the front wheel alignment (see page 18-4).
Enter the anti-theft code for the radio, then enter
the customer's radio station presets.
Do the engine control module (ECM) idle learn
procedure (see page 11-139).
32.
33.
34.
35.
36.
31.
38.
39.
13-13

Manual Transmission
Transmission Disassembly
Exploded View-Clutch Housing
,.Y
-'- R
,ot/u
,t- v -1A' i6 t3l
\?
q'/V^
.!) 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
t€4
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}
:
r'<__J'.@t / ,, tl
' j=-X ri ,1.-6
'-==-Yh,_-9
13-14