d15 HONDA CIVIC 1997 6.G Workshop Manual

Cylinder Head
Removal (cont'd)
9. Relieve fuel pressure (see section 11),
E@E Do not smoke while working on tho fuelsystem. Ke6p opgn flame or gpark away from lhework area, Drain fuel only into an app.oved containgr.
10. Remove the evaporative emission (EVAP) controlcanister hose, fuel feed hose and breather hose.
D16Y7 engine:
BANJO BOLT33 N.m {3.4 kgt m,25 tbf.ftt
BREATHER HOSE
D15Y5, Dl6YB engines:
BANJO AOLT33 N.m (3.4 kgf.rn,25 tbf.ftt
EVAP CONTROLCANISTER HOSE
6-28
(
1 1. Remove the brake booster vacuum hose. fuel returnhose and vacuum hose (see page S_4).
12. Remove the water bypass hose and positive crank_case ventilation (pCV) hose.
016V7 engine:
PCV HOSE
D16Y5, D16Y8 engines:
\a
I
WATER EYPASS
PCV HOSE

Crankshaft
Inspection
. Clean the crankshaft oil passages with pipe cleaners
or a suitable brush.
. Check the keyway and threads.
Alignment
. Measure runout on all main journals to make
sure the crank is not bent.
. The difference between measurements on eachjournal must not be more than the service limit.
Crankshaft Total Indicated Runout:
Bl6A2 engine:
Standard (Newl: 0.020 mm {0.0008 in} max.
Service Limit: 0.030 mm {0.0012 inl
D16Y5, D15Y7, D15Y8 engines:
Standsrd {New): 0.03 mm (0.001 in} max.
Service Limit; 0.0i1 mm 10.002 in)
Support with lathetype tool or V blocks.
7-14
Out-of-Round and Tapet
. Measure out-of-round at the middle of each rod
and main journal in two places.
a The difference between measurements on eachjournal must not be more than the service limit.
Joulnal Out-of-Round:
81642 engine:
Standard (New): 0.0004 mm {0.0002 in) max.
Service Limit: 0.006 mm {0.0002 in)
Dr6Y5, Dl6Y7, D16Y8 engines:
Standard (Newl: 0.0025 mm (0.0001 inl max.
Service Limh: 0.005 mm (0.0002 inl
round at middle.
. Measure taper at the edges of each rod and mainjournal.
. The difference between measurements on eachjournal must not be more than the service limit.
JournalTaDer:
B16A2 ongine:
Standard lNewl: 0.005 mm (0.0002 inl max.
Service Limit: 0.010 mm (0.00i1 inl
D16Y5, D16Y7, Dl6YB engines:
Standard (New): 0.0025 mm {0.0001 in) max.
Service Limit: 0.005 mm (0.0002 in)
\

D15Y8 engine:
8 x 1.25 mm2,1 N.m (2.a kgf'm,
17 tbf.ftl
GASKETReplace.
8 x 1.25 mm31 N.m 13.2 kgf'm,23 lbf.ftlReplace.
PRIMARY HO2S44 N.m (4.5 kgf.m, 33 lbtft)Replacement, page 9-13
EXHAUST MANIFOLDBRACKET10 x 1.25 rnm
(cont'd)
9-7
/r4 N.m {4.5 kgf.m, 33 lbf.ft)
v

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)

lv
Engine Hose Connections:
D15Y7 engine:
CONNECTINGPIPE
HEATERHOSES
{cont'd)
IAC VALVE
WATEF BYPASS
THERMOSTATHOUSING
VALVE
10-3

Electrical Gonnections ('96 - 98 Models,'99 - 00 Dl6Y5 engine with M/T)
(
I .a: arr .nd Drar, .nsrF=.5 Er..d afr.nd Dla 6eh.
r?, cvt (D,t6ys ddn.tDd Oiew d!lh..8:'S6 Dr6Y3 dsin. td|p.), '97 Dl6Y8 {tin.{cou9.; .ll Dod.b..r!.t: lG nod.ll, sa Or6Y5 mdn',
'10: MfI lD1aV5 .ncir.lrrt. Exc.or M/I (D15Y5.ntin.lr12: O16Y5. Ol6Ya.ncln.
rt5. i9? Ot0\., ssid l6up.; (L mod.l,..d..:Kl ttxl mod.ll, 9a Dl6rr.ndn.
To A/C PlEStUnC 6wrctt
No, 13 l{ Et tU[9 ll5 Al
No. ri Al'ltElATOll gt l€Ntol lt,5 Alt{o. 3l EtAatEn gc at lt.5 al
clEc{
.2. Arr pt6rt, DraYt .nlh.t
.a: AfI .nd Drart .ndn
o [rnEnoR UGtlT lt.s Ar
o HoRx tr5 AF
o rcr l|o Ar
(cont'd)
11-29
r: h tL o.d..{ood io/t l.v bor

System Description
Electrical Connections ('96 - 98 Models,'99 - 00 Dl6Y5 engine with M/Tl
(cont'dl
GA|l/OfiN
Cl3i C,ta6cart c5o2t--l c5t2
o",.uonr. l FSIX' {| | FYEI l
g
.lc5t0GRN/aaX: rdYEr. ILrGiN' -8rK/8ru -
BEo - -J
IGRN-_'-
8ru'--1
Orl0 C50il
LT
IYTENLOC|(CO TROT UMI
FronIAD|AtOh FAx
T' - RElAv EqtswIrEH
BLu/REo,- l f B!u/FEo,-----l ro a/c swrrcH
t_.1
,10: M/T {D16Y5..sin.l.11: Erc.pt M/l lOr5Y5.nginel'12: Ol6Y5, DlSYa.ngin.
'15: 97 Dl5Y7.ngin. {coup.: Klmod.l, $d.n:(l lLXlmod.ll, 9A DIOYT.nsin.
GRN/BIXI.
- LT GRflr-
T 8r"K/8ru
f"*
fr
ct3t c&t6
12: A/l (Dr5Y7, Dl6Y8.nglnelr3: CyI lOl5Y5..sinel'.: A/T.nd Dr6Y7.nsin.15: Erc.pt A/T .nd D16Y7.ngin6'5r A/i {Dl6Ya.ngin€l17: CVT (D16Y5 .noin.) rnd O16Ya .ngine'8r'96 015Y3 .ngin. lcoup.), 9t O16Ya sngin.(coop.r.llnod.l.,..d.n:KLmod.l), 98ol6Y5o.gins,'94 Di6YA .ngin., '99 - 0O D15Y5 lM/Tl 6ngin.
".*,".u---f
REo--__-
YEri -Gur{ -------
Brur- - l
L
- Etur
ArGEAR ?O6frO Swlrcs
1 1-36

System Connectors [Fuel Pumpl
'95 - 98 models, '99 - 00 Dl6Y5 engine with M/T:
ffi
c565
E
c792*r,.'5c793|.,.s
*1r USA mod€l'2: A/T {O16Y7, D16Y8 ensine}13: CVT {O16Y5 ensin€l*4: A/T ind D16Y7 .ngane*5: ExceFt A/T end D16Y7 engine'6: A/T lDl6Y8 enginel*7: CvT (Dl6Y5 enginoland 016Yg engine'8: ,96 Dl6YB engine {coupe),'97 Dl6Y8 sngine
{coupe: sll models, s€d.nr KL modell,'98 Dl5Y5.ngine,'98 D16Y7 engine,'99 - OO Dl6Y5 (M/Tl enginer9: D16Y5 onginet10: M/T {D15Y5 ensinelr1t: ExceDt M/T (D16Y5 engine)tl2: D16Y5, Dl6Yg engine*13: Dl6Y8 enginer14: D16Y7 engine*15:'97 Dl6Y7 ensine {coupe: KL model, sodan:
KL (LX) modeu,'98 Dt6Y7 engine
NOTE: . Different wires with the same color have been given a number suffix to distinguish them (for example' YEUBLK1
and YEVBLK' are not the samel.
. O: Related to Fuel and Emissions System'
. - Connector with male terminals (dou ble outline): View f rom term inal side
- Connector with female terminals (single outline): View from wire side
c7931...15
ffi
1 1-51

System Description
System Connectors lEngine Compartmentl {cont,dl
36 - 98 D15Y7 €ngine:
\
'l'
1 1-56
\,

IHeated Oxygen Sensor (HO2S) Heater
i'ss - oo Mb-dels except D16Y5 engine with M/Tl
The scan toot indicates Diagnostic Trouble Code (DTC) P0135: An electrical problem in the Primary Heated
Oxygen Sensor (Primary ttOiS) (Sensor 1) Heater system {Except D15Y5 engine with M/T)'
The
-scan tool indicates Diagnostic Trouble Code (DTC) P0141; A problem in the Secondary Heated Oigen Sensor
(Secondarv HO2S) {Sensor 2) Heater circuit
Fo13sl
Fol11l
lntermiftent failuro, sYstom b OK
at thit limo. Ch6ck lor Poor oon'
nectiont or looso wita! at
C131'* {loc.tod und.t right ido
ol drshl, C432'* (located undel
middlo of dashl, C123 (PrimarY
HOzS, Sensor 1) C125 (Ct82lr'
(socondary HO2S, Sensor 2)t
.nd ECM/PCM.
PRIMAFY HO2S ls.n.or ll rrP CONNECTOR
SECOITIDARY HO2S (Srn.ol21 4P CONNECTOR'
Terminal side of male terminals
PRIMARY HO2S {SENSOR 1} ilP @NI{ECTOR lc123l
sEcoNDARY HO2S ISENSOR 2) aP @NNECTOR (C125)'
3l-, l-tl-t Fo2sHrc. so2sHrc
ver.t l ^-1 .'l {BLK/wHrl
11 '!'l-l
| --=- Iu----{v)'---..-'
Wire side of {emale terminals
SECO'TIDARY Ho2S (SENSOR 2,
4P CONNESTOR {C7&llt'
so2sHTc(BLKnflHTlIBLK/WHT)
(cont'd)
1 1-159
Wire side oI female terminals
r: p0141 {To page 11-160}**: D16Yg engine
- The MIL has been reponed on.- DTC P0135. and/or P0141 are
storod.
Problem vorification:1. Do the ECM/PCM Reset Pro-
cedute.2. Stan the englne.
Chock foi an open or short in the
HO25:1. Turn the ignition switch OFF
2. Disconnect the HO2S (Primary
or Secondary*) lSensor 1 or
Sensor 2) 4P connector'
3. At the H02S side, measure
resistance between the HO2S
4P connector terminals No. 3
and No.4.
ls there 10 - 40 n?
Check for continuity between
body ground and the HO2S 4P
connector terminals No. 3 and
No.4 individuallY.
Check for an opon or short in lho
wire (PO2SHTC, SO2SHTC+ line):'1. Turn the ignition switch ON (ll).
2. Measure voltage between the
H02S 4P connector termlnalsNo.3 and No.4.
{To page 11-160}