Sus HONDA CIVIC 1997 6.G Workshop Manual

Lift and SupPort Points
L,O
Lift and SafetY Stands
t!ffi when heavv rear components such as suspension' fuel tank' spare tire' hatch' and trunk lid are to be
-aEremoved, place additional wetght Inihe luggage arga before hoisting. when substantial weight is lemoved from the rear
of the vehicls. the center of gravity may change and can cause the vehicle to tip tolward on the hoisi
NOTE:
. Since each tire/wheel assembly weighs approximately 30 lbs (14 kg)' placing the front wheels in the luggage area can
assist with the weight distribution
. Use the same support points to suppon the vehicle on safety stands'
Place the lift blocks as shown.
Raise the hoist a lew inches (centrmeters) and rock the vehicle to be sure it is firmly supported'
Raise the hoist to full height, and inspect lift points for solid support
1.
2.
3.
REAR SUPPORT POINT
1-41

Towing
lf the vehicle needs to be towed, call a professional tow-
ing service. Never tow the vehicle behind another vehi
cle with iust a rope or chain lt is very dangerous'
Emergency Towing
There are three popular methods of towing a vehicle:
Flat-bed Equipment - The operator loads the vehicle on
the back of a truck. This is the best way of transporting the
vehicle.
Wheel Lift Equipment - The tow truck uses t\ivo pivoting
arms that go under the tires {front or rear} and lifts them
off the ground. The other two wheels remain on the
ground.
Sling-type Equipment - The tow truck uses metal cables
with hooks on the ends. These hooks go around parts of
the frame or suspension, and the cables lift that end of
the vehicle off the ground The vehicle's suspension and
body can be seriously damaged if this method of towing
is attemDted.
lf the vehicle cannot be transported by flat-bed. it should
be towed with the front wheels off the ground lf due to
damage, the vehicle must be towed with the front
wheels on the ground, do the following:
lvlanual Transmission and CW
. Release the parking brake
. Shift the transmission to neutral (CW to E position)'
Automatic Transmission
. Release the Parking brake.
. Sta rt the engine.
. Shift to LDll position, then E position.
. Turn oif the engine
CAUTION;
o lmploper towing preparation will damage ihe tfans-
mission. Follow the above procedute exaqtly lf you
cannot shift the tlansmission or start the engino
laulomatic transmissionl, yout vehicle must be trans-
ported on a flat-bed.
. lt is best to tow the vehicle no farther than 50 mil€s
(80 km), and ksop thE speed below 35 mph (55 km/hl
. Trying to lift 01 tow your vehicle by tho bump€F will
caus€ setious damagg. Ths bumpers are not dEigned
to supportthe vshicle's weigh.
tJO
1-43
Front:
Rear:
TIE DOWN HOOKS
TOWING HOOK

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'

81642 engine:
8 x 1.25 mm
22N,n 12 2 kdl'rn,
Replace.
,&16 rbt.ftl
Replace.
SELF.LOCKING8 x 1.25 mm16 N.m t1.6 kg{ m, 12 lbl'ft)
Replace.
GASKETSReplace.
10 x 1 .25 mm
s4 N.m {5.5 kgf m, 40 lbf'ftl
32.
PIPE A
RePlace'
Remove the damper forks (see section 18).
Disconnect the suspension lower arm ball joints
(see section 18).
Remove the driveshafts.
CAUTION:
o Do not pull on th€ drivoshaft. the CV ioint may
com9 apart.
o Use care whgn prying out the assombly.
Pull it straight to avoid damaging the differential
oil seal or intermediate shaft dust seal.
NoTE: Coat all precision-finished surfaces with
clean engine oil. Tie plastic bags over the driveshaft
enos.
34.
HO2S CONNECTOR
!^.
35.
36.
Lower the hoist.
Remove the upper and lower radiator hoses and
heater hoses,
37. Removs the ATF cooler hoses, then plug the ATF
cooler hoses and PiPes (A,/T)
UPPERRADIATOR HOSE
HOSES
(cont'd)

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

Troubleshooting
Eng ine/P_owertrain Control Module Term inal Arrangement
('99 - 00 Models except Dl6Y5 engine with M/Tl (cont,d)
ECM/PCM CONNECTOR C {31P)Wire side of female terminalsNOTE;Standard
*1;4"/T lD16Y7, D16Y8 ensinel
43: CVI(016Y5 engine)'4: D16Y5, D16Y8, 81642 engin€
ECM/FCM CONNECTOR C 13lPI
is 12 V.
Sig.al
lBLK4/VHTPO2SHTC (PNIMARY HEATEOOXYGEN SENSOB HEATES CONTROL)
Drivss primary hoated orygen sensofWith ignition switch ON (lr)rbanery volageWrh fJly warned up €ngir. ru..i19: duty.oaro ed
2WHT/GFNALTC (ALTESNATOB CONTSOL)Sends aliernalo. control sig nal,With fullywa.med upengine ronning; banery vohaseDuring d.iving with smallelect.icatioad; O V38ED/BLUK5 (KNOCK SENSOR)with sngine knocking: pulses
5WHT/REDATTF {AITEFNATOR FR SIGNAL'Detects slternaror FR si9n.l.With tullywarmed up engine running:O V- batteryvortage(dependingon erectficat toad)
WHT/8LKEGRL (EGN VAIVE LIFTSENSOR)Dete.ts EGR valve lrft sensorsignat.
GRN,4r'l/flTSGl ISENSOE GBOUND)Groond fo. MAP s€nsor.L€ss rhan 1.0 v at alltimes88luCKPP (CKP SENSOR P SIOE'With engine running: pulses9CKPM {CKP SENSOR M SIDEIGround for CKP sensor.
BLU/BLKwlvl (wEc PREssuSE swtTcllSIGNAI)D€tocts VTEC pfessure switch signat,With €ngine at low enginospeed:0VWith engin€ at high engino speed : banery vo ttaae
16PHO25 (PRII\,1AFY HEATEDOXYGEN SENSOR, SENSOR 1)Oetects primary heated oxygen s6nsor lsen-With lhrottle f!l1y open€d from idtewith tuly,wa.med !p engin€: Ebove 0.6 VWilh thronl€ quickly closed: b€tow 0.4 V
FED/GRNMAP (I\,4ANIFOLD ASSOLUIEPFESSUSE SENSOB}Dotocrs i,4AP sensor signsl.With ignitioh switch ON (ll):about 3 VAt idlei6boul 1.0 V (depending on engine speed)18GBN/8LKSG2 (SENSOR GSOUND)Less than 1.0 V aralttimes'19YEUNEDVCCl (SENSOR VOLTAGEIPowersourcero MAPsenso..With ignition swilch ON {ll):about 5 VWirh iqnition switch OFF]0 V20GNNIDCP (TDC SENSOB P SIDEIWith ongine running: pulses218EDTDCI\,I (TDC SENSOR M SIOE)Ground lor TOC aensor.22BTU/NEDCKFP (CKF SENSOR P SIDE)With engine running: p!lses
23VSS {VEHIClE SPEED SENSOR)Wilh ignrt|on swich ON rllr snd lront wl-ee' rotating.cycles 0 V about 5V or baneryvottage
25BED/YELIAT ONTAKE AIF TEi,4PEBA.TUEE SENSOR)Detects IAT senso. signat.With ignition switch ON (ll): about 0.1 4.8 Vldepending on i.take air ternpe.atu re)
268ED,ryVHTECT (ENGINE COOLANTTEI\,I.PESATUBE SENSOR)Oelects ECT sensor signal.With ignirion swirch ON {ll):about0.1 -4.8 V(depending on engine coolant temperatu re)
21NED/BLKTPS (THROTTLE POSITION SEN,SOF)Detects TP sensor signal.Wilh th.onle fully op€n: about 4.a VWith rhronle f!lly closed: about 0.5 V
2aYEVBLUVCC2 (SENSOR VOLTAGE)Provides s6nsor voltag€.With ignirion swirch ON (tt):about 5VWith ignilion swiich OFF:0 V29YELCYPP (CYP SENSOR P SIDE)Wilh €ngrne running: pruses3oBLKCYPM (CYP SENSOR M SIDE]G,ound for CYP sonsor.J1WHT/FEDCKFM (CKF SENSOB M SIDE)Ground fo. CKF sonsorsign6i.
11-94

Troubleshooting
Diagnostic Trouble Code (DTCI Ghart (cont'd)
DTClMlL indicationlDetegtion homProbablo CsussPage
P1491*! \12J
EGR ValveLift InsufficientDetected
EGR valve (with lift sensor)EGR valve lift sensor circuitEGR control solenoid valve (A,/I)
EGR control solenoid valve circuitEGR lineEGR valve circuit (M/T)
ECM
't1-256
P1498*. 112)
EGR ValveLift SensorHigh Voltage
EGR valve (with lift sensor)EGR valve lift sensor circuitECM11-265
Pl508*10 (14)
ldle Air Control ValveCircuit FailureIAC valveIAC valve circuitECM
'11-194
{14)
ldle Air Control ValveCircuit FailureOpen or short in IAC valve circuitIAC valveECM/PCM1l-198
P1607 1-)
Engine ControlModule/Powertrain Control lvlodulelnternalCircuit Failure A
. ECM/PCM
11-188
P1655*1 (30)TMA,/TMB Signal Line FailureODen or sho.t in TMA,/TMB circuit11-189
P1705P1706P 1753P1758P1768P1785P1790P1791P1793 (70)*
P1870P1873P1879P1885P1886P1888P1890P1891
Automatic Transaxle
Section 14
*: The E indicator light and the Malfunction Indicator Lamp {MlL) may come on simultaneously.*4: D16Y5 engine (M/T)+10: Except A/T and Dl6Y7 engine*11: A,/T and D16Y7 engine*18: D16Y5 engine (CW) (except '99 - 00 models)
11-102

PGM-FI System
Barometric Pressure (BAROI Sensor
The scan tool indicates Diagnostic Trouble code (DTC) Pi106: A range/performance problem in the BaromerrrcPressure (BARO) Sensor circuit.
The scan tool indicates Diagnostic Trouble code (DTc) P1107: A low voltage probtem in the Baro sensor circurr.
The scan tool indicates Diagnostic Troubre code {DTC) p1108: A high vortage probrem in the Baro sensorcircuit.
fF1lot
tPlloal
The MIL ha3 been r€Dortsd on.DTC Pl106 is stored.
Problem verification:1. Do the ECM/PCM reset pro-cedure,2. Start the engine. Hold theengine at 3,000 rpm with noload (in Park or neutral) untilthe radiator fan comes on, thenlet it idle.3. Connect the SCS service connector.4. Test drive with the A/T in Eposition, M/T in 4th gear.5. Accelerate for five secondsusing wide open throttle.
Intormittont tailure, system is OKat this time.ls DTC P1106 indicated?
Substitut€ e known-good ECM/PCM and recheck. ll symptom/indication goes .way, .oplsce theo.iginal ECM/PCM.
The MIL has been .oported on.DTC P'l107 o. Pl108 is stored.
P.oblem veritication:1. Do the ECM/PClvl Reset pro
cedure,2. Turn the ignition switch ON (ll).
Intormittent frilure, syitem i3 OKat this time.ls DTC P1 107 or Pl108 indicated?
Substitute a known-good ECM/PCM and rechock. It symptom/indication goes away, .6placethe original ECM/PCM.
11-178

Fuel Supply System
Fuel Pump
Testing
!@ Do not smoke during the test, Keep open
flame away from your work atea,
lf you suspect a problem with the fuel pump, check that the
fuel pump actually runs; when it is ON (ll), you will hear
some noise if you hold your ear to the fuel fill port with the
fuel fill cap removed. The fuel pump should run for two
seconds when ignition switch is first turned ON (ll). lf the
fuel pump does not make noise, check it as follows:
L Remove the seat cushion {see section 20).
2. Remove the access panel from the floor.
3. Make sure the ignition switch is OFF, then discon-
nect the Iueltank 2P connector.
4. Connect the PGM-FI main relay 7P connector termi-
nal No. 4 and No. 5 with a jumper wire.
PGM-R MAIN RELAY 7P CONNECTOR lC4,(|l
FUEL PUMP
IYEL/GRN}
IGN 1(YEL/GRNI
tcs6s)
FUEL PUMP(YEL/GRNI
Wire side oftemale torminals
JUMPER WIRE
Wire side of temale terminals
Check that battery voltage is available between the
fuel pump connector terminal No. 1 and body ground
when the ignition switch is turned ON (ll).
CONNECTOR
=
[t
L3l .i)
T
lf battery voltage is available, check the fuel pump
ground. lf the ground is OK, replace the fuel pump.
lf there is no voltage, check the wire harness (see
page 11-238).
11-236
Replacement
@E Do not smoke while working on tuel svs-
tem. Keep open llames away from your work area.
1. Remove the seat cushion (see section 20).
2. Remove the access panel trom the floor.
3. Disconnect the 2P connector from the fuel pump.
4. Remove the fuel pump mounting nuts.
5. Remove the fuel pump from the fuel tank.
6. Install pans in the reverse order of removal.
ACCESS PANEL
i