remove the air cleaner HONDA CIVIC 2003 7.G User Guide

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.
vsB02c00001s
Installthe engine hanger (A) and the engine support
hanger {B) to the vehicle, then attach the hook to the
sDeciai tool.
tJ.
14.
vs802c000015
Remove the two upper transmission mounting
bolts.
(cont'd)
13-5

Manual Transmission
Transmission Removal (cont'd)
15. Remove the transmission mount bracket (A) and
transmission mounting bolt (B).
Remove the air cleaner bracket {C).
Raise the vehicle, and make sure it is securely
supponed.
Drain the transmission fluid. Reinstall the drain bolt
with a new washer (see page 13-3).
Remove the splash shield.
€Ds
to.
17.
18.
19.
db--qF
13-6
20.
21.
22.
23.
Remove the three way catalytic converter (TWC)
assembly (see step 30 on page 5-5)
Remove the driveshafts (see page 16-3).
Remove the intermediate shaft {see page 16-19).
Remove the front engine mount bracket mounting
bolt.
Remove the three bolts securing the transmission
rear mounI.
24.

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.

Motor Removal/lnstallation
Bemoval
1. Make sure you have the anti-theft code for the radio,
then write down the frequencies for the preset
buttons.
2. Disconnect the negative cable from the battery, and
wait 3 minutes before beginning work.
3. Remove the air cleaner assembly (A).
4. Remove the connector bracket (A) onthegearbox
housing, and disconnect the motor 2P connector(B).
9.8 N.m {1.0 kgf.m,
5. Remove the motor {A) from the gearbox housing.
6. Remove the O-ring (B) and discard it.
(cont'd)
17-49

Frequent inhalation of brake pad dust, regardless of
material composition, could be hazardous to your
Front Brake Pads Inspection and Replacement
. Avoid breathing dust particles.
. Never use an air hose or brush to clean brake
assemblies. Use an OSHA-approved vacuum
cleaner.
lnspection
1. Raise the front of the vehicle, and support it with
safety stands in the proper location {see page 1'8).
Remove the front wheels.
2. Check the thickness of the inner pad iA) and outer
pad {B). Do not include the thickness of the brake
pad backing plate.
Brake pad thickness:
Standard: 9.5 10.5 mm (0.37 0.41 in.l
Service limit: 1.6 mm (0.06 in.)
Inner pad:
Outer pad:
lf the brake Dad thickness is less than the service
limit, replace allthe pads as a set.
Replacement
1. Remove the bolt (A), and pivot the caliper (B) upout
of the way. Check the hose and pin boots for
damage and deterioration.
'..'
, .a
&
\
A
2. Remove the pad shim iA) andpads{B).
.^h v/
\ tJ I
v ."r------B
(cont'd)
19-11

Conventional Brake Components
{Front Brake Caliper Overhaul
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.. Avoid breathing dust particles.' Never use an air hose or brush to clean brake assemblies. use an osHA-approved vacuum cleaner.
Remove, disassemble, inspect, reassemble, and install the caliper, and note these items:' Do not spill brake fluid on the vehicle; it may damage the paint; if brakefluidgetsonthepaint,washitoffimmediately with water.. To prevent dripping, cover disconnected hose joints with rags or shop towels.. Cleanall partsinbrakefluidandairdry;blowoutall passageswith compressed air.. Before reassembling, check that all parts are free of dust and other foreign particles.. Replace parts with new ones as specified in the illustration.. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid,' When reusing pads, always reinstallthem in their original pos itio ns to prevent loss of braking efficiency.. Do not reuse drained brake fluid.'AlwaysuseHondaDOT3brakefluid.Non'Hondabrakefluidcancausecorrosionandshortenthelifeofthesvstem.
. Do not mix different brands of brake fluid as they may not be compatible.. Coatthe piston, piston seal groove, and caliper borewithclean brakefluid.. Make sure no grease or oil gets on the brake discs or pads.. Replace all rubber parts with new ones whenever disassembled.. After installing the caliper, check the brake hose and line for leaks, interference, and twistinq.
>:@:Honda caliper sreaso tplN 08C30-80234M)
Boors 3i,l'1.'"
-ffiFA / isli\ii ^ zsw ttt
/paq\tl ll /
,\L,.'iE/ [
-ffi \--l u";;;lqEtCALIPER PIN A / 3.4N.m y' >vr / {3.5 kef m, / ,,' / 25 lbf ft) //'t / SEAL|NG)- I ---=-? WASHEaS
BRAKE HOSE / /8LEEO SCREW/ / /eNm/ / / (o.s kgr'm./ / | itbt.ftl,1(}', ^ l^ /caLl
-ffi \:7 "=;lGoX-
*fL-f
/) I .===? WAStrtXS \t9..- | #.'@ RepracF /7\- (hA PAD RETATNERS !s- / \
*d':ffi
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vlJ ffi
Es,lry:' E*,e,a ["fif:i#l1t*"_,,. \.==f@ tz x t.zsmm ourEB paD sHrM
19-14
108 N.m 111.0 kgf.m,80 tbt.ft)

Master Cylinder Replacement
NOTE: Do not spill brake fluid on the vehicle; it may
damage the paint; if brake fluid does contact the paint,
wash it off immediately with water,
1, Remove the air cleaner assembly (A).
2, Disconnect the brake fluid level sensor connector
(A).
15 N.m{1.5 kgt.m, 11 lbt.ft)
3. Remove the clutch reservoir (B) andenginewire
harness clip (C)from the master cylinder mounting
base (D).
4. Remove the reservoir cap and brake fuid from the
reservoir.
5. Remove the reservoir (E) on the master cylinder
mountrng Dase.
6, Disconnect the brake lines (F)from the master
cylinder (G). To prevent spills, cover the hose joints
with rags or shop towels.
7. Remove the master cylinder mounting nuts {H) and
washers.
8. Remove the master cylinder from the brake booster.
Be careful not to bend or damage the brake lines
when removing the master cylinder.
9. Remove the rod seal (l) from the master cylinder.
10. Installthe master cylinder in the reverse order of
removal, and note these items:
. Replace all the rubber parts with new ones
whenever the master cylinder is removed.
. Check the pushrod clearance before installing the
master cylinder. and adjust it if necessary (see
page 19-16).. Use a new rod seal on reassemblY. Coat the inner bore lip and outer circumference
of the new rod seal {A) with the recommended
seal grease in the master cylinder set.
. Installthe rod seal ontothe master cylinder with
its grooved side (B)toward the master cylinder.
. Check the brake pedal height and free play after
installing the master cylinder, and adjust it if
necessary (see page 19-6).
19-15

Conventional Brake Components
Rear Brake Pads Inspection and Replacement
Frequent inhalation of brake pad dust, regardless ofmaterial composition, could be hazardous to your
hea hh.. Avoid breathing dust particles.. Never use an air hose or brush to clean brake
assemblies, Use an OSHA-approved vacuum
cleaner.
Inspection
'1. Raise the rear of the vehicle, and support jt with
safety stands in the proper location (see page 1-8).Remove the rear wheels,
2. Check the thickness of the inner pad (A) andouterpad (B). Do not include the thickness of the brakepad backing plate.
Brake pad thickness:
Standard: 8.5 9.5 mm {0.33-0.37 in.}
Service limit: 1.6 mm (0.06 in.)
B -::--
lf the brake pad thickness is less than the servicelimit, replace allthe pads as a set.
3.
19-20
Replacement
1. Remove the bolt (A) and brake hose {B} from themounting bracket.
Remove the caliper bolts (C), and remove thecaliper (D) from the caliper bracket.
Remove the pad shims (A) and pads (B).3.
A
t{
\
tIA
A
\
r\
))
\

Rear Brake Caliper Overhaul
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
' Avoid breathing dust particles.
. Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner'
Remove, disassemble, inspect, reassemble, and installthe caliper, and note these items:
. Donotspill brake fluid on the vehicle; it may damage the paint; if brake f luid gets on the paint, wash it off
immediately with water.. To prevent dripping. cover disconnected hose joints with rags or shop towels.
. Cleanall partsinbrakefluidandairdry;blowoutall passageswith compressed air'
. Before reassembling, check that all parts are free of dust and other foreign particles
. Replace pans with new ones as specified in the illustration.. Make sure no dirt or other foreign matter contaminates the brake fluid.
. When reusing pads, always reinstallthem in their original positions to prevent loss of b ra king efficie ncy.
. Do not reuse drained brake fluid.
. Use only clean Honda DOT 3 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the
system.. Do not mix different brands ot brake fluid as they may not be compatible.
. Coatthe piston, piston seal groove, and caliper bore with clean brake fluid.
. Make sure no grease or oil gets on the brake discs or pads.
. Replaceall rubber parts with new ones whenever disassembled.
. After installing the caliper, check the brake hose and line for leaks, interference. and twisting.
oG , nonau."rip6r qreas€ lP/N 08c30-aoa4Ml34 N.m (3.5 kgf m,25lbtft)BOLT
WASHERS
BRAKE HOSE
a
l,i,,'IltE" / !!;,ff
olT-J,.o"c.O.RING CUPBeplace. Beplace.
.ARKING NUr lii.'i rz.r rgr.. Gd ffi27Nm{2.8kgtm,
\-"o, V((rA ",1 ;[.,.JF /;;;;---
t H\a \l / t,i*t'*"
?,,.t/*"^.,,.:,"", /"V4#
ADJUSTING BOLT
,/
27Nm{2.8kgf.m,20 tbf.ftr PAD SPRING
A,n Na 7lfl,lif,loffi ',,0,n, ,,:,o" \
--t)(*ff l^7k ''"'t!1'ry#'
INNEBPA'SHIM
/ .r.:._U i*E'( ":;*" *dF ,.2>a>-
fr.x{_>@ fftt **-->**^'"
,,.-"iV ,/q &'"o.,"."""o"^.,
: 10 MM FLANGE BOLTS.:r=,9!q!q}l 55 N m (5.6 lgf-m, 4r lbt ft)
19-23