cv joint HONDA CIVIC 1999 6.G Workshop Manual

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

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)

VTEC Control System
Troubleshooting Flowchart (cont,d)
VTEC PRESSURE SWITCH 2PCONNECTOR
Wire side of temaleterminals
OIL PRESSURE GAUGE(Comm.rcially avail.bte)
GAUGE JOINT ADAPTERSNAP.ON MT26.1710 x 1.0 ftm. Use new washer wheninstalling the sealing bott.
NOTE: Keep measuring time as shorr aspossible because engine is running witn noload lless than one minute).
6-52
(
VTEC SOLENOID VALVE lPCONNECTOF
Ir------r I
lLl.ll-r
II
It
Terminal side ofmale terminal
I
(From page 6-5l l
(To page 6-53)
Test tha VTEC P.es3uro SwitchWi.e:Measure voltage across the VTECpressure switch 2P connector.
Ropair opon in the wiro batwoenVIEC pr...urc switch and G lot .lf the wiro is OK, 3ubltitutr aknown-good ECM and rochack.
ls there battery voltage?
Test the VTEC Solenoid V.tve:1. Turn the ignition switch OFF.2. Disconnect the VTEC solenoidvalve 1P connector.3. Check for continuity betweenthe VTEC solenoid valve 1Pconnector terminal No, I andbody ground.
ls there 14 - 30 O?
Te3t the VTEC Sotonoid Vatve:'1. Remove the VTEC pressureswitch and install the specialtool as shown. then reinstallthe VTEC pressure switch.2. Reconnect the VTEC solenoidvalve 1P connector and VTECpressure switch 2P connector,3. Connect the tachometer (seesection 1l).4. Start the engine.5. Warm up engine to normaloperatrng temperature (cool-ing fan comes on).6. Check oil pressure at enginespeed of 1,000,3,000 and5,000 rpm.
ls pressure below 49 kPa(0.5 kgflcm,,7 psi)?Inipoct thg VTEC aolenoid valvel3ee P8go 6-54).
I

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

Dl6YT engine ('97 coupe: KL model,'97 sedan: KL ILX) model,'98 model"gg model"oo model):
To EVAPORATIVE EMISSION{EVAP} THREE WAY VALVE
l'97 coupe: KL model,'97 sedan: KL (LX) model,'98 modellTo EVAPORATIVE EMISSION
{EVAP) CONTROL CANISTER
FILTER ('99 - 0O models)
EVAPORATIVE EMISSION {EVAP)CONTROL CANISTERVENT SHUT VALVE
EVAPORATIVE EMISSION (EVAP)
CONTROL CANISTERVENT SHUT VALVE
To EVAPORATIVE EMISSIONIEVAPITWO WAY VALVE
PURGE JOINTEVAPORATIVEEMISSION {EVAP}PURGE CONTROLCANISTERFUEL PRESSUREREGULATOR_.\,,..,_..-.
{'97 coupe: KL model,'97 sedan: KL (LX) model.'98 model)
MANIFOLD ABSOLUTEPRESSURE {MAP) SENSOR
To CRUISECONTROLDIAPHRAGM
lwith cruise control)
EVAPORATIVEEMISSION (EVAP}gtt
FRONT OF VEHICLE
PURGE CONTROL SOLENOID
VALVE
(cont'd)
11-17

System Description
Vacuum Connections (cont'd)
D16Y5 engine ('98 modet):
-: Vacuum hose No,*: CW only
(9 POSITIVE CRANKCASE VENTILATION {PCV} VALVE?!J EXHAUST GAS BECIRCULATION (EGR}CONTROLSOLENOIO VALVE'1 ExHAUST GAs RECIRCULATIoN IEGRI VALVE22 EXHAUST GAS RECIRCULATION {EGR} VALVE LIFISENSOR€J EvApoRATtvE EMtsstoN {EvAp} puRGE coNTRoLSOLENOID VALVEq4 PURGE JOINT@ EVAPoRATIVE EMIssIoN {EVAP) coNTRoL CANISTER@ EVAPORATIVE EMISSION IEVAP} BYPASS SOLENOIDVALVE?? EVAPORATIVE EMISSION {EVAP) THREE WAY VALVEITII EVAPORATIVE EMISSION IEVAP} CONTROL CANISTERVENT SHUT VALVEO FUEL TANK PRESSURE sENsoRQlI EVAPORATIVE EMISSION {EVAP}TWO WAY VALVE8' THREE WAY CATALYTIC CONVERTER {TWCI
il) PRIMAFY HEATED OXYGEN SENSOR IPRIMARY HO2S.SENSOR 1)O SECoNDARY HEATEo oxYGEN sENsoR {sEcoNDARYHO2S. SENSOB 2)iq] MANIFOLD ABSOLUTE PRESSURE (MAPI SENSORO ENGINE COOLANT TEMPERATURE IECT) SENSOR5 INTAKE AIR TEMPERATURE {IATI SENSOR! KNOCK SENSOR tKSlO CRANKSHAFT SPEED FLUCTUATIoN {cKF) sENsoFO IDLE AIR coNTRoL {IAc) vALvE99 THROTTLE BODY ITBI@ FUEL INJECToRO FUEL PULSATION DAMPER@ FUEL F -TER@ FUEL PRESSURE REGULAToR[4 FUEL PUMP IFPI(9 FUEL TANK(D FUEL TANK EVAPoRATIVE EMIssIoN IEVAPI VALVEO' AIR CLEANER(D RESoNAToR
11-20

D16Y5 engine ('99 - 00 modelsl:
O) PRIMARY HEATED OXYGEN SENSOR (PBIMARY HO2S,
SENSOR 1)
O SECONDARY HEATEO OXYGEN SENSOR {SECONDARY
HO2S. SENSOR 2)
6] MANIFOLD ABSOLUTE PRESSURE IMAPI SENSOR
rO CruCIruC COOUruT TEMPERATURE IECTI SENSOR
o rrurlxe ln ETUpERATURE 0AT) SENSOR
.d KNOCK SENSOR (KS}
O CN,NruXSXITT SP:ED FLUCTUATION (CKFI SENSOR
@ rou an corurnoL 0Ac) valvE
O THROTTLE BODY (TB)
@ FUEL INJECTOR
E) FUEL PULSATION OAMPER
t? FUEL FILTER
G) FUEL PRESSURE REGULATOR
OI FUEL PUMP (FP)
Gi FUEL TANK
G) AIR CLEANERfi? RESONATOR
Gl posmvr cnglrcAsE VENTILATION (PCV) VALVE
@ EXHAUST GAS RECIRCULATION IEGR} CONTROL
SOLENOID VALVE6 EXHAUST GAS RECTRCULATION (EGR) VAI-VE
rf exxlust cls nectRcuLATloN IEGR) vALvE LIFT
SENSOR@ EVAPORATIVE EMISSION (EVAPI PURGE CONTNOL
SOLENOID VALVE
O} PURGE JOINTio :vaponanve eutssloN (EVAP) coNTRoL cANlsrER
d rvlponlrtve EmtsstoN tEvAPl BYPASS soL-eNolD
VALVE
6 EVAPORATIVE EMISSION {EVAP) CONIROL CANISTER
FILTER
@ EVAPORATIVE EMISSION (EVAPI CONTROL CANISTER
VENT SHUT VALVEOA FUEL TANK PRESSURE SENSOR
6 :vlponlnvg er,/tlssloN tEvAPl TWO WAY VALVE
6 oNgoano nerueltNc vAPoR REcovERY {onvRl VENT
SHUT VALVE
€!) ONBOARD REFUELING VAPOR RECOVERY (ORVRI VAPOR
RECIBCULATION VALVE
@ THREE WAY CATALYTIC CONVERTER (TWCI
(cont'd)
11-21
L

Dl6Y7 engins ('99 - 00 modelsl:
PRIMARY HEATED OXYGEN SENSOR {PRIMARY HO2S,
SENSOR 1)iiconoanv neareo oxYGEN sENsoR ISECoNDARY
HO2S, 9ENSOR 2)MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
ENGINE COOLANT TEMPERATURE (ECT} SENSOR
INTAKE AIR TEMPERATURE (IATI SENSOR
CRANKSHAFT SPEED FLUCTUATION ICKFI SENSOR
IOLE AIR CONTROL (IAC} VALVE
THROTTLE BODY (TBl
FUEL INJECTORFUEL FILTERFUEL PRESSURE REGULATOR
FUEL PUMP (FP)
FUEL TANKAIR CLEANERRESONATOR
6d POSITIVE CRANKCASE VENTILATION (PCV) VALVE
6 rvapoamve eutssloN tEvAP) PURGE coNTRoL
SOLENOID VALVECO PURGE JOINT6 evlponnnve eutssloN (EvAPl coNTRoL cANlsrER
i evlponnnve eussloN {EVAP} BYPASS solrNolD
VALVE
6) EVAPORATIVE EMISSION (EVAPI CONTROL CANISTEN
FILTER
@ EVAPORATIVE EMISSTON (EVAP) CONTROL CANISTER
VENT SHUI VALVEA FUEL TANK PRESSURE SENSON
d rvlpoamve emtsstoN tEvAPl rwo wAY vALvE
6 orueonno nerueLING vAPoR REcovERY loRvnl vENT
SHUT VALVE
€) ongolno neruellNc VAPOR RECOVERY {ORVR) VAPOR
RECIRCULATION VALVE
€) THREE WAY CATALYTIC CONVERTER (TWC)
a
6t
@!.,
o@ao
@@
(}
@@
(cont'd)
11-27

I
a
System Description
Vacuum Connections (cont'd)
816A2 engine:
@ EvApoRATtvE EMtsstoN tEvAp) puRGE coNTRoLSOLENOID VALVE@ PURGE JoINT€t EvApoRATtvE EMtsstoN (EVApt coNTRoL caNtsTERQA EVAPORATIVE EMISSION (EVAP) BYPASS SOLENOIDVALVE
@ EVApoRATtvE EMtsstoN lEvApl coNTRoL caNtsrERFILTER@ EvApoRATtvE EMtsstoN {EvApt coNrRoL cANtsrERVENT SHUT VALVE@ FUEL TANK PRESSURE sENsoRGI EVAPORATIVE EMISSION (EVAP} TWO WAY VALVE@ ONBOARD REFUETING VAPOR RECOVERY {ORVR} VENTSHUT VALVE@ oNBoAnD REFUELING vApoR REcovERy (oRvRl vApoR. RECIRCULATION VALVE(c} THREE WAY CATALYTIC CONVERTER {TWCI
(' PRIMARY HEATED OXYGEN SENSOR IPRIMARY HO2S.SENSOR 1l.?) SECONDARY HEATED OXYGEN SENSOR {SECONDARYHO2S, SENSOR 2)13] MANIFOLD ABSoLUTE PRESSURE (MAP) sENsoBi' ENGINE COOLANT TEMPERATURE IECT) SENSORO INTAKE AIR TEMPERATURE ITATI SENSORi6l KNOCK SENSOR {KS}O oRANKSHAFT SPEED FLUCTUATIoN {cKF} sENsoR@ IDLE AIR coNTRoL (IAc} VALVE€) THRoTTLE BoDy trB|(D FUEL INJECToRO FUEL PULSATIoN DAMPER[D FUEL FILTER@ FUEL PRESSURE REGULAToR!I FUEL PUMP IFP)f,' FUEL TANK(iD ArR CLEANERt' RESONAToR'.1]i POSITIVE cRANKcAsE VENTILATIoN {Pcv} VALVE
11-28

I
FuelFilter
Replacement
r@. Do not smoke whilc working on fuel system. Keep
open flame away from your work arsa.
. While replacing the tuel filter, be catelul to koep a
sale distance betwoen battery torminals and any
tools.
The fuel filter should be replaced whenever the fuel
pressure drops below the specified value [260 - 310 kPa
12.7 - 3.2 ksl/cm',38 - 46 psi), |270 - 320 kPa (2.8 - 3 3
kgf/cm,, 40 - 47 psi))* with the fuel pressure regulator
vacuum hose disconnected and pinchedl after making
sure that the fuel pump and the fuel pressure regulator
are OK. *: 81642 engine
1. Place a shop towel under and around the fuelfilter.
2. Relieve fuel pressure (see pages 11-230,231]-
Remove the 12 mm banjo bolt and the fuel feed
pipe from the fuel filter, while supporting it with the
another wrench, as shown.
Remove the fuel filter ciamp and fuel filter'
lnstall the new fuel filter in the reverse order
removal, and note these items:
a When assembling, use new washers as shown
. Clean the flared joint of high pressure hoses
thoroughly before reconnecting them.
I
,96 MODELS:
(3.4 kgl.m,25 rbf.ftl
,97 AND LATER MODELS:
12 mmBANJOBOLT33 N.m
12 mmBANJOBOLT33 N.mt3.4 kgf m,25 lbf.fr)
\i(o-r
)
11-235