Disc HONDA CIVIC 1997 6.G Workshop Manual

Llo
CANADA model ('00 model)
CAUTIONTO AVOID SERIOUS INJURYT. FOR MAXIMUM SAFETY PROTECTION lN ALL TYPES OF
CRASHES, YOU MUST ALWAYS WEAR YOUR SAFETY
BELT.. DO NOT INSTALL REARWARD-FACING CHILD SEATS lN
ANY FRONI PASSENGER SEAT POSITION.
. DO NOT PLACE ANY OBJECTS OVER THE AIRBAG OR
BETWEEN THE AIRBAG AND YOURSELF.. SEE THE OWNER'S MANUAL FOR FURTHER
INFORMATION AND EXPLANATIONS.
Except Cx tor passenger side
F: ASSISTANT INFoRMATION: US MODEL ('96. '97 mod€l)
AIRBAG SEE OTHER SIDE,
U.S. model l'98 - 00 modell
AIRBAG WARNINGFLIP VISOR OVER
Llo
G: STEERING COLUMN NOTICE
NOTICETO PBEVENT SRS DAMAGE, REMOVE STEERING WHEEL
BEFORE REMOVING STEERING SHAFT CONNECTING
BOLT.
ll: MONITOR CAUTION
NOTICE. NO SERVICEABIf PABTS lNSlDE.. REFER TO SERVICE MANUAL FOR DETAILED INSTRUC'
TtoNs.
DANGEREXPLOSIVE/FLAMMABLECONTACT WITH ACID, WATER OR HEAVY METALS SUCH
AS COPPER, LEAD OR MERCURY MAY PRODUCE HARM.
FUL AND IRRITATING GASES OR EXPLOSIVE COM-
POUNDS, STORAGE TEMPERATURES MUST NOT EXCEED
2OO'F I1OO"C}. FOR PROPER HANOLING, STORAGE AND
DISPOSAL PNOCEDURES REFER TO SERVICE MANUAL'
SRS SUPPLEMENT.POISONCONTAINS POISONOUS SODIUM AZIDE AND POTASSIUM
NITRATE.FIRST AIDIF CONTENTS ARE SWALLOWEO, INDUCE VOMITING. FOR
EYE CONTACT, FLUSH EYES WITH WATEB FOR 15 MIN-
UTES. IF GASES IFROM ACID OB WATER CONTACT) ABE
INHALED. SEEK FRESH AIR. IN EVERY CASE, GET PROMPT
MEDICAL ATTENTION.KEEP OUT OF REACH OF CHILDREN,
WARNINGTHE AIRBAG INFLATOR IS EXPLOSIVE AND, IF ACCIDEN-
TALLY OEPLOYED, CAN SERIOUSLY HUBT OR KILL YOU.
. DO NOT USE ELECTRICAL TEST EOUIPMENT OR
PROBING DEVICES.TH€Y CAN CAUSE ACCIDENTAL DEPLOYMENT'
. NO SERVICEABLE PABTS lNSlDE. oO NoT
DISASSEMBLE.. PLACE AIRBAG UPRIGHT WHEN REMOVED. FOLTOW SERVICE MANUAL INSTRUCTIONS CAREFULLY
I: FRONT SEAT PASSENGER MOOULE DANGER
Jr SRS WARNING IHOOD)
' Exceot CANADA CX
K: PASSENGER AIRBAG CAUTION
u.S. model l'98 - 00 model)
WARNINGCHILDREN CAN 8E KILLED OR INJUREO BY PASSENGER
AIRBAG,THE BACK SEAT IS THE SAFEST PLACE FOR CHILDREN 12
AND UNDER. MAKE SURE ALLCHILDREN USE SEAT BELTS
OR CHILD SEATS.
(cont'd)
1-35
SUPPLEMENTAL RESTRAINT SYSTEM ISRS}
THIS VEHICLE IS EOUIPPED WITH DBIVER AND FRONT
SEAT PASSENGER AIRBAGS'.ALL SRS ELECTRICAL WIRING AND CONNECTORS ABE
COLORED YELLOW.TAMPERING WITH, DISCONNECTING OR USING
ELECTRICAL TEST EOUIPMENT ON THE SRS WIRING CAN
MAKE THE SYSTEM INOPERATIVE OR CAUSE ACCIDENTAL
FIRING OF THE INFLATOR.
WARNINGTHE AIRBAG INFLATOR IS EXPLOSIVE AND, IF ACCIDEN.
TALLY DEPLOYED, CAN SERIOUSLY HURT YOU. FOLLOW
SERVICE MANUAL INSTRUCTIONS CAFEFULLY'

Unit of length: mm (in)
Fuel and Emission - Section
MEASUREMENTSTANOARO (NEW)
260 310 (2.7 - 3.2, 38 - 46)
260 - 310 (2.7 - 3.2, 38 - 46i
260 - 310 (2.7 - 3.2, 38 - 46)
210 - 320 Q.A - 3.3, 40 - 47 1
45 {11.9, 9.9)
M/T (neutral) I A/T or C\.T (lE or fd positioni
Fuel paessure
regulator
Pressure wilh fuel pressure regulator vacuum hose
disconnected kPa (kgvcm', Psi)D16Y5D 16Y7D16Y881642
FueltankCapacity I (US gal, lmp gal)
E ngineldle speed rpm
016Y5D16Y7D16Y8816A2
u.s.A.CanadaU,S,A.Canada
670 1 506701 50670150700 t 50
7501 507501 507501 50
700 t 50700 I 507001 50750150750 r 50
ldle CO %0.1 max.
Clutch - Serrtion 12
MEASUREMENTSTANDARD {NEWI I SERVICE LIMIT
Clutch pedalPedal height to floor
StrokePedal play
Disengagement height to floorto carpet
16s (6 1/2)130 140 (5 1/8 5 1/2)
12 -21 t1l2 - 13/16183 (3 1/4)44 (1 3/4) min. Reference
FlywheelClutch surface ruoout
Rivet head depthThickness
0.05 (0.002) max.0.15 (0.006)
Clutch disc1.3- 1.9 (0.05 - 0.07)
8.5 - 9.1 (0.33 - 0.36)
0.2 {0.01)5.5 (0.22)
Pressure plateWarpageDiaphragm spring fingers alignment
0.03 (0.001) max0.6 (0.02) max
0.15 (0.006)
1.0 (0.04)
Lro
3-7
lfllHlllllllllrltllli[

Automatic TtssronSection 14Unit of lengthi mm (in)
fansmtssron -
MEASUREMENTSTANOARD {NEWISERVICE LIMIT
Transmissionfluid
Capacity f (US qt, lmp qti5.9 (6.2, 5.2)Ior overhaul2.7 (2.9, 2.4) for fluid chanse
sgO g8ol85 SO,rzO rSO, rAo,e'0 I 0,Hydraulic
kPa
(kgf/cm', psa)
Line pressure at 2,000 rpm in E or E position
1st clulch pressure al 2,O0Orpmin D. position
2nd clutch pressure at 2,000 rpm in El position800 - 850 (8.2 -8.7, 120 - 124)760 (7.7, 110)
3rd and 4th clutch pressure at 2,000 rpm in lFl posi-
tion
810- 860 (8.3 - 8.8, 118 - 125)760 (7.8, 1l 1)
Stall speed rpm (Check with vehicle on level ground)2,10028 1_ ffi9
30.0 (1.18)
28.5 \1.12)29.1 (1.15)
28.511.121Untilgrooves worn out
Discoloration
ClutchClutch initial clearance
Clutch return spring free length(A4RA, B4RA Transmission)
lM4RA Transmission)
Clutch disc thicknessClutch plate thickness
Ctr t"h ""d pl"t" thl"t**(A4RA, B4RA Transmission)
1st,2nd3rd,4th
1st2nd,3rd,4thlst2nd,3rd,4th
1st2nd,3rd,4th
Mark 1Mark 2Mark 3Mark 4Mark 5Mark 6Mark 7Mark IMark I
M"*lMark 2Mark 3Mark 4Mark 5Mark 6Mark 7Mark 8Mark 9Mark 10Mark 11Mark 12Mark l3Mark 14Mark 15Mark 16Mark 17Mark 18
Clutch end plate thickness(M4RA Transmassioni
0.65 , 0.85 (0.026 - 0.033)0.40 - 0.60 (0.016 - 0.024)
32.0 (1.26)
30.s (1.20i
31 .1 11.22130.5 (1.20)
1.88 - 2.00 {0.074 - 0.079)
1.55 - 1.6510.061 -0.065)
1.95 - 2.05 (0.077 0.081)
2.05 2.10 (0.081 - 0.083)2.15 - 2.20 (0.085 - 0.087)2.25 - 2.30 {0.089 - 0.091i
2.35 - 2.40 (0.093 - 0.094)
2.45 - 2.50 (0.096 - 0.098)2.55 - 2.60 (0.100 - 0.102)
2.65 - 2.70 (0.104 0.106)2.75 - 2.80 (0.108 0.110)
2.85 2.90 (0.112 - 0.114)
Discoloration
1
I
IDiscoloration
2.3 - 2.4 {0.091 0.094)2.4, 2.5 {0.094 - 0.098)2.5 2.6 (0.098 - 0.102)2.6 - 2.7 (0.102 - 0.106)
2.7 , 2.8 (0.106 - 0.110)2.8 - 2.9 10.110 0.114)
2.9 - 3.0 (0.114- 0.118)
3.0,3.1 (0.118-0.122)
3.1 - 3.2 \O.122 -0.1261
3.2 - 3.3 {0.126 - 0.130}2.0 - 2.1 (0.079 - 0.083)2.1 - 2.2 (0.083 - 0.087)2.2 - 2.3 (0.087 - 0.091)3.3 - 3.4 (0.130 0.134)
3.4 - 3.5 (0.134 - 0.138)3.5 - 3.6 (0.138 0.142)
3.6 3.7 {0.142- 0.146)
3.7 ,3.8 10.146 - 0.150i
Discoloration
1
I
I
L
I
Discoloration
(cont'd)
3-11

Standards and ServiceLimits
Section '14Automatic Transmission (cont'd)
UO
MEASUREMENTSTANDARD {NEW}
Wire Dia.o.D.Free LongthNo. ol CoilsHegulator valve spring ARegulato. valve spring BStator reaction springModulator valve springTorque convener check valve springCooler relief valve springRelief valve spring2nd oritice control valve spring1-2 shift valve spring2-3 sh ift valve spring3 4 shift valve spring'l st accumulator spring4th accumulator spring B4th accumulator spring A2nd accumulator spring A3rd accumulator spring A2nd accumulator spring B3rd acc!mulator spring B2nd accumulator spring CLock up shift valve springLock up timing valve springLock-up control valve spring3 4 ofifice control valve springServo control valve springCPC valve springCPB valve spring4th exhaust valve spring
Springs1.8 {0.071)1.8 {0.071)4.5 \O.117)1.4 (0.055)
1.0 10.039)1.0 (0.039)
1.1 (0.043)
0.7 (0.028)
0.9 (0.035)
0.9 (0.035)
0.9 (0.035)
2.1 (0.083)
2.3 (0.091)
2.610.102)2.4 (0.094)
2.8 (0.'110)
1.6 (0.063)
2.2 (0.087)
2.2 t0.041)0.9 (0.035)
0.9 (0.035)
0.7 (0.028)
0.7 (0.028)
1.0 (0.039)
0.6 (0.024)
0.9 {0.035)0.9 (0.035)
14.7 (0.584)
9.6 (0.381)
3s.4 (1.407)
9.4 (0.374)8.4 (0.334)
8.4 (0.334)
8.6 {0.342)6.6 (0.262)
7.6 (0.302)
7.6 (0.302)
7.6 (0.302)16.0 (0.636)10.2lo.402l17.0 {0.676)29.0 (1.152)
17.5 (0.6951
9.0 (0.358)
31.0 (1.220)
14.5 {0.576)7.6 (0.302)
8.1 (0.319)
6.610.262)6.6 (0.262)
8.1 (0.322)
5.6 (0.2231
8.1 10.322)6.1 10.242)
87.8 (3.457)
44.0 i.732l'30.3 (1.193)
35.0 {1.378)33.8 (1.331)
33.8 (1.331)
37.1 (1.461)
34.8 (1.370)
41.3 (1.626)
57.0 (2.2441
51 .0 \2.244189.1 {3.508)51.6 (2.031)
87.0 (3.425)
39.011.535)89.3 (3.516)
20.7 (0.815)
35.1 11.382)68.012.671173.7 12.902)80.7 (3.177)38.0 {1.496)37.5 fi.476)52.1 (2.051)
12.2 (0.480)
47.2 {1.858}36.4 {1.433)
16.511.01.910.94.24.213.422.016.326.826.a16.213.814.22.915.66.12.413.932.045.814.124.620.4
18.319.5
CVTSection 14
3-14
MEASUREMENTSTANDARD INEWISERVICE LIMITTransmissionfluidCapacity f {US qt, lmp. qt)6.4 {6.8, 5.6) for overhaul3.9 (4.1, 3.4) for fluid change
Hydraulicpressure
1kgflcm,, psi)
Forward clutch pressure at 1,500 rpm in E position1.4 - 1.15 114.3 - 11.A,203 - 2531Reverse brake pressure at 1,500 rpm in E position1.4 - 1.75 (14.3 11.8,203 2531Dr;ve pulley pressure at 1,500 rpm in E posrtrono.2 -0.7 12.0 -7.1,28- 1011Driven pulley pressure at 1,500 rpm in N positionr.5 - 2.3 115.3 - 23.5, 218 - 334)Lubrication pressure at 3,000 rpm in E posrtronAbove 0.212,30)Stall speed fpm (Check with vehicle on level ground)
E position
E, E, El positions2,5003,0002,350 - 2,6502,800 - 3, r00ClutchClutch initial clearance Forward clutchStart clutchReverse brakeClutch return spring free length Forward clutchStart clutchReverse brakeClutch disc thickness Forward clutchStart clutchReverse brakeClutch plate thickness Forward clutchSta rt clutchReverse brake
0.6 - 0.8 (0.024 - 0.031)0.5 - 0.7 (0.020 0.028)0.45 - 0.75 (0.018 - 0.030)30.5 {1.201)40.9 (1.610)
29.4 (1.157)
1.88 - 2.00 (0.074- 0.079)1.88 2.00 (0.074 - 0.079)1.94 - 2.06 (0.076 - 0.081)1.95 - 2.05 (0.077 -0.081)
2.25 2.35 (0.089 - 0.093)1.90 - 2.00 (0.075 0.079)
,*x.ar}38.9 (1.531)
27.411.019l'Until grooves worn out
Until grooves worn outDiscolorationDiscolorationDiscoloration
L.

cwSection 14[Jnit of length: mm (in)
MEASUBEMENTSTANDARD {NEW}SERVICE LIMIT
Forward clutch end plate thickness Mark 1 or 15Mark 2 or 16Mark 3 or 17Mark 4 or 18Mark 5 or 19Mark 6 or 20Mark 7 or 21Mark 8 or 22Mark I or 23Mark 10 or 24Mark 11 or 25Mark 12 or 26Matk 13 ot 21
3.4 - 3.5 10.134 - 0.138)
3.5 - 3.6 (0.138 - 0.142)3.6 - 3.7 (0.142 - 0.146)3.7 3.8 (0.146 0.150)3.8 - 3.9 (0.150 - 0.154)3.9 - 4.0 (0.154 - 0.157i4.0 - 4.1 (0.157 - 0.161)4.1 - 4.2 (0.161 - 0.165)4.2 - 4.3 (0.165 - 0.169)4.3 - 4.4 (0.169 - 0.173)4.4 - 4.5 10.173 - 0.177i4.5 4.6 (0.177 0.181)4.6 - 4.7 (0.181 - 0.185)
Discoloration
Discoloration
Reverse brake end plate thickness Mark 1Mark 2Mark 3Mark 4\44 rk 5Mark 6Mark 7Mark 8
3.55 - 3.65 (0.140 0.144)3.75 - 3.85 10.148 - 0.152)
3.95 - 4.05 (0.156 - 0.159i4.15 - 4.25 (0.163 0.167)4.35 - 4.45 (0.171 - 0.175)
4.55 - 4.65 (0.179 - 0.183)4.75 - 4.85 (0.187 - 0.191)4.95 - 5.05 (0.195 - 0.199)
Discoloration
1
IDiscoloration
ATF pumpATF pump drive gear shaft O.D.ATF pump driven gear shaft O.D.ATF pump body bushing l.D. Drive gear shaftDriven gear shaft
ATF pump gear side clearanceATF pump gear-to-body clearance Drive gear
Driven gear
9.98 - 9.99 (0.3929 0.3933)9.98 - 9.99 {0.3929 - 0.3933)10.000 - 10.015 (0.3937 0.3943)10.000 - 10.015 (0.3937 0.3943)
0.01s - 0.035 (0.0006 0.0014)
0.035 - 0.0505 (0.0014- 0.0020)
0.035 - 0.0505 (0.0014 - 0.0020)
Wear or damagedWear or damagedWear or damagedWear or damaged
TransmissionDiameter of needle bearing contact areaInput shaft - flywheel sideInput shaft forward clutch sideDrive pulley shaft - start clutch sideDrive pulley shaft - flywheel side
Drive pulley shaft - forward clutch side
Thrust clearanceCarrier and ring gear
Driven pulley shaft and start clutch hub
Input shaft and ATF pump driven sprocketSecondary gear shaft and flywheel ball bearing
19.987 - 20.000 (0.7869 - 0.7874)19.987 - 20.000 (0.7869 - 0.7874)43.981 - 43.991 (1.7315 - 1.7319)24.007 - 24.020 (0.945 - 0.946)24.007 - 24.020 (0.945 - 0.946)
0.050 - 0.110 (0.0020 - 0.0043)
0.000 - 0.130 10.000 - 0.005)
0.370 - 0.650 (0.015 - 0.026)0.00 0.15 (0.00 0.006)
Wear or damagedWear or damagedWear or damagedWear or damagedWear or damaged
(cont'd)
3-15

MEASUREMENTSTANOARO INEW}SERVICE LIMIT
algnmenlCamber FrontRearCaster FrontTotaltoe FrontBearFront wheel turning angle Inward wheelOutward wheel
0"00'1 1"-1.1 1'1'40' I 1"In'1.01 2.0 {1/16 t 1/'16)In 2.0 ljB (1/161 1/16)39.50'33'10'(Reference)
Bim runout Aluminum wheel AxialBadialSteelwheel AxialRadla I
0 0.7 (0 - 0.03)0- 0.7 (0 - 0.03)0 - 1.0 (0 0.04)0 - 1.0 (0 0.04)
2.0 (0.08)
1.5 10.06)2.0 {0.0B)1.5 (0.06)Wheel bearingEnd play FrontRear0 0.0s (0 - 0.002)0 0.05 (0 0.002)
Standards and Service Limits
Suspension - Section 18
Brakes - Section 19
*1. 5410 Stamped on the caliper body.*2. 2056 Stamped on the caliper body.
Air Conditioning - Section 22
*: When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it of{.Readjust deflection or tension to used belt values.
3-18
MEASUREMENTSTANDARO INEWISERVICE LIMIT
Parklng brakePlay in stroke at 196 N (20 kgf, 44 lbfi lever forceTo be locked when pulled6 - I notchesFoot brakepeoalPedal height (with floor mat removed) M/TA/'T, CVTFree play
156.5 {6.16)161 (6 5/16)1 5(1/16-3/16)
Master cvlinderPiston to pushrod clearance0 - 0.4 (0 0.02)
Disc brakeDisc thickness FrontRearDisc runout FrontRearDisc parallelism Front and rearPad thackness Front
Rear
20.9 - 21.8 (0.82 - 0.86)8.9 - 9.1 (0.350 - 0.358)
9.5 10.5*'8.5 - 9.5*'7.0 8.0 (0.28-0.3r)
19.0 (0.75)
8.0 (0.31)
0.10 (0.004)
0.10 (0.004)
0.015 (0.0006)
1.6 (0.06)1.6 (0.06)'r.6 (0.06)
Rear brakedrumLD.Lining thickness200 17.a7l4.0 (0.16)201 \7 .9112.0 {0.08}
MEASUREMENTSTANDARD INEWI
Conditioning
SANDEN
Lubricant type: SP 10 (P/N 38897 - Pl3 - A01AH or 3889Lubricant capacity Condensermf (floz, lmp oz) EvaporatorLine or hoseReceiver
I - P13 A0li lFor refrigerant: HFC-134a (R,134a))
| 20 \2t3 0.11
I 45 (1 2/3, 1.6)10 (1/3,0.4)
10 t1/3,0.4)NIPPONDENSOLubricant type: ND'O|L8 (P/N 38899 - PR7 - 003) (For ReLubricant capacity Condensermf (floz, lmp oz) EvaporatorLine or hoseReceiver
f.igerant: HFC,134a (R-134a))25 (s/6 0.9)60 (2,2.11
10 (1/3,0.4)
10 (1/3.0.4)
CompressorSANDENLubricant type: SP-10Lubricant capacity ml lfl oz, lmp oz)Field coil resistance at 68'F (20"C) OPulley-to-pressure plate clearance
130 150 (4 1/3 4.6, 5.0 - 5.3)
0.5 r 0.15 10.020 t 0.006)
NIPPONDENSOLubricant type: ND-OlL8 {P/N 38899 - PR7 ,003 or P/N 38899 pR7 - AO1) (For Refrigerant: HFC 134a {R,134a))Lubricant capacity m{(fl oz, lrnpoz) | 14O(4.7,4.9J -15S{5.2.5.4)Stator coil resistance at 20'C (68.F) 0Pulley-to-pressure plate clearance3.4 - 3.80.510.15 (0.0210.006)
Compressorbelt*Deffection with 98 N (1Okgl.22lbllbetween pulleys7.5 - 9.5 (0.30 0.37) with used belt5.0 - 6.5 (0.20 - 0.26)with new belt
Belt tension N (kgf, lbf)Measured with belt tension gauge340 490 i35 50, 77 - 110) with used bell690 - 830 (70 - 85, 150 190) with new belt

ITEMMETRICENGLISHNOTESTEERINGSYSTEMTvpe P/sM/SOverall Ratio p/S
M/STurns, Lock-to Lock p/S
M/SSteering Wheel Dia.
Power assisted, rack and pinionRack and pinion1l.120.33.64..1380 mm 15.0 inSUSPENSIONTYPe Front and RearFront and RearIndependent double wishbone, coil springTelescopic, hydraulic nitrogen gas-filled
WHEELALIGN| 4ENTCamber FrontRearCaster F.ontTotalToe FrontRear
0.00,- 't'
1.40'ln 1 mm ln 1/16In 2 mm In 1/16EBAKE SYSTEMType FrontRea r
Pad Surface Area Front
Rea r
Parking Brake Type
Power assisted self adjusting ventilated discPower assisted self adiustjng solid discPower assisted sell adjusting dr!m37.5 cm'x 4 5.8 sq in x 4
44.1ctn,x4 ] 6.84sq-inxa
67.2 cmz x 4 | to.+ sq in ' I21.2 cm, x 4 3.3 sq in x 4Mechanical actuating, rear two wheelbrakes
5410 stamped onthe caliper body2056 stamped onthe caliper bodyDrumDisc
TIRESize and PressureSee lire intormation label
WASHERCapacity 2door Coupe/4,door Sedan
2,door Hatchback
2.5 f (2.6 LJS qt, 2.2 lmp qt)4.5 | (4.8 US qt,4.0lmp qt)2.51 (2.6 US qt, 2.2 lmp qt)4.5 f (4.8 US qt, 4.0 lmp qt)
USA modelCanada modelDXExcept DXELECTRICALBafteryStarterAlternatorFuses In Under dash Fuse/Felay BoxIn Under-hood Fuse/Belay 8oxIn Under hood ABS FLrse/Relay BoxHeadlightsFront Turn Signal/Parking LightsRear Turn Signal LaghtsBrake/TaillightsInner Taillights*,High Mount Brake LightBack up LightsLicense Plate LightsCeiling Light
Trunk LightsGauge LightsIndicator Lightslllumination and Pilot LightsHeater Control Panel Lights
12 V 38 AH/5 HR12 V 1.0 kW, 1.2 kW12V 75 A,80 A7.5 A, t0 A, 15 A, 20 A7.5 A, 10 A, 15 A, 20 A, 30 A, 40 A, 80 A7.5 4.20 A, 40 A12V_60/55W12V -2115W
12V - 21W12V - 21/5W12V-5W12 V 18 W*" 21 W+" *3
12V 21W12v-5wl2V-8W(Withmoonroofl12 V - 5W (Without moonroof)
12V-1.4W,3W't2 v 1.12W. 1.4 W12v-0.84w, 1.4 W12V 1.4 W
Design Specifications
(cont'd)
P/S: Power Steering M/S: Manual Steering*l: 2-door Coupe *2: 2door Hatchback *3: 4-door Sedan*4: USA (HAM), Canada (HCM) produced *5: Japan produced
3-22
L'

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

8. Remove the intake air duct and air cleaner housing.
D16Y, ongino:
a. Remove the resonator and intake air duct.
6x1.0mm9.8 N.m (1.0 kgt m, 7.2 lbf.tt)
INTAKE AIR
Disconnect the intake air tempsrature (lAT) sen-
sor connector, then r€move thg air cleaner hous-
Ing.
6x1.0mm9.E N.m (1.0 kgtm, t.2lbtft,AIR CI."EANERHOUSING
IAT SENSORCONNECTOR
016Y5, Dl6Y& 815A2 engin€sl
a. Disconnect the IAT sensor connector, then
remove the intake 8ir duct and air cleaner hous-
Ing.
6x1.0mm9.8 N m {1.0 kgtm, 7.2 lbl'ft)
AIR CITANERHOUSING
INTAKE AIRDUCT
IAT SENSORCONNECTOR
9. Disconnect the engine wire harness connector on
the left side of the engine compartment.
(cont'd)
5-3

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