D16y8 HONDA CIVIC 1996 6.G Workshop Manual

Intake Air System
Throttle Cable (cont'dl
4. Set the locknut on the cable bracket. Adjust theadjusting nut so that its free play is O mm.
5. Bemove the cable sheath from the throttle bracket,reset the adjusting nut and tighten the locknut.
O16Y5, D16Y8 engino:
ADJUSTING NUT
9.8 N.m{1.0 kgl.m,1.2 tbt.ttl
DtGYT 6ngine:
11-246
816A2 engine:
1. Open the throttle valve fully, then install the throttlecable in the throttle linkage. and install the cablehousing in the cable bracket,
THROTTLE LINK
LOCKNUTADJUSTINGNUT
Start the engine. Hold the engine at 3.000 rpm withno load (in Park or neutral) until the radiator fancomes on, then let it idle.
Hold the throttle link to the throttle lever; thereshould be no clearance.
Hold the cable sheath, removing all slack from thecable.
Turn the adjusting nut untit it is 3 mm {1/8 in.) awayfrom the cable bracket,
LOCKNUT9.8 N.m(1.0 kgt m,7.2 tM.ttl
ADJUSTING NUT
Tighten the locknut. The cable deflection shouldnow be 10 - 12 mm l3/B - 1/2 in.). lf nor. seeInspection/Adjustment.
3 mm 11/8 in.)

IThrottle BodY
Description
The throttle bodY is either a single-barrel side-draft type
(D16Y5, D16Y8, 816A2 engine) or a down-draft type
(D16Y/ engine). The lower portion ot the throttle valve is
heated by engine coolant from the cylinder head' The
idle adjusting screw which regulates the bypass air is
located on the top of the throttle body
THROTTLEPOS|T|ON lTPlSENSOR
IDLE AD.'USTINGSCREW
t
In3pection
1. Check that the throttle cable operates smoothly
without binding or sticking.
lf there are any abnormalities, check for:
. Excessive wear or play in the throttle valve shaft'
. StickY or binding throttle lever at the fully closed
Position.. Clearance between throttle stop screw and throt-
tle lever at the fully closed position'
D16Y5, Dl6Y8 engine:
THROTTLE STOP SCREW
{Do not adjust.)
Dl6Y7 ongine:
816A2 engins:
THROTTLE LINK
STOP SCREW
THROTTTE STOP SCREW(Do not adjust.)
Replace the throftle body if thsre is excessive play in the
throttle valve shaft or iJ the shaft is binding or sticking'
(cont'd)
11-247
{Do not adjust.)

Emission Gontrol System
System Description
The emission control system includes a Three Way Cata-lytic Convener (TWC), Exhaust Gas Recirculation (EGR)
system,. Positive Crankcase Ventilation (pCV) system andEvaporative Emission (EVAP) Control system. The emis-sion control system is designed to meet federal and stateemission standards.*: D16Y5 engine
Tailpipe Emission
Inspestion
@@ Do not smoke during ihis procedure. Keepany open flame away from your work area.
1. Start the engine. Hold the engine at 3,000 rpm withno load (in Park or neutral) until the radiator fancomes on. then let it idle.
2. Connect a tachometer.
Check and, if necessary, adjust the idle speed (see
page 11-220 - 223).
Warm up and calibrate the CO meter according to themeter manufacturer's instructions.
Check idle CO with the headlights, heater blower,rear window defogger, cooling fan, and air condition-er off.
NOTE: (Canada) Pull the parking brake lever up.Start the engine, then check that the headlights areoff.
CO mete. should indicate 0.1% maximum.
NOTE: '98 Dl6Y5 engine - lf the idle speed incress-es to 8101 50 rpm, this means the EVAp system ispurging the canister. To stop the purging temporari-ly. raise the engine speed above 1,000 rpm with theaccelerator pedal, then slowly release the pedal.
11-252
eFORWARD -
Three Way Catalytic Converter
(TWCI
Doscription
The Three Way Catalytic Converter (TWC) is used toconven hydrocarbons (HC), carbon monoxide (CO), andoxides of nitrogen (NOx) in the exhaust gas to carbondioxide (COr), dinitrogen (N,) and water vapor.
D15Y5, D16
, engine:
'99 - 00 D16Y8, 81642 engine:
ENGINE SIDE
t

Emission Control System
Positive Crankcase Ventilation IPCVI System
Descripiion
The Positive Crankcase Ventilation (PCV) system is
designed to prevent blow-by gas from escaping to the
atmosphere. The PCV valve contains a spring-loaded
plunger. When the engine starts, the plunger in the PCV
valve is lifted in proportion to intake manifold vacuum
and the blow-by gas is drawn directly into the intake
manifold.
D15Y5, D16Y8, 816A2 ongins:
BREATHERHOSE
Dl6'|11 6ngin6:
-: aLOW-BY VAPOR-: FnESH AIF
11-266
tJ
lrcpection
1. Check the PCV hoses and connections for leaks and
clogging.
2. At idle, make sure there is a clicking sound from the
PCV valve when the hose between the PCV valve
and the intake manifold is lightly pinched with your
fingers or pliers,
D16Y5, D16Y8 ongins:
BREATHERHOSE
PCV VALVE
Gently pinch here.
Bl6A2 engins:VALVE
lf there is no clicking sound, check the PCV valve
grommet for cracks and damage. If the grommet is
OK, replace the PCV valve and recheck.
PCV

1\
Evaporative Emission (EVAPI Controls
Description
The evaporative emission controls are designed to minimize the amount of fuel vapor escaping to the atmosphere. The
system consists of the foliowing components:
A. Evaporative Emission (EVAP) Control Canisto]
An EVAP control canister is used for the temporary storage of fuel vapor until the fuel vapor can be purged from the
EVAP control canister into the engine and burned.
B. Vapor Purge Control System
EVAP control canister purging is accomplished by drawing fresh air through the EVAP control canister and into a port
on the intake manifold. The purging vacuum is controlled by the EVAP purge control solenoid valve.
I'96 D16Y5 engine,'96 Dl6Y7 engine,'96 D16Y8
engine (sedan),'97 D16Y5 engine,'97 D16Y7
engine (couper KA, KC models, sedan: KA, Kc'
KL iDX) models, hatchback: all models), '97
D 16Y8 engine (sedan: KA, KC models)l
I'96 D16Y8 engine (coupe),'97 D16Y7 engine
(coupe: KL model, sedan: KL (LX) model)"97
D16Y8 engine (coupe: all models, sedan: KL model)'98-all models,'99-all models,'00-all modelsl
I
c.
D.
or
l'lc COMPRESSOR CLUTCH ON
and
INTAKE AIR TEMPERATURE ABOVE 160"F (41'C)
Fuel Tank Vapor Control System
When fuel vapor pressure in the fuel tank is higher than the set value of the EVAP two way valve, the valve opens and
regulates the flow of fuel vapor to the EVAP control canister.
Onboard Refueling Vapor Recovery (ORVRI System {'99 - 00 models}
During refueling. the oRVR {onboard Refueling Vapor Recovery) vent shut valve opens with the pressure in the fuel
tank. and feeds the fuel vapor to the EVAP control canister.
t(cont'd)
11-267
EVAP PURGE CONTROL SOLENOID VALVE DUTY CON-
TROLLED AFTER STARTING ENGINE
ENGINE COOLANT TEMPERATURE ABOVE 154'F {68"C)
INTAKE AIR TEMPERATURE ABOVE 32'F (O'C)
and
VEHICLE SPEED ABOVE O MILE (O KM/h}
ENGINE COOLANT TEMPERATURE ABOVE 154'F (68'C)

Emission Control System
Evaporative Emission IEVAPI Controls (cont'd)
'96 D16Y8 ongins (coupol.'97 D16Y8 €ngino (coups: all mod€ls, sedan: KL model),'98 D16Y5 engine (all mod6lsl,'98
Dl5YB engine {all modols):
{BLK/YEL
From
< No. 15
FUELTANKPRESSURESENSOR
EVAP PURG€CONTROLSOLENOID VALVE
. LT GRN
GRN/BLK
ALTERNATORSP SENSOR(7.5 A)
VARIOUSSENSORS
YEL/BLU
V€NT SHUT
EVAPBYPASSSOLENOIDVALVEL BLU
WHTRED/YEL
L __ LT GRN/
EVAPTWO WAYVALVE
INTAKEMANIFOI.I'
'97 D16Y7 engin. (coupa: KL model, sedan: KL {LX) model},38 Dl6
/ engine:
?:y- -<
FromNo. 15ALTERNATORSP SENSOR17.5 A)
FUELTANKPRESSURESENSOR
YEL/BLULT G]GRN/BLK
LT GRN/WHT
BLU
YEL
EVAPBYPASSRED/
VALVE
EVAPTWO WAVALVE
EVAP CONTROLCANISTER
FUEL FILLCAP
BLK
11-268
FUEL TANK

J
'96 Dl6Y5 engine,'96 D16Y8 engine (sodanl,'97 Dl6Y5 sngino,'97 Dl6Y8 sngine (sedan: KA, KC modols):
EVAPTWO WAY
EVAPPURGECONYROLSOLENOIDVALVEVALFromNo. 15
BLK/YEL__ _ < ALTERNATOR- SP SENSOR
FUELFILLCAP
VARIOUSSENSORS
(cont'd)
11-269
I
'96 D16Y' engin.,.9? D16Y7 engine {coupe: KA, KC models, sedan: KA. KC, Kl- IDX) modols, hatchback: all models}:
FromNo. 15
3lI/- - - -{ ALTERNAT'RSP SENSORRED/YEL
EVAPPUBGECONTROLSOLENOIDVALVE
FUELFILLCAP
8LK
+
t\,"ro*,
MANIFOLD

J\
(From page 11-272)D16Y5 engine:
JUMPER WIRE
D16Y7, D16Y8 engine
VACUUMPUMP/GAUGE,
VACUUMPUMP/GAUGE,0 - 30 in.HgAs73x - 0il1 -
xxxxx
0 - 30 in.HgA973X -
otl -
xxxxx
I
EVAP CONTROLCANISTER
ECM/PCM CONNECTOH D I32PI
VACUUM/PBESSUREGAUGE0-4in.Hg07JAZ - 0010008
Wire side otfemale terminals
D16Y7, Dl6Y8 engine:
t
VACUUM/PRESSUREGAUGE0-4 in.Hgo?JAZ - 001fl)OB(cont'd)
11-273
PGl IBLKI
Check lhe EVAP Purge control
solsnoid valve:
1. Disconnect the vacuum hose
from the EVAP controlcanister'
2. Connect the vacuum PumP to
the hose and aPPIY vacuum
Does it hold vacuum?
Check the EVAP control canister:
1. Reconnect the vacuum hose to
the EVAP control canlster.
2. Connect the vacuum/Pressuregaugeto the Purge aar hose
3. Connect ECM/PCM connector
terminals A15 and A10 with a
iumper wire.4. Start the engine5. Check the vacuum
Check the EVAP two way valve(see page 11-193)
Does the EVAP two waY valveReplace the EVAP two wsY valve.
Sub3titute a known-good ECM/
PCM .nd recheck. lt symPtom/
indicrtion go6s away, rePlace the
original ECM/PCM.
D16Y5 sngin€:

\J
Fuel Tank Pro3sure sensor 196 D16Y8 engine (coupe).'97 D15Y7 engine {coupe: KL model, sedan: KL (LX) modeu,'97
D16Y8 engine (coupe: all models, sedan: KL model, '98-all models) '99 - 00 D16Y5 engine with M/Tl:
\
PTANK
{LT GRNI
vcc2(YEL/BLU}
Wire side oI female terminals
FUEL TANKPRESSURE SENSOR3P CONNECTOR (C7921
sG2IGRN/8LK)
Foc2l::il":"toolindicatesDiagnosticTroublecode(DTc)P0452:A|owvo|tageprob|emintheFue|TankPressure
The fuel tank pressure sensor converts fuel tank absolute pressure into electrical signals and inputs the EcM/PCM.
OUTPUTVOLTAGEtvt4.5
-? kPa(-50 mmHg,-2 in.Hg)
ECM/PCM CONNECTOR O I16P)
Wire side of female terminals
+7 kPs150 mmHg,2 in.Hg)
PRESSURE
(cont'd)
11-275
- The MIL has been reported on- DTC P0452 is stored.
Check the vacuum lines:
Check the vacuum lines of the
fuel tank pressure sensor for mis-
routing, leakage, breakage and
cloggrng.
Are the vacuum lines OK?
Problem v€ritication:1. Do the ECM/PCM Reset Proce
dure.2. Remove the luel fill caP.
3. Turn the ignition switch ON lll)4. Monitor the FTP Sensor volt_
age with the Honda PGM
Tester, or measure voltage
between bodY ground and
ECM/PCM terminal Dl5.lntermittent tailuro, sYstem i5 OK
dt this timo. Chock for Poot con-
neciion3 or loose wir* at C131
llocatod under right side ot dashl,
C4O1 (located .bove under'da3htuso/ielay box), C574 1C568)*
{located under acc€ss Panell.C792 lfuel tank pressule sen3or)
and EcM/PCM.
ls there approx. 2.5 V?
Check tol an op€n in wite (VCC2
line):1. Turn the ignition switch OFF
2. Reinstallthe fuel fill caP.3. Disconnect the fuel tank Pres'sure sensor 3P connector-4. Turn the ignition switch ON (ll)
5, Measure voltage between the
fuel tank pressure sensor 3P
connector No. l terminal and
No. 2 terminal.
Repair open in the wite betweenthe fuel tank Pr€s3ure a€n3or andth6 EcM/PcM (D1ol.ls there approx. 5 V?
(To page 11'276)

\
t,96 D16Y8 engine (coup6l,'9? Dl6Y7 engine (coupe: KL model, sedan: KL (LX) model)"g7 Dl6Y8 ongine (coupe: all mod-
els, sedan: KL model,'98-8ll modelsl 39 - 00 Dl5Y5 engine with M/Tl:
The scan tool indicates Diagnostic Trouble code (DTc) P1456: Evaporative Emission (EVAP) control system leak
detected (fuel tank sYsteml
The scan tool indicates Diagnostic Trouble Code (DTC) P1457: Evaporative Emission (EVAP) control system leak
detected (EVAP control canister system).
Fr4t6l
fF14s7
Possible Causs
. Fuel fill cap
. Vacuum Connections
. Fuel Tank
. EVAP Control Canister Vent Shut Valve
. EVAP Control Canister Vent Shut Valve Circuit
. EVAP Purge Control Solenoid Valve
. EVAP Purge Control Solenoid Valve Circuit
. EVAP Bypass Solenoid Valve
. EVAP Bypass Solenoid Valve Circuit
. Fuel Tank Pressure Sensor
. Fuel Tank Pressure Sensor Circuit
. EVAP Control Canister
. Throttle Body
Troublsshooting Flowchart
VACUUMPUMP/GAUGE,0 - 30 in.HgA973X - 041 -
xxxxx
I
EVAPCONTROL
.4, cANrsrER
re ./ VALVE
{S----r*::n
\(cont'd)
- The MIL ha3 been rePofted
on.- DTC P1456 or P1457 is stored.
Check the EVAP control canbtol
vent shut valve:1. Disconnect the vacuum hose
Irom the EVAP three waY
valve and connect a vacuurnpump to the hose.
2. Remove the EVAP control
canister vent shut valve Irofi
the canrster.3. Turn the ignition switch ON (lli
4. Apply vacuum to the hose.
Chock for . shon in the wire(VSv linel:Disconnect the 2P connector {rom
the EVAP control canister vent
Does the valve hold vacuum?
Repair short in the wir€ betwcen
the EVAP control canister vent
shut v.lve and tho ECM/PCM
tA29|.
Does the valve hold vacuum?
Check the EVAP control canister
vent shui valve:1. Turn the ignition switch OFF.
2. Connect ECM/PCM connectorterminal A29 to body ground
with a iumPer wire.
3. Turn the ignition switch ON (ll).
4. Applyvacuum to the hose
Reohce the EVAP control canis-
ter vent shttt valve.
Does the valve hold vacuum?
ECM/PCM CONNECTOR A {32P)
37I9t01t't2t3t5t6ItItt9202a2a
25aA
ILT GRN/W{T) I JUMPER WIRE
Wire side of femll terminals
(To page 11-284i(To page 11 284)
11-283