HONDA CIVIC 1999 6.G Workshop Manual

Exhaust Pipe and Muffler
Replacement {cont'dl
NOTE: Use new gaskets and self-locking nuts when reassembling.
D16Y8 engine:
MUFFLER
HEAT SHIELD
6x1.0mm9.8 N.m (1.0 kgl m, 7.2 lbf.ft)
EXHAUST PIPE
SECONDARY HO2544 N.m {4.5 kgl.m, 33 lbtftlReplacement, page 9-10
GASKETSReplace.
EXHAUST PIPE A
SELF-LOCKING NUT10 x 1.25 mm54 N.m {5.5 kgl.m, 40 lbtft}Replace.16 N.m {1.6 kgl.m, 12lbf.ft}Replace-
d'*'ou"'"'""'
6x1.0mm9.8 N.m (1.0 ksf m,7.2lbf ft)
8 x 1.25 mm22 N.rn 12.2 kgl.m,16 tbt.ft)Replace.Tighten the bolts insteps, alternatrngside-to-side.
SELF.LOCKING NUT10 x 1.25 mm33 N.m {3.4 kgf.m,25 tbtftlReplace.
TWCinspection, page 9-12
I x 1-25 mm22 N m (2.2 kgf.m. 16 lbfft)
Tighten the bolts in steps,alternating side'to sade.e)GASKETHeplace.
9-10

816A2 engino:
MUFFLER_.,. EXHAUST PIPE
-/- tlP
g
\6r1.omm
9.8 N m 11.0 kgf'm, 7.2 lbl'ttl
GASKETReplace.
8 x 1.25 mm2. N'm 12.2 kgl-m,t6 tbtf0Replace.Tighten the bolts insteps, alternatrngside-to-side.6x1,0mm9,8 N.m 11.07.2lbl4rl
SELF-LOCKING NUTl0 x 1.25 mm
3:t N.m {3.4 kgf m,24lbf'ftl
ReDlace.PRIMARY IIEATEDOXYGEN SENSOR{PRIMARY HO2S)ll N.m (4.5 kgl.m,33 tbt f0Replacement,
SECONDARY HEATEDOXYGEN SENSOR{SECONDARY HO2SIlrt N.m 14.5 kgf.m,33 rbl.ft)Replacement, page 9-13
GASKETR€place.
twcInspection, page 9-12GASKEISReplace.
SELF.L(rcKNG NUT10 x 1.25 mm5,r N.m 15.5 kgf.m, ,|{} lbf.ft)ReDlace.
8x1.25mm22 N.m {2.2 kgt m, 16 lbf.ftlReplsce.Tight6n the bolts in st6ps,alternating side-to-side.8 x 1.25 mm16 N.m 11.6 kgt.m,12 rbf.ft)F€pl8ce.
I
Replaca.
9-11

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)

Bt6A2, Dl6Y8 engines:
a. Disconnect the primary HO2S connector then
remove the primary HO2S.
816A2 engine
D16Y8 engine
PRIMARYH02S CONNECTOR
PRIMARY HO2S44 N.m {4.5 kgt'm.33 lbf'ft)
L
2. Install the primary HO2S in reverse order of removal'
Secondsry H02S:
1. Remove the secondary HO2S
Dl6Y5, Dt6Y7 engines:
a. Disconnect the secondary HO2S connector.
then remove the secondary HO2S'
02 SENSOR
816A2, Dt6Y8 ongin6s:
a. Remove the grommet, and pull out the secondary
HO2S connector, then disconnect the secondary
HO25 connector'
SECONOARY H()2S
CONNECTOR
{cont'd)
9-13

HO2S
Replacement (cont'd)
b, Remove the secondarv HO2S.
02 SENSOR WRENCH
SECONOARY HO2S4,r N.m (4.5 kgf.m, 33 tbf.ft)
Install the secondary HO2S in reverse order ofremovat.
9-14
wa

Cooling
fllustrated Index ."..."... ""' 10-2
Radiator
Replacement .'....'...."..."
Engine Coolant Refilling and
Bleeding
Cap Testing
Testing
Thermostat
Replacement .............'....
Testing
10-6
10-7
10-9
10-9
10-10
10-10
Engine Goolant TemPerature
(ECT) Switch
Testing """ 10-11
Water PumP
fffustrated Index ......'... " 10-12
Inspection ' 10'14
Replacement ..'..'...."...'.'....'..'.....'.""" 10-14
!

lllustrated Index
@@ system is under high pressure when theengine is hot. To avoid dangsr of rsleasing scaldingengine coolant, removo the cap only when the engine iscoot.
Total Cooling System Capacity flncluding heater andfoservoir (0.4 f (0.42 US qt, 0.35 tmp qt)ll:
*2: 81642 engine*3: D16Y7 engine*4: D16Y8 engine
CAUTION: lf any engine coolant spills on painted por-tions of the body, rinse it off immediately.
NOTE:
. Check all cooling system hoses for damage, leaks ordeterioration and replace if necessary.. Check all hose clamps and retighten if necessary.. Use new O-rings when reassembling.
RADIATOR CAPPressure test, page '10 86x1.0mm9.8 N.m {1.0 kgtm,7.2 tbt.ltl
UPPERRADIATORHOSE
UPPER BRACKETAND CUSHION
COOLANT
RAOIATOREngine coolant refilling and bleeding,page 10 7Leak test, page 10-9Inspect soldered joints andseams for leaks,Blow out dirt Irom betweencore fins with compressed air.lf insects, etc,, are cloggingradiator, wash them off withrow pressure water.
RESERVOIR
5x0.8mmA: ,1.4 N.m {0.45 kgf.m, 3.3 tbtftlg: 5.4 N.m (0.55 kgtm.4.0 tbf.ft)
6x1.0mm7.2 N.m (0.73 kgt.m,5.3 tbtftl
LOWERCUSHION
RADIATOR FANBADIATORFAN
DRAINPLUG
O-RINGReplace.
LOWEBRADIATORHOSE
FAN MOTOR SHROUD
Ar TOYO RADIATOR manufactured radiatorB: NIPPONDENSO manufacfared raoraror
10-2
Refer to section 14when installing.
Mt-|-4.2 f (4.4 US qt,3.7 tmp qt)*j
5.0 / (5.3 U$ q1, 4.4 16p q11*z
4.1 f (4.3 US qt, 3.6 lmp q0*3
4.31 (4.5 US qt, 3.8 tmp qt)*a
CVT4.3 f (4.5 US qt,3.8 Imp qt)
*1i D16Y5, D16Y7, D16Y8 engines
iil

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

lllustrated Index
(cont'd)
Engine Hose Connections:
D16Y5, D16Y8 engines:
Replace.
IAC VALVE(M/TI
IAC VALVE{A/T)
WATER BYPASSHOSE
THERMOSTATHOUSING
O.RINGReplace.
\
\
\
\h
CONNECTINGPIPE
HEATERVALVE
HEATERHOS€S
10-4

CONNECTINGPIPE
Engine Hose Conneqtions:
81642 engine:
O-RINGReplace.
b
WATER BYPASSHOSE
HEATERVALVE
HEATERHOSES
THERMOSTATHOUSING
ENGINE OIL COOLER
10-5