Clutch HONDA CIVIC 2003 7.G Owner's Manual

Engine Assembly
Engine Installation {cont'dl
Install the select cable (A) and shift cable (B) using
the plastic washers (C), washers (D), and new cotter
pins (E).
6x1.0mm9.8 N.m (1.0 kgf.m,7.2 tbl.ftl
Install the clutch slave cylinder (A) and clutch line
bracket mounting bolt (B).
6x1.0mm9.8 N.m{1.0 kgf.m,7.2 tbt.ft)
"-.----->)
"------'6
8 x '1.25 mm24 N.m (2.4 kgl.m,
5-14
37. Installthe battery cables (A) on the under-hood
fuse/relay box, then install the harness clamp (B).
Installthe ground cable (C).
Installthe intake air duct.
6x1.0mm12Nm{1.2kgf.m,8.7 tbf.ft)
39.
\"
\-
a
6x1.0mm12Nm{1.2kgt.m,8.7 rbf.ft)

J/-\-1\_/
BEIAY2
A/C CLUTCH RELAY
RAOIATOR
I
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T
UNDER.HOODFUSE/RELAY BOX:ONo. 19 BATTERY (8oA)ONo. 6 ECU (ECM) (15A1(3)No.20lG {40A1{Canada:50A}ONo. l4 OPTION {40A1€)No. 9 BACK uP (7.5A1lo)No. 7 HORN, STOP {15A}
UNDER.DASHFUSE/RELAY BOX:ONo. 17 FUEL PUMP{15A}@No. ,t ACG {10A)ONo. 1 IGN COIL (1sA)q)No. 10 METER (7.5A)0)No. 14 A/C CLUTCHRELAY IlOA)@No.2 +B LAF (A/F)HEATER (2OA)
(cont'd)
11-15

Fuel and Emissions Systems
System Descriptions (cont'dl
ECM lnputs and Outputs at Connector E (31P}
L
u
1iMoFPR
2sr-{]zs3LG34SG3
6$1025HTC
1M RLY
8AFSHTCR
I
14FTP15ELD
16EPSLD
18ACC20Z/VBS21VSV
22BKSW23K-LINE24SEFMJ26NEP
21rMoCD
29scs30WEN31MIL
Wire side of female terminals
NOTE: Standard battery voltage is '12 V.
TerminalnumberWire colorferminal nameDescription Signal
GRNI/ELIMO FPR (IMMOBILIZERFLJEL PUMP RELAYIDrives PGM Fl main relay 20Vfor2 seconds after turning ignition switch ON{ll). then batterv voltaoe2WHT/REDSHO2S (SECONDARYHEATED OXYGEN SENSOR(SECONDARY HO2S),SENSOR 2r
Detects secondary HO2S{sensor 2) signalWith throttle Jully opened from idle with fullywarmed up engine: above 0.6VWith throttle quickly closed: below 0.4 V
3BRN/YELLG3 (LOGIC GROUND)cround forthe ECM/PCMcontrolcircuitLess than 1.0 V at all times
4PNKSG3 {SENSOR GBOUND)Sensor oroundLess than 1.0 V at all times5YEUELUVCC3 {SENSOR VOLTAGE)Provides sensor voltageWith ignition switch ON (ll): about 5 VWith ionition switch OFF: about 0 V6BLKATr'HTSO25HTC (SECONDARYHEATED OXYGEN SENSOR(SECONDARY H02S)HEATER CONTROL)
Drives secondary HO2SheaterWith ignition switch ON (ll): baftery voltageWilh fullv warmed up engine running: dul,controlled
1REDA/ELMRLY (PGM.FI MAINRELAY}Drives PGM-Flmain relay 1Power source forthe DTCWith ignition switch ON (ll): about 0 VWith ignition switch OFF: battery voltage
IORNAFSHTCR {AIR FUEL BATIO(Iy'F)SENSOR HEATERCONTROL RELAY)
Drives air fuel ratio sensorheater relayWith ignition swirch ON {ll): 0 V
IYEUBLKIGl (IGNITION SIGNAL)Detecrs ignition signalWith ignition switch ON (ll): battery voltageWith iqnition switch OFF: about 0 V't4LT GRNFIP lFUEL TANKPRESSURE (FTP) SENSOR)Detects FTP sensor signalWith ignition switch ON (ll) and fuel fill cap open:about 2.5 VGRN/REDELD (ELECTRICAL LOADDETECTOF)Detects ELD signalWith ignition swjtch ON itt):aOoutO.t V l-gV(deDendino on electrical load)LT GRN/8LKEPSLD (ELECIRICALPOWEB STEEBING LOADDETECT)
Detects Power steering loadsrgnalAt idle with steering wheel in straight aheadposition: about 0 VAt idle with steering wheelatfull lock: momentary
'18REDACC (Ay'C CLUTCH RELAY)Drives P,/C clutch relayWith compressor ON: about 0 VWith comoressor OFF: batterv voltaoe
11-22
\-

""rr"a* JIr''lHr/cnN 1
CONNECTOR E
CONNECTOi K
CONNECTOFJ/GRN
IGNITIONSWITCH
lG2
'I
TESTTACHOMETERCONNECTO8
UNDER.HOOD
UNDER.DASHFUSE/RELAY BOX:
UNDER.DASHFUSE/FELAY BOX
Brake pedal pressed: closedBrake pedal releasedr open
POStTtON SWTTCH
,or"-9J3{51re* _{F "_.rl
4 ACG (1oAt1 tGN CO|L t15A)2 A/F HEATER {2OA)17 FUEL PUMP I15A}1O METER {7.5AI14 A/C CLUTCH RELAY {1OA}
11-45

A/G Signal Circuit Troubleshooting
Turn the ignition switch ON (ll).
Momentarily connect ECM connector terminals 424
and E18 with a jumper wire several times.
1.
2.
5.
Wire side of female terminals
ls there a clicking noise I rom the NC compressor
clutch?
YES Go to step 3.
NO-Go to step 6.
Sta rt the engine.
Turn the blower switch ON.
Turn the Ay'C switch ON.
Does the NC operate?
YES-The air conditioning signal is OK.I
NO Update the ECM if it does not have the latest
software, or substitute a known-good ECM. then
recheck (see page 11-6). lf the symptom/indication
goes away with a known-good ECM, replace the
original €CM.l
6. Momentarily connect under-hood tuse/relay box
14P connector terminal No. 10 to body ground with
a jumper wire several times.
UNDER.HOOD FUSE/RELAY BOXI4P CONNECTOR
12356
1891011IJ14
ACC (RED)
JUMPER WIRE
Wire side of female terminals
ls there a clicking noise f rom the NC compressor
clutch?
YES- Repair open in the wire between the ECM(E'18) and the Ay'C clutch relay.l
NO- Check the A/C system for other symptoms.l
11-133

Clutch
Special Tools ......... 12-2
Comoonent Location Index .......................,............. 12-3
Clutch Pedal, Clutch Pedal Position Switch, and
Clutch Interlock Switch Adiustment .................... 12-4
Cf utch Master Cylinder Rep|acement ..................... 12-5
Slave Cylinder Replacement .'........ 12-7
Clutch Replacement ................... ..... 12-9

a
a
l.
l_l
'l-r
o
SpecialTools
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Clutch
I
12-2
Ref. No.Tool NumberDescription Oty(1,
@
o
@
OTJAF-PM7O11A
07LAB-PV001 00 or 07924-PD20003
07zAF-PR8A100
07936-3710100
,l
1
1
1
Clutch Alignment Disc
Ring Gear Holder
Clutch Alignment Shaft
Remover Handle

Component Location Index
""*--/\,L_.Ei
/i
(,'.'
CLUTCH INTERLOCK SWITCHAdjustment, page 12-4
CLUTCH PEDALPOSTTTON SWITCHAdjustment, page'12-4
RETAINING CLIPReplace.
_,___-,-s\
O-RINGReplace.UTCH PEDALAdjustment, Page 12 4
CLUTCH MASTER CYLINDERReplacement, page l2-5
CLUTCH DISCBemoval, page 12-9Installation, page'12-12
PRESSURE PLATERemoval, page'12-9lnstallation, page 12-12
FLYWHEELInspection, page'12-1 1Replacement, page 12-1 1
SLAVE CYLINDERReplacement, page 12-7
RELEASE BEARINGBeplacement, page 12-13
\".rr"*"o*
CLUTCH HOSECLIP
12-3

Clutch
Clutch Pedal, Clutch
Adjustment
NOTE:. To check the clutch pedal position switch(see page 4-45).. To check the clutch interlock switch (see page 4-6).. Remove the driver's side floor mat before adjusting
the clutch pedal.. The clutch is self-adjusting to compensate for wear.. lf there is no clearance betweenthe mastercylinderpiston and push rod, the release bearing will be held
against the diaphragm spring. which can result in
clutch slippage or other clutch problems.
1. Loosen the clutch pedal position switch locknut (A),
and back off the clutch pedal position switch (B)
until it no longer touches the clutch pedal (C).
J9.8 N.m(1.0 kgf.m,7.2 lbf.ft)
A9.8 N.m11.0 kgf.m, 7.2 lbf.ft)
o18 N.m{1.8 kgf.m,13 tbf.ftl
Loosen the clutch push-rod locknut (D). and turn
the push rod (E) in or out to get the specified height(F), stroke (G). free play (H) and disengagement
height (l) atthe clutch pedal.
Clutch PedalStroke: 130 140 mm(5.12 5.51 in.l
Clutch Pedal Free Play: l0 16 mm (0.39-0.63 in.)
Clutch Pedal Height: 193 mm (7.60 in.)
Disengagement
Height: 115 mm (4.53 in.)
Between Floor And
Carpet Height(Approximate Valuel: 38 mm {1.50 in.l
12-4
Pedal Position Switch, and Clutch Interlock Switch
3. Tighten the clutch push-rod locknut (D).
4. With the clutch pedal released. turn the clutchpedal position switch (B) in until it contacts the
clutch pedal (C).
5. Turn the clutch pedal position switch {B) in an
additional 3/4 to 1 turn.
6. Tighten the clutch pedal position switch locknut (A).
7. Loosen locknut (J)and the clutch interlock switch(K).
8. Press the clutch pedal to the floor.
9. Release the clutch pedal 10 'l6mm(0,39 0.63in.)
from the fully pressed position, and hold it there.
Adjust the position of the clutch interlock switch (K)
so that the engine will start with the clutch pedal in
thls position.
10. Tighten the clutch interlock switch locknut (J).

Clutch 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 immediatelV with water.
1. Pry out the lock pin (A), and pullthe pedal pin (B)
out of the yoke. Remove the master cylinder
mounting nuts (C).
Remove the air cleaner housing cover and the air
cleaner housing (see step 6 on page 5-2).
Remove the brake fluid from the clutch master
cylinder reservoir with a syringe.
Remove the clutch line bracket from the frame rail,
and remove the clutch line clip.
Remove the clutch master cylinder (A), and pull it
toward the middle of the engine compartment.
Remove the retaining clip (B). Disconnect the clutch
line (C). Plug the end of the clutch line with a shop
towelto prevent brake fluid from coming out.
g-E
3.
6. Disconnect the reservoir hose (D) fromtheclutch
master cylinder reservoir. Plug the end of the
reservoir hose with a shop towel to prevent brake
fluid from coming out.
7. Remove the O-ring (E) and the clutch master
cylinder seal (F) from the master cylinder.
8. Installthe clutch master cylinder in the reverse
order of removal. Install a new O-ring.
9. Make sure the hose clamps (A) are positioned on
the master cylinder (B) and reservoir (C) as shown.
(cont'd)
UP
i
12-5