clutch HONDA CIVIC 2003 7.G Workshop Manual

ItemMeasulementOualificationStandard or New Service LimitFuel pressure
regulator
Pressure with fuel pressure gauge
connected
320-370 kPa 13.3-'3.8 kgtcm', 47 52psi)
FueltankCapacity50 4 (13.2 US galiEngine idleldle speed with headlights and radiator
fan off
Neutral750 50 rpm
Fast idleNeutral1,600150 rpm
Standards and Service Limits
Fuel and Emissionsf
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Clutch
ItemMea3urem€nlOualificationSlandard or NewService LimitClutch pedalHeight from the floor193 mm (7.60 in.)Stroke130 140 mm 15.1 5.5in.)
10 16 mm (0.39 0.63 in.)Disengagement height from the floor1'15 mm (4.53 in.) min.Bunout on clutch mating surface0.05 mm 10.002 in.) max.0.15 mm (0.006 in.)Clutch discBivet head depth1.65 2.25 mm (0.065 0.089 in.)0.7 mm {0.03 in.)Ihickness8.3 8.9 mm (0.33 0.35 in.)6.0 mm (0.24 in.)Pressure plateWarpage0.03 mm (0.001 in.)max.0.15 mm (0.001 in.)Height of diaphragm spring fingersMeasured with
specialtool and
feeler gauge
0.6 mm (0.02 in.) max.0.8 mm (0-03 in.)
2-6
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2-7
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nual Transmission and M/T Differential
ItemM€asurementOualificationStandard or NewSe.vice Limit
Transmission
fluid
CapacityFor fluid change: 1.5 0 (1.6 US qt)
For overhaul: 1.7 011.8 US qt)
MainshaftEnd plav0.1 'l -0.17 mm (0.004 0.007in.)Adiust
Diameter of bushing surface20.80 20.85 mm {0.819 0.821 in.)20.75 mm 10.817 in.)
Diameter of distance collar31.984-32.000 mm (1.2594 1.2598 in.)3'1.93 mm (1.257 in.)
Diameter of ball bearing contact area
(clutch housing side)
27.977 27s90 mm \1.1015 - 1.1020 in.)27.92 mm (1.099 in.)
Diameter of needle bearing contact
area
38.984 39.000 mm (1.5348 '1.5354 in.)38.93 mm (1.533 4n.)
Diameter of ball bearing contact area
(transmission housing side)
27.987 28.000 mm (1.10'19 1.1024 in.)27.93 mm {1.100 in.)
Runout0.02 mm (0.001 in.) max.0.05 mm (0.002 in.)
Mainshaft 3rd,
4th and sth
gears
t.D.44.009 44.025 mm 11.7326 1.7333 in.)44.08 mm (1.735 in.)
End play0.06 0.16 mm {0.002 0.006;n.)0.25 mm (0.010 in.)
Thickness23.92 23.97 mm (0.94'1 0.944 in.)23.80 mm (0.937 in.)
CountershaftDiameter of needle bearing contact
area (clutch housing side)
35.000-35.015 mm (1.3780 '1.3785 in.)34.95 mm (1.376 in.)
Diameter of distance collar contact
alea
39.937 39 950 mm (1.5723 1.512ain.|39.88 mm (1.570 in.)
Diameter of ball bearing contact area
(transmission housing side)
30.020-30.033 mm (1.1819- 1.1824 in.)29.97 mm (1.180 in.)
Runout0.02 mm {0.001 in.) max.0.05 mm (0.002 in.)
35 mm shim-to'bearing inner race
clearance
0.04 0.10 mm (0.0016 0.0039 in.)Adjust
CountershaftLD.52.010 52.029 mm (2.0476-2.0484 in.i52.08 mm (2.050 in.)
End play0.06 0.16 mm (0.002 0.006 in.)0.25 mm 10.010 in.)
Thickness22.92 22.91 $m 10.902 -0.904 in.)22.87 mm (0.900 in.)
Countershaft
2nd gear
t.D.52.010 52.029 mm (2.0476 2.0484 in.)52.08 mm {2.050 in.}
End play0.06 0.16 mm (0.002 0.006 in.)0.25 mm 10.010 4n.)
Thickness21.92 27.91 mtn \1.099 1.101 in.)27.87 mm 11.097 in.)
Countershaft'l st gear
distance collar
LD.39.95 39.96 mm (1.572a 1.5132 in.)39.97 mm (1.574 in.)
o.D.46.989- 47.000 mm (1.8499- 1.8504 in.)46.94 mm (l.848 in.)
Length23.03 23.08 mm (0.907-0.909 in.i
Countersha{l
2nd gear
distance coliar
l.D.39.95 39.96 mm {1.5728'- 1.5732 in.l39.97 mm (1.574 in.)
o.o.46.989 47.000 mm (1.8499 1.8504 in.)46.94 mm (1.848 in.)
Length28.03 28.08 mm (l.104 1.106in.)

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2-11
Design Specifications
O
o
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|temMeasurementOualificationSpecilication
DIMENSIONSOveralllength4,210 mm {165.8 in.)
Overallwidth1,695 mm 166.7 in.)
Overallheight1,440 mm (56.7 in.)
2,570 mm (101.2 in.)
Trackrront1,470 mm (57.9 in.)
Rear'1,470 mm (57.9 in.i
Ground clearance152 mm (5.98 in.)
Seating capacityfour {4)
wEtGt-iT {u.s.A.)Gross Vehicle Weight Rating
(GVWR)
3,660 rbs
WEIGHT
(CANADA)
Gross Vehicle Weight Rating
{GVWR)
1,660 kg
ENGIN ETvpeWater cooled. 4 stroke DOHC V-EC engin(
Cylinder arrangementInline 4'cylinder, transverse
Bore and stroke86 x 86 mm (3.39 x 3.39 in.)
Displacement1,998 cm'(122 cu in.)
Compression ratio9.8
Valve trainChain drive. DOHC VTEC 4 valves per cylinder
Lubrication systemForced, wet sump, with trochoid pumP
Oil pump displacementAt 6,000 engine
rpm
54.3 0 (57.4 US qo/minute
Water pump displacementAt 3,400 engine82 0 (87 US qt)/minute
F!el requiredUNLEADED gasoline with 86 pump octane number or higher
STARTERTvpeGear reduction
Normaloutput
Nominalvoltage12V
Hour rating30 seconds
Direction of rotationClockwise as viewecl from gear end
CLUTCHClutch tvpeSinqle plate dry, diaphragm spring
Clutch friction material surface area174 cm'{26.97 sq in.)
I\,1AN UAL
TRANSMISSION
TvpeSvnchronized, s-speed forward, 1 reverse
Primarv reductionDirect 1:1
Gear ratiolst3.062
2nd1.769
3rd1.212
4th0.921
5th0.738
Reverse3.583
FinalreductionTypeSinole helicalgear
Gear ratio4.164

cont'
ItemMeasuremeniOualificationSpecilicationSTEERINGTypeElectric, Power assisted rack and pinion
Overall ratio15.1Turns,lock to-lock
Steering wheel diameter360 mm (14.2 in)SUSPENSIONTypeIndependent srrul with stabiliTer. coil springRearDouble wishboneShock absorberFrontTelescopic, hydraulic. nitrogen gas-frlled
RearTelescopic, hydraulic, nitrogen gas,filledWHEEL
ALIGNMENT
CamberFront0"00'
Bear0.45'
CasterFront1'33'TotaltoeFront0 mm (0 in.)
RearIn 2 mm (1/16 in.)BRAKESType of service brakeFrontPowerassisted self-adjusling ventilated disc
BearPower-assisted self-adjusting solid discType of parking brakeMechanical actuating, rear wheelsPad friction surface areaFront45 cm'(7.0 sq in.)x2
Rear28 cm'(4.3 sq in.) x 2TIRESSize offront and reartiresPl95/60 815 88VSize o{ spare tireT125r0 D15 95MAIR
CONDITIONING
CompressorTypeScroll
Number of
cylinders
Capacity85.7 m015.23 cu in.)/rev.
Maximum speed12,000 rpm
Lubricant capacity130 m0 {4 1/3 floz)
LubricanttypeSP-10 (P/N 38897'P13-A01AH or38899-P13 A01)CondenserTypeCorrugated finEvaporatorTvpeCorrugated fin
BlowerTypeSirocco fan
Motor type220 Wl12 V
Speed control4 Speeo
Maximum capacity480 m" 116.900 cu ft)/hTemperature controlAirmixtype
Compressor clutchTvpeDry, single plate, poly-V belt drive
Electricalpower
cons!mptron at
68"F (20.C)
42 W maximum at 12 V
RefrigerantTypeHFC 134a (R-134a)
Capacity500 550 g (17.6 19.4 oz)
Design Specifications
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Lubricants and Fluids
For details of lubrication points and type of lubricants to be applied, refer to the illustrated index and various work
ures {such as Assemoverhaul. lnstallation. etc.) contained in each section.
NO.LUBBICATION POINTSLUBBICANT
1E ng ineHonda Motor Oil (P/N 08798-9023). The oil container
must disolav the API Cenification seal shown below.
Make sure it says "For Gasoline Engines." SAE
Viscositv: See chart below.
2TransmissionHonda MTF*' (P/N 08798-9016)
3Brake svstem (includes ABS line)Honda DOT 3 Brake Fluid*' (P/N 08798-9008)
4Clutch line
5
6
Release fork (manual transmissionl
Throftle cable end (throttle Iink)
Super High Temp Urea Grease {P/N 08798-9002)
7
I
Shift and select cable ends (manual
transmission)
Throttle cable end (dashboard lower panel hole)
Silicone grease
9
10
111'
14
16
17
Brake booster clevis
CIutch booster clevis
Shift lever pivot
Pedal linkage
Battery terminals
Fuel f ill door
Hood hinges and hood latch
Hatch hinges
Door hinoes, uoDer and lower
Multi-purpose grease
18Caliper piston boot, caliper pins and bootsHonda CaliDer Grease (P/N 08C30-80234lvl)
19Air conditioning compressorCompressoroil: SP-10 (P/N 38897-P13-A01AH or
38899-P'13-A01)
For refriqerant; HFC'134 a (R-134 a)
I
Recommond6d Engine OilEngine oilviscosily for amb enttemperalure fanges
-30 -20 -10 0 t0 20
*1:
"2:
Always use Honda Manual Transmission Fluid (MTF). Using motor oii can cause stiffer shifting because it does
not contain the Drooer additives.
Always use Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of
the system.
3-2

\.
Engine Electrical
Engine Electrical
SpecialTools
Starting System
Comoonent Location Index ...............
Circuit Diagram
Starter Circu it Troubleshooting
Clutch Interlock Switch Test
Starter Solenoid Test ..............
Sta rter Performance Test
Starter Reolacement ...............
Starter Overhaul .......................
lgnition System
Component Location Index ...............
Circuit Diagram
lgnition Timing Inspection
lgnition Coil Removal/1nsta11ation .......................
Spark Plug Inspection
Charging System
Component Location Index .................................. 4-2O
Circuit Diagram ........................... 4-21
Charging Circuit Troubleshooting ....................... 4-22
Drive Belt Inspection ................... 4-26
Drive Beft Replacement .............. 4-26
Drive BeftAuto-tensioner Inspection .................. 4-27
Drive Beft Auto-tensioner Replacement .............. 4-28
Alternator Reolacement ............. 4-29
Alternator Overhaul ................ .... 4-30
Cruise Control
Component Location Index .................................. 4-36
Circuit Diagram ........................... 4-37
Symptom Troubleshooting Index ....................... 4-38
Cruise Control Unit lnDut Test ............................. 4-40
Main Switch TesVReolacement ........................... 4-42
SeVResume/Cancel Switch TesVReplacement .. 4-42
Cruise Control Actuator Test ...... 4-43
Cruise Control Actuator/Cable Replacement ...... 4-44
Actuator Cable Adjustment .................................. 4-45
Clutch Pedal Position Switch Test ....................... 4-45
4-2
4-J
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-15
4-16
4-17
4-18
4- 19
-+
ENGINE

\-
Starting System
Component Location Index
UNDER-DASHFUSE/RELAY BOX
CLUTCH INTERLOCK SWITCHTest, page 4-6
STARTERStaner Circuit Troubleshoot,ng, page 4 5Solenoid Test, page 4-7Performance Test, page 4-8Replacement, page 4-9Overhaul, page 4 '10
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STARTER CUT RELAYTest, page 22-51
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4-3

Starter Circuit Troubleshooting
NOTE:. Airtemperature must be between 59'and 100'F (15'
and 38'C) during this procedure.
. After this test, or any subsequent repair, reset the
engine controle module (ECM) to clear any diagnostlc
trouble codes (DTCS) {see page 11-4).. The battery must be in good condition and fully
charged.. lf you disconnect the baftery, do the ECM idle learn
procedure (see page 11-139).
Recommended Procedure:. Use a starter system tester.. Connect and operate the equipment in accordance
with the manuf acturer's instructions.
Alternate Procedure
1. Hook up the following equipment:. Ammeter, 0 400 A. Voltmeter, 0 20 V (accurate within 0.1 volt). Tachometer,0 1200 rpm
2.Remove the No. 17 (15A) fuse from the under-dash
fuse/relay box.
With the clutch pedal pressed, turn the ignition
switch to start (lll).
Did the starter crank the engine normally?
YES-The starting system is OK.I
NO-Go to step 4.
3.
L
4-5
4. Check the battery condition. Check electrical
connections at the battery, the negative baftery
cable to body, the engine ground cables and the
starter for looseness and corrosion. Then try
starting the engine again.
Did the statter crank the engine?
YES Repairing the loose connection fixed the
problem. The starting system is now OK.!
NO lf starterwill notcranktheengine atall, goto
step 5. lf it cranks the engine erratically or too
slowly, go to step 7. lf it won't disengage from the
flywheel ring gear when you release the key, check
for the following until you find the cause.
. Solenoid plunger and switch malfunction. Dirty drive gear or damaged overrunning clutch
5. Make sure the transmission is in neutral, then
disconnect the starter subharness 1P connector (A)
from the engine wire harness 'lP connector (B).
Connect a jumper wire from the battery positive
terminal to the starter subharness 'l P connector.
Did the starter crank the engine?
YES-Go to step 6.
NO Check the BLK,ANHT wire between the starter
subharness 1P connector and the starter. lf wire is
OK, remove the starter, and repair or replace as
necessary.
(cont'd)

Starting System
Starter Circuit Troubleshooting
(cont'dl
6. Check the following items in the order listed untilyou find the open circuit.
. Check the BLIVWHT wire and connectors
between the under-dash fuse/relay box and theignition switch, and between the under-dash
fuse/relay box and the starter.. Check the ignition switch {see page 22-53).. Check the clutch interlock switch and connector.. Check the starter cut relay (see page 22-51).. Check LT GRN wire between the starter cut relayl
under-dash fuse/relay box and the clutch
interlock switch.. Check the BLK wire between the clutch interlock
switch and G501.
7, Check the cranking voltage and current draw.
ls ctanking voltage greatet than or equal to 8.7 V
and current draw less than or equal to 230 A?
YES-Go to step 8.
NO Replace the starter. or remove and
disassemble it, and check these items until you find
the cause.
. Starter armature dragging. Shorted armatu re winding. Excessive drag in engine
8. Check the engine speed while cranking the engine.
ls the engine speed above 100 tpm?
YES Go to step 9.
NO-Replace the starter, or remove and
disassemble it, and check for the following untilyou find the cause.
. Excessively worn starter brushes. Open circuit in commutator brushes. Open circuit in starter armature commutator
segments. Dirty or damaged helical splines or drive gear. Faulty drive gear clutch
9. Remove the starter, and inspect its drive gear andthe flywheel ring gear for damage. Replace anydamaged pans.I
4-6
Clutch Interlock Switch Test
1. Disconnect the clutch interlock switch 2P connector.
2. Remove the clutch interlock switch (A).
Check for continuity between the terminals
according to the table.
. lf the continuity is not as specified, replace the
clutch interlock switch.. lf OK, install clutch interlock switch and adjust
the pedal height (see page 12-4l..
Terminal
Cl","f ri"t.tf ."tS""*Jrl2
PRESSEDo--- --o
RELEASED

Starting System
Starter Overhaul
Disassembly/Reassembly
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SOLENOID LEVER
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STARTER SOLENOID
4-10
BRUSH HOLDER