PCM HONDA CIVIC 1996 6.G Workshop Manual

Engine RemovaUlnstallation
Removal
@@
1.
. Make sure iacks and salety stands are placed ploperly
and hoist brackets are attached to the correct posi-
tions on the engine.
. Make sure the vehicle will not roll off stands and fall
while you are working under it.
CAUTION:
. Use fender covers to avoid damaging painted sur-face.
. Unplug the wilin9 connectors caretully while holdingthe conngstor portion to avoid damage,. Mark all wiring and hosos to avoid misconnoction.
Also, be sure that they do not contact other wiring or
hoses or interfere with other parts,
Secure the hood as open as possible.
Disconnect the battery negative terminal first. thenthe positive terminal. Remove the battery.
Remove the strut brace (B'16A2 engine).
8 x 1 .25 mm24 N.m {2.4 kgl.m, 17 lbf.ft}
Disconnect the battery cables from the under-hood
fuse/relay box and battery positive terminal.
STRUT BRACE
UNDER.HOODFUSE/RELAYBOX
BATTERY CABLES
5-2
ECM/PCM
(
5. Remove the battery and battery base.
8 x 1.25 mm24 N.m (2.4 kgf.m, 17 lbf ftl
7.
Disconnect the connectors from the ECM/pCM.
Disconnect the main wire harness connector.
MAIN WIRE HARNESSCONNECTOR

13. Remove the throftle cable by loosening the locknut,
then slip the cable end out of the accelerator link-
age.
NOTE;
. Take care not to bend the cable when removing
it. Always replace any kinked cable with a new
one.
. Adjust the throttle cable when installing (see sec-
tion 1 1).
D16Y7 engine:
D16Y5, D16Y8, B16A2 engines:
LOCKNUT
LOCKNUT
14,Disconnect the connectors from the PCM.
Remove the grommet and wire harness clamps,
then pull out the ECM/PCM connectors
6x1.0mm
16. Remove the mounting bolt and lock bolt, then remove
the power steering (P/S) pump belt and pump
NOTE: Do not disconnect the P/S hoses.
816A2 engine:
Remove the adjusting bolt and mounting boits,
then remove the P/S pump belt and pump
(cont'd)
5-5
AOJUSTING

VTEC Control System
Troubleshooting Flowchart
tFtrsrl #ilH:::lj1t:"J:T,?ffnostic
rrouble code (Drc) Pr25e: A probrem in the vrEc Pressure switch circuit or
Reter to page 1 l-38 th roug h 1 1-55 before trou bleshooting.
* Road Test:Accelerate in 1st gear to an engine speed over 3,000 rpm(D16Y5 engine) or 6,000 rpm (D'16Y8 engine).Hold that engine speed for at least two seconds.It DTC P1259 is not repeated during the first road test, repeatthis test two more tames.
VTEC PRESSURE SWITCH 2PCONNECTOR
Terminal side ofmale terminals
Wire sid6 ol femalerermtnats
VTM
l1 (BLu/BLK)
f;-) |I
I
Y
I
The MIL has been reoorted on.DTC P1259 is sto.ed.
Check the VTEC Cont.ol Syst6m:1. Do the engine control module(ECM)/powertrain control module lPCM) Reset Procedure (see
section 11).2. Stan the engine.3. Warm up the engine to normaloperating temperature (cool-
ing fan comes on).4. Do the Boad Test.*Intermittont tailura, 3y3t.m is OKat thia time.Check for ooor connoctionr o.loose wirea at VTEC oiassurclwitch, VTEC solonoid valvo .ndECM/PCM,
ls OTC P1259 indicated?
Test rhe VTEC Prensure Switch:1. Turn the ignition switch OFF.2. Disconnect the VTEC Pressureswitch 2P connector.3. Check for continuity betweenVTEC pressure switch 2P con-nector terminal No. 1 and No.2.
Replace the VTEC preasure 3witch.ls there continuity?
Te3t the VTEC Pressure SwitchWire:1. Turn the ignition switch ON lll).2. Measure the voltage betweenVTEC press u re switch 2Pconnector No. l and bodyground.
In3poct for en opon or shod toground in thG wi.. bctwoon thoVTEC pro$ur6 switch rnd ECM/PCM l'96 - 9a: C15,'99 - 00: C101.lf tha wiro i3 OK,3ubrtitute aknown-good ECM/PCM andrecheck.
ls there battery voltage?
{To page 6'4i

I
VTEC Control System
Troubleshooting Flowchart (cont'd)
VTEC PRESSURE SwlTCH 2PCONNECTOR
Wire side of female(€rmrnats
VTEC SOLENOID VALVE lPCONNECTOR
I r----'t I
ll ' ff---r'-'1
I
I
-L
Terminal side ofmale terminal
A/T LOW PRESSUREw/PAt{EL07406-0070300
NOTE: Keep measuring time as short aspossible because engine is running with noload (less than one minute).
PRESSURE GAUGEADAPTER07NAJ - P07010A
A/T PRESSURE I{OSE07406 - 0020201
ot
A/T PRESSURE HOSE.2,210 mm07MAJ - PY&llA andA/T PRESSURE ADAPTER07MAJ - PY,()120
6-4
(From page 6-3)
(To page 6-5)
Test the VTEC Pr6suro SwitchWiro:Nleasure voltage across the VTECpressure switch 2P connector.
. Rcpai. opon in tho wirebrtw.en VTEC pr6.urc switchand G101.. lf th. wir6 b OK, sub.thuto alnown-good ECM/PCM !ndracheck.
ls there baftery voltage?
Te3t the VTEC Solonoid V.lve:1. Turn the ignition switch OFF.2. Disconnect the VTEC solenoidvalve 1P connector.3. Check for continuity betweenthe VTEC solenoid valve 1Pconnector terminal No. 1 andbody ground.
ls there 14 - 30 0?
Te3t tho WEC Solonoid Vatvo:'1. Remove the VTEC pressureswatch and install the specialtool as shown, then reinstallthe VTEC pressure switch.2. Reconnoct the VTEC solenoidvalve 1P connector and VTECpressure switch 2P connector.3, Connect the tachometer (seesection 11).4. Stan the engine.5, Warm up engine to normaloperating temperature (cool,ing fan comes on).6. Check oil pressure at enginespeeds D16Y5 engine: 1,000and 3.000 rpm, D16Y8 engine:1,000,3,000 and 5,000 rpm.
ls pressure below 49 kPa(0.5 kgflcm,, 7 psi)?In.poct the VTEC aolonoid vllvols.c p.g. &6).
:(
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I
t
:
t
I
I

(From page 6'4)
Test the VTEC Solenoid Valve:1. Turn the ignition switch OFF.2. Disconnect the wEC solenoidvalve 1P connector.3. Attach the battery positave
terminal to the VTEC solenoidvalve terminal.4. Start the engine and checkthe oil pressure at enginespeed of 5,000 rpm.
Inspect lhe VTEC solonoid valve
lsee p6ge m).ls the pressure above 390 kPa(4.0 kgtcm',57 psi)?
Test the VTEC Pressure Switch:With the battery positive terminalconnected to the VTEC solenoidvalve, measure voltage betweenthe ECM/PCM connector terminal'96 - 98: Cl5,'99 - 00: C10 andbody ground.
ls there battery voltage above5,000 rpm?
T6st the VTEC Solenoid Valvewire:1. Turn the ignition switch OFF.2. Check for continuity betweenthe VTEC solenoid valve 1Pconnector terminal and theECM/PCM connector terminal'96 - 98: A8, '99 00r B'12.
Repair open in the wire betweenthe ECM/PCM ('96 - 98: A8, '99 -
0o: 8l2l and VTEC solenoid v.lv6connoc{or.
Test the VTEC Solenoid Valve
Check for continuity between theVTEC solenoid valve 1P connectorterminal €nd body ground.
ReDair 3hort in the wire betweenthe ECM/FCM ('96 - 98: A.8, '99 -
0O: Bl2l and VTEC aolenoid valveconnectot,
ls there continuity?
Substitute a known-good ECM/PCM and recheck. lf symptom/indication goes away, replacethe original ECM/PCM.
VTEC SOLENOID VALVE1P CONNECTOR
Terminalside ofmale terminal
ECM/PCM CONNECTOR C {31P}
'99 - 00:'96 - 98:
CONNECTOR
'99 - 00:
VTEC SOLENOIDVALVE
ECM/PCM CONNECTORB {25Pt1P CONNECTOR'96 - 98:
VTEC SOLENOIDVALVE
ECM/PCM CONNECTOR
A {32P1
VTS{GRN/YEL)
wire side o{ femaleterminals
wire side oI temaleterminals
VTM

!
Fuel and Emrsslons
SoecialToofs .....,...."..,. 11-2
Component Locations
lndex ....................., ......... 11-3
Svstem Description
Vacuum Connections ................,,..,.. ......... 11-12
Electrical Connections ...............,.,.,... ....... 11-29
System Connectors ........,.,.,.......................... 1 1-51
Troubleshooting
Troubleshooting Procedures ................. .. 11-81
Engine Control Module/PowertrainControl Module TerminalAfiangement ....,.,..... 11-88
Diagnostic Trouble Code Chart .................,., 11.97
How to Read Flowcharts .,.......................... . 11-103
PGM-Fl System
System Description ...... 11-10,1
Troubleshooting Flowcharts
Engine Control Module/PowertrainContlol Module ........ 11-107
Manitold Absolute Pressure Sensor .....'. . ... 11-115
fntake Air Temperatuie Sensor ..... . . ., . 11'121
Engine Coolant Temperatuae Sensol ........., 11-128
Throttle Position Sensor ...................,........... 11-132
Primary Heated Orygen Sensor (Sensor 1l ... 11-139
Secondary Heated Oxygen Sensor(Sensor 21.................................................... 1 1-153
Heated Oxygen Sensor Heater ...................,. 11-157
Fuel Supply System ...... 11-164
Random Mislire ......., ..11-166
Misfire Detected in One Cylindsr ................. 11-167
Knock Sensor .,.,............ 11-170
CKP/TDC/CYP Sensor ................................... 11'172
Vehicle Speed Sensor ...........,......,...,.,........... 1t-176
Barometric Pressure Sensor ...............,......... I 1-178
Electrical Load Detector,.,,............................ 1 1-179
CKF Sensor .................... 11-183
ECM/PCM Internal Circuit ............................. I 1-188
A/T Signal {TMA/TMBI .................................. I 1-189
ldle Control System
System Doscriplion ............ 11-190
Troubleshooting Flowcharts
ldle Control System ...... 11-192
ldle Air Control Va1ve .................................... I 1-19i1
Starter Switch Signal .................................... 1 1'202
Air Conditioning Signal ................................. 11'201
Ahernator FR Signal .................................... . 1 1-208
BrakeSwitch Signal ..................................... f 1"210
Power Sleering Prossure Switch Signal ......11-212
A/T Gear Position Signal ............................... 11-216
Clutch Swiich Signal ................................-.... 11-214
ldte Speed Setting . .............11-220
Fuel Supply System
Fuel Lines .,...................,.,.,.,11-221
Fuef Tube/Ouick-Connect Fittings ..........,.,........ 11 -227
System Description ....'.... 11-230
Fuel Pressure .......,.,,........... 11-230
Fuef fniectors ......................11-232
Fu€f Pressure Regulator .....,.......................'...,. 11-231
Fuef Fifter ............................11-235
Fuel Pump .............'.......'.... 11-236
PGM-FI Main Relay .............11'237
Fuel Tank ................ ....,...'.'.' 11'211
Intake Air System
System Description ....-.-.....11-243
Air Cfeaner ...........,......."". .11-211
Throttle Cable .....................11-211
Throttfe Body ........ ..'... . . .,.11-211
Fuel Iniestion Air Control System ,.,.,....-........... 11-250
Emission Control System
System Description .-..........11-252
Taifpip€ Emission ...............11-252
Three Way Catafytic Convert€r ............,.,,.,.,.,.... 11 -252
Exhaust Gas Racirculaiion System ...,.,,,,.,.,.,.,,. 11'254
Positive Crankcas€ Ventilation System .... . . .. 11-266
Evaoorative Emission Controls ..................,,..,.,. 11 -267

I
CLUTCH SWITCH lDl6Y5 onginoM,/TITroubleshooting, page 1 1-218
'96 - 98 modsls:
Sell-diagnostic Procedures.page 11 81
ENGINC CONTROL MOOUI.T(FCMI/POWERTRATN
CONTROL MODULE IPCMITroubleshooting, page 1 1-107
'9!, - 0o modol3:
PGM.FI MAIN RELAYRslay Testing, page 11-237Troubleshooting, page 1 1-238PGM.FI MAIN RELAYRelay Testing, page l1 237Troubleshooting, pago 1'! 238
SERVICEl2Pl
CONNECTOR
ENGINE CONTROL MODU1T(ECM}/POWERTRAIN
CONTROL MODULE IPCMITroubleshooting, page 11 111SERVICE CHECK CONNECTORtzPlSelf-diagnostic Procedures,page 11-81
Self-diagnostic Procedures,page 11-81
{cont'd)
11-7

System Description
Electrical Connections ('96 - 98 Models, ,99 - 00(cont'd)
PRESSURESENSOE
EGR
UFTsENsoR *3
EGR
uF
D16Y5 engine with M/Tl(
SENSOF
solENoto vALvE *3
wec soLeton vltve'!2
SENSOR
SPEED sENsoR'2
COUNTEFSHAFIsPEED sENsoR*2
soeeloto vltve l*2
ToI|{TEFLOCKCONTBOLUNIT
*l: t SA model*2: A/T(DI6W, oi6y8 engine)*3:CVT(DI6Y5 6ngine)1.4 : A"/T and Dl6Y7 engine*5; Except A/T and Dl6Y7 engine*6: A/T(O16YO engin6)*7:CW(DI6y5 ongine) and D16y8 engino*8;'96 Ol6Y8 sngine (coupe), ,97 D16y5ongine (coup€: all modol!, sedan: KLmodoD, '98 Dl6Y5 engine, '98 ot6Y8en9ne*9:D16Y5 engin.*10 : |!UT(D16Y5 engine)*ll : Except iUT(Dl6Y5engine)*12: D16y5, 016yo engino*13: DI6YO engine*14:Dl6Y7 engine*15:'97 D16Y7 engine [coupe: KL modet,ssdan: KL(LX) modetl, '9gDt6y7 engine
c-rrusren vem srur vtvrlf;
ECM/PCMA(32P)ECM/PCi/lBEsP)
ECM/PCMD(16P)
1 1-30
TERMINAL LOCATIONS

-'
GAUGEASSEMALY
DRIVE PULLEYSPEED SENSOR
ORIVEN PULLEYSPEED SENSOR
SECONOARYGEAB SHAFTSPEED SENSOR
SOLENOID
To INTERLOCK CONIBOL UNIT
*l : USA model
*2: a/T(D16Y/, D16Y8 engine)
,.3: CW(016Y5 engine)
*4: A/T and D16W engine
*5: Except A/T and Dl5Y7 engine
*6: Cw(Dl6Y5 engine), Dl5Y8 engine and 816A2 engine
(cont'd)
11-41
EcM/PcMA(32P)EcM/PcMB(25P)
7II1011
t41617181920121222324
ECM/PCMC(31P)ECM/PCMD(I6P)
I
TERMINAL LOCATIONS

(O16Y5, Dl6Y8.nlin.3llOl6Y?.ngir.l
ct33.r tFcM-B)C134 {EC[r,l/FCMal
cr35lEcM/PCM-D)
NOTE: e
f'Tfl'n
I-IBLffiHJ-IltlcRr'r/wlr l]l
l-''lwHtREcp -l
liELx/wNr' --l
ca3l
ffi
Tttr-Ei ---
FltEtstK ll
FfwNr/RED''_llTltHr/BL( l
ffi
@
F Irt
Irli I
tilwHT,"Ed-l| . lcFMMr I11 BLX^VHT' I11 B!x.^rHr I
Different wires with the same color have been given a number suffix to distinguish them (for example, YEUBLKT
and YEUBLK' are not the same).
O: Related to Fuel and Emissions System
- Connector with male terminals (double outline): View from terminal side
- Connector with female terminals (single outline): View from wire side
c t32 {ECt/r/pcM-a)
26E9l0tl
12t3l/a'tst6171El92024
25212a2930
c{t3
l.7
9rolrt12t3
I2al589t0
l!121317t8l9
11-63