PC box HONDA CIVIC 1998 6.G Workshop Manual

Unit of length: mm lin)
STANDARD {NEW) SERVICE LIMITMEASUREMENT
Differential
Dtri"*"t"|p'.b"gear
S"t rrg-t" b""il"s
Pinion shaft contact area LD.
Carrier-to pinion clearanceDrive shaft contact area l.D.Carrier to driveshaft clearance
BacklashLD.Pinion gear to-pinion shafl clearance
)uter race clearance
18.010 18.028'0.7091 - 0.7098)
0.023 0.057 (0.0009 - 0.0022) 0.1 (0 004)
26.025 - 26.045 (.0246 1 0254\0.045 0.086 (0.0018 - 0.0034) 0.12(0.005)
0 05 - 0.15 i0 002 0.006)18 042 18.066 {0.7103 0.7" l3)
0.055 - 0.095 (0.0022 - 0.0037) 0.15 {0.006)
0 0.15 (0 - 0.006) Adjlrst
MEASUBEMENT Wire DiaO.D. Free Length I No. of Coils
SpringsPH regulator valve spring 1 2 (0 047)
PH control valve spring 1 7 {0.067)PL regulator valve spring 0 9 (0.035)
PH'PL control valve spring 1 0 (0 039)
crutlh reduc'ns vdrve spnns ] :19 9]:lLLbrication valve spring I b (u ubJr
Shitt valve spring 1 4 (0.055)
Shift control valve spring 1 0 (0.039)
Stan clutch control valve spring 0.4 (0 016)
Pitot regulator valve spring 0.6 (0 024)
Start clutch valve accumulator spring 1 2 \0 O47)
Reverse control valve spring 1 2 (0.047)
Shift inhibitor valve spring 1 3 (0 051)
9.0 {0.354)13.4 (0.528)
1.2lO.2A3\10.0 (0.394)
16.8 (0.661)
13.4 (0.528)
8.2 (0.323)
1 .4 t0.29114.1 (0.161)
5.7 t0.224)8.3 {0.327)9.4 (0.370)
13.2 (0.520)
26.7 (1.051)
39.4 (1.551)
14.6 (0.575)
31.4 (1.236)
44.4 \1.14al51.6 (2.031)
34.1 (1.343)
19.3 (0.760)
12.1 (0.476)
9.5 (0.374)
29.8 (1.173)
31.4 (1.236)
48.3 (1.902)
r0.08.11.28.68.0
13.01.56.85.012.311.010.6
Section 14
SteeringSection 17
M/S: [,4anual steering, P/Sl Power steering*: When using a ne; bett, adjust dellection or tension to new values. Run the engine for 5 minutes then turn it off-
Readjust the deflection or tension to used belt values.
cw
MEASUREMENTSTANDARD {NEWI
Steering wheelPlay at steering wheel circumferenceStarting load at steering wheelcircumferenceN (ksf, lbf)Manual steeringPower steering Engine running
0 - 10 (0 0.4)
15 (1.5,3.3)
29 (3.0,6.6)
GearboxAngle of rack guide screw loosened M/S
from locked position P/S
Preload at pinion gear shaft N m (kglcm, lbfin) M/S
20!5"20'Max0.5 - 1.7 (5 - 17,4.3 - 14.8i
0.6 1.2 (6 - 12, 5.20 - 10.42)
Pump pressure with valve closed(oil temp./speed: 40'C (105"F) min./idleDo not run for more than 5 seconds).kPa (kgtcm?, psi)
6,400 - 7,400 {65 - 75, 920 - 1,070)
Power steeringfluidRecommended power steering fluid
Fluid capacity | {US qt, lmp q0Reservoir
HONDA Power Steering Fluid
0.85 (0.90,0.75) at disassembly0.4 {0.42.0.35}
7.5 11.0 {0.30 - 0.43)with used belt
5.0 7.0 (0.20 0.28) with new belt10.5 - 14.0 10.41 - 0.55) with used belt7.5 10.010.30 0.39) with new belt
390 540 {40 55,88 '120) wrth used bek
340 - 490 (35 - 50, 77 - 110) with used belt
740 880 (75 - 90, 170 - 200) with new belt
640 780 (65 - 80, 143-176)with newbelt
Power steeringbelt*
Deflection with 98 N (10 kgf,22 lbf)
between pulleys '99 modell 81642 Engine Type only
'96 '99 models: Other Engine TYPes
ron.ionffiN (kgf, lbf) '99 model: 81642 Engine Tvpe only'96 -'99 models: Other Engine TYPes'99 modelr 81642 Engine TYPe onlY'96 '99 models: Other Engine TYPes
3-17

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'

ILubrication Points
For the details of lubrication points and types of lubricants to be applied, refer to the lllustrated Index and various workprocedures (such as Assembly/Reassembly, Replacement, Overhaul. Installation, etc.) contained in each section.
No.LUBRICATION POINTS
Engine
LUBRICANT
"Energy Conserving" grade oil,The oil container may also display the Apl Certification markshown below. Make sure it says ,,For Gasoline Engines.,,SAE Viscosity: See chart below,
I
TransmissionManualGenuine Honda MTF*1
Genuine Honda Premium FormulaAutomatic Transmission Fluid (ATF)*,
Genuine Honda CVT Fluid*3
Genuine Honda DOT3 Brake Fluid*a
Automatic
CVT
3Brake Line
ClL,tci t""e4
I
Genuine Honda DOT3 Brake Fluid*aPower steering gearboxSteering grease P/N 08733 - BO70EShift lever pivots (manual transmission)Grease with molybdenum disulfide7-:ti
9
10'l'l
l3
14
't7
18
19
20
2122
Release fork (manual trancmi<si^nl
Steering bootsTailgate hinges and latches (2-door HatchbacklSteering ball joints
Shift lever (automatic transmission)Pedal linkageBrake master cylinder pushrod
Super High Temp Urea crease (p/N 08798 - 9OO2)
i Multi-purpose grease
I
I
Honda White Lithium Grease
Multi-purpose grease
Silicone grease
@
Trunk hinges and latch (4-door Sedan and 2-doorCoupe)Door hinges upper and lowerDoor opening detentsHood hinge and hood latch-FUet T ter ttd
Clutch master cylinder pushrodThrottle cable end and throttle linkageRear brake shoe linkagesSteering wheel (back side)
23
E-
Caliper piston seal, dust seal,caliper pin. pistonThrottle cable end (dashboard lower panel)
Power steering system (for cars with p/S)
Air conditioning compressorComDressor oil:SANDEN: SPlo P/N 38897 - p13 -A01AH or 38899 - p13_ A01{For Refrigerant: HFC-134a (R-134a))
CERTIFICATION SEAL
ffi
NorE: The items m arked * 1, *2, +3, *4 and +5 on above chan are described as folows:*1: Always use Genuine Honda Manual Transmission Fluid (MTF). Using motor oil can cause stiffer shifting because itdoes not contain the proper additives.*2: Always use Genuine Honda premium Formula Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affectshift quality.+3: Use Genuine Honda cVTfluid only usingotherfluid can affect tra nsmission operation and may reduce transmission life.*4: Always use Genuine Honda DoT3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and dec.ease the lifeof the svstem.*5: Always use Genuine Honda Power steering Fluid. using any other type of power steering fluid or automatrc transmissionfluid can cause increased wear and poor steering in cold weather.
4-2
Recommended Engine Oil
Engine oil viscosity forambrent temperature ranges
API SERVICE LABEL

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

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

UGIfI &AMRYo5A) 60a)
A//C CIUICH
-wHT/gtU
c354
-BLVRED
- GRN/REO
f"*
F*n* -*r -l
I lsrc Aros^ |
f*-__l I|iil?-\.p--lII ncB lllI FIJEL PII/|P III
ln*llltl
nll5-,- i II Na15 | |l arlnrl Ton l L lI sPsE*soa oia l ll<\-,o lilI NczsMErER II 05$ |
F-l
*t*'fi
8ru/wHr -.1
YEUGRN a
".-;"{
BtK,$rtf t
'*+
u o€R.HOODFUSE/REIAY BOX
uN0€n-oAsHFTJSE/FEIAY BOX
(cont'd)
11-37
ct31
WH'/ALU

Electrical Connestions ('99 - 00 Models except Dl6Y5 engine with M/Tl
L ChUISE COXTnOI UNII
lo CO|IPi€33OR CUrrcH BEI Y
lo A/c PRESSUiE alYrc|l
To FAoIAIOR FAI REL Y EcT3wllcll
SENSOF
FIJSES:(D IN1ERIOR UGHT O5A) '
@ BACK UP O5A*@HonN (15A).(DSATTERY OOA*@ rcl (104*
@FrvM (r5A*
@No. I3FUELPLMP (lEA)
@ No. 25 MEIER CrsA)@ ib. 15 ALTERNATOR SP SEI{SOR OJA)
O ib. 3l STARTER SIGML (75A)': h lhc ud.rhood lu..//rcbY box(cont'd)
11-39
-:
T
)
I
FUEI II{JECIOBS

A/CO-UfAl
ELD''
;:l
T BLK
YEVGRI{
UNDER-HOODFUSE/RELAY BOX
UNDER-DASHFUg€/FELAY AOX
(cont'd)
BLtCWlfi -
*tT
sLrc /trt 1BLvwHr 1c501r.. -{
11-49

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

I
Engine Control Module/Powertrain Control Module (ECM/PCM)
t'96 - 98 Models,'99 - 00 Dl6Y5 engine with M/Tl
L
NOTE: lf th is svmptom is intermittent, check for a loose fuse No. 25 {METER 7.5 A) in the
underdash {use/relay box, a poor connection at ECM/PCM terminal A18, or an intermit
tent ooen in the GRN/ORN wire between the ECM/PCM (A18) and the gauge assemblv.
ECM/PCM CONNECTOR A I32PIPGl {BLKI
Wire side ot female terminals
ECM/PCM CONNECTOR A (32P}
Wire side of female terminals
(cont'd)
11-107
The Malfunc{ion Indicator Lamp
{MlLl never comes on (even lor
two secondsl atter ignition is
turned on.
Turn the ignition switch ON (ll).
- Repair short or open in thewile botwoen No. 25 {M€TERI
17,5 Altus€ and gau99 assem'
bty.- Replaco No.25 IMETERI (7,5
A)tuse.
ls the low oil pressure light on?
Try to start the engine.
Does the engine stan?
Check lor an open in the wiles
{PG linosl:1. Turn the ignition switch ON (ll).
2. ldeasure vo ltage betweenbody ground and ECM/PCMconnector terminals A10 andA23 individually.
Check tor an open in the wire ot
bulb (MlL line):1. Turn the ignition switch OFF.
2. Connect the ECM/PCM con-nector terminal A'18 to bodyground with a jumper wire.3. Turn the ignition switch ON (ll).
Repair open in the wire(s)
between ECM/PCM and G101(localod at the thetmostat hous_ingl that had more than 1.0 V.
ls thore less than 1.0 V?
Substituto . known-good ECM/PCM and recheck. It symptom/indication go6s away, roPlace
the origin.l ECM/PCM.
- Repair open in th€ wiresbetwoen ECM/PCM lAl8l andgaug6 a$embly.- Replace the MIL bulb,
ls the MIL on?
Substitute a known-good ECM/
PCM and .echeck. lf symptom/indication goes away, replacothe origin.l ECM/PCM.
268l011
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2527xt30
MrL I luanpen wrnrIGRN/ORN) I
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