2003 HONDA CIVIC %27

25.
26.
24. Check for continuity between EVAP canister vent
shutvalve 2Pconnectorterminal No.2 and body
ground.
VATVE 2P CONNECTOR
-4-
lr 2l-T_*u
ILTGFN/REDI
@
wn€ s de ol l€ma1e terminals
ls therc continuity?
YES Go to step 25.
NO Repair open in the wire between the EVAP
canister vent shut valve and the ECIVI (E21).1
Turn the ignition switch oN (ll).
Measure voltage between EVAP canister vent shut
valve 2P connector terminal No. 1 and body ground.
EVAPCANISTER VENT SHUTVALVE 2PCONNECTOR
Wlreside oflem. € rerm na s
ls there battery voltage?
YES Replace the EVAP canister vent shut valve
(A) and the o-ring (B).I
NO Repair open in the wire between the EVAP
canister vent shut valve and the No. 4 ACG (10A)
fuse.I
Canister System Leak Test
27. Turn the ignition switch oFF.
28, Connecttwo, three-way T-fittings (A) intothehose
from the EVAP canister to the EVAP two way valve.
Connect the FTP sensor to one of the T-fittings and
the vacuum pump to the othel
29. Remove the vent hose from the EVAP canister vent
shut valve (A), and cap the port (B) to seal the fresh
air vent of the EVAP canister.
30. Turn the ignition switch ON (ll).
(cont'd)
11-183

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

o,. @\
'\b
e
P\B
z-W
-
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iq { "
Exploded View-Transmission Housing
@------
tt-P
"=-@
{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
@
rai\€:/
o
f/
dd
\@
O=-rlF,z
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/----------__-
"^\
\-/r*---------..-,
@) 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

Reverse Shift Fork Clearance
Inspection
1. Measure the clearance between the reverse idler
gear {A) and the reverse shift fork (B) with a feeler
gauge (C). lf the clearance is more than the service
limit, go to step 2.
Standard: 0.20-0.59 mm (o.oo7 0.024 in.l
Service Limit: r.3 mm {0.051 in.)
Measu re the width of the reverse shift fork.
. lf distance is notwithinthestandard, replacethe
reverse shift fork with a new one.. lf distance is within the standard, replacethe
reverse gear wrln a new one.
Standard: 13.4 13.7 mm (0.527 0.539 in.l
I
Change Lever Clearance Inspection
1.Measure the clearance between change lever (Al
and the select lever (B) with a feeler gauge (Cf. lf
the clearance is more than the service limit, go ro
step 2.
Standard: 0.05 0.25 mm (0.002-0.010 in.)
Service Limit: 0.50 mm {0.020 in.)
2.Measure the groove of the change lever'
. lf distance is not within the standard, replace the
change lever with a new one.
. lf distance iswithinthe standard, replacethe
select lever with a new one.
15.00 15.10 mm (0.591-0.594 in.)Standard:
,tl
I
qI
13-19

Manual Transmission
Mainshaft Disassembly (cont'dl
3. Supportthe 3rd gear (A) on steel blocks, and press
the mainshaft out of the 3rd/4th synchro hub (B).
Use of a jaw-type puller can damage the gear teeth.
13-26
Mainshaft Inspection
1. Inspect the gear surface and bearing surface for
wear and damage, then measure the mainshaft at
points A, B, C, D, and E. lf any part of the mainshaft
is less than the service limit, reDlace it with a new
o ne.
Standard:
A Ball bearing surface (transmission housing side):
27.987 28.000 mm (1.1019 1.1024in.)
B Distance collar surtace:
31.984 32.000 mm {1.2594 1.2598in.)
C Needle bearing surlace:
38.984-39.000 mm (1.53/t8 1.5354 in.)
D Ball bearing surface (clutch housing side):
27 .977 -27 .990 mm (1.1015 1.1020in.)
E Bushing surface:
20.80 20.85 mm (0.819 0.821 in.)
Service Limit;
A: 27.93 mm 11.100 in.l
B: 31.93 mm |.1.257 in.l
C: 38.93 mm 11.533 in.l
Di 27.92 mm {1.099 in.l
E: 20.75 mm 10.817 in.l
{

2. Inspect the runout by supponing both ends of the
mainshaft. Rotate the mainshaft two complete
revolutions when measuring the runout. lf the
runout is more than the service limit. reolace the
mainshaft with a new one.
Standard: 0.02 mm (0.001 in.) max.
Service Limit: 0.05 mm (0.002 in.)
13-27

Manual Transmission
Countershaft Assembly Clearance
Inspection (cont'd)
5. Measure the th ickness of the distance collar.
. lf thethickness is notwithin the standard, replace
the distance collar with a new one.. lf thethickness iswithinthe standard, goto
step 6.
Standard: 28.03 28.08 mm {1.104-1.106 in.)
6. Measure the thickness of the 2nd qear.
. lf thethickness of 2nd gearis lessthan the
service limit, replace 2nd gear with a new one.. lf thethicknessof 2nd geariswithintheservice
limit, replace lhe 1sV2nd synchro hub with a new
one.
Standard: 27 -92-21.97 mm|.1.099 1.r01 in.l
Service Limit: 27.87 mm 11.097 in.)
13-32
Countershaft Disassembly
1.Securely clamp the countershaft assembly in a
bench vlse with wood blocks.
Remove the special bolt (left-hand threads).
Support the ball bearing (A) on steel blocks, then
use a press (B) and an attachment (C)to press the
countershaft out of the ball bearing.
4. Remove the 35 mm shim and distance collar.
I

14. Install the distance collar (A), 35 mm shim, and old
ball bearing (B) using the special tools and a press
(c).
Measure the clearance between the old bearing
and the 35 mm shim (B) with a feeler gauge (C).
Standard: 0.04 0.10 mm 10.002 0.004 in.)
(A)t5.
16. lf the clearance is more than the standard, select a
new shim from the following table. lf the clearance
measured in step 15 is within the standard, replace
only the ball bearing.
35 mm Shim
Part NumberThickness
23981-PPP-0000.87 mm (0.0343n.
B23981-PPP-9000.91 mm {0.0358n,
c23982-PPP-0000.95 mm (0.0374n.
D23982-PPP-9000.99 mm (0.0390n,
E23983-PPP-0001.03 mm 10.0406n,
F23983-PPP-9001.07 mm (0.0421n.
23984-PPP-0001.1 1 mm (0.0437n.
1123984-PPP-9001.15 mm (0.0453n.
J23985-PPP-0001.'19 mm (0.0469n.
K23985-PPP-9001.23 mm (0.0484n
L23986-PPP-0001.27 mm (0.0500n.
M23986-PPP-9001.31 mm (0.0516 in.
N23987-PPP-0001.35 mm (0.0531 in.
P23987-PPP-9001.39 mm (0.0547n.
o23988-PPP-0001.43 mm (0.0563 in.
R23988-PPP-9001.47 mm (0.0579 in
23989-PPP-0001.51 mm (0.0594 in
T23989-PPP-9001.55 mm (0.0610 in
U23990-PPP-0001.59 mm {0.0626 in.
1.63 mm {0,0642 in.23990-PPP-900
X23991-PPP-0001.67 mm (0,0657 in
Y23991-PPP-9001.71 mm {0.0673 in
z23992-PPP-0001.75 mm (0.0689 in
23992-PPP-9001.79 mm (0.0705 in
AB23993-PPP-0001.83 mm (0.0720 in
AC23993-PPP-9001.87 mm (0.0736 in
AD23994-PPP-000'1.91 mm (0.0752 in
AE23994'PPP-9001.95 mm (0.0768 in.
AF23995 PPP-0001.99 mm (0.0783 in.
{cont'd)
13-37