Honda CIVIC 10G 2016 Clutch Page 1

Clutch Component Location Index
1.5 L Engine
Clutch Component Location Index 7056 http://techinfo.honda.com/rjanisis/pubs/sm/1/2/Contents/enu/61TBAD/...
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Contents Summary of Clutch

  • Page 1Clutch Component Location Index cardiagn.com 1.5 L Engine
  • Page 2cardiagn.com 2.0 L Engine
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  • Page 4Clutch Component Location Index cardiagn.com
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  • Page 6Clutch Hose and Line Inspection NOTE: Replace the clutch hose if it is twisted, cracked, and leaks. Replace the clutch lines if it is damaged, rusted, and leaks. When attaching the clutch reservoir hose, align the paint mark on the hose to the connector rib on the clutch master cylinder connection a
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  • Page 8Clutch Hose and Line Inspection NOTE: Replace the clutch hose if it is twisted, cracked, and leaks. Replace the clutch lines if it is damaged, rusted, and leaks. When attaching the clutch reservoir hose, align the paint mark on the hose to the connector rib on the clutch master cylinder connection a
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  • Page 10Clutch Hydraulic System Bleeding NOTE: Do not reuse the drained fluid. Always use Honda DOT 3 Brake Fluid from an unopened container. Using a non-Honda brake fluid can cause corrosion and shorten the life of the system. Make sure no dirt or other foreign matter is allowed to contaminate the brake fl
  • Page 116. Check the clutch operation, and check for leaks. cardiagn.com
  • Page 12Clutch Master Cylinder Removal and Installation NOTE: Use fender covers to avoid damaging painted surfaces. Do not spill brake fluid on the vehicle; it may damage the paint or plastic. If brake fluid gets on the paint or plastic, wash it off immediately with water. Plug the ends of the clutch reserv
  • Page 131. 12 Volt Battery - Remove cardiagn.com
  • Page 142. 12 Volt Battery Base - Remove 3. Clutch Hose and Line - Disconnect 4. Lock Pin - Remove 5. Clevis Pin - Remove 6. Clutch Master Cylinder - Remove cardiagn.com NOTE: Use fender covers to avoid damaging painted surfaces. Do not spill brake fluid on the vehicle; it may damage the paint or plastic. I
  • Page 15cardiagn.com Torque: N·m (kgf·m, lbf·ft) Replace Multipurpose grease 1. Clutch Master Cylinder - Install 2. Clevis Pin - Install 3. Lock Pin - Install 4. Clutch Hose and Line - Connect
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  • Page 175. Clutch Hydraulic System - Bleed 6. 12 Volt Battery Base - Install 7. 12 Volt Battery - Install 8. Clutch Pedal and Clutch Pedal Position Switch - Adjust 9. Test Drive - Check cardiagn.com
  • Page 18Clutch Pedal and Clutch Pedal Position Switch Adjustment NOTE: If there is no clearance between the master cylinder piston and the push rod, the release bearing will be held against the diaphragm spring, which can result in clutch slippage or other clutch problems. Before adjusting the clutch pedal
  • Page 19(D) Clutch Pedal Disengagement Height (Reference): Without clutch 115.3-133.5 mm pedal pad cover (4.539-5.256 in) With clutch pedal 117.2-135.4 mm pad cover (4.614-5.331 in) 9. Measure the clutch pedal stroke (A). If the clutch pedal stroke is not within the standard, go to step 10. If the clutch pe
  • Page 2013. Connect the HDS to the data link connector (DLC). 14. Loosen the clutch pedal position switch A locknut (B). 15. Fully press the clutch pedal to the floor, then release the clutch pedal 10-15 mm (0.39-0.59 in) and hold it there. NOTE: Measure the clutch pedal height from middle of the clutch ped
  • Page 21Clutch Pedal and Clutch Pedal Position Switch Adjustment NOTE: How to read the torque specifications. If there is no clearance between the master cylinder piston and the push rod, the release bearing will be held against the diaphragm spring, which can result in clutch slippage or other clutch probl
  • Page 229. Measure the clutch pedal stroke (A). If the clutch pedal stroke is not within the standard, go to step 10. If the clutch pedal stroke is within the standard, go to step 13. (A) Clutch Pedal Stroke Standard: 125-135 mm (4.92-5.31 in) (B) Clutch Pedal Free Play (Reference): 4.32-17.63 mm (0.1701-0.
  • Page 2313. Connect the HDS to the data link connector (DLC). 14. Loosen the clutch pedal position switch A locknut (B). 15. Fully press the clutch pedal to the floor, then release the clutch pedal 10-15 mm (0.39-0.59 in) and hold it there. NOTE: Measure the clutch pedal height from middle of the clutch ped
  • Page 24Clutch Pedal Assembly Removal and Installation NOTE: Where icon is shown, click for further information. 1 cardiagn.com
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  • Page 26Detailed information, notes, and precautions 1. Connector (Clutch Pedal Stroke Sensor and Clutch Pedal Position Switch A) - Disconnect 2. Lock Pin - Remove 3. Clevis Pin - Remove 4. Clutch Pedal Adjusting Bolt - Remove 5. Clutch Pedal Position Switch A - Remove cardiagn.com 6. Clutch Pedal - Remove
  • Page 27cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) Multipurpose grease 1. Clutch Pedal - Install NOTE: Wipe off any excess grease.
  • Page 28Make sure the wire harness is not pinched. cardiagn.com
  • Page 292. Clutch Pedal Position Switch A - Loosely Install NOTE: Do not contact clutch pedal position switch A to the clutch pedal. Make sure the installation position of clutch pedal position switch A. 3. Clutch Pedal Adjusting Bolt - Loosely Install NOTE: Do not contact the clutch pedal adjusting bolt to
  • Page 30Clutch Pedal Pad Cover Removal and Installation Wear goggles or safety glasses to prevent eye injury. 1. Clutch Pedal Pad Cover - Exploded View Exploded View cardiagn.com
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  • Page 32Clutch Pedal Position Switch Removal and Installation 1 Torque: N·m (kgf·m, lbf·ft) cardiagn.com 1. Connector (Clutch Pedal Position Switch A) - Disconnect 2. Clutch Pedal Position Switch A - Remove 3. All Removed Parts - Install 1. Install the parts in the reverse order of removal. NOTE: Before ins
  • Page 33Clutch Pedal Position Switch Test 1. Connector (Clutch Pedal Position Switch A) - Disconnect 2. Clutch Pedal Position Switch A - Test cardiagn.com 1. Check for continuity between the terminals according to the table. If the continuity is not as specified, replace clutch pedal position switch A.
  • Page 343. All Removed Parts - Install 1. Install the parts in the reverse order of removal. cardiagn.com
  • Page 35Clutch Removal and Installation Special Tool Required Image Description/Tool Number Weight, Remover 07741-0010201 cardiagn.com Bearing Driver Attachment, 37 x 40 mm 07746-0010200 Driver Handle, 15 x 135L 07749-0010000
  • Page 36Image Description/Tool Number Remover Handle 07936-3710100 Bearing Remover Shaft Set, 20 mm 07936-3710600 cardiagn.com Ring Gear Holder Attachment 070AB-5S10100 Center Shaft 07AAF-RAWA140
  • Page 37Image Description/Tool Number Clutch Alignment Disc 07JAF-PM7011A Ring Gear Holder 07LAB-PV00100 cardiagn.com Clutch Alignment Shaft 07ZAF-PR8A100 Engine Side 1. Transmission - Remove 2. Height of Diaphragm Spring Finger - Check
  • Page 381. Check the evenness of the height of the diaphragm spring fingers using the clutch alignment disc, the clutch alignment shaft, the remover handle, and a feeler gauge (A). If the height difference is more than the standard, replace the pressure plate. Standard (New): 0.6 mm (0.02 in) max. cardiagn.
  • Page 394. Pressure Plate - Inspect cardiagn.com
  • Page 401. Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area. 2. Inspect the pressure plate surface (A) for wear, cracks, and cardiagn.com burning. 5. Clutch Disc - Remove
  • Page 411. Remove the clutch disc (A) and the center shaft. cardiagn.com 6. Clutch Disc - Inspect 1. Inspect the lining of the clutch disc for signs of slippage or oil. If the clutch disc looks burnt or is oil soaked, replace the clutch disc. If the clutch disc is oil soaked, find and repair the source of t
  • Page 423. Measure the depth of the rivet from the clutch disc lining surface (A) to the rivets (B) on both sides. If the measurement is less than the service limit, replace the clutch disc. Standard (New): 1.15-1.75 mm (0.0453-0.0689 in) Service Limit: 0.85 mm (0.0335 in) cardiagn.com 7. Flywheel - Inspect
  • Page 431. Check the pilot bearing for wear and damage. 2. Check the inside surface of the pilot bearing with your finger. If the flywheel pilot bearing is not smooth, replace it. cardiagn.com 9. Flywheel Pilot Bearing - Remove 1. Remove the flywheel pilot bearing (A) using the remover weight, the remover h
  • Page 441. Loosen the flywheel mounting bolts in a crisscross pattern in several steps. Remove the bolts, then remove the flywheel, the the ring gear holder, and the ring gear holder attachment. Transmission Side cardiagn.com 1. Transmission - Remove 2. Release Bearing - Remove 1. Remove the release fork bo
  • Page 451. Check the play of the release bearing by spinning it by hand. If there is excessive play or noise, replace the release bearing. NOTE: The release bearing is packed with grease. Do not wash it in solvent. NOTE: How to read the torque specifications. Engine Side cardiagn.com 1. Flywheel - Install 1
  • Page 461. Install a new flywheel pilot bearing (A) until it bottoms using the 15 x 135L driver handle and the 37 x 40 mm bearing driver attachment. cardiagn.com 3. Clutch Disc - Install 1. Apply super high temp urea grease (P/N 08798-9002) to the splines (A) of the clutch disc (B). NOTE: Wipe off any exces
  • Page 471. Install the pressure plate (A) and the pressure plate mounting bolts (B) finger-tight with aligning the point marks (C) across the pressure plate and the flywheel (D) as shown. 2. Tighten the pressure plate mounting bolts in the numbered sequence shown. Tighten the bolts in several steps to preve
  • Page 481. 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 guide (D) in the shaded areas. NOTE: Do not use silicone grease. Replace the release fork bolt if necessary. 2. Set the release fork set spring (
  • Page 492. Transmission - Install cardiagn.com
  • Page 50Clutch Removal and Installation Special Tool Required Image Description/Tool Number Clutch Alignment Disc 07JAF-PM7011A cardiagn.com Ring Gear Holder 07LAB-PV00100 Clutch Alignment Shaft 07ZAF-PR8A100 Engine Side
  • Page 511. Transmission - Remove 2. Height of Diaphragm Spring Finger - Check 1. Check the evenness of the height of the diaphragm spring fingers using the clutch alignment disc, the clutch alignment shaft, the remover handle, and a feeler gauge (A). If the height difference is more than the standard, repla
  • Page 521. Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area. cardiagn.com 2. Inspect the pressure plate surface (A) for wear, cracks, and burning. 5. Clutch Disc - Remove
  • Page 531. Remove the clutch disc (A), the clutch alignment shaft, and the remover handle. cardiagn.com 6. Clutch Disc - Inspect 1. Inspect the lining of the clutch disc for signs of slippage or oil. If the clutch disc looks burnt or is oil soaked, replace the clutch disc. If the clutch disc is oil soaked,
  • Page 54Standard (New): 1.15-1.75 mm (0.0453-0.0689 in) Service Limit: 0.85 mm (0.0335 in) cardiagn.com 7. Flywheel - Inspect 1. Inspect the ring gear teeth (A) for wear and damage. 2. Inspect the clutch disc mating surface (B) on the flywheel for wear, cracks, and burning. 8. Crankshaft Pilot Bushing - Che
  • Page 551. Loosen the flywheel mounting bolts in a crisscross pattern in several steps. Remove the bolts, then remove the flywheel and the ring gear holder. cardiagn.com Transmission Side 1. Transmission - Remove 2. Release Bearing - Remove 1. Remove the release fork boot (A). 2. Remove the release fork (B)
  • Page 561. Check the play of the release bearing by spinning it by hand. If there is excessive play or noise, replace the release bearing. NOTE: The release bearing is packed with grease. Do not wash it in solvent. Engine Side 1. Flywheel - Install 1. Install the flywheel (A) on the crankshaft, and install
  • Page 571. Apply super high temp urea grease (P/N 08798-9002) to the splines (A) of the clutch disc (B). NOTE: Wipe off any excess grease. 2. Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft. 3. Install the clutch di
  • Page 581. Torque the pressure plate mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring. Make sure that there is not clearance between the pressure plate and the flywheel. Specified Torque: 26 N·m (2.7 kgf·m, 19 lbf·ft) 2. Remove the ring gear
  • Page 593. With the release fork (A) slide between the release bearing pawls (B), install the release bearing on the mainshaft while inserting the release fork through the hole in the clutch housing. 4. Align the detent (C) of the release fork with the release fork bolt (D), then press the detent of the rel
  • Page 60Clutch Removal and Installation Special Tool Required Image Description/Tool Number Ring Gear Holder Attachment 070AB-5S10100 cardiagn.com Ring Gear Holder 07LAB-PV00100 Clutch Alignment Tool Set 07PAF-0020000
  • Page 61Image Description/Tool Number Clutch Alignment Pilot, 21 mm 07PAF-0020370 Engine Side cardiagn.com 1. Transmission - Remove 2. Height of Diaphragm Spring Finger - Check 1. Check the evenness of the height of the diaphragm spring fingers using a dial indicator (A). If the height difference is more th
  • Page 621. Install the ring gear holder attachment, the ring gear holder, the clutch alignment tool set, and the 21 mm clutch alignment pilot. 2. To prevent warping, loosen the pressure plate mounting bolts (A) in a crisscross pattern in several steps, then remove the pressure plate (B). cardiagn.com 4. Pre
  • Page 632. Inspect the pressure plate surface (A) for wear, cracks, and burning. 5. Clutch Disc - Remove cardiagn.com 1. Remove the clutch disc (A), the clutch alignment tool set, and the 21 mm clutch alignment pilot. 6. Clutch Disc - Inspect 1. Inspect the lining of the clutch disc for signs of slippage or
  • Page 643. Measure the depth of the rivet from the clutch disc lining surface (A) to the rivets (B) on both sides. If the measurement is less cardiagn.com than the service limit, replace the clutch disc. Standard (New): 1.15-1.75 mm (0.0453-0.0689 in) Service Limit: 0.85 mm (0.0335 in) 7. Flywheel - Inspect
  • Page 651. Inspect the ring gear teeth (A) for wear and damage. 2. Inspect the clutch disc mating surface (B) on the flywheel for wear, cracks, and burning. 8. Flywheel Pilot Bushing - Check cardiagn.com 9. Flywheel - Remove 1. Loosen the flywheel mounting bolts in a crisscross pattern in several steps. Rem
  • Page 661. Remove the release fork boot (A). 2. Remove the release fork (B) from the clutch housing (C) by squeezing the release fork set spring (D). Remove the release bearing (E). cardiagn.com 3. Release Bearing - Check 1. Check the play of the release bearing by spinning it by hand. If there is excessive
  • Page 671. Install the flywheel (A) on the crankshaft, and install the mounting bolts finger-tight. 2. Install the ring gear holder attachment and the ring gear holder. 3. Torque the flywheel mounting bolts (B) in a crisscross pattern in several steps. cardiagn.com 2. Clutch Disc - Install 1. Apply super hi
  • Page 681. Install the pressure plate (A) and the pressure plate mounting bolts (B) finger-tight with aligning the point marks (C) across the pressure plate and the flywheel (D) as shown. 4. Pressure Plate Mounting Bolt - Tighten cardiagn.com
  • Page 691. Torque the pressure plate mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring. Make sure that there is not clearance between the pressure plate and the flywheel. Specified Torque: 26 N·m (2.7 kgf·m, 19 lbf·ft) 2. Remove the ring gear
  • Page 701. 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 guide (D) in the shaded areas. NOTE: Do not use silicone grease. Replace the release fork bolt if necessary. 2. Set the release fork set spring (
  • Page 716. 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. Wipe off any excess grease. 2. Transmission - Install cardiagn.com
  • Page 72Clutch Slave Cylinder Removal and Installation NOTE: Use fender covers to avoid damaging painted surfaces. Do not spill brake fluid on the vehicle; it may damage the paint or plastic. If brake fluid gets on the paint or plastic, wash it off immediately with water. Plug the ends of the slave cylinder
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  • Page 743. Intake Air Duct F - Remove (1.5 L Engine) 4. Slave Cylinder - Remove 5. All Removed Parts - Install 1. Install the parts in the reverse order of removal. 6. Clutch Hydraulic System - Bleed 1. Bleed the clutch hydraulic system. 2. Check the clutch operation and check for leaking fluid. cardiagn.co
  • Page 75Clutch System Description - Clutch Pedal Position Switch Clutch Pedal Position Switch Clutch pedal position switch A is installed on the clutch pedal. Clutch pedal position switch A is mostly used to start up the engine by turning the vehicle to the ON mode or to restart the engine when recovering f
  • Page 76Clutch System Description - Clutch Pedal Stroke Sensor Clutch Pedal Stroke Sensor A clutch pedal stroke sensor is installed on the clutch pedal. The clutch pedal stroke sensor detects the level of clutch pedal force and reduces the number of the clutch pedal position switches used in the system. car
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  • Page 78Forward Clutch Clearance Inspection Special Tool Required Image Description/Tool Number Clutch Compressor Attachment 07ZAE-PRP0100 cardiagn.com Clutch Compressor Attachment 64 mm 07ZAE-PRPA110 1. Forward Clutch Clearance - Inspect
  • Page 791. Secure the input shaft assembly (A) in a bench vise (B) with wood blocks (C). NOTE: After this procedure, remove any wood chips that may be stuck to the spline. 2. Set a dial indicator (A) on the forward clutch end-plate (B). cardiagn.com 3. Zero the dial indicator with the forward clutch end-pla
  • Page 805. Put the clutch compressor attachment and the 64 mm clutch compressor attachment on the forward clutch end-plate. cardiagn.com
  • Page 816. Press the clutch compressor attachment down with 39.2 N (4.00 kgf, 8.81 lbf) (the weight of the clutch compressor attachment is included) using a force gauge, and read the dial indicator. 7. The dial indicator reads the clearance (D) between the forward clutch end-plate and the top disc (E). Take
  • Page 82Forward Clutch Clearance Inspection Special Tool Required Image Description/Tool Number Clutch Compressor Attachment 07ZAE-PRP0100 cardiagn.com Clutch Compressor Attachment 64 mm 07ZAE-PRPA110 1. Forward Clutch Clearance - Inspect
  • Page 831. Secure the input shaft assembly (A) in a bench vise (B) with wood blocks (C). NOTE: After this procedure, remove any wood chips that may be stuck to the spline. 2. Set a dial indicator (A) on the clutch end-plate (B). cardiagn.com
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  • Page 853. Zero the dial indicator with the clutch end-plate lifted up to the snap ring (C) by lifting the top disk (D) up. 4. Release the top disk. 5. Put the clutch compressor attachment with the 64 mm clutch compressor attachment on the clutch end-plate. NOTE: Be sure to set the clutch compressor attachm