Index HONDA CIVIC 1997 6.G Owner's Manual

Component Locations
Index (cont'd)
D16Y8 enginc:
THROTTLE POSITION {TPISENSORTroubleshooting, page 1 1-132
ELECTRICAL LOADDETECTOR IELDI {USAI
INTAKE AIR TEMPERATUREIIATISENSORTroubleshooting, page 1 1,124
MANIFOLO ABSOLUTEPRESSURE {MAPI SENSORTroubleshooting, page 1 1-1 15
IDI.E{A/T)
IDI.E AIR CONTROL IIACI VALVElMtflTroubleshooting, page 1 1-194
Troubleshooting, page 1 1-179EVAPORATIVE EMISSIONIEVAPI PURGE CONTROLSOLENOIO VALVETroubleshooting, page 1 1 27 1. 283CRANKSHAFTPOSTTTON/TOP DEAD CENTER/CYLINDERPOStTtON
POWER STEERING PRESSURE(PSPI SWTTCH |USA)Troubleshooting, page 1 1-212{CKP/TI'C/CYPI SENSOR(Built into the distributor)Troubleshooting. page 1 1-172KNOCK SENSOR IKSITroubleshooting, page 11 170
CRANKSHAFT SPEEDFLUCTUANON ICKFI SENSORTroubleshooting, page 1 1,183
CONTROL {IACI VALVE
ENGINE COOLANTTEMPERATURE{ECTI SENSORTroubleshooting, page 11 128
Troubleshooting, page 11 198
PRIMARY HEATED OXYGEN SENSOR{PRIMARY HO2S} (SENSOR 1l {'96 - 98 modolslTroubleshooting, page 1 1-139
'9!t - 00 modols:'96 - 98 modols:
THREE WAY CATALYNCCONVERTER ITWCITroubl6shooting, page 1 1-252
THREE WAY CATALYNCCONVERTER ITWCITroubleshooting. page 1 1-252
SECONDARY HEATED OXYGENSENSOn(SECONDARY HO2SI (SENSOR 2ITroubleshooting, page 1 1-153
SECONDARY HEATED OXYGENSENSOBISECONDARY HO2S} ISENSOR 2ITroubloshooting, page 1 1-155
PRIMARY HEATEO OXYGEN SENSORIPRIMARY HO2SI ISENSOR 1ITroubleshooting, page 1 1-141
11-4

Component Locations
Index (cont'dl
Bl6A2 engine:
INTAKE AIR TEMPERATURE{IAT} SENSORTroubleshooting, page 1'1-125
MANIFOLO AESOLUTEPRESSURE IMAPI SENSORTroubleshooting. page 11-1 19IOLE AIR CONTROL {IAC) VALVETroubleshooting, page 1 1,196
ELECTRICAL LOADDETECTOR IELDI (USA)
Troubleshooting, page 1 1-180
THROTTLE POSITION ITPISENSORTroubleshooting, page 11-134
CRANKSHAfiPOStTtON/TOP DEAD CENTER/CYLINDERPOStTtON{CKP/TDC/CYPI SENSOR(Bualt into the distributor)Troubleshooting,page 11-174
POWER STEERING PRESSURE{PSPI SWTTCH (USA)
Troubleshooting, page 1 1-214
VEHICLE SPEED SENSOR {VSS}Troubleshooting, page 1 1-177
ENGINE
CRANKSHAFT SPEEDFLUCTUATION (CKFI SENSORTroubleshooting, page 11- t85TEMPERATUREIECTI SENSORTroubleshooting, page I 1-128
THREE WAY CATALYTICCONVERTER ITWC)Troubleshooting, page 1 1,252
S€CONOARY HEATED OXYGENsf rlsoR
sfCoNDARY HO2SI {SENSOR 2): ?shootrng, page 11 155
-6
PRIMARY HEATED OXYGEN SENSORIPRIMARY HO2S) ISENSOR 1ITroubleshooting, page 1 1-141
11

Component Locations
Index (cont'dl
'96 D16Y8 engine (coupel,'97 D16Y7 engine (coupe: KL model, sedan: KL (LXl model),'97 D16Y8 engine (coupe: all models, sedan: KL modell,'98-all models:
FUEI- VAPOR PIPEFUEL FEED PIPEFUEL GAUGE SENDING UNITTesting, see section 23FUEL PUMPTesting, page 11 236Replacement, page 11 236FUEL FILTERReplacement,
€VAPOFATIVE EMISSION(EVAPI CONTROL CANISTERVENT SHUT VALVETroubleshooting, page l1'283
FUEL FILLCAP
FUEL TANKReplacement, page I l-241
EVAPORATIVE EMISSIONIEVAPI CONTROLCANISTERTroubleshooting, page 11 283
EVAPORATIVE EMISSIONIEVAP) BYPASS SOLENOIDVALVETroubleshooting, page 1 1 -283
FUEL INJECTORSReplacement, page 1 1-232EVAPORATIVE EMISSION(EVAPI TWO WAY VALVETesting, page 11 294
FUELREGULATORTesting, page 11-234
TANK PRESSURESENSORTroubleshooting, page 11-275
Replacement, page 1 1-234
'96 Dt6Y5 engine,'96 D16Y7 engin€, '96 D16Y8 engine (sedanl,'97 D16Y5 engine,'97 Dl6Y7 engins (coupe: l(A, KC models,
sedan: KA, KC, KL (DXl models, hatchback: all models),'97 Dl6Y8 engine (sedan: KA, KC modelsl:
FUEL FEED PIPE
FUELFITTINGSPrecautions, page 1 1-227Disconnection, page 11 227Connection, page 11-228
FUEL VAPOR PIPE
FITTINGS
EVAPORATIVE EMISSIONIEVAPI CONTROL CANISTERTroubleshootiog, page 1 1-271
FUEL FILTERReplacement, page 1 1-235FUEL PUMPTesting, page 11-236Replacement, page 11-236
FUEL TANKBeplacement, page 11 241
TIVE EMISSION{EVAP) TWO WAY VALVETesting, page 11-294
TUBE/OUICK.CONNECT
FUEL PRESSUREREGULATORTesting, page 11'234Beplacement, page 11 234
Precautions, page 1 1-227Disconnection, page 11'227Connection, page 1 1-228
11-8
FUEL RETURN PIPE

Component Locations
Index (cont'd)
D16Y5, D16Y8 ongine:
RESONATOR
D16Y7 6ngin€:
AIR CLEANER IACLIReplacement, page 11-244
THROTTLE BODY (TBIInspection, page 1 1-247Removal, page 11-248Disassembly, page 11 249
THROTTLE CABLElnspection/Adjustment. page 1 1 -244
Installation, page 11 245
AIR {FIA} CONTROLVAIVE{'99 modeliD16Y8 6ngin6)Testing, page 11,250
POSITIVE CRANKCASEVENTILATION IPCV) VALVEInspection, page 11-266
AIR CLEANER IACLIReplacement, page 11,244
THROTTLE CABITf nspection/Adjustment. page 1 1,244Installation, page 1 1-245
.iBoov ffetInspection, page 11 247Removal, page 11,248Disassembly, page 1 1-249
POSITIVE CRANKCASEVENTILATION IPCVI VALVEInspection, page 1 1-266
1 1-10
RESONATOR

J
t
Clutch
Speciaf Tools .......... ...........12-2
f lfustrated Index .......... ......12-3
clutch Pedal
Adjustment .................... 12'4
Clutch Master Cylinder
Removal/lnstallation ..... 12-5
Slave Cylinder
Removal/lnstallation .....12'6
Pressure Plate
Removal/lnspection ...... 12-7
Clutch Disc
Removal/lnspection ...... 12-8
Flywheel
Inspection ....................... 12-9
Replacement ....................................... 12-9
Clutch Disc, Pressure Plate
lnstallation ..................... 12-10
Release Bearing
Removal/lnspection ......12-11
f nstalfation .................,... 12-12
\

lllustrated Index
\
NOTE:
. Whenever the transmission is removed, clean and grease the release bearing sliding surface
. lf the parts marked with an asterisk (*) are removed, the clutch hydraulic system mustbe bled (seepage 12-6)
. Inspect the hoses for damage, leaks, interference, and twisting
'RESERVOIF TANK
ASSIST SPRING
LOCK PIN
5x1,0mm9.8 N.m (1.0 kgf.m,7.2 tbtftl*CLUTCH LINE15 N.m {1.5 kgJ m,11 tbt.ft)
RELEASE BEARINGRemoval/lnspection, page 12-1 1Installation, page 12-'12
*CLUTCH MASTER CYLINDERRemoval/lnstallation, page 12 5
6x1.0mm9.8 N.m (1.0 kgf.m,7.2 tbf.ft)
FLYWHEELInspectaon, page 12IReplacement, Page 12-9
CLUTCH DISCRemoval/lnspection, page 1 2-8
lnstallation, page 12-'10
'12 x 1.0 mm118 N.m {12.0 kgt'm,86.8lbfft)
PBESSURE PLATEBemoval/lnspection, page 12 7Installation, page 12''10
8 x 1.25 mm22 N m (2.2 kgf.m, 16lbf ft)
ISLAVE CYLINDERRemoval/lnstallation, page 12_6
12-3

\
S40 Model (All except'99 - 00 2-door Si' SiR)
Manual Transmission
Special Tools ..'.......... 13-2
Maintenance
Transmission Oil .............................. 13-3
Back-up Light Switch
Replacement ......... 13-3
Troubleshooting '....... 13-4
Transmission AssemblY
Removal ................. 13-5
lnstallation ............. 13-8
lllustrated Index ...............'........."........ 13-10
Transmission Housing
I Removaf .."""""""' 13-12
J R"rr"r"" Shift Holder
Clearance lnspection ....................... 13-13
Reverse ldler Gear
Removal ....'.........." 13-14
Mainshaft, Countershaft, Shift Fork
Disassembly ......'... 13-14
Mainshaft AcsemblY
Index ............... ....... 13-15
Clearance Inspection ..'.................... 13-16
Disassembly .......... 13-17
Inspection ....'......... 13-18
Reassembly ........... 13-19
Countershaft AssemblY
lndex ................ ...... 13-20
Clearance lnspection ."..........'......." 13-21
Disassembly ..."""' 13-22
Inspection .............. 13-23
Reassembly ..'.""... 13-23
Shift Fork AssemblY
lndex ............... ."'... 13-25
Clearance lnspection ."......."........'.. 13'26
MBS Shift Piece Inspection ....-.....'.. 13'27
Synchro Sleeve, Synchro Hub
f nspection/lnstallation .......'...... ".... 13'27
Synchro Ring, Gear
Inspection '....'..".... 13'28
Shift Rod
Removal .'......".""" 13'29
Differential
lndex ......."'...... .'."' 13-30
Backlash Inspection ..........."......."... 13-30
Bearing Beplacement'.............'.".... 13'31
Final Driven Gear Replacement '..... 13-31
Thrust Shim Adiustment ..."........... 13-32
Clutch Housing Bearing
Replacement .......'. 13-34
Mainshaft Thrust Shim
Adiustment '....'..".. 13-36
Transmission
Reassembly ........... 13-39
Oil Seals
Replacement ......... 13-43
Gearshift Mechanism
Overhaul ................ 13-44
\

Countershaft Assembly
Index
I.r
NOTE:
-re
The 3rd, 4th, and sth gears are installed with a press.
Prior_to reassembling, clean all the parts in solvent, dry them and apply lubricant to all contact surfaces except the3rd, 4th, and 5th gears.
Snap ring groove faces up.
LOCKNUT Replace.108-O- 108 N.m
I 11.0-O-11.0 kst.ml
I 79.6-0- 79.6 lbt.ft I
SYNCHRO SPRING
SYNCHRO RINGInspectaon, page 13-28
FRICTION DAMPER
Thin edge ol outerrace faces down.
Check for wear andoperatron,
/ BALL EEAR|NG t*1)
t NEEDLE BEARTNG (.2)
Check for wearand operatron,
WASHERBEARING
GEAR
4TH GEAR
3RD GEAR2ND GEAR
FRICTION DAMPER
SYNCHRO SPRING
SYNCHRO RINGInspection, page 13-2836 x 41 x 25.5 mmNEEDLE BEARINGCheck for wear and operataon.
Inspection, page 13-23
1ST GEARlnspection, page 13 21, 28lnspection, page 13-21, 2839x44x27mmNEEDLE BEARIfI'GCheck for wear andoperation.
SPACER COLLARInspection, page 13-21
REVERSE GEARlnspection, page 13 27
1ST/2ND SYNCHRO HUB
*1: D'16Y7 engine*2: D16Y5, D16Y8 engines
13-20

lllustrated Index
t
Refer to the drawing below for transmission disassembly/reassembly.
Clean all the parts thoroughly in solvent and dry with compressed air.
I Luoricate att the pans with oil before reassembly.
NOTE:
. This transmission uses no gaskets between the majorhousings; use liquid gasket (P/N 08718-0001 or08718-0003)
(see page '13-93).
. Always clean the magnet @ whenever the transmission housing is disassembled.
. Inspect all the bearings for wear and operation.
?-c
\I
ir 6d
a h Plt tia.fl
) K1T\A
l,l 1r
@rt? u
L6q
i"\^Br 'u
t@)
E,M A
#&f
o-*ffiX,
@
I
R
h"ii
'F@
,
€D
13-54

Gountershaft Assembly
Index
DAMPER
ST GEARInspection, page 13-75
EALL EEARING
and operation.
NEEDLE BEARINGlnspect for wearano operaton.
5TH GEAR
4TH GEAR
3RD GEAR
NOTE:
3
The 4th and sth gears are installed with a press.
Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces. The 4thand 5th gears. however, should be installed with a press before lubricating them.
REVERSE GEAR
LOCKNUT Replace108"0-108N.m
i11.0 - 0- l1.0kgtm,180-0-80lbttr
WASHER
DISTANCECOLLAR
COUNTERSHAFTInspection, page 13-77
NEEDLE BEARING
and operatron,
Inspection, page 13-75
NEEDLE BEARING
ano operatron,
SPACER
FRICTION DAMPER
DOUBLE CONE
Inspection, page 13 81
SYNCHRO SPRING
13-74