VALVE CLEARANCE ADJUSTMENT SPECIFICATIONS

• 1.5L Engine:
  • Intake: .007-.009 Inches (.17-.23mm)
  • Exhaust: .009-.011 Inches (.23-.28mm)
• 1.6L Engine
  • D16Z6 Engine:
    • Intake: .007-.009 Inches (.17-.23mm)
    • Exhaust: .009-.011 Inches (.23-.28mm)
  • B16A Engine:
    • Intake: .006-.007 Inches (.18-.22mm)
    • Exhaust: .007-.008 Inches (.23-.27mm)

B16A Dual Overhead Camshafts (DOHC)

1. With engine cold, remove upper timing belt cover, valve cover, spark plugs and distributor cap. Adjustment of exhaust and intake valves are done at same time. FYI: On some applications, the word UP will be cast into the camshaft pulley. On other applications the UP mark will be represented by an arrow pointing to the outer edge of the camshaft pulley.
2. Rotate crankshaft to bring piston No. 1 to TDC on compression stroke. UP marks on camshaft pulleys should be at top, and TDC grooves on camshaft pulleys should align with cylinder head surface. Distributor rotor should point to spark plug wire No. 1 on cap.3.
   
3. Loosen lock nuts on valves for cylinder No. 1, and adjust valve clearances to specification.
   
4. Tighten valve adjuster lock nuts to 15 ft. lbs. (20 N.m). Recheck valve clearance. Readjust valve clearance, if necessary.
5. Rotate crankshaft counterclockwise 180 degrees. Ensure cylinder No. 3 is at TDC. Adjust valves on cylinder No. 3. For remaining cylinders, repeat steps 3) – 5).
6. Replace valve cover and distributor cap. Tighten timing cover bolts and valve cover crown nuts to 7 INCH lbs. (10 N.m).

Single Overhead Camshaft (SOHC)

1. With engine cold, remove timing belt upper cover, valve cover, spark plugs and distributor cap. Adjust exhaust and intake valves at the same time.
2. Rotate crankshaft to bring piston No. 1 to TDC on compression stroke. UP mark on camshaft pulley should be at top, and TDC grooves on camshaft pulley should align with cylinder head surface. Distributor rotor should point to spark plug wire No. 1 on distributor cap.
   
3. Loosen lock nuts on valves for cylinder No. 1, and adjust valve clearances to specification.
   
4. Tighten valve adjuster lock nuts on D15Z1 or D16Z6 engines to 14 ft. lbs. (20 N.m). On all other applications, tighten valve adjuster lock nuts to 10 ft. lbs. (14 N.m). Recheck valve clearance and repeat adjustment, if necessary.
5. Rotate crankshaft counterclockwise 180 degrees. Ensure cylinder No. 3 is at TDC. Adjust valves on cylinder No. 3. For remaining cylinders, repeat steps 3) through 5).
6. Replace valve cover and distributor cap. Tighten timing cover bolts and valve cover crown nuts to 7 INCH lbs. (10 N.m).

Got questions or comments? Leave them below!

All specs applies to Honda Civic models between 1992-1995. Use this article to quickly find specifications related to servicing, adjustments and just about everything. This is a quick reference article to use when you are familiar with an adjustment procedure and only need a specification.

BATTERY SPECIFICATIONS

• Honda Civic 1992-1995 EG and EJ: 52 Amp Hr. Rating
• Honda Civic Del Sol: 36 Amp Hr. Rating

FLUID CAPACITIES

• Crankcase (Includes Filter):
  • Except B16A3 Engine: 3.5 Qts. (3.3L)
  • B16A Engine: 4.2 Qts. (4.0L)
• Cooling System (Includes Heater):
  • Automatic Transaxle:
    • 1.5L Engine: 4.6 Qts. (4.4L)
    • 1.6L Engine: 5.0 Qts. (4.7L)
  • Manual Transaxle:
    • 1.5L Engine (D15B7 & D15B8): 4.8 Qts. (4.5L)
    • 1.5L Engine (D15Z1): 4.6 Qts. (4.4L)
    • 1.6L Engine (B16A3): 5.1 Qts. (4.8L)
    • 1.6L Engine (D16Z6): 4.6 Qts. (4.4L)
• Automatic Transaxle (Dexron-II):
  • Honda Civic Eg and EJ:
    • Oil Change: 3.0 Qts. (2.8L)
    • Overhaul: 6.2 Qts. (5.9L)
  • Honda Civic Del Sol:
    • Oil Change: 2.9 Qts. (2.7L)
    • Overhau:l 6.2 Qts. (5.9L)
• Manual Transaxle (SAE 30W, 10W-40 & 20W-40):
  • Except B16A Engine:
    • Oil Change: 1.9 Qts. (1.8L)
    • Overhaul: 2.0 Qts. (1.9L)
  • B16A Engine:
    • Oil Change: 2.3 Qts. (2.2L)
    • Overhaul: 2.4 Qts. (2.3L)

REPLACEMENT & SERVICE INTERVALS

• Air Filter: 30,000 miles
• Brake Fluid: 30,000 miles
• Coolant: 45,000 miles
• Fuel Filter: 60,000 miles
• Oil & Filter: 7500 miles
• Spark Plugs: 30,000 miles
• Transaxle Fluid: 30,000 miles

BELT ADJUSTMENT – Deflection – In. (mm)

• Alternator (With 22 lbs. pressure applied midway on longest belt run): 17/64-13/32 (7-10.5)
• A/C Compressor (With 22 lbs. pressure applied midway on longest belt run): 3/16-9/32 (5-7)
• Power Steering (With 22 lbs. pressure applied midway on longest belt run): 5/16-15/32 (8-12)

ENGINE COMPRESSION
Check engine compression at specified cranking speed, with engine at normal operating temperature, all spark plugs removed and throttle wide open.

ENGINE COMPRESSION – Maximum variation between cylinders is 28 psi (2.0 kg/cm2 )

• Non B16A
  • Standard psi (kg/cm2 ): 185 (13.0) at 250 rpm
  • Minimum psi (kg/cm2 ): 135 (9.5) at 250 rpm
• Non B16A
  • Standard psi (kg/cm2 ): 220 (15.5) at 250 rpm
  • Minimum psi (kg/cm2 ): 135 (9.5) at 250 rpm

VALVE CLEARANCE ADJUSTMENT SPECIFICATIONS

• 1.5L:
  • Intake In. (mm): .007-.009 (.17-.23)
  • Exhaust In. (mm): .009-.011 (.23-.28)
• 1.6L:
  • B16A3 Engine:
    • Intake In. (mm): .007-.009 (.18-.22)
    • Exhaust In. (mm): .007-.010 (.23-.27)
  • D16Z6 Engine
    • Intake In. (mm): .007-.009 (.17-.23)
    • Exhaust In. (mm): .009-.011 (.23-.28)

IGNITION COIL RESISTANCE – Ohms @ 68°F (20°C)

• Civic and Civic Del Sol”
  • Primary: .6-.8
  • Secondary: 12,800-19,200

DISTRIBUTOR SENSORS
Triggering of fuel injectors is dependent upon pulsed voltage signals generated by TDC/CKP/CYP sensors.

TDC/CKP/CYP SENSOR RESISTANCE

• Civic, Civic Del Sol:
  • 350-700 Ohms

HIGH TENSION WIRE RESISTANCE

• Civic & Civic Del Sol:
  • 25,000 Maximum Ohms

SPARK PLUG TYPE

• Honda Civic EG and EJ
  • 1.5L Engine (D15B7): ZFR5F-11 (NGK)
  • 1.5L Engine (D15B8 & D15Z1): ZFR4F-11 (NGK)
  • 1.6L Engine (D16Z6): ZFR5J-11 (NGK)
• Civic Del Sol
  • 1.5L Engine (D15B7): ZFR5F-11 (NGK)
  • 1.6L Engine (B16A3): PFR6L-13 (NGK)
  • 1.6L Engine (D16Z6): ZFR6J-11 (NGK)

SPARK PLUG SPECIFICATIONS

• All models:
  • Gap In. (mm): .039-.043 (1.0-1.1)
  • Torque Ft. Lbs. (N.m): 13 (18)

FIRING ORDER AND TIMING MARKS

REGULATED FUEL PRESSURE
Measure pressure w/vacuum hose connected & disconnected from press. regulator.

• Vacuum Hose Disconnected 40-47 idle psi (2.8-3.3 kg/cm2)
• Vacuum Hose Connected 30-38 idle psi (2.1-2.7 kg/cm2)

FUEL INJECTOR RESISTANCE

• Injector: 10-13

IDLE SPEED SPECIFICATIONS
With Electronic Air Control Valve (EACV) disconnected, headlights and cooling fan off, and transmission in Neutral or Park.

• AT: 650-750 rpm
• MT:
  • Except B16A3 Engine: 620-720 rpm
  • B16A3 Engine: 650-760 rpm

IDLE CO LEVEL

• Civic and Civic Del Sol: 0.1%

THROTTLE POSITION (TP) SENSOR

• Throttle Valve Fully Closed: .5 volts
• Throttle Valve Wide Open: 4.5 volts

Got questions or comments? Leave them below!

Manual transmission overhaul applies to Honda Civic 1992-1995.

TRANSMISSION DISASSEMBLY
Place clutch housing on supports high enough to keep mainshaft from hitting workbench. If it is necessary to heat transmission case for component removal, DO NOT exceed 212°F (100°C).

1. Remove back-up light switch and cable bracket. Remove transmission attaching bolts, and disconnect breather tube. Remove 32-mm sealing plug (plug has square hole). Expand snap ring on countershaft ball bearing. Separate transmission housing from clutch housing. See figure 1 and figure 2.
2. Measure clearance between reverse shift fork and shift piece pin. See figure Clearance should be .002-.014″ (.05-.35 mm). Service limit is .020″ (.50 mm). If clearance exceeds limit, measure width of “L” groove in reverse shift fork. See figure Width should be .278-.285″ (7.05-7.25 mm). Replace reverse shift fork if width exceeds specification.
3. Measure clearance between reverse idler gear and reverse shift fork. See figure Clearance should be .020-.043″ (.50-1.10 mm). Service limit is .071″ (1.80 mm). If clearance exceeds service limit, measure width of reverse shift fork pawl opening. Width should be .500-.512″ (12.70-13.00 mm). If width exceeds limit, replace shift fork.
4. Remove reverse shift fork. Remove reverse idler gear shaft and gear. Remove interlock guide bolt from under clutch housing. Remove shift arm “B” bolt. Tape mainshaft splines for protection. Remove mainshaft and countershaft with shift forks as an assembly from clutch housing. Remove differential assembly.

COMPONENT DISASSEMBLY AND REASSEMBLY

Mainshaft Inspection

1. Measure clearance between 2nd and 3rd gears. See figure. If clearance is greater than service limit, measure thickness of 3rd gear. If thickness is within specifications, replace 3rd/4th synchro hub. If thickness is not within specifications, replace 3rd gear.
2. Measure clearance between 4th gear and spacer collar. If clearance is greater than service limit, measure distance “A” on spacer collar. If distance “A” is greater than specifications, replace spacer collar. If distance “A” is within specifications, measure thickness of 4th gear. Replace 4th gear if thickness exceeds specification. If thickness is within specifications, replace 3rd/4th synchro hub.
3. Measure clearance between 5th gear and spacer collar. If clearance exceeds specifications, measure distance “B” on spacer collar. If distance “B” is greater than service limit, replace collar. If distance “B” is within specifications, measure thickness of 5th gear. Replace 5th gear if thickness exceeds specifications. If thickness is within specifications, replace 5th synchro hub.

Mainshaft Specifications

• 2nd-To-3rd Gear Clearance
  • Standard .002-.008″ (.06-.21 mm)
  • Service Limit .013″ (.33 mm)
• 4th Gear-To-Spacer Collar Clearance
  • Standard .002-.007″ (.06-.19 mm)
  • Service Limit .12″ (.31 mm)
• 5th Gear-To-Spacer Collar Clearance
  • Standard .002-.007″ (.06-.19 mm)
  • Service Limit .12″ (.31 mm)
• 3rd Gear Thickness
  • Standard 1.190-1.192″ (30.22-30.27 mm)
  • Service Limit 1.187″ (30.15 mm)
• 4th Gear Thickness
  • Standard 1.186-1.188″ (30.12-30.17 mm)
  • Service Limit 1.183″ (30.05 mm)
• 5th Gear Thickness
  • Standard 1.119-1.121″ (28.42-28.47 mm)
  • Service Limit 1.116″ (28.35 mm)
• Spacer Collar Height “A”
  • Standard .899-.900″ (22.83-22.86 mm)
  • Service Limit .898″ (22.81 mm)
• Spacer Collar Height “B”
  • Standard .926-.928″ (23.53-23.56 mm)
  • Service Limit .926″ (23.51mm)

  Remove synchro hubs using press and steel blocks. Use of jaw-type puller can damage gear teeth.

Disassembly
Use puller to remove bearing. Support 4th gear on steel blocks, and press mainshaft out of 5th synchro hub. Support 3rd gear on steel blocks, and press mainshaft out of 3rd/4th synchro hub. Remove remaining components.

Inspection

1. Inspect all parts for damage and wear. Replace if necessary. Clean all parts in solvent, then dry and lubricate all parts. Ensure oil passages are free of contamination.
2. Measure mainshaft at points “D”, “E”, “F” and “G”. See figure. Support mainshaft on “V” blocks. Using dial indicator, measure runout while rotating mainshaft 2 complete revolutions. Replace mainshaft if runout or any part of shaft is not within service limit.

MAINSHAFT BEARING SURFACE SPECIFICATIONS – “D”, “E”, “F” and “G” are measuring points. See figure

• “D”
  • Standard In. (mm).8657-.8661 (21.99-22.00)
  • Service Limit In. (mm): .8634 (21.93)
• “E”
  • Standard In. (mm): 1.062-1.063 (26.98-26.99)
  • Service Limit In. (mm): 1.060 (26.93)
• “F”
  • Standard In. (mm): 1.338-1.339 (33.98-34.00)
  • Service Limit In. (mm): 1.336 (33.93)
• “G”
  • Standard In. (mm): 1.022-1.023 (25.98-25.99)
  • Service Limit In. (mm): .002 (.05)

Reassembly
Assemble components on mainshaft in reverse order of disassembly. Ensure proper installation of synchro hub, synchro sleeves and ball bearing. See figure.

Mainshaft Thrust Shim Adjustments

1. Remove thrust shim and oil guide plate from transmission housing. Install 3rd/4th synchro hub, spacer collar, 5th synchro hub (5-speed) or collar (4-speed), and ball bearing on mainshaft. Install mainshaft in transmission housing.
2. Measure distance “B” between transmission housing end and thrust washer using straight edge and feeler gauge. Measure at 3 locations, and average readings. See figure
3. Measure distance “C” between clutch housing surface and bearing inner race using straight edge and feeler gauge. Measure at 3 locations, and average readings.
4. Calculate shim thickness as follows: “B” + “C” – .95 = shim thickness. The number .93 is mid point of flex range of clutch housing bearing spring washer. DO NOT use more than 2 shims. Shims are available in 0.3-mm increments. Shim thickness ranges from .0236″ (.60 mm) to .0709 (1.80 mm). On 1.5L engines, shim diameter is 2.55″ (65 mm). On 1.6L engines, shim diameter is 2.75″ (70 mm). Shim thickness is the same for both shim sizes. Part numbers for 1.5L engines are 23931-PL3-A10 through 23971-PL3-A10. Part numbers for 1.6L engines are 23931-PL3-B00 through 23971-PL3-B00.
5. Install selected shim in transmission housing. Install spring washer on mainshaft. Clean spring washer and shim thoroughly before installation. Install mainshaft in clutch housing.
6. Install transmission housing onto clutch housing. Install and tighten bolts. Tap mainshaft with a plastic hammer. Attach Mainshaft Base (07GAJ-PG20130) and Collar (07GAJ-PG20120). Attach Mainshaft Holder (07GAJ-PG20110) to mainshaft. Attach magnetic base to clutch housing, and set dial gauge on top of mainshaft. See Figure. Turn bolt clockwise, and measure clearance. DO NOT turn shaft holder more than 60 degrees after needle of dial indicator stops moving.
7. Clearance should be .004-.007″ (.11-.18 mm). If reading is not correct, recheck shim thickness.

COUNTERSHAFT MEASUREMENTS

1. Measure clearance between 1st gear and countershaft. See figure. If clearance exceeds service limit, measure thickness of 1st gear. If thickness is less than service limit, replace 1st gear. If thickness is within specification, replace 1st/2nd synchro hub
2. Measure clearance between 2nd gear and 3rd gear. If clearance exceeds service limit, measure distance “A” on spacer collar. If distance “A” is less than service limit, replace collar. If distance “A” is within specification, measure thickness of 2nd gear. Replace 2nd gear if thickness is less than service limit. If thickness is within specification, replace spacer collar.

COUNTERSHAFT SPECIFICATIONS

• 1st Gear-To-Countershaft Clearance
  • Standard .001-.004″ (.03-.10 mm)
  • Service Limit .009″ (.22 mm)
• 2nd Gear-To-3rd Gear Clearance
  • Standard .001-.004″ (.03-.11 mm)
  • Service Limit .009″ (.23 mm)
• 1st Gear Thickness
  • Standard 1.197-1.198″ (30.41-30.44 mm)
  • Service Limit 1.195″ (30.36mm)
• 2nd Gear Thickness
  • Standard 1.257-1.259″ (31.92-31.97 mm)
  • Service Limit 1.254″ (31.85 mm)
• Spacer Collar Height “A”
  • Standard 1.261-1.262 (32.03-32.06 mm)
  • Service Limit 1.260″ (32.01 mm)

  Remove synchro hubs using press and steel blocks. Use of jaw-type puller can damage gear teeth.

Disassembly
Using chisel and hammer, raise lock nut tab away from groove in countershaft. Remove lock nut and spring washer. Use bearing puller to remove top ball bearing. Use bearing splitter or appropriate blocks to support 4th gear. Press countershaft out of 4th gear and 5th gear. Support 1st gear, and press countershaft out of 3rd gear. Remove remaining parts.

Inspection

1. Inspect all parts for damage and wear. Replace if necessary. Clean all parts in solvent, then dry and lubricate all parts. Using press, install 3rd, 4th and 5th gears before lubricating.
2. Measure the countershaft at points “D”, “E” and “F”. See figure. Support countershaft on “V” blocks. Using dial indicator, measure runout while Rotating countershaft 2 complete revolutions. Replace countershaft if runout or any part of countershaft is not within service limit.

COUNTERSHAFT BEARING SURFACE SPECIFICATIONS – “D”, “E” and “F” are measuring points.

• “D”
  • Standard In. (mm): .983-.984 (24.98-24.99)
  • Service Limit In. (mm): .981 (24.93)
• “E”
  • Standard In. (mm): 1.416-1.417 (35.98-36.00)
  • Service Limit In. (mm): 1.415 (35.93)
• “F”
  • Standard In. (mm): 1.181-1.182 (30.00-30.02)
  • Service Limit In. (mm): 1.179 (29.95)
• “G”
  • Standard In. (mm): 1.022-1.023 (25.98-25.99)
  • Service Limit In. (mm): .002 (.05)
• Runout Limits
  • Standard In. (mm): .0008 (.020)
  • Service Limit In. (mm): .0020 (.050)

Reassembly
Assemble components in the reverse order of disassembly. See figure. Ensure friction dampers are properly indexed to mating grooves . Install ball bearing using a press. Install spring washer. Tighten lock nut to 80 ft. lbs. (108 N.m), then stake NEW lock nut tab into groove.

SHIFT FORK ASSEMBLY INSPECTION

1. Measure clearance between each shift fork and its matching synchro sleeve. Clearance should be .010-.018″ (.25-.45 mm). Service limit is .031″ (.80 mm). If clearance exceeds service limit, measure thickness of shift fork fingers. Finger thickness should be .252-.256″ (6.40-6.50 mm). If either measurement is not within specifications, replace sleeve and shift fork.
2. Measure clearance between 3rd/4th gear shift fork and shift arm “B”. See figure. Clearance should be .008-.020″ (.20-.50 mm). Service limit is .024″ (.62 mm). If clearance exceeds service limit, measure width of shift arm “B”. Replace shift arm “B” if minimum width is not .508″ (12.9 mm).

SYNCHRO RING AND GEAR

Disassembly
Separate synchro ring and gear. Lubricate and install synchro spring on synchro ring and set aside.

Inspection

1. Inspect gear teeth for wear, galling, roughness and cracks. Ensure ring and gear turn freely. If replacement is necessary, replace ring and gear as a unit.
2. Measure ring-to-gear clearance all the way around. See figure. Ensure ring is held evenly against gear while measuring. Ring- to-gear clearance should be .033-.043″ (.85-1.10 mm). Service limit is .016″ (.40 mm). If clearance exceeds limit, replace ring and gear as a unit.

Reassembly
Each synchro sleeve has 3 sets of longer teeth (120 degrees apart) that must be matched with 3 sets of deeper grooves when hub is assembled. See figure.

Installing synchro sleeve with its longer teeth in 1st/2nd synchro hub slots will damage spring ring.

DIFFERENTIAL

FYI: Ring gear bolts have left-hand threads.

Disassembly

1. Check bearings for wear and rough rotation. If bearings need replacing, use bearing puller to remove bearings from differential carrier.
2. Remove ring gear. Differential carrier assembly is not serviceable. DO NOT disassemble. If carrier assembly is damaged or backlash is not .002-.006″ (.05-.15 mm), replace the assembly. See figure.

Reassembly
After inspecting condition of carrier assembly, coat all parts with molylube. Mount carrier assembly in Vblocks, with axles inserted into carrier side gears. Mount dial indicator to measure backlash. See figure. Backlash should be .002-.006″ (.05-.15 mm). If backlash exceeds specification, replace differential carrier assembly.

Before differential assembly can be adjusted perform step 1) under Transmission Reassembly

Adjustments

1. Using 40 mm I.D. driver, ensure differential assembly is seated in clutch housing. Install original thrust shim in transmission housing. See figure. Install transmission housing. DO NOT apply sealer at this time.
2. Install and torque housing bolts. Measure clearance between thrust shim and outer race in housing. Maximum clearance is .004″ (.10 mm). If not within limits, select proper thrust shim. Disassemble transmission housing and replace original thrust shim with selected thrust shim. Reassemble transmission housing and recheck side clearance.
3. If differential side clearance is not within specifications, repeat step 2). If differential side clearance is okay, adjustment is complete.

DIFFERENTIAL THRUST SHIM THICKNESS (D16Z6 ENGINE)

• Part Number – Thickness
  • 41441-PL3-B00 .039″ – (1.00 mm)
  • 41442-PL3-B00 .043″ – (1.10 mm)
  • 41443-PL3-B00 .047″ – (1.20 mm)
  • 41444-PL3-B00 .051″ – (1.30 mm)
  • 41445-PL3-B00 .055″ – (1.40 mm)
  • 41446-PL3-B00 .059″ – (1.50 mm)
  • 41447-PL3-B00 .063″ – (1.60 mm)
  • 41448-PL3-B00 .067″ – (1.70 mm)
  • 41449-PL3-B00 .071″ – (1.80 mm)
  • 41450-PL3-B00 .041″ – (1.05 mm)
  • 41451-PL3-B00 .045″ – (1.15 mm)
  • 41452-PL3-B00 .049″ – (1.25 mm)
  • 41453-PL3-B00 .053″ – (1.35 mm)
  • 41454-PL3-B00 .057″ – (1.45 mm)
  • 41455-PL3-B00 .061″ – (1.55 mm)
  • 41456-PL3-B00 .065″ – (1.65 mm)
  • 41457-PL3-B00 .069″ – (1.75 mm)

DIFFERENTIAL THRUST SHIM THICKNESS (EXCEPT D16Z6 ENGINE)

• Part Number – Thickness
  • 41441-PL3-A00 .039″ – (1.00 mm)
  • 41442-PL3-A00 .043″ – (1.10 mm)
  • 41443-PL3-A00 .047″ – (1.20 mm)
  • 41444-PL3-A00 .051″ – (1.30 mm)
  • 41445-PL3-A00 .055″ – (1.40 mm)
  • 41446-PL3-A00 .059″ – (1.50 mm)
  • 41447-PL3-A00 .063″ – (1.60 mm)
  • 41448-PL3-A00 .067″ – (1.70 mm)
  • 41449-PL3-A00 .071″ – (1.80 mm)
  • 41450-PL3-A00 .041″ – (1.05 mm)
  • 41451-PL3-A00 .045″ – (1.15 mm)
  • 41452-PL3-A00 .049″ – (1.25 mm)
  • 41453-PL3-A00 .053″ – (1.35 mm)
  • 41454-PL3-A00 .057″ – (1.45 mm)
  • 41455-PL3-A00 .061″ – (1.55 mm)
  • 41456-PL3-A00 .065″ – (1.65 mm)
  • 41457-PL3-A00 .069″ – (1.75 mm)

TRANSMISSION REASSEMBLY

1. Install magnet and reverse lock cam. Place shift arm “A” in clutch housing, then push shift rod through . Install spring washer and shift arm “A” bolt. Install steel ball, spring and spring bolt. Install shift arm “B” into interlock, and set interlock in clutch housing. Insert shift arm shaft “B” in clutch housing. Install shift arm “C” in shift arm “A”, then insert shift arm shaft. Install reverse select retainer and reverse select spring. Install differential assembly.
2. Insert mainshaft and countershaft into shift forks, and install them as an assembly. Fit tab of interlock assembly into notches of shift forks. Lower mainshaft and countershaft into clutch housing. Install shift arm “B” attaching bolt. Install 1st-2nd select spring and plug bolt. Install interlock guide bolt under clutch housing.
3. Install reverse idler shaft. Install reverse shift holder. Install oil guide plate and mainshaft thrust shim into transmission housing. Apply sealant to transmission mating surface of clutch housing. Install dowel pins. FYI: This tranny uses no gaskets between major housings. Use Sealant (08718-550000). Assemble housings within 20 minutes after applying sealant, and allow it to cure for at least 30 minutes after assembly before filling it with oil.
4. Insert snap ring pliers into 32-mm sealing plug hole. Spread snap ring and install onto countershaft ball bearing, then install transmission housing over clutch housing. Ensure to line up shafts. Install 32-mm sealing plug. Install transmission housing bolts in sequence. See figure. Install back-up light switch.

TORQUE SPECIFICATIONS

• Back-Up Light Switch – 18 (25) Ft. Lbs. (N.m)
• Breather Tube Bolt – 21 (28) Ft. Lbs. (N.m)
• Countershaft Lock Nut – 81 (110) Ft. Lbs. (N.m)
• Interlock Guide Bolt – 30 (40) Ft. Lbs. (N.m)
• Oil Drain Plug 30 – (40) Ft. Lbs. (N.m)
• Oil Filler Plug 33 – (45) Ft. Lbs. (N.m)
• Plug Bolt 41 – (55) Ft. Lbs. (N.m)
• Reverse Lock Cam Bolt – 11 (15) Ft. Lbs. (N.m)
• Set Ball
  • Spring Bolt – 16 (22) Ft. Lbs. (N.m)
  • “A”, “B” and “C” Bolts – 21 (28) Ft. Lbs. (N.m)
• Transmission Housing Bolts – 21 (28) Ft. Lbs. (N.m)
• 32-mm Sealing Bolt – 18 (25) Ft. Lbs. (N.m)
• 10-mm Sealing Bolt: 96 (11) INCH lbs. (N.m)

Got questions or comments on how to overhaul the manual transmission found in 1992-1995 Honda Civic? Let us know below.

Manual transmission removal and installation applies to Honda Civic 1992-1995.

Manual Transmission Removal

1. Disconnect negative and positive battery cables. Remove battery base and air cleaner and tube assembly. Disconnect starter and transaxle ground cables. Remove engine harness clamp. Disconnect Vehicle Speed Sensor (VSS) connector. Disconnect back-up light switch.
2. Remove clutch pipe bracket and clutch slave cylinder. Drain transaxle fluid. Remove starter. Remove engine and right wheelwell splash shields. Remove header pipe. Separate lower control arms from ball joints. Remove right radius rod. Using 2 large screwdrivers, pry both axle shaft inner CV joints out of transaxle. Protect axle shaft ends.
3. Using drift punch, drive out shift rod roll pin. Remove shift and extension rods. Remove inspection cover and engine stiffener brackets. Install hoist at cylinder head attachment points of engine, and lift engine slightly to unload engine mounts. Remove splash guard and front stopper bracket.
4. Place a jack under tranny, and slightly raise it to take weight off transaxle mounts. Remove front transaxle mount. Remove rear transaxle mount bracket. Remove side transaxle mount. Remove transaxle housing mount bolts. Pull transaxle away from engine, and remove tranny.

Manual Transmission Installation

Before installation, install NEW circlips on inboard side of axle shafts. Use NEW self-locking nuts on front end of radius rod and header pipe bracket. Use NEW through bolt on firewall side transaxle mount. To install transaxle, reverse removal procedure. Tighten nuts and bolts to specification.

TORQUE SPECIFICATIONS Ft. Lbs. (N.m)

• Battery Base Mounting Bolts: 16 (22)
• Extension Rod Bolt 16 (22)
• Flywheel Housing-To-Engine Bolts: 44 (60)
• Header Pipe
  • At Manifold 41 (55)
  • At Flange 16 (22)
• Intake Manifold Bracket Bolts: 16 (22)
• ntermediate Shaft Support Bolt: 29 (39)
• Rear Mount-To-Transmission Bolt: 41 (55)
• Slave Cylinder-To-Housing: 16 (22)
• Starter Bolts: 33 (45)
• Stiffener Bolt: 33 (45)
• VSS Mounting Bolts: 14 (19)
• Wheel Lug Nuts: 80 (109)

Got questions or comments on how to remove the manual transmission on Honda Civic 1992-1995.

The ignition system applies to Honda Civic 1992-1995.

IGNITION TIMING CONTROL

ECM or ECU has complete control of ignition timing. Timing is controlled in response to signals from various sensors. Input signals from TDC, CRANK and CYL, throttle angle, coolant temperature, and MAP sensors are all used by ECM to determine optimum ignition timing control.

Battery voltage is supplied through ignition switch to ignition coil and Ignition Control Module (ICM). ECM triggers ICM based upon signals from TDC, CRANK and/or CYL and other sensors. High voltage from ignition coil is distributed to each spark plug by distributor.

DISTRIBUTOR REMOVAL AND INSTALLATION

Disconnect 2-pin and 8-pin connectors from distributor. Disconnect spark plug wires and coil wire from distributor cap. Remove distributor hold-down bolts. Remove distributor from cylinder head. To install, coat NEW “O” ring with engine oil and put into place. To complete installation, reverse removal procedure. Set timing to specification.

IGNITION COIL REMOVAL AND INSTALLATION

Ensure ignition switch is in OFF position. Remove distributor cap, cap seal and leak cover. Remove 2 screws to disconnect Black/Yellow and White/Blue wires from coil primary terminals. Remove 2 mounting screws. Slide ignition coil out of distributor housing.

IGNITION TIMING

1. Timing marks are on timing belt cover and crankshaft pulley. Start and warm engine to normal operating temperature (cooling fan comes on). Connect timing light.
2. Ignition timing check connector is located behind passenger-side kick panel. See Fig. 5 . Connect jumper wire between Brown and Black wire terminals.
3. Check ignition timing and adjust to specification, if necessary. To adjust, loosen distributor hold-down bolts and turn distributor housing counterclockwise to advance or clockwise to retard timing. Align pointer with Red timing mark.
4. Tighten distributor hold-down bolts to 16 ft. lbs. (22 N.m). Recheck timing. Remove jumper wire from ignition timing check connector.

IGNITION TIMING – Degrees BTDC @ RPM

• 1.5L Engine (D15B7):
  • Automatic tranny: 16 @ 650-750
  • Manual tranny: 16 @ 620-720
• 1.5L Engine (D15B8): 12 @ 620-720
• 1.5L Engine (D15Z1): 16 @ 550-650
• 1.6L Engine (B16A3): 16 @ 650-750
• 1.6L Engine (D16Z6):
  • Automatic tranny: 16 @ 650-750
  • Manual tranny: 16 @ 620-720

TORQUE SPECIFICATIONS – Ft. Lbs. (N.m)

• Distributor Retaining Nuts: 18 (24)
• Mounting Nuts: 16 (22)
• Oxygen Sensor (O2S) 33 (45)
• Service Bolt 16 (22)
• Throttle Body Mounting: Nuts 16 (22)

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Wiper and washer system testing and removing applies to Honda Civic models between 1992-1995.

A 2-speed front wiper motor with intermittent feature is used on all Honda Civic EG models. Wiper switch is part of the combination switch on the steering column. Some models are also equipped with a rear wiper/washer system.

FRONT WIPER MOTOR TEST

1. Disconnect front wiper motor 5-pin connector. Using jumper wires, connect positive battery terminal to Green/Black wire terminal and negative battery terminal to Blue wire terminal at wiper motor connector. Ensure wiper motor operates on low speed.
2. Using jumper wires, connect positive battery terminal to Green/Black wire terminal and negative battery terminal to Blue/Yellow wire terminal at wiper motor connector. Wiper motor should operate on high speed. Replace front wiper motor if it fails to operate.

REAR WIPER MOTOR TEST

1. Remove tailgate lower trim panel. Disconnect rear wiper motor 4-pin connector. Connect positive battery terminal to terminal No. 1 (Yellow/Green wire) and negative battery terminal to terminal No. 2 (Green wire). See figure. Wiper motor should operate smoothly. Replace rear wiper motor if it fails to operate.
2. Reconnect 4-pin connector. Turn rear wiper switch on. While motor is running, check voltage between terminal No. 3 (Light Green/Black wire) and terminal No. 4 (Black wire). Voltage should alternate from zero volts to more than 4 volts. If voltage is not as specified, replace rear wiper motor.

WASHER MOTOR TEST
Remove front bumper. Disconnect washer motor 2-pin connector. Connect battery voltage across washer motor terminals. Washer motor should operate smoothly. If motor runs smoothly but little or no washer fluid is pumped, check for disconnected or blocked washer fluid hose or a clogged pump outlet in motor.

WIPER/WASHER SWITCH TEST – HONDA CIVIC
Remove steering column covers. Disconnect 6-pin and 8-pin connectors from wiper/washer switch. Check continuity between specified terminals with switch in indicated positions. See figure. If continuity is not as specified, replace wiper/washer switch.

WIPER/WASHER SWITCH TEST – HONDA DEL SOL
Remove steering column cover. Disconnect 8-pin connector from wiper/washer switch. Check continuity between specified terminals with switch in indicated positions. See figure. If continuity is not as specified, replace wiper/washer switch.

TROUBLESHOOTING

• Wipers Do No Operate in Any Position – Blown fuse No. 14 (20-amp) in dash fuse block. Faulty wiper motor assembly. Disconnected wiper linkage. Faulty wiper switch. Poor ground. Inspect Green/Black wire for open circuit. Check for loose or disconnected terminals.
• Wipers Do Not Operate in Int. (Intermittent) – Faulty wiper switch. Faulty wiper motor assembly. Faulty intermittent wiper relay circuit (in integrated control unit). Inspect Blue/Green, Blue/White and/or Yellow/Blue wires for open circuit. Check for loose or disconnected terminals.
• Wipers Do No Operate in LO or HI Position – Faulty wiper switch.
• Wipers Do Not Operate in Mist Position - Faulty mist switch.
• Rear Window Wiper Does No Operate (Civic) – Blown fuse No. 14 (20-amp) in dash fuse block. Faulty wiper motor assembly. Faulty wiper switch. Poor ground. Inspect Green/Black and/or Green wires for open circuit. Check for loose or disconnected terminals.
• Wipers Do No Return to Park Position With Switch Turned Off – Faulty wiper motor assembly. Faulty wiper switch. Check for open circuit in Blue/White and/or Light Green/Black wire. Poor ground. Check for loose or disconnected terminals.
• Erratic or no Intermittent Cycle – Faulty wiper switch. Faulty intermittent wiper relay circuit (in integrated control unit). Inspect Blue/Green, Blue/White, Green/Black (Civic Del Sol) or Yellow/Blue wire(s) for open circuit. Check for loose or disconnected terminals.
• Little or No Washer Fluid is Pumped – Insufficient washer fluid in reservoir. Disconnected or blocked washer fluid hose. Clogged washer fluid nozzle. Faulty washer motor. Faulty washer switch. Poor ground. Inspect Black/Green and/or Green/Yellow wire for open circuit. Check for loose or disconnected terminals.

REMOVAL AND INSTALLATION

Front Wiper Motor

1. Open hood. Remove cap nuts from wiper arms. Carefully remove wiper arms. Remove hood seal and air scoop by prying off trim clips and removing screws.
2. Disconnect wiper motor 5-pin connector. Remove 3 bolts, nut and wiper linkage assembly. Remove wiper motor assembly. To install, reverse removal procedure.3

Rear Wiper Motor
Outside vehicle, remove wiper arm cover, nut, wiper arm, seal retainer nut and washer, and outer seal rubber from wiper motor shaft. Inside vehicle, remove hatch or tailgate trim panel. Disconnect rear wiper motor 4-pin connector. Remove 3 bolts and rear wiper motor. To install, reverse removal procedure.

WIPER AND WASHER SWITCH

WARNING: Air bag system MUST be disabled BEFORE removing any steering column component.

Disable air bag system. Remove dash lower trim cover. Remove steering column covers. On Civic, disconnect wiper/washer switch 6-pin and 8-pin connectors. On Civic Del Sol, disconnect wiper/washer switch 8-pin connector. Remove 2 screws and slide wiper/washer switch out of housing. To install, reverse removal procedure.

WASHER FLUID RESERVOIR AND NOZZLE
Remove front bumper. Remove 3 bolts and washer fluid reservoir. Disconnect hose and 2-pin connector from washer motor. Remove deflector, washer nozzles and washer fluid hoses as necessary. To install, reverse removal procedure.

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Rear struts, trailing arm and wheel bearing removal and installation applies to Honda Civic 1992-1995.

Use NEW self-locking bolts if nut can be threaded easily past nylon locking area. Use NEW self-locking nuts any time a self-locking nut is removed. When tightening retaining bolts used on parts containing rubber mounting bushings, ensure vehicle weight is supported on strut assembly.

STRUT ASSEMBLY

Removal - From inside of your Civic, remove strut upper cover (if equipped). Remove 2 upper strut mounting base nuts. Raise mand support vehicle. Remove rear wheels. Place wheels in trunk to provide ballast. Remove speed sensor wire bracket (if equipped). DO NOT remove speed sensor. Remove lower strut mounting bolt. Lower rear suspension, and remove strut from vehicle.

Inspection and Reassembly – Check for weak spring tension. Inspect components for deterioration and damage. Strut assembly must be replaced if rod does not move smoothly through full travel or signs of oil leakage exist. Replace worn or damaged components. To assemble, reverse disassembly procedure. Install NEW strut shaft nut. Tighten nut to specification.

Installation

1. Lower rear suspension, and place strut assembly in its original position. Loosely install lower strut mounting bolt. Loosely install upper strut mounting nuts. Ensure vehicle weight is supported on strut assembly before tightening lower strut mounting bolt to specification.
2. Raise rear suspension so strut assembly supports vehicle weight. Loosely install strut mounting. Reverse removal procedure for remaining components. Raise rear suspension until weight of car is on strut. Tighten bolts to specification. Install strut cap (if equipped).

TRAILING ARM REMOVAL AND INSTALLATION

1. Raise and support Civic. Remove rear wheels. Place wheels in trunk to provide ballast. Remove brake drum or rotor.
2. Remove parking brake cable from backing plate (if necessary). Disconnect brake line from brake flexhose. Support lower arm using a floor jack. Remove trailing arm pivot bushing-to-body retaining bolts.
3. Remove compensator arm from trailing arm. Remove lower arm bolt at trailing arm. Remove trailing arm assembly. To install, reverse removal procedure. Final tightening of nuts and bolts should be performed with vehicle on ground. Reconnect brake hose.
4. Bleed hydraulic brake system. Check rear toe-in adjustment.

WHEEL BEARING REMOVAL AND INSTALLATION

1. Raise and support your Honda Civic. Remove wheel assembly and brake drum or rotor. Remove hub cap, nut, washer and hub bearing assembly. Replace hub and bearing assembly as a unit.
2. To install, reverse removal procedure using new hub retaining nut. Tighten nut to specification. Stake hub retaining nut against spindle.

REAR SUSPENSION TORQUE SPECIFICATIONS – Ft. Lbs. (N.m)

• Backing Plate Nut: 48 (65)
• Compensator Arm Bolts: 48 (65)
• Lower Arm-To-Body Bolt: 41 (55)
• Lower Arm-To-Trailing Arm Bolt: 41 (55)
• Spindle Nut: 136 (185)
• Strut Assembly Lower Mounting Bolt: 41 (55)
• Strut Mount Base Nut: (2) 29 (39)
• Strut Shaft Nut: 22 (30)
• Trailing Arm Bushing Bracket Bolts: 48 (65)
• Upper Arm Bracket-To-Body Bolts: 29 (39)
• Upper Arm-To-Trailing Arm Bolt: 41 (55)
• Wheel Lug Nut 81 (110)

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Shocks removal and installation applies to Honda Civic 1992-1995.

Removal

Raise and support front of your Honda Civic. Remove wheel assembly and brake hose clamp from shock. Remove shock-to-fork self-locking pinch bolt and shock fork bolt. Remove shock fork assembly. Remove cap and nuts from top of shock. Remove shock assembly.

CAUTION: Shock contains pressurized nitrogen gas. To dispose of properly, drill a 5/64″ (2.0 mm) hole at base of shock. Always wear eye protection when drilling.

Disassembly

Using spring compressor, compress spring slightly to remove spring tension. Hold shock rod using an Allen wrench and remove nut retaining spring seat and mounting base. Slowly release spring compressor and lift spring off. Disassemble shock assembly, noting relative position of assembled parts.

Reassembly

Check parts for cracks, deterioration and damage. Check shock absorber for leaks and improper operation. Replace shock if resistance is weak, uneven or jerky when shock is compressed. Replace worn or damaged parts. Position mounting base with one stud aligned with tab on shock housing. To complete reassembly, reverse disassembly procedure.

Installation

1. Install shock fork on lower control arm. Position shock assembly so tab on shock housing aligns with slot in fork. Align upper shock studs with shock tower holes. Place jack under knuckle, and raise it until vehicle just lifts off safety stands. Shock mount base nuts must be tightened with vehicle weight on shock.
2. Install upper shock mount nuts. Tighten shock assembly while shock is under load. Reverse removal procedure to complete installation. Tighten retaining nuts and bolts to specification.

TORQUE SPECIFICATIONS Ft. Lbs. (N.m)

• Ball Joint Nut:
  • Lower 37-44 (50-60)
  • Upper 30-35 (40-48)
• Brake Caliper Mounting Bolt: 81 (110)
• Lower Control Arm Pivot Bolt: 47 (64)
• Spindle Nut: 136 (185)
• Stabilizer Bar Mounting Bolts: 16 (22)
• Shock Assembly Shaft Nut: 22 (30)
• Shock Fork Pinch Bolt: 33 (45)
• Shock Fork-To-Control Arm Nut: 48 (65)
• Tie Rod Lock Nut: 41 (55)
• Upper Control Arm Anchor Bolt Nut: 48 (65)
• Upper Control Arm Bushing Bolt: (2) 22 (30)
• Upper Shock Mounting Nut: 29 (39)
• Wheel Lug Nut: 81 (110)

TORQUE SPECIFICATIONS INCH Lbs. (N.m)

• Ball Joint Shield Bolt: 89 (10.0)
• Brake Line Clamp Bolt: 89 (10.0)

Both the 1992-1995 USDM and JDM Honda Civic EG and Del Sol use independent, double wish-bone, strut type suspension. The coil-over strut assembly is attached to the steering knuckle through the lower control arm. The steering knuckle is attached to upper and lower control arms by ball joints. A stabilizer bar and strut rod are attached to lower control arm.

Removal

1. Raise and support front of your Honda Civic. Remove wheel assembly. Remove strut fork and strut rod (radius arm) bolts. Remove nut, bolt and bushings from stabilizer bar.
2. Remove cotter pin from lower control arm ball joint, and remove castle nut. Using puller, separate lower control arm from ball joint. Pull arm down until clear of lower ball joint stud. Remove lower control arm pivot bolt, and remove control arm.
3. Remove steering knuckle. Remove dust boot snap ring, dust boot and external ball joint snap ring.
4. Install Ball Joint Remover/Installer (07965-SB00100) Place installer over ball joint stud with large diameter opening facing away from ball joint. Install stud nut.
5. Position Ball Joint Remover Base (07JAF-SH20200) with open end over ball joint flat surface. Place assembly in vise. Tighten vise and press ball joint from steering knuckle.

Installation

1. Position ball joint in steering knuckle. Install ball joint remover/installer on stud end of ball joint with large diameter opening facing ball joint. Position Ball Joint Installer Base (07965-SB00200) over end of ball joint. Using vise, press ball joint into knuckle.
2. Install ball joint snap ring and dust boot. Using Dust Boot Snap Ring Guide (07974-SA50700), install dust boot snap ring.
3. Reverse removal procedure to install control arm. Use a NEW lower control arm pivot bolt. Tighten bolt to specification.

Inspection
Raise and support the front of your Honda Civic. Remove wheel assembly. Rock upper ball joint front to back. Replace upper control arm bushings if any play exists.

Removal

1. Raise and support front of vehicle. Remove wheel assembly. Remove cotter pin and nut from upper ball joint stud.
2. Using ball joint remover, separate upper ball joint from steering knuckle. Remove upper control arm anchor bolts-to-body retaining nuts. Remove upper control arm. Clamp each upper arm anchor bolt in a vise. Remove upper arm bushings.

Bushing Replacement

Remove control arm bushing nuts and bolts. Clamp upper control arm anchor bolt in a soft-jawed vise. Drive out bushing. Grease and install NEW control arm bushing. Ensure bushing is centered in anchor bolt. Install bushing nuts and bolts, and tighten them to specification.

Installation

To install, reverse removal procedure. Tighten lug nuts and bolts to specification. Check camber, and adjust if necessary.

TORQUE SPECIFICATIONS Ft. Lbs. (N.m)

• Ball Joint Nut:
  • Lower 37-44 (50-60)
  • Upper 30-35 (40-48)
• Brake Caliper Mounting Bolt: 81 (110)
• Lower Control Arm Pivot Bolt: 47 (64)
• Spindle Nut: 136 (185)
• Stabilizer Bar Mounting Bolts: 16 (22)
• Strut Assembly Shaft Nut: 22 (30)
• Strut Fork Pinch Bolt: 33 (45)
• Strut Fork-To-Control Arm Nut: 48 (65)
• Tie Rod Lock Nut: 41 (55)
• Upper Control Arm Anchor Bolt Nut: 48 (65)
• Upper Control Arm Bushing Bolt: (2) 22 (30)
• Upper Strut Mounting Nut: 29 (39)
• Wheel Lug Nut: 81 (110)

TORQUE SPECIFICATIONS INCH Lbs. (N.m)

• Ball Joint Shield Bolt: 89 (10.0)
• Brake Line Clamp Bolt: 89 (10.0)

Got questions and comments on how to remove and install the upper and lower control arms on Honda Civic 1992-1995? Let us know below!

Hub and knuckle removal and installation applies to Honda Civic models between 1992-1995.

Removal

1. Loosen lug nuts with the Civic’s weight on the tires. Pry lock tab away from spindle nut, and loosen nut. Raise and support vehicle. Remove lug nuts and spindle nut. Remove wheel assembly. Remove caliper assembly, and support aside. DO NOT put weight on flexible brake line.
2. Remove brake disc retaining screws. Install two 8 x 12-mm bolts in brake disc, and tighten bolts to force brake disc from hub. Alternate tightening of bolts to prevent brake disc from binding on hub. Remove cotter pin and nut from tie rod end.
3. Using Ball Joint Remover (07MAC-SL00200), separate tie rod ball joint and lift tie rod end out of knuckle. Remove cotter pin from lower control arm ball joint, and loosen castle nut half length of joint threads. Using ball joint separator, separate lower ball joint from control arm.
4. Remove upper ball joint shield. Remove cotter pin and upper ball joint stud nut. Using ball joint remover, separate ball joint from steering knuckle. Remove steering hub/knuckle assembly from axle shaft.

Installation

To install hub/knuckle, reverse removal procedure. Tighten bolts and nuts to specification. Use NEW spindle nut, and stake after tightening.

Got questions and comments on hub and knuckle assembly for Honda Civic 1992-1995? Let us know below!