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Honda Civic 2006

M/T Assembly Installation (K20Z: M/T)

M/T Assembly Installation

1.Loosen the upper torque rod mounting bolt (A).

 


A

2.Check that two dowel pins are installed in the clutch housing.

3.Apply urea grease UM264 (P/N 41211-PY5-305) to the release fork (A) and the release bearing (B). Install the release fork and the release bearing.

 


1.0-1.6 g
(0.04-0.06 oz)ACB
0.4-1.0 g
(0.01-0.04 oz)0.4-1.0 g (0.01-0.04 oz)

4.Place the transmission on the transmission jack, and raise it to the engine level.

5.Install the transmission mounting bolts.

 


12 x 1.25 mm
64 N·m (6.5 kgf·m, 47 lbf·ft)12 x 1.25 mm
64 N·m (6.5 kgf·m, 47 lbf·ft)

6.Install the clutch cover.

 


6 x 1.0 mm
12 N·m (1.2 kgf·m, 9 lbf·ft)

7.Install the intermediate shaft.

8.Install the driveshafts inboard joint.

9.Support the subframe with a 4 x 4 x 40 in. Piece of wood and a jack.

 


10.Install the front suspension subframe (A). Loosely install the new subframe mounting bolts (B).

 


B
14 x 1.5 mm
103 N·m
(10.5 kgf·m, 76 lbf·ft)
Replace.B
14 x 1.5 mm
103 N·m
(10.5 kgf·m, 76 lbf·ft)
Replace.A

11.Align all reference marks on the body (A) and subframe (B). Tighten the subfram mounting bolts to the specified torque.

 


AB

12.Install the rear engine mount bracket mounting bolt.

 


12 x 1.25 mm
64 N·m
(6.5 kgf·m,
47 lbf·ft)
Replace.

13.Install the front engine mount bracket (A) onto the transmission (B).

 


12 x 1.25 mm
74 N·m (7.5 kgf·m, 55 lbf·ft)AB

14.Install the front engine mounting bolt (A) and nut (B).

 


A
10 x 1.25 mm
88 N·m (9.0 kgf·m, 65 lbf·ft)B

15.Install the middle subframe mounting bolts.

 


10 x 1.25 mm
54 N·m
(5.5 kgf·m,
40 lbf·ft)

16.Install the steering gearbox stiffner plates (A) and harness clip (B). Tighten the mounting bolts to the specified torque.

 


10 x 1.25 mm
54 N·m
(5.5 kgf·m, 40 lbf·ft)10 x 1.25 mm
59 N·m
(6.0 kgf·m, 43 lbf·ft)AB

17.Install the stiffner plate (A) and mounting bracket (B). Tighten the mounting bolts. Connect the exhaust pipe mounting rubber (C).

 


10 x 1.25 mm
54 N·m
(5.5 kgf·m, 40 lbf·ft)10 x 1.25 mm
59 N·m
(6.0 kgf·m, 43 lbf·ft)10 x 1.25 mm
38 N·m
(3.9 kgf·m, 28 lbf·ft)ABC

18.Connect the lower arm.

19.Install the transmission mount bracket (A) and connect the ground cable (B).

 


12 x 1.25 mm
74 N·m
(7.5 kgf·m,
55 lbf·ft)12 x 1.25 mm
74 N·m
(7.5 kgf·m, 55 lbf·ft)6 x 1.0 mm
9.8 N·m
(1.0 kgf·m,
7.2 lbf·ft)12 x 1.25 mm
74 N·m
(7.5 kgf·m, 55 lbf·ft)AB

20.Loosen and retighten the lower torque rod mounting bolt.

 


12 x 1.5 mm
93 N·m
(9.5 kgf·m, 69 lbf·ft)

21.Install the splash shield.

 


22.Tighten the upper torque rod mounting bolt.

 


12 x 1.25 mm
64 N·m (6.5 kgf·m, 47 lbf·ft)

23.Install the engine control module (ECM) stay (A), then install the clutch pipe clamp (B).

 


10 x 1.25 mm
38 N·m
(3.9 kgf·m, 28 lbf·ft)

24.Install the under-hood fuse/relay box (A) on the under-hood fuse /relay stay.

 


A

25.Install the two transmission upper mounting bolts.

 


12 x 1.25 mm
64 N·m (6.5 kgf·m, 47 lbf·ft)

26.Remove the chain hoist and engine hanger (A) from engine. Install the air cleaner housing bracket (B).

 


8 x 1.25 mm
22 N·m
(2.2 kgf·m, 16 lbf·ft)AB

27.Install the engine harness caver (A).

 


A

28.Install the air cleaner housing mounting bracket.

 


6 x 1.0 mm
12 N·m (1.2 kgf·m, 9 lbf·ft)

29.Install the harness clips (A) on the clutch cable bracket (B) and harness bracket (C).

 


ABCA

30.Apply a light coar of urea grease UM264 (P/N 41211-PY5-305) to the cable ends (A), and the surface of the wire end rubber (B) with silicone grease.

 


8 x 1.25 mm
27 N·m (2.8 kgf·m, 20 lbf·ft)CB(P/N 41211-PY5-305)A(Silicone grease)ED

31.Install the cable bracket (C) and cables (D), then install the new cotter pins (E).

32.Connect the back-up light switch connector (A) and the vehicle speed sensor (VSS) connector (B). Install the harness clips (C).

 


ABC

33.Apply urea grease UM264 (P/N 41211-PY5-305) to the end of the cylinder rod. Install the slave cylinder. Take care not to bend the clutch line.

 


6 x 1.0 mm
9.8 N·m
(1.0 kgf·m, 7.2 lbf·ft)8 x 1.25 mm
22 N·m (2.2 kgf·m, 16 lbf·ft)(P/N 41211-PY5-305)

34.Install the battery base (A) with the reserver (B).

 


6 x 1.0 mm
9.8 N·m
(1.0 kgf·m, 7.2 lbf·ft)6 x 1.0 mm
9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)6 x 1.0 mm
9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)BACCD

35.Install the harness clips (C) and the intake air duct (D).

36.Install the air cleaner housing.

37.Install the battery. Connect the positive (+) cable first, then the negative (-) cable to the battery.

38.Install the under-cowl panel and cowl cover.

39.Refill the transmission fluid.

40.Test-drive the vehicle.

41.Check the clutch operation.

42.Check the front wheel alignment.

43.Enter the anti-theft code for the radio and navigation system, then enter the customer's radio station presets.