engine wire HONDA CIVIC 1996 6.G User Guide

13. Remove the upper radiator hose' heater hose and
water bYPass hose
WATEREYPASSHOSEUPPERRADIATORHOSE
14.
HEATERHOSE
Remove the engine wire harness connectors and
wire harness clamps from the cylinder head and the
intake manifold.
o Four fuel injector connectors
. Engine coolant temperature (ECT) sensor con-
nector
a
a
a
ECT switch connector
ECT gauge sending unit connector
Throttle position sensor connector
Manitold absolute pressure (MAP) sensor con-
nector
Primary heated oxygen sensor (primary HO2S)
connector
Secondary heated oxygen sensor (secondary
HO2S) connector (D16Y7 engine)
Exhaust gas recirculation (EGR) valve lift sensor
connector (D16Y5 engine)
. VTEC solenoid valve connector (Dl6Y5, D16Y8
engrnes)
. VTEC pressure switch connector (D16Y5. D16Y8
engrnes,
. ldle air control (lAC) valve connector
15.Remove the spark plug caps and distributor from
the cylinder head.
Remove the uPPer bracket.
NOTE:
. Use a jack to support the engine before the
upper bracket is removed.
. Make sure to place a cushion between the oil
pan and the jack.
12 x 1.25 mm
74 N.m {7.5 kgf m.
sil lbl.ftl
UPPERBRACKET
'17. Remove the cylinder head cover'
CYLINDERHEAD COVER
(cont'd)
6-29

VTEC Control SYstem
The scan tool indicates Diagnostic Trouble Code {DTC) Pl259:
VTEC Solenoid Valve circuit
Refer to page 1'l-38 through 11 55 before troubleshooting
Troubleshooting Flowchart
YES
A problem in the WEC Pressure Switch circuit or
* Road Test:Accelerate in 1st gear to an engine speed over 6,000 rp '
Hold that engine speed for at leasttwo seconos'
lf the DTC P1259 is not repeated during the first road test'
repeat this test two more times
VTEC PRESSURE SWITCH 2P
CONNECTOR
Terminalside ofmale termtnals
WM
/1 IBLU/BLKI
/ 1 Y------rt--------- l I
\1-/ |I
I
I1
Wire side of femaleterminals
(cont'd)
6-51
The MIL has been teported on.
DTC P1259 is siored.
Check the VTEC Control SYsiem:
1. Do the engine control module(ECM ) Reset Procedure (see
section 11).
2. Start the engine
3. Warm uP the engine to normal
operating temPerature (cool
ing fan comes on).
4. Do the Road Test.*lntermittent failure, sYstem is OK
at this time.Check for Poor connectlons or
loose wires at VTEC Pressureswilch. VTEC aolenoid valvo and
ECM.
ls DTC P1259 indicated?
Test the VTEC Pressure Switch:
1. Turn the ignition switch OFF.
2. Disconnect the VTEC Pressure
switch 2P connector.
3. Check for continuity between
VTEC pressure switch 2P con
nector telminal No 1 and
No.2.
Reolace the VTEC Pre3sure switch.
Test the VTEC Pressure Switch
Wire:1. Turn the ignition switch ON (ll).
2. N4easure the voltage between
VTEC press u re switch 2P
connector No. 1 and bodyground,
Inspect lor an open or short toground in the wire between the
VTEC orassure swilch and ECM
{c101.lf the wire i3 OK, substitute a
known-good ECM and recheck.
{To page 6 52)

VTEC Control System
Troubleshooting Flowchart (cont,d)
VTEC PRESSURE SWITCH 2PCONNECTOR
Wire side of temaleterminals
OIL PRESSURE GAUGE(Comm.rcially avail.bte)
GAUGE JOINT ADAPTERSNAP.ON MT26.1710 x 1.0 ftm. Use new washer wheninstalling the sealing bott.
NOTE: Keep measuring time as shorr aspossible because engine is running witn noload lless than one minute).
6-52
(
VTEC SOLENOID VALVE lPCONNECTOF
Ir------r I
lLl.ll-r
II
It
Terminal side ofmale terminal
I
(From page 6-5l l
(To page 6-53)
Test tha VTEC P.es3uro SwitchWi.e:Measure voltage across the VTECpressure switch 2P connector.
Ropair opon in the wiro batwoenVIEC pr...urc switch and G lot .lf the wiro is OK, 3ubltitutr aknown-good ECM and rochack.
ls there battery voltage?
Test the VTEC Solenoid V.tve:1. Turn the ignition switch OFF.2. Disconnect the VTEC solenoidvalve 1P connector.3. Check for continuity betweenthe VTEC solenoid valve 1Pconnector terminal No, I andbody ground.
ls there 14 - 30 O?
Te3t the VTEC Sotonoid Vatve:'1. Remove the VTEC pressureswitch and install the specialtool as shown. then reinstallthe VTEC pressure switch.2. Reconnect the VTEC solenoidvalve 1P connector and VTECpressure switch 2P connector,3. Connect the tachometer (seesection 1l).4. Start the engine.5. Warm up engine to normaloperatrng temperature (cool-ing fan comes on).6. Check oil pressure at enginespeed of 1,000,3,000 and5,000 rpm.
ls pressure below 49 kPa(0.5 kgflcm,,7 psi)?Inipoct thg VTEC aolenoid valvel3ee P8go 6-54).
I

(From page 6-52)
Test the VTEC Solenoid Valve:
1. Turn the ignition switch OFF
2. Disconnect the VTEC solenoid
valve 1P connector,
3. Attach the batterY Posrtrveterminal to the VTEC solenoid
valve terminal.4. Start the engine and check
the oil Pressure at engine
speed ol5,000 rPm
lrcoect the VTEC solenoid valve(see page S54)ls the pressure above 390 kPa(4.0 kgt/cm?, 57 Psi)?
Test the VTEC Pressure Switch:
With the battery Positive terminal
connected to the VTEC solenoid
valve, measure voltage between
the ECM connector terminal C10
and body ground.
ls there battery voltage above
5,000 rpm?
Test the VTEC Solenoid Valve
Wire:1. Turn the ignition switch OFF
2. Check for continuitv between
the VTEC solenoid valve 1P
con nector terminal and the
ECM connector terminal 812
Repair open in the wire between
the ECM lB12| and VTEC aolenoid
Test lhe VTEC Solenoid Valve
Wire:Check for continuity between the
VTEC solenoid valve'lP connector
terminal and body ground.
Repair short in the wiro b€'tween
the ECM ( 812) and VTEC aolenoid
Substitute a known'good ECM
and recheck. lI sYmptom/indica'tion goes away. repleca the origi-
nal ECM.
VTEC SOLENOID VALVE
1P CONNECTOR
Terminal side ofmale terminal
VIEC SOLENOIDVALVE1P CONNECIOR
ECM CONNECTORB l2sP)
ECM CONNECTOR C (31PI
WM
Wire side ot female
termrnals
VTEC SOLENOID VALVE
1P CONNECTOR
I'ft
I
I
Wire side of female
termanal
6-53

VTEC Solenoid ValveVTEC Rocker Arms
a
I
(
Inspection
1. Remove the VTEC solenoid valve assembly fromthe cylinder head. and check the VTEC solenoidvalve filter for clogging.
. lf there is clogging, replace the engine oilfilter andengine oil.
6x1.0mm12 N.m (1.2 kgf.m, B,7 tbf.ftl
lf the filter is not clogged. push the VTEC solenoidvalve with your finger and check its movemenr.
. lf the VTEC solenoid valve is normal, check theengine oil pressure.
6x1.0mm12 N.m (1.2 kgtm,8.7 lbt.ft)
6-54
L-
SOLENOID
Manual Inspection
1. Set the No. 1 piston at TDC.
2. Remove the ignition wire cover and the wires.
3. Remove the ignition clamps while pulling up on theIock.
6xl.0mm9.8 N.m (1.0 kgl.m, 7.2 tbtftl
IGNITIONWIRE COVER
IGNITIONWIRE
\
LOCK

Cylinder Head
lllustrated Index
CAUTION:
. To avoid damaging the cylinder head, wait until the engine coolant tempsraturo drops below 100"F (38"C1 bofote
removing it,
. when handling a metal gasket, take caro not to fold the gaskot or damage the contact surface of the gasket.
NOTE: Use new O-rings and gaskets when reassembling.
CYLINDER HEAO
PLUGReplace.
)@
DISTRIBUTOR
8 x 1 ,25 mm
27 N.m P.E kgl m.
20 tbf.foApply engine oil to
the threads.
cr.rMp.S
CAMSHAFT A"o''*t*'; wes@
OIL SEALReplace.
6 x l,omm9.8 N'm tl.0 kgt'm,7.2lbf ft)
RUBBER SEALReplace when damaged
or detedorated.
6x1.0mm9.8 N.m (1.0 kgf'm,
7.2 rbnftl
fi%
IGNMONWIRE COVER
CYLINOER HEAD
COVERRefer to page 6-86
when installing
HEAD COVER GASKETReplace when leaking, damaged
or deteriorated.Apply liquid gasket at thecorners of the recesses, Page 6-86
8 x 1,25 mm24 N.m {2.4 kgf'm,
1? tbf.ftl
EXHAUST
10 x 1.25 mm56 N.m (5.7 kgf m,,r1 lbl.ft)
(cont'd)
6-65

WATER BYPASS
HOSE
14. Remove the upper radiator hose, heater hose and
water bvpass hose.
HEATER
Remove the engine wire harness connectors and wlre
harness clamps from the cylinder head and the intake
manifold.
Four fuel injector connector
Engine coolant temperature (ECT) sensor connec-
tor
ECT gauge sending unit connector
ECT switch connector
ldle air control (lAC) valve connector
Manifold absolute pressure (MAP) sensor connec-
tor
Throttle position sensor connector
Primary Heated oxygen sensor (Primary HO2S)
connecror
VTEC solenoid valve connector
15.
a
a
a
a
a
\
16.
17.
Remove the spark plug caps and distributor form
the cylinder head.
Remove the upper bracket.
NOTE:
. Use a jack to support the engine before removing
the upp€r bracket is removed.
. Place a cushion between the oil panandthejack.
12 x 1.25 fin74 N.m 17.5 kgtm,
UPPER BRACKET
18. Remove the cylinder head cover.
{cont'd)
6-69

Main Bearing
Selection
CAUTION: lf the codes are indecipherable because of anaccumulation of dirt and dust, do not scrub them with a
wire brush or scraper. Clean them only with solvent ol
deiergent.
Crankshaft Bore Code Location
81642 engine:
Letters have been stamped on the end of the block as acode for the size of each of the 5 main journal bores.
Use them, and the numbers or bars stamped on the
crank {codes for main journal size), to choose the correct
beaflngs.
Main JournalCode Locations {Nombers or Barc)
Eearing ldentificationColor code rson lhe edge ofthe bear ng.Larger crank bore
acD
-----------""' Smallerbeanngtlhrcker)
9""1B':""
Alack
Black
Alue
7-10
\
D16Y5, D16Y7, D16Y8 engines:
Letters have been stamped on the end of the block as acode for the size of each of the 5 main journal bores.
Use them, and the numbers stamped on the crankshaft(codes for main journal size), to choose the correct bear-
Ings.
Main Journal Code Location (Numbers)
\
Color codeon theedge ofthe bearing-
Ldrger crank bore
Smaller bea ng {th'cker)
lr-l
t#lt+,tlf l 4 tlf '- 't
Smaller Smallermaan bearingjournal {thicker)
RedPinkGreen
PinkGreenBrown
GreenBrownBlack
GreenBrownBlackElue
I
Bearing ldentification
BcD

Piston Rings
End Gap
1.Using a piston, push a new ring into the cylinderbore 15 - 20 mm (0.6 - 0.8 in) from the bottom.
Measure the piston ring end-gap with a feeler gauge:
. lf the gap is too small, check to see if you have
the proper rings for your engine.. lf the gap is too large. recheck the cylinder borediameter against the wear limits on page 7-16,
lf the bore is over the service limit, the cvlinderblock must be rebored.
Pkton Ring End-cap:
Top Ring
81642 engino
Siandtrd (New): 0.20 - 0.35 mm
{0.008 - 0.01,1 in)
Service Limit: 0.60 mm l0-02i1 inl
D16Y5. Dl6Y7, D16Y8 enginos
Standard lNewl: 0.15 - 0.30 mm
{0.006 - 0.012 in)
Ssrvic€ Limit 0.60 mm {0.024 inl
Socond Ring
816A2 ongina
Standard (Nowl: 0.40 - 0.55 mm
10.016 - 0.022 inl
Service Limit: 0.70 mm (0.028 inl
D16Y5, D16Y7, Dt6Y8 engines
Standard (New): 0.30 - 0.ia5 mm
{0.012 - 0.018 in)
Sorvice Limit 0.70 mm 10.028 inl
Oil Ring
81642 ongine
Standard {Now): 0.20 - 0.50 mm(0.008 - 0.020 inl
Sorvico Limit: 0.70 mm (0.028 in)
Dl6Y5. Dl6Y7, D16Y8 €nginos
Standard (Nowli 0.20 - 0.70 mm(0.008 - 0.028 inl
Servica Limit: 0.80 mm 10.031 in)
7-20
Replacement
1.Using a ring expander. remove the old piston rings.
Clean all ring grooves thoroughly.
NOTE:
. Use a squared-off broken ring or ring groove
cleaner with blade to fit piston grooves.
o Top ring groove is 1.0 mm (0.039 in)wide.. Second ring groove is 1.2 mm (0.047 in) wide.. Oil ring groove is 2,8 mm (0.11 in) wide.. File down the blade if necessary.
CAUTION: Do noi use a wire blush to clean ringlands. or cut ring lands deepol with cleaning tool.
NOTE: lfthe piston is to be separated from the con-necting rod, do not install new rings yet.
3. Install new rings in the proper sequence and posi-
taon (see page 7-22).
NOTE: Do not reuse old piston rings.
(Commercially available)

System Description
Electrical Connections ('96 - 98 Models,'99 - 00 Dl6Y5 engine with M/Tl
(cont'dl
GA|l/OfiN
Cl3i C,ta6cart c5o2t--l c5t2
o",.uonr. l FSIX' {| | FYEI l
g
.lc5t0GRN/aaX: rdYEr. ILrGiN' -8rK/8ru -
BEo - -J
IGRN-_'-
8ru'--1
Orl0 C50il
LT
IYTENLOC|(CO TROT UMI
FronIAD|AtOh FAx
T' - RElAv EqtswIrEH
BLu/REo,- l f B!u/FEo,-----l ro a/c swrrcH
t_.1
,10: M/T {D16Y5..sin.l.11: Erc.pt M/l lOr5Y5.nginel'12: Ol6Y5, DlSYa.ngin.
'15: 97 Dl5Y7.ngin. {coup.: Klmod.l, $d.n:(l lLXlmod.ll, 9A DIOYT.nsin.
GRN/BIXI.
- LT GRflr-
T 8r"K/8ru
f"*
fr
ct3t c&t6
12: A/l (Dr5Y7, Dl6Y8.nglnelr3: CyI lOl5Y5..sinel'.: A/T.nd Dr6Y7.nsin.15: Erc.pt A/T .nd D16Y7.ngin6'5r A/i {Dl6Ya.ngin€l17: CVT (D16Y5 .noin.) rnd O16Ya .ngine'8r'96 015Y3 .ngin. lcoup.), 9t O16Ya sngin.(coop.r.llnod.l.,..d.n:KLmod.l), 98ol6Y5o.gins,'94 Di6YA .ngin., '99 - 0O D15Y5 lM/Tl 6ngin.
".*,".u---f
REo--__-
YEri -Gur{ -------
Brur- - l
L
- Etur
ArGEAR ?O6frO Swlrcs
1 1-36