Susp 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

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

Slave Gylinder
Removal/lnstallation
CAUTION:
. Do not spill brake tluid on the vehicle; it may damage
the paint; if brake fluid does contact th€ paint, wash
it off immodiatoly with water,
. Plug the end ot the clutch line with a shop towel to
prevsnt brake fluid from coming oul.
-61'srp", High Temp Urea crease (p/N
08798 - 90021.
: Brake Assembly Lube or equivalent rubber
grease.
1. Disconnect the clutch line from the slave cvlinder.
2. Remove the slave cylinder from the clutch housing.
12-6
3. Install the slave cylinder in the reverse order of
removal.
NOTE: Make sure the boot is installed on the slave
cvlinder.. CLUTCH LINE15 N.m (1 .5 kgf.m, 1 1 lbf.It)
SLAVE CYLINDER
-G4(P/N 08798- 90021
8 x 1.25 mm22 N.m 12.2 kgl.n,16 lbl.lt)
:^..:i!!!!! :l
(Brak€ AssemblyLubol
Bleed the clutch hydraulic system.
a Attach a hose to the bleeder screw, and suspend
the hose in a container of brake fluid.
. Make sure there is an adequate supply of fluid at
the clutch master cylinder, then slowly pump the
clutch pedal until no more bubbles appear at the
bleeder hose.
. Refill the clutch master cylinder with fluid when
done.
. Always use Genuine Honda DOT 3 Brake Fluid.
Using a non-Honda brake fluid can cause corro-
sion and decrease the life of the system.
. Confirm clutch operation, and check for leaking
flu id.

Troubleshootin g Procedures
Chccking the Diagnostic Trouble Code IDTC)with an OBD ll Scan tool or Honda PGM Tester
when the PCM senses an abnormality in the input or output systems, the pl indicator light in the gauge assembly willblink. When the 16P Data Link Connector (DLC) (located under the dash on the driver,s side) is connected to the OBD llScan Tool or Honda PGM Tester as shown, the scan tool or tester will indicate the Diagnostic Trouble Code (DTC) whenthe ignition switch is turned ON{ll).
lf the El indicator light or the MIL has been reported on, or lf a driveability problem is suspected, follow this procedure:
1. Connect the OBD ll Scan Tool (conforming to SAE J19781 or Honda PGM Tester to rhe 16p DLC. (See the OBD ll ScanTool or Honda PGM Tester user's manual for specific instructions. lf you are using the Honda PGM Tester, make sure itis set to the SAE DTC type.)
2. Turn the ignition switch ON (lll, and observe the DTC on the screen,3, Record all fuel and emission DTCS, A/T DTCS, and freeze data.4 lf there is a fuel and emissions DTC, first checkthe fuel and emissions system as indicated bythe DTC (except for DTCP0700). DTC P0700 means there is one or more A,/T DTC, and no problems were detected in the fuel and emissions cir-cuit of the PCM.
5. Write down the radio station oresets.
6. Reset the memory with the PGM Tester or by removing the BACK UP fuse in the passenger's under-dash fuse/relay boxfor more than 10 seconds.
7. Drive the vehicle for several minutes at speeds over 30 mph (50 km/hr), and then recheck for DTCS. lf the A"/T DTCreturns, go to the Symptom-to Component Chart on pages 14-52 and 14-53 for'96 - 98 models, and pages 14-54 and14-55 for the'99 - 00 models, lf the DTC does not return, there was an intermittent problem within the circuit. Makesure all pins and terminals in the circuit are tight, and then go to step g.
8. Reset the radio preset stations, and set the clock.
OBD ll SCAN TOOL orHONDA PGM TESTER
DAYA LINK CONNECTOR {16P}
14-44

Troubleshooting
General Troubleshooting
Check the following before you begin:. Has the suspension been modified in a way that would affect steering?. Are tire sizes, tire variety and air pressure correct?. lsthe steering wheel original equipment or equivalent?. lsthe powersteering pump belt properlyadiusted?
. ls steeringfluid reservoirfilledto proper level?. ls the engine idle speed correct and steady?
Hard Steering (Check the powor assist. se€ page 17-3o. lfthe torce is over 29 N (3.0 kgf, 6.6lbo, Procede with this troubleshootinq.)
Abnormallluid pressure
{fluid pressureis too high)
Faulty valve body unit
Relief pres-sure too low
Abnormal
Faulty llow control valve(Replace the pump es anassembly)
Ch€ck the feed snd return circuit lin€s ano nosebetw6€n the gearbox and pump for clogging andd€lormation.
Normal line and hose
Check the pump fluid pressure(soe page 17-34).l/easure steady-state tluid pres-s!re while idling with the bothvalves tully open.It should be 1.500 kPa (15 kgf/cmr,213 psi) or below.
Normal
Check th€ flow control vslve (see page 17-42).. Chock the valvo lor smooth movement in the hous-ing.. Check the reliefvalve for leaks.
Check the pump fluid pressure
{see page 17-34).Measure pump relief pressurewhile idling with the pressure con-trol valve Iully closed.It should be 6,400 - 7,400 kPa (65 -
75 kgflcm,,920 - 1,070 psi)
Normal relisf pressure
17-22
Go to page 17-23Faulty pump assembly