Torque HONDA CIVIC 1997 6.G Manual PDF

Differential
Bearing Replacement
NOTE: Check the bearings for wear and rough rotation.
lf the bearings are OK, removal is not necessary.
'1. Remove the ball bearings using a bearing puller.
Install the new ball bearings
with a press as shown.
BAI-L BEARING
using the special tool
ORIVER 10 mm l.O.
07746 - 0030100
14-330
BALL BEARING
Differential Carrier Replacement
1. Remove the final driven gear from the differential
carner.
NOTE: The final driven gear bolts have left-hand
threads.
BOLTS10 x 1,0 mm98 N'm 110,0 kgf.m,72 tbl.ttlLeft-hand threads
DIFFERENTIALCARRIER
Install the final driven gear with its chamfered side
on the inner bore facing the differential carrier.
Tighten the bolts to the specified torque in a crisscross
Paftern.
TOROUE: 98 N.m (10.0 kgt.m, 72 lbf.ft)

Flywheel/Drive Plate
DRIVE PLATE
/,1vl
a
o0
a9
WASHERInstall in this direction.
FLYWHEELlnspect the teeth of the ring gear for excessive wear'
../
.t
12 x 1.0 mm74 N.m (7.5 kgf.m, 54lbfft)
Torque in a crisscross Pattern

Transmission
Installation
Flush the ATF cooler as described on pages 14-352and 14-353.
Remove the used grease in the flywheel hub caDand flywheel splines.
Fill the inside of the flywheel hub cap, and coat the fly-wheel hub splines with Super High Temp Urea Grease(P/N 08798 - 9002) as shown.
L
SEALING RING{RUEBER)
SPLINESApply SUPEB HlcH TEMPUREA GREASElPlN 08798 - 90O2t
SUPER HIGH TEMPUREA GREASE(P/N 08798 - !)00211.5-2.5 g 10.05-0.t9 oz)
Install a new sealing ring (rubber) on the inoutshaft, and install two '14 x 20 mm dowel Dins in theflywheel housing.
Install the flywheel securely on the input shaft, theninstallthe starter motor on the flywheel housing.
4,1Nmla.5 kgt.m, 33 tbt.ft)
INPUT SHAFT
STARTER
l4 x 20 mm DOWEL ptN
.4;i "lrj
,i rr,"r., ., a
14-348
FLYWHEEL
MOUI{T74 N.m (7.5 tstm,5a tbtftt
6. Place the transmission on s jack, and raise it to theengine assembly level.
7. Anach the transmission on the engine, then installthe transmission housing mounting bolt and rearengine mounting bolts.
TRANSMISSION HOUSINGMOUNTING BOIT6,1 N.m 16.5 kgl.m,47 tbtttl59 Nrn {6.0 kgl.m. ,€ lbt ftl
WASHER
lnstall the transmission mount bracket. Tighten thelong bolt loosely, and tighten the nuts and bott onthe mount bracket to the specified torque. Thentighten the long bolt to the specified torque.
REAR ENGINE MOUNTINGBOLTReplace.12 x 1.25 mm
12x 1.25 mn6,r N'm 16.5 kgtm,47 tbtftl
l-".--..-,^
G\V
TRANSMISSONMOUNT BRACKET
12 x 1.25 mn

l.
9. Install the remaining transmission housing mount-
ing bolts.
PRIMARY OXYGEN SENSOR
Remove the transmission jack and the hoist. then
remove the hoist bracket from the engine'
Attach the flvwheel to the drive plate with eight
bolts and torque as follows:
Rotate the crankshaft pulley as necessary to tighten
rhe bolts to half of the specified torque, then to the
final torque, in a crisscross pattern.
After tightening the last bolt. check that the
crankshaft rotates freelY.
10.
11.
12. Install the flywheel cover and the engine stiffeners
DRIVE
6xl.0mm12 N.m
- l12 kgf'm'rE 8.7 tbf.ftl
ENGINESTIFfENEB10 x 1.25 mmart N.m la.s kgt.m,33 tbtftt
8 x 1.25 mm24 N.m(2.1 kgf'm,17 tbt.ftt
DRIVE PI.ATE BOLT
6x1.0x14mm12 N.m {1.2 kgt m.
8.7 lbf,ftl8 x 1.25 mm26 N.m
12.7 kqfin,20 rbt'ftlFLYUTHEEL
ENGINE STIFFENER
8 x 1.25 mm10 x 1.25 mmr,a N.m {4,5 kgf m,
33 tbf.ftl
TRANSMISSION HOUSING
MOUNNNG BOLT
6il N.m {6.5 kgf.m, 47 lbf'ftl
24 N.m (2.4 kgt'm, '17 lbf'ftl
22 N.m t2.2 kgl m, 16lbf'ftl
14-349
13.
14.
Tighten the crankshaft pulley bolt, if necessary (see
section 6).
Connect the ATF cooler hoses to the ATF cooler lines
(see page 14-357).
CAUTION: Whilo connecting the ATF cooltr hGes,
b€ sure not lo allow dust and other loreign parti-
cles to entg. into the transmission.
15. Installthe right front mounvbracket'
10 x 1.25 mm
a,r N.m {4.5 kgf'm,33 lbt ftl
RIGHT FRONTMOUNT/BRACKET
ATF COOLER LINE
10 x 1 .25 mm54 N.m {5.5 kgt'm,
4{) tbl.ftt
ATF COOI,TR HOSE
16. Installthe exhaust PiPe A.
EXHAUST PIPE A
GASKETReplace.
@
\SELF.LOCKING NUTReplace.10 x 1.25 mm5/a N.m {5.5 kgt m,irc lbf.ft)
(cont'dl
*s$o
oor*rr-@Replace.
SELF.LOCKINGReplace.8 x 1.25 mmSELF.LOCKING NUT
Replace.8 x 1.25 mm16 N.m {1.6 kgl'm,12 tbl.ftt

3. lnsert the inboard end of the driveshaft into the dif-
terential or intermediate shaft until the set ring
locks in the groove
NOTE: Clean the areas where the driveshaft contact
the transmission (differential) thoroughly with solvent
or carburetor cleaner, and dry with compressed air'
INBOARD JOINT
INBOARD JOINTReplace.
GROOVE
an
DIFFERENTIAL
lnstall the knuckie on the lower arm. then trghten
the castle nut and install a new cotter pin
NOTE: wipe off the grease before tightening the
nut at the ball ioint.
CAUTION:
. Be careful not to damago the ball ioint boot'
. Torque the castle nut to the lower torque sp€ci-
fication, thsn tighten it only far enough to align
the slot with th€ pin hol6. Do not align the nut
by loosening.
CASTLE NUT12 x 1 .25 mm
COTTER PINReplace.On reassemblY,bend the cotter pinJi$ - 59 N.m 15.0 - 6.0 kgl m,35 - 43 lbf ftl
16-19
5. lnstall the damper tork over the driveshaft and onto
the lower arm. Install the damper in the damper
fork so the aligning tab is aligned with the slot in
the damPer fork.
FLANGE BOLTl0 r 1.25 mmrit N.m t4.a kgf.m, 32 lbf.ft) AIIGN|NG TAB
1.
SELF-LOGKING NUT12 x 1.25 mm6,1N.m 16.5 kgi.m, a7 lbfftl
Replace.
Loosely install the flange bolts and the new self-
locking nut.
Apply oil to the seating surface of the new spindle
nut.
181 N m 118.5 kgt'm, 13il lbt'ftl
NOTE: Aftortightening, use a drift to
stake the spindle nut shoulder against the drivoshaft'
8. Install a new spindle nut, then tighten the nut'
9. Clean the mating surfaces ot the brake disc and the
wheel. then install the front wheel with the wheel
nuts.
10. Tighten the flange bolts and the new self-locking
nut with the vehicle's weight on the damper.
11. Refill the transmission with recommended fluid (see
section 13 or 14).'t2. Check the front wheel alignment and adjust if nec-
essary (see section 18),
FRONT WHEEL
SPINDLE NUT 22 x 1.5 mm
WHEEL NUT 12 x 1.5 mm108 N.m (11.0 kgl'm, g) lbl ftl

Steering Gearbox
Installation (cont'dl
Center the cable reel by first rotating it clockwise
until it stops. Then rotate it counterclockwise(approximately two turns) until the arrow mark on
the label points straight up. Reinstall the steering
wheel (see page 17-35).
Install the steering joint cov€r with the clamps and
clrps.
7.
STEERING JOINI COVER
17-14
9. Reconnsct the ti€-rod ends to the steering knuckles,
thon tightsn th€ castle nut ('96 -'97 models) or nut('98 -'00 models) to the specified torque, and install
new cotter pins.
NOTE: Before connecting the tie-rod ends, wipe off
any grease contamination from the ball joint
tapered section and threads.
CAUTION: Torque lhe ct3tle nut to thr lowsr torque
spocification, th€n tighton it only tar anough to
align the 3lot with tho pin hob. Do not align the
nut by loosening ('96 - '97 modcls onlyl.
TIE.ROD
COTTER PINSR6plac6.On rgassombly, b6nd
'96 - 37 model3:
cotter prn as shown.'98 - '00 modol3:
NUT4a N.m(4.5 kgf.m,33 lbr.ftl
CAST1T NUT,O - ilt N'm{4,0 - 4.8 kgf.m.29 - 35 tbtftl
10.Installthe exhaust pipe A or TWC (see section 9).
Connect the shift linkage (see section 13 or section
14).
Install the front wheels.
After installation, perform the following checks.
. Adjust the front toe (see section 18).. Check the steering wheel spoke angle. Adjust by
turning the right and left tie-rods, if necessary.
NOTE: Turn the right and left tie-rods equally.
ll.

Troubleshooting
Noise and Vibration
NOTE; Pump noise in first 2 - 3 minutes after starting in cold weather is normal.
Humming
Rattle or chattering
Humming due to pulsation of fluid is normal, particularlv when the wheel isturned with the vehicle stooDed.
lf equipped with automatic trans-mission, the hum could be thetorque conveater or pump noise.
Confirm by temporarily removingthe pump belt.
High-pressure line touching theframe.Reposition the line.
Loose steering shaft connector,tie-rod. or balljoint.Check and tighten, or replacepaats as necessary.
Column shaft wobbling.Replace the column assembly.
Check the rack guide tor properadjustment (see page 17,33).Adiusi, if necess€ry.
Rattling sound and feeling when turning the steering wheel raght and left with theengine OFF is normal.
Pump noise, though not loud. trom the valve body unit can be heard whon turn-ing the steering wheel right or left. This is normat.
CAUTION: When imp€sting, do not hold the steering wheet a[ the way tothe right or the left.
17-26

Steering Gearbox
Reassembly (cont'd)
b. Install the valve body unit on the gearbox, andtighten the flange bolts to the specified torque.
VALVE BODY UNTTFLANGE BOLT20 N.m {2.0 ksl.m, 14lbI.ftl
Measure the clearance between the gearbox andvalve body unit using a feeler gauge as shown.
NOTE: Measure the clearance at the point midwaybetween the two mounting bolts.
Determine the required thickness of the 32 mmshims by subtracting the clearance obtained in thestep "c" from the total thickness of the four shims.(Total thickness of the 4 shims) - (Clearance) =
Required thickness of the shims
NOTE: Select the shims so that the total thicknessis close to. but less than, the required thickness,
17-62
54.
Example:
Measurement is 0.28 mm (0.011 in):0.70 - O.28 = 0.42 mm (0.028 - 0.011 = O.Ot7 inl
The selected shims should be 0.28 mm lO.OtO in) and0.15 mm {0.006 in} in thickness.
lf the r€quired shim thickness is 0.10 mm or less, noshims are necessarv.
50. Sot the selected 32 mm shims (,96 - ,97 modelsonly) on the bearing surface ofthe gearbox housing.
FLANGE BOLT20 N.m 12.0 ksf.m, 1l lbtftl
VALVE BODY UNIT
'96 - 37 modsl3 only:32 mm SHIMS{S.loctod numb.r of3him!l
Coat ths new O-ring with grease, and carefully fit iton the valve housing.
Apply grease to the needle bearing in the gearboxhousing.
Install the valve body unit on the gearbox housingby engaging the g€ars.
NOTE: Note the valve body unit installation posi-
tion (direction of line connection).
Tighten the flange bolts to the specified torque.
O-RINGReplace.
-A-l
NEEDLE BEARING
-R1
51.
EA

)
55. Installthe cylinder lines A and B.
NOTE:
. Clean the joints of the cylinder lines A and B
thoroughly. The joints must be free of foreign
materlal.
. Install the cylinder lines A and B by tighting the
flare nuts by hand first, then tighten the flare
nuts to the specified torque.
56.
57.
Grease the sliding surface of the rack guide, and
install it onto the gear housing
36 - '97 models:
Apply a thin coat of grease to the new O-ring, and
install it on the rack guide screw.
38 - '00 models:
Remove the old sealant off of the threaded section,
then apply new sealant all around the threads
Install the spring, rack guide screw and locknut on
the gear housing.
Adjust the rack guide screw (see page 17-33)'
NOTE: After adjusting, check that the rack moves
smoothly by sliding the rack right and left'
'1 l:.r1
58.
-GlO.BINGReplace.
17 N.m {1.7 kgt'm, 12 lbl.ft)
28 N.m (2.7 kgf m,20 lbf ftl
CYLINDER LINE 8 CYLINDER LINE A
l/LOCKNUTS
60, lnstall the new lockwasher in the groove in the
steering rack.
61. Screw each rack ends into the rack'
62. Hold the steering rack with a wrench ('98 -'00 mod-
els: left end onlY), and tighten the rack ends'
CAUTION: Bo cateful nol to damage ihe rack sur-
face with the wranch.
NOTE: '96 -'97 model is shown.
STEERING RACK END
54 N'm t5 5 kgt m' 40 lbl'ft)
STEERING RACK
After tightening the rack ends, stake the four sec-
tions of lock washer with a drift and a mallet.
Place the wood block on the press table. then set
the lock washer section of the rack end on the
wood block securelY.
Be sure the tool is aligned with the flst sections
of the steering rack end belore pressing.
Stake the lock washer in the center ot the flat
section of the steering rack end.
LOCK WASHER
NOTE: This drift has a flat,
to prevent puncturing
WOODEN BLOCK
{cont'd}
17-63

)
1?
12, Install the steering joint cover with the clamps and a
clrp.
Reconnect the tie-rod ends to the steering knuckles,
tighten the castle nut ('96 -'97 models) or nut ('98 -
'OO models) to the specified torque, and install new
cotter plns.
NOTE: Before connecting the tie-rod ends, wipe off
any grease contamination from the ball joint tapered
section and threads.
CAUTION: Torquo the castle nut to the lower torque
sp€cification, then tighten it only tar enough to align
the slot with the pin hole. Do not align the nut by
loosening {,96 -'97 models only).
COTTER PINSReplace.On reassembly, bend
the cotter Pin 6s shown.'96 -'97 models:'98 -'00 mod€ls:
tr
CASTLE NUT40 - a8 N'm(4.0 - 4.8 kgf'm,29 - 35 lbf.ftl
NUT&l N.m{a.5 kgf'm, 33 lbl'ftl
NE-ROD END
(l-,
17-67
14.
15.
16.
17.
18.
Install the exhaust pipe A or TWC (see section 9).
Connect the shift linkage (see section 13 or section
14).
lnstall the front wheels
Fill the system with power steering fluid, and bleed
air from the system (see page 17-331
After installation, perform the following checks
. Start the engine, allow it to idle, and turn the
steering wheel from lock-tolock several times to
warm up the fluid. Check the gearbox for leaks
(see page 17-39).
. Adjust the front toe (see section 18).
. Check the steering wheel spoke angle. Adjust by
turning the right and left tie-rods, if necessary.
NOTE: Turn the right and left tie-rods equallv