Engine remove HONDA CIVIC 1997 6.G Repair Manual

Oil Pump
RemovaUlnspection/lnstallation (cont'dl
13. Check the housing-to-outer rotor radial clearance.lf the housing-to-outer rotor radial clearanceexceeds the service limit, replace the set of innerand outer rotors and/or the pump housing.
Housing-to-Outer Rotor Badial Clearanco:Standard {Newl: 816A2 sngine 0.10 - 0.19 mm(0.004 - 0.007 in)
D16y5, Di6y7, Dt6y8 engines0.10 - 0.18 mm {0.00it _ 0.007 in)Service Limit: 0.20 mm (0.008 in)
lnspect both rotors and pump housing for scoringor other damage. Replace parts if necessary.
Remove the old oil sealfrom the oil pump.
Using the special tool, gently tap in the new oil sealuntil the driver bottoms against the pump.
NOTE: The oil seal alone can be replaced withoutremoving the oil pump.
DRIVER ATT52x55mm077a6 - 0010ao0
14.
15.
16.
8-14
PUMP HOUSING
17. Reassemble the oil pump, applying thread lock tothe pump housing screws.
18. Check that the oil pump turns freely.
19. Apply a light coat of oilto the seal lip.
20. Install the two dowel pins and new O-ring on the oilpump.
21. Apply liquid gasket to the cylinder block mating sur_face of the oil pump.
NOTE:
. Use liquid gasket, Part No.08718 - oOOj or 08718- 0003.. Check that the mating surfaces are clean and drybefore applying liquid gaskel. Apply liquid gasket evenly, in a narrow bead cen-tered on the mating surface.o To prevent leakage of oil, apply liquid gasket tothe inner threads of the bolt holes.. Do not install the parts if five mtnures or morehave elapsed since applying liquid gasket.Instead. reapply liquid gasket after removing theold residue.
. After assembly, wait at least 30 minutes beforefilling the engine with oil.
81642 engine:
\
D16Y5, D16Y7, D16Y8 engines:
along the broken line.

TWCHO2S
Inspection
l. Using a flashlight, make a visual check for plugging,
melting and cracking of the catalyst.
D16Y5, D16Y7 engines:
816A2, D16Y8 engines:
-\6{-)\
lT
a
A
FLASHLIGI{T
9-12
Replacement
Primary HO2S:
1. Remove the primary HO2S.
D16Y5, D15Y7 engines:
a. Disconnect the primary HO2S connector, thenremove the cover.
8 x'1.25 mm24 N.m {2.4 kgl.m,
PRIMARY H02SCONNECTOR
b. Remove the primary HO2S.
| \l ,l(
I bK/l
l llw.
/
(
PBIMARY HO2S44 N m (4.5 kgf.m, 33 tbI.ft)

Bt6A2, Dl6Y8 engines:
a. Disconnect the primary HO2S connector then
remove the primary HO2S.
816A2 engine
D16Y8 engine
PRIMARYH02S CONNECTOR
PRIMARY HO2S44 N.m {4.5 kgt'm.33 lbf'ft)
L
2. Install the primary HO2S in reverse order of removal'
Secondsry H02S:
1. Remove the secondary HO2S
Dl6Y5, Dt6Y7 engines:
a. Disconnect the secondary HO2S connector.
then remove the secondary HO2S'
02 SENSOR
816A2, Dt6Y8 ongin6s:
a. Remove the grommet, and pull out the secondary
HO2S connector, then disconnect the secondary
HO25 connector'
SECONOARY H()2S
CONNECTOR
{cont'd)
9-13

Radiator
Replacement
Drain the engine coolant.
Remove the upper and lower radiator hoses, andATF cooler hoses.
Disconnect the fan motor connector.
Remove the radiator upper bracket, then pull up theraotator,
RADIA
ATF COOLERHOSES (A/T)Refer to sectionwhen installing.
UPPER RAOIATOR HOSE
6x1.0mm7.2 N.m (0.73 kgf.m.5.3 tbf.ft)
1.
2.
3.
5. Remove the fan shroud assemblies and other partsfrom the radiator.
Install the radiator in the reverse order of removal:
NOTE:
. Set the upper and lower cushions securely.. Fill the radiator with engine coolant and bleedthe air.
6x1.0mmCAPY|lT,PS:|" i.i ru- ii b rgr.-,AND CUSHION7.2 tbr.ftl
14
(
I
RESEBVOIR TANK
RADIATOR
LOWER CUSHION
RAOIATOR FAN/SHROUDASSEMBLY
DRAIN PLUGO-RINGReplace.
LOWER RAOIATOR HOSE
ATF COOLERPIPES {A/T)
,iiiiii
10-6

tl
Engine Coolant Refilling and Bleeding
CAUTION: when pouring engine coolant, be sure to
shut the relay box lid and not to lst coolant spill on the
eleqtrical parts or the paint. lf any coolant spills, rinse it
off immediately.
1. Slide the heater temperature control lever to maxl-
mum heat. Make sure the engine and radiator are
cool to the touch.
Remove the radiator caP.
Loosen the drain plug, and drain the coolant'
Remove the drain bolt from the cylinder block'
D16Y5. D16Y7, Dl6Yg sngines:
DRAIN PLUG
0d
I ro
78 N.m {8.0 kgl m.58lbt'ft)
6.
1.
B1642 engin€:
WASHERReplace.
DRAIN BOLT78 N m (8 0 kgf m' 58lbfft)
Apply liquid gasket to the drain bolt threads, then
reinstall the bolt with a new washer and tighten 't
securely.
Tighten the radiator drain plug securely
Remove, drain and reinstall the reservoir' Fill the
tank halfway to the MAX mark with water, then up
to the MAX mark with antitreeze.
(cont'd)
10-7
MAX MARK

Cap Testing
1. Remove the radiator cap, wet its seal with engine
coolant, then install it on the pressure tester'
RADIATOR PR€SSURE TESTER(CommerciallY available)
RAOIATOR
(for 32 mm neck' low Pro{ile)
Apply a pressure of 93 - 123 kPa (0.95 - 'l 25 kgflcm''
14 - 18 psi).
Check for a drop in Pressure.
lf the pressure drops, replace the cap
I
t
ADAPTOR
Testing
LWait until the engine is cool, then carefully remove
the radiator cap and fill the radiator with engine
coolant to the top of the tiller neck
Attach the pressure tester to the radiator and apply
a pressure of 93 - '123 kPa (0.95 - 1.25 kgflcm', 14 -
18 psil.
RADIATOR PRESSURE
TESTER
lCommerciallY available)
ADAPTOR(for 32 mm neck, low Profile)
Inspect for engine coolant leaks and a drop In pres-
sure.
Remove the tester and reinstall the radiator cap
NOTE: Check for engine oil in the coolant and/or
coolant in the engine oil.
10-9

EGT Switch
-f
Testing
Replace the thermostat if it is open at room temperature'
To test a closed thermostat:
1, Suspend the thermostat in a container of water as
shown.
THEBMOMETER
THERMOSTAT
Heat the water, and check the temperature with a
thermometer. Check the temperature at which the
thermostat first opens, and at which it is fully open
CAUTION: Do not let the thermometer touch the
bottom of the hot Gonlainel.
Measure lift height of the thermostat when fully
open.
STANDARD THERMOSTAT
Lift height above 8.0 mm (0.31 inl
Starts opsning: 169' - 176'F (76' - 80'Cl
Fully open: 194'F {90"C1
!'o
10-1 1
Testing
!!@ Romoving the EcT swhch while lhs engine
i!-ot can cause the coolant to sPray out, seriously scald-
ing you. Always lst th€ ongine and rediator cool down
before removing ihe ECT switch.
NOTE: Bleed air from the cooling system after installing
the ECT switch (see Page 10-7)
1. Remove the ECT switch from the thermostat hous-
ing (see Page'10-10).
2. Suspend the ECT switch in a container of water as
shown.
Heat the water, and check the temperature with a
thermometer.
CAUTION: Do not let the thermomoter touch tho
bottom of the hot container'
Measure the resistance between the A and B termi-
nals according to the table.4.
Terminal
Oo"rffi
swlTcH
ON196' - 203"F
(91" - 95'C)o--o
OFF
5" - 15'F {3" - 8'C)
lower than the temPera-
ture when t goes on

Water Pump
Inspection
't.
2.
Remove the timing belt (see section 6).
Turn the water pump pulley counterclockwise.Check that it tarns freely.
Check for signs of seal leakage.
NOTE: A small amount of "weeping,,from the bleedhole is normal.
Dl6Y5, Dl6Y7, D16Y8 engines:
BLEEDHOLE
B16A2 engine:
BLEED HOLE
BLEED HOLE
BLEED HOLE
10-14
Replacement
6x1.0mm
1.Remove the timing belt (see section 6).
Remove the water pump by removing five bolts.
NOTE: Inspect, repair and clean the O-ring grooveand mating surface with the cylinder block.
D16Y5, D16Y7, D16Y8 engines:
12 N.m {1.2 kgf.m, l0 x 1.25 mm8.7 lbt.ft) {4 N.m 14.5 kg{.m.33 tbt.ft)
Bl642 engine:
WATERPUMP
@;2
6x1.0mm12 N.m 11.2 kg{.m,8.7 tbf.ft)
O.RINGReplace.
3. Install the water pump in the reverse order of removal.
NOTE:
o Keep the O-ring in position when installing.. Clean the spilled engine coolant.
d
orp,
I

Troubleshooting
Troubleshooting Procedures (cont,dl
ll, Engine Control Module (ECM)/powertrain Control Module (pCM) Reset procedure
NoTE: Resetting the EcM/PcM will erase any stored DTcs and any freeze data. lt will also restart all readiness codemonitors.
Either of the following actions will reset the ECM/PCM.
. Use the OBD ll scan tool or Honda pGM Tester to clear the EClM,s/pCM,s memory.
NorE: see the oBD ll scan tool or Honda PGM Tester user's manuals for specific operating instructions.
' Turn the ignition switch oFF. Remove the BACK uP (7.5 A) fuse from the under-hood fuse/relay box for 10 sec-onds.
NorE: Bemoving the BACK uP (7 5 A) fuse cancels the clock and the radio presets. Make note of the customer,spresets so you can reset then
lll. Final Procedure (this procedure must be done after any troubleshoottng)
1. Remove the SCS Service Connector if it is connected.
NoTE: If the Scs service connector is connected and there are no DTcs stored in the EcMipcM, the MtL will stayon when the ignition switch is turned ON 0l).
2. Do the ECM/PCM Reset procedure.
3. Turn the ignition switch OFF.
1-82

!Manifold Absolute Pressure (MAPI Sensor -
i;idlga lil;dels,'99 - 00 Dl6Y5 ensine with M/T)
ll
The scan tool indicates Diagnostrc Trouble code (DTC) Po108: A high voltage (low vacuum) problem in the
Manifold Absolute Pressure (MAP) sensor.
MAP SENSOR 3P CONNECTOR ICl11}
MAPIRED/GRNI
JUMPER WIRE
Wire side ol female terminals
vcclIYEL/RED)
ECM/PCM CONNECTOR D (16PI
MAP(RED/GRN)
sG1(GRN/WHT)
Wire side of female terminals
(cont'd)
11-121
The MIL has been reported on
OTC m108 is stolod.
Problem vetitication:
1. Start the engine. Hold the
engine at 3,000 rPm with no
load (in Park or neutral) until
the radiator fan comes on, then
let it idle.
2. Check the MAP with the scan
tool.
lntormittent lailure, sFtom k OK
.t thb time. Chock lor Poor con'
nections or loorg wires at Cll'l
|MAP sensorl snd ECM/PCM.
ls 101 kPa (760 mmHg,30 0 in.Hg)
or higher indicated?
Check tor an open in the MAP
36nSOt:1. Turn the ignition switch OFF
2. Disconnect the MAP sensor
3P connector.3. Install a jumper wire betlveen
the MAP sensor 3P connector
terminals No 3and No 2.
4. Turn the ignition switch ON (ll).
5. Check the MAP with the scan
tool.
ls 101 kPa (760 mmHg, 30 0 in.Hg)
or higher indicated?
Check for an open in wire (SG1
line):1. Remove the iumper wire.
2. Measure voltage between the
MAP sensor 3P connector te.
minals No. 1 and No 2
Rapai. open in the wito batwoen
ECM/PCM (D12) .nd MAP !en.or.ls there approx. 5 V?
Check for an oPon in the wiie
(MAP linel:1. Turn the ignition switch OFF.
2. Connect the ECM/PCM con-
nector terminals D3 and D12
with a iumPer wire.
3. Turn the ignition switch ON (ll).
4. Check the MAP with the scan
tool.
Repair opon in the wiles bstlt oon
ECM/PCM (D3l and MAP 3oGor.ls 101 kPa (760 mmHg, 30 0 in.Hg)
or higher indicated?
Substituto a known'good ECM/
PCM and rochock. ll normal MAP
is indicated, replace tho original
ECM/PCM.
JUMPER WIRE
lr,