HONDA CIVIC 2003 7.G Workshop Manual

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

Clutch
Clutch Master Cylinder Replacement (cont'd)
10. To prevent the retaining clip (A) from coming off,
pry open the tip of the retaining clip (B) with a
screwdriver,
Tighten the master cylinder mounting nuts to 13 N
m (1.3 kgf m, 9.4 lbf.ft).
Bleed the clutch master hydraulic system (see step
1 1 on page 12-8).
NOTE: The reservoir filling is covered in the
bleeding procedure.
lnstallthe air cleaner housing (see step 37 on page
5-15).
11.
12-6
I

Slave Cylinder Replacement
NOTE:. Use fender covers to avoid damaging painted
surfaces.. 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. Write down the frequencies for the radio's preset
buttons. Disconnect the negative ( ) cable first,
then the positive (+)cable from the battery.
Remove the battery.
2. Remove the battery tray.
a
Remove the air cleaner housing cover and the air
cleaner housing (see step 6 on page 5-2).
Remove the intake air duct (see step 8 on page 5-3) .
Remove the clutch line bracket (A).
4.
5.
6. Remove the mounting bolts (A) andtheslave
cylinder (B).
Remove the roll pins (C). Disconnect the clutch line(D), and remove the O-ring (E). Plug the end of the
clutch line with a shop towel to prevent brake fluid
f rom coming out.
Installthe slave cylinder in the reverse order of
removal. Install a new O-ring (A).
7.
,,6NJ'
=--#.q!4sEn(P/N 08798-90021
9.
(Brak6 Assembly Lube)
Pullthe boot (B) back, and apply brake assembly
lube to the boot and slave cylinder rod (C). Reinstall
the boot.
Apply super high temp urea grease (P/N 08798-
9002) to the push rod of the slave cylinder. Tighten
the slave cylinder mounting bolts to 22 N m (2.2
kgf m, 16lbf.ft).
(cont'd)
12-7
10.

Clutch
Slave Cylinder Replacement (cont'd)
11. Bleed the clutch hydraulic system.
. Aftach a hose to the bleeder screw (A), and
suspend the hose in a container of brake fluid.. Make sure there is an adequate supply offluid in
the clutch master cylinder, then slowly pump the
clutch pedal until no more bubbles appear atthe
bleeder hose.. lt may be necessary to llmit the movement of the
release fork (B) with a block of wood to remove
all the air from the system.. Tighten the bleed screw to I N.m (0.8 kgf.m, 6 lbf
ft); do not ovenighten it,. Refill the clutch master cylinder with fluid when
done.. Always use only Honda DOT 3 brake fluid.
Install the intake air duct (see step 36 on page 5-14).
Installthe air cleaner housing (see step 37 on page
5-15).
Install the battery tray.
Install the battery, connect the positive (+) cable
first, then the negative (- ) cable.
Reset the frequencies for the radio station preset
buttons,
12.
13.
14.
t5.
16.
12-8
L

Clutch Replacement
Spscial Tools Required. Clutch alignment disc 07JAF-PM701 1A. Ring gear holder 07LAB-PV00100 or
07924-PD20003. Clutch alignment shaft 07ZAF-PR8A100. Remover handle 07936-3710100
Pressure Plate and Glutch Disc Removal
1. Check the diaphragm spring fingers for height
using lhe special lool and feeler gauge. lf the height
is more than the service limit, replace the pressure
ptate.
Standard lNewl: 0.6 mm (0.02 in.) max.
Service Limit: 0.8 mm {0.03 in.)
07zAF-PR8A10007936-3710100OTJAF-PM7O11A
2. Installthe special tools.
A
\-
A-.- nl I\ffim9fra-I tP|-
07LAB-PV00100 or07924-PD20003
To prevent warping, unscrew the pressure plate
mounting bolts (A) in a crisscross pattern in several
steps, then remove the pressure plate (B).
Inspect the fingers of the diaphragm spring (A) for
wear at the release bearing contact area.
5. Inspect the pressure plate 1A) surfaceforwear,
cracks. and burning.
(cont'd)
12-9

Clutch
Clutch Replacement (cont'd)
6. Inspecl for warpage using a straight edge (A) and
feeler gauge (B). l\4easure across the pressure plate
(C). lf the warpage is more than the service limit,
replace the pressure plate.
Standard {New): 0.03 mm (0.001 in.) max.
Service Limit: 0.15 mm (0.006 in.)
7. Remove the clutch disc and sDecialtools.
Inspectthe lining ofthe clutch disc for signs of
slipping or oil. lf the clutch disc is burned black or
oil soaked. reolace it.
1d
12-10
9. lvleasu re th e clutch d isc th ickness. lfthethickness
is less than the service limit, replace the clutch disc.
Standard lNew): 8.3 8.9 mm(0.33 0.35 in.)
Service Limit: 6.0 mm {0.24 in.)
Measure the rivet depth from the clutch disc lining
surface (A) to the rivets (B) on both sides. lf the
rivet depth is less than the service limit, replace the
clutch disc.
Standard (New): 1.65 2.25 mm(0.065 0.089 in.)
Service Limit: 0.7 mm (0.03 in.)
10.
L

Flywheel Inspection
1. Inspect the ring gear teeth for wear and damage.
2. Inspect the clutch disc mating surface on the
flywheel for wear, cracks, and burning.
3. Measure the flywheel (A) runout using a dial
indicator (B) through at least two full turns. Push
against the flywheel each time you turn it to take up
the cra nksh aft th rust washer clea rance. lf the
runout is more than the service limit, replace the
flywheel and recheck the runout. Resurfacing the
flywheel is not recommended.
Standard (New): 0.05 mm (0.002 in.) max.
Service Limit: 0.15 mm (0.006 in.)
Flywheel Replacement
1. Installthe special tool.
2.
3.
4.
Remove the flywheel mounting bolts in a crisscross
pattern in several steps, then remove the tlywheel.
Installthe flywheel on the crankshaft, and install
the mounting bolts fingertight.
Installthe specialtool, then torque the flywheel
mounting bolts in a crisscross pattern in several
sreps.
12 x 1.0 mm103 N.m(10,s kst.m. 76 lbf ftl
(cont'd)
12-11

Glutch
Clutch Replacement (cont'dl
Clutch Disc and Pressure Plate Installation
'L Temporarily install theclutch disc ontothesplines
of the transmission mainshaft, Make sure the clutch
disc slides freely on the mainshaft.
2. lnstallthe ring gear holder.
{P/N 08798-9002)
07LAB-PVo0'100 or0792,1-PD20003
Apply super high temp urea grease (P/N 08798-
9002) to lhe splines (A) of the clutch disc (B), then
install the clutch disc using the special tools.
Installthe pressure plate (A) and the mounting
bolts (B) finger-tig ht.
\---,
/v
07936-3710100
3.
O?ZAF.PRSAIOO
12-12
5. Torque the mounting bolts in a crisscross pattern,
Tighten the bolts in several steps to prevent
warping the diaphragm spring.
PRESSURE PLATE MOUNTING BOLT TOROUE:
25 N.m {2.6 kgt.m, 19 lbt.ft)
o
Remove the special tools.
Make sure the diaphragm spring fingers are all the
same height.
1.

Release Bearing Replacement
'L Remove the release fork boot (A)from the clutch
housing (B).
Xrl-RlIt\'1f-l\-._-A
Remove the release fork (C)from the clutch
housing (B) by squeezing the release fork set spring(D)with pliers. Remove the release bearing (E).
Check the release bearing for play and noise by
spinning it by hand. lf there is excessive play or
noise, replace the release bearing with a new one.
NOTE: The release bearing is packed with grease.
Do not wash it in solvent.
2.
3.
4.Apply super high temp urea grease {P/N 08798-
9002) to the release fork (A), the release fork bolt(B), the release bearing (C), and the release bearing
gu ide (D) in the shaded areas.
1.0 1.6 g10.04 0.06 oz)
l-'..\
\
!ac
))/
/-/
0.4 1.0 g10.01 0.04 o
7.
{re\
I L!),l-*E
6.
" 0.t 1.0 9 (0.01 0.04 oz)
With the release fork slid between the release
bearing pawls. installthe release bearing on the
mainshaft while inserting the release fork through
the hole in the clutch housing.
Align the detent of the release fork with the release
fork bolt, lhen press the release fork over the
release fork bolt squarely. Make sure the release
fork set spring (F) is properly set.
Installthe release fork boot {E). Make sure the boot
seals around the release fork and clutch housing.
Move the release fork (A) right and left to make
sure that it fits properly against the release bearing(B) and that the release bearing slides smoothly.
8.
12-13