gear position HONDA CIVIC 1996 6.G Workshop Manual
[x] Cancel search | Manufacturer: HONDA, Model Year: 1996, Model line: CIVIC, Model: HONDA CIVIC 1996 6.GPages: 2189, PDF Size: 69.39 MB
Page 1086 of 2189
Inspection and Adjustment
Steering Operation
Place the front wheels in the straight ahead position,
and measure the distance the steering wheel can beturned without moving the front wheels.
ROTATIONAL PLAY: 0 - 10 mm l0 - 0.39 inl
lf the play exceeds the service limit. perform rack guide
adjustment (see page 17-33).
lf the play is still excessive after rack guide adjustment.inspect the steering linkage and gearbox as describedon the nel(t pag€.
ROTATIONAL PLAY
17-30
Power Assist Gheck with
Vehicle Parked
1. Check the power steering fluid level (see page 17-33) and pump belt tension (see page 17-32).
2. Start the engine, allow it to idle. and turn the steer-ing wheel from lock-tolock several times to warm
up the fluid.
3. Attach a spring scale to the steering wheel. With theengine idling and the vehicle on a clean, dry floor,pull the scale as shown and read it as soon as thetires begin to turn.
The scale should read no more than 29 N (3.0 kgf.
6.6 lbf). lf it reads more, check the gearbox andpump,
D0
Page 1107 of 2189
t
t5.
16.
14. Assemble a 12 x 1.25 mm flange nut onto a 12 x 175
mm grade 10 flange bolt as shown.
NOTE: Wrap the tlange portion of the bolt with
vinyl tape to protect the cylinder.
12,mm FLANGE
BOLT12 mm FLANGE NUTVINYL TAPG {p/N 90i77 - SLo - 000}
Install the flange bolt into the end of the steering
rack until it bottoms in the hole, then back the
flange bolt out 'll4 turn. Hold the flange bolt, and
tighten the flange nut against the rack by hand.
Install the bearing separator on the gearbox housing
a5 snown.
FLANGE BOLT
BEARING SEPARATOR0 - 1112" I
lCommercially availablo)
STEERING RACK
CYLINDER END SEAL
Set the gearbox in a press so the gear housing point
upward, then press the cylinder end seal and steer-
ing rack out of the gearbox
NOTE: Hold the steering rack to keep it from falling
when pressed clear.
CAUTION:
. Be carsful not damage to inn6l surface ot the
cylinder housing with the flange bolt.
. Do not place your lingers under th€ ste€ring
rack.
t./
17.
12 x 175 mm Ptess
1.,
the spe-
srcle.
securely
Replace. J__--'- ,----)t'| ,-----'" ,-,-'-'| fiN ----'
| .Wl'----
I
t
-'4a
| ^--.'--4
A ooY----- \
Q) * srerhtnc nact
20. lnsert a 24" long,3E" drive extension and
cial tool into the cylinder from the gearbox
NOTE: Make sure that the special tool is
positioned on the backup ring edges'
18, Remove the 12 mm bolt and nut from the steering
rack,
19. Remove the cylinder end seal from the steering
racK.
CYLINDER HOUSING
CAUTION: Be caroful not damago to inner surfaco
of the cylinder housing with the specisl tool'
21. Set the gearbox in a press, then press out the cYlin-
der end seal and backup ring from the gearbox,
GAUTION:
. Keep the tool sttaight to avoid damaging the cylin'
der wall. Check th€ tool angls, and corr€st it if nec-
€ssary, whon rsmoving the cylinder snd seal.
. Uss a pross to removs tho cylinder end seal. Do
not try to removo ths seal by striking the tool h
will br€ak the backup ring. and the cylinder snd
s€al will lemain in tho gearbox.
BACKUP RING
CYLINDER END SEAL
CYLINDER END SEALREMOVER ATTACHMENT07NAD - SR3020A
(cont'd)
17-51
Pross
Page 1112 of 2189
Steering Gearbox
Reassembly (cont'd)
Valve Body Unit Reassembly
1. Apply vinyl tape to the stepped portion of the pin-
ion shaft, and coat the surface of the vinyl taoe with
the power steering fluid.
2. Install the backup ring ('96 -'97 models) or wavewasher ('98 -'00 models) with its tapered side as
shown below.
3. Coat the inside surface of the new valve oil sealwith power steering fluid.
4. Slide the valve oil seal over the pinion shaft, being
careful not to damage the sealing lip.
Vinyl t.po{Stepped ponion}
Tap6red position.
BACKUPGroove side.
sure the spring isseatod in the oil seal.
'98 - '00 mod.b:
CAUTION: InstEll ihe valve oil seal whh its groov.d
3ide tacing opposite tho boaring.
Apply vinyl tape to the splines and stepped portion
of the shaft, and coat the surface of the vinyl tapewith the power steering fluid.
Fit the new O-ring in the groove of the pinion shaft.Then slide the new valve seal ring over the shaft
and the groove in on the pinion shaft.
Remove the vinyl tape from the pinion shaft,
'96 - '97 models:
lip
7.
VALVE SEAL RIiIGReplace.Do not over-expand.
17-56
8. Apply power steering fluid to the surface of the
valve seal ring that was installed on the pinion
shaft.
9. Apply power steering fluid to the inside of the spe-cial tool. Set the larger diameter end of the specialtool over the valve seal ring.
10. Move the special tool up and down several times tomake the valve seal ring fit in the pinion shaft.11, Remove the soecial tool.
12. Turn the special tool over, and set the smaller diam-eter end of the special tool over the valve seal ring.Move the special tool up and down several times tomake the valve seal ring fit snugly in the pinion
shaft.
PISTON SEAL BINGSIZING TOOL07NAG - SR:togoAol07NAG - SR3|X)00
(g(m
Use the larger diameterend of the specialtool first to makethe valve seal ringfit in the pinionshaft.
Make the valve seal ringfit snugly in the pinionshaft using the other end(smaller diameter end) ofthe specialtool.
Page 1117 of 2189
)
41.Coat the inside surface of the new cylinder end seal
with power steering fluid.
Install the cylinder end seal onto the steering rack
with its grooved side toward the piston'
Push in the cylinder end seal with your finger'
CAUTION: When installing the cylinder end sesl'
be carelul not damage the sealing face ot the seal
with the threads and burrs at the staked position oI
the cylinder housing.
trCYLINDES END SEAL
Replace.Make sure the sPring
is in the cylincler end seal
CYLINDER END
SEAL
Remove the vinyl tape from the steering rack'
NOTE: Remove any residue oftape adhesive
Hold the steering gearbox using a C-clamp as shown'
GEARBOX
C-CLAMP:
l-,
46.
47.
Coat the inside surface of the cylinder end with
power steering fluid, then installthe cylinder end by
screwing it into the cylinder housang.
Remove the C-clamp from the steering gearbox'
After tightening the cylinder end' stake the point of
the cylinder housing shown below For'98 -'00
models go to step 51.
NOTE: Stake the cylinder in the position opposite
from where the stake was removed during disas-
semoly.
Be careful not to damage
the bushing when inserting
the cylinder end.
49. Select the 32 mm shim(s) ('96 -'97 model only)'
NOTE: Only reinstall the original 32 mm shim(s)
when the steering gearbox is reassembled without
replacing the pinion shatt, valve housing, and gear
box housing with new ones.
lf the pinion shaft, valve housing, and gearbox
housing are replaced, select the new shim{s) as fol-
lows.
Shim selection:
a. Set the four 32 mm shims on the bearing surface of
the gearbox housing. Total thickness of the four
shims should equal no more than 0 70 mm'
Shim set: four 32 mm shims (Thickness: 010 mm'
0.15 mm, 0.20 mm, 0.25 mm respectivelyl
CAUTION: Th€ four 32 mm shims do not have
thickness identification marks Measure the thick-
ness of each shim using a micrometsr, and mark
the shim lor identification.
(cont'd)
17-61
Stake point. Depth: 1 0 mm (0.04 in)
Page 1120 of 2189
Steering Gearbox
Reassembly (cont'dl
64. Apply grease to the circumference of the rack endhousing.
RACK END GROOVE
=^.#-q!:s!!H
SILICONE GREASE
Apply a light coat of silicone grease to the bootgrooves on the rack ends.
lnstall the boots in the rack end with the tie-rodclips.
NOTE: Install the boots with the rack in the straightahead position (right and left tie-rods are equal inlength).
66.
RACK END
NOTE: Wipe the grease offthe thread section.
17-64
TIE.ROD CLIP
67. Adjust the air hose fitting position of the boots bvturning it as shown below.
LEFT BOOT(Viewed from theleft side)
RIGHT BOOT{Viewed from theright side)
AIR HOSE FITTING
Install new boot bands on the boot, and bend bothsets of locking tabs.
CAUTION: Stlke ths band locking tabs firmly.
Lightly tap on the doubled-over portions to reducetheir height.
Slide the rack right and left to be certain that theboots are not deformed or twisted.
Page 1122 of 2189
Steering Gearbox
Installation (cont'dl
5. Install the stiffener plate with the two gearbox
mounting bolts and stiffener plate aftaching bolts.
CAUTION: Be sure the air tube is not caught orpinched by stiffener plate,
NOTE: Install the bolts loosely first, then tighten
them securely.
7.
8.
6.Install the return hose joint by tightening the l6 mm
flare nut.
Connect the relurn hose securely, and tighten the
adjustable hose clamp from the engine compart-ment.
Connect the feed line and tighten the 14 mm flare
nut.
NOTE: Make sure that there is no interference
between the fluid lines, the rear beam or any otherparts.
ADJUSTABLE HOSECLAMP(see page 17-39)
16 mm FLARE NUT28 N.m {2.9 ksl.m. 20 lbf.ft)
RETURN
1a mm FLARE NUT37 N.m (3.8 kg{.m, 27 lbt.ftl
ATTACHING AOLTS38 N.m 13.9 kgf.m, 28 lbf.ftl
MOUNTING BOLTS(} N.m (4.a kgt m, 32 lbf.ftl
17-66
9.Center the steering rack within its stroke.
Slip the lower end of the steering joint onto the pin-
ion shaft (line up the bolt hole with the groove
around the shaft), and tighten the upper and lower
steering joint bolt.
NOTE:
. Connect the steering shaft and pinion with the
cable reel and steering rack centered.. Be sure that the lower steering joint bolt is securely
in the groove in the steering gearbox pinion.
. lf the steering wheel and rack are not centered,
reposition the serrations at lower end of the
steering joint.
10.
STEERING JOINTUPPER BOLT22 N.m (2.2 kgf.m,16 tbt.ftl
PINION SHAFT
Groove,
STEERING JOINTLOWER BOLT22 N.m (2.2 kgt.m, 16lbtttl
11.Center the cable reel by first rotating it clockwise
until it stops. Then rotate it counterclockwise(approximately two turns) until the arrow mark onthe label points straight up. Reinstall the steeringwheel (see page 17 35).
Page 1243 of 2189
![HONDA CIVIC 1996 6.G Workshop Manual t}
4. Carefully remove the glass from the window slot.
c\
REARCHANNELCOLLAR
Remove the outer molding, then
Ier grass.
remove the quar-5.
\
6. Disconnect the connector, and detach the harness
clip, the](/img/13/6068/w960_6068-1242.png "HONDA CIVIC 1996 6.G Workshop Manual t}
4. Carefully remove the glass from the window slot.
c\
REARCHANNELCOLLAR
Remove the outer molding, then
Ier grass.
remove the quar-5.
\
6. Disconnect the connector, and detach the harness
clip, the")
t}
4. Carefully remove the glass from the window slot.
c\
REARCHANNELCOLLAR
Remove the outer molding, then
Ier grass.
remove the quar-5.
\
6. Disconnect the connector, and detach the harness
clip, then remove the regulator through the hole in
the door.
>: Bolt locataons
A>,2 ]6x1.0mm L
[l o t't.- to.a rsl -. j
fr e ttt ttt )--- .---.-,/
B >,26 x 'l.0 mmI N.m {0.8 ksl'm,6 tbf.ft)
I
)
OUARTER
20-13
7.
CLIP
Grease all the sliding surfaces of the regulator where
shown.
NOTE:
a lf necessary, remove the power window motor
from the regulator.
. Before removing the power window motor, scrloe
a line across the sector gear and regulator.
SECTOR GEARREGULATOR
POWER WINDOWMOTOR
>: Bolt locations,3POWERwTNDOWMOTOR
l'
-... er
A nicuuron
8. lnstallation is the reverse of the removal procedure.
NOTE: Rollthe glass up and down to see if it moves
freely without binding. Also make sure that there is
no clearance between the glass and glass run chan-
nel when the glass is closed. Adjust the position of
the glass as necessary (see page 20-20).
Page 1250 of 2189
Doors
Glass/Regulator Replacement (cont'dl
Grease all the sliding surfaces of the regulator where
shown.
NOTE:
. lf necessary, remove the power window motorfrom the regulator.
. Before removing the power window motor, scribe
a line across the sector gear and regulator.
REGULATOR
5. Installation is the reverse of the removal orocedure.
NOTE: Roll the glass up and down to see if it moves
freely without binding. Also make sure that there isno clearance between the glass and glass run chan-nel when the glass is closed. Adjust the position ofthe glass as necessary.
SECTOR GEAR
20-20
Glass Adjustment
NOTE:
. Place the vehicle on a firm, level surface when adjust-
ing the glass.
. Check the weatherstrips and glass run channel for dam-
age or deterioration, and replace them if necessary.
1. Remove:
. Door panel (see pages 20-4, 10, 16). Plastic cover (see pages 20-2,8, 14)
2. Adjust the glass.
4D:
Raise the glass fully.
Loosen the glass mounting bolts (front door)
and regulator mounting bolts.
Push the glass rearward (front door glass) or
iorward (rear door glass).
Tighten the glass mounting bolts (front door)
and regulator mounting bolts.
A >: Gl.3s mounting boltlocations.B >: Regulrtor moutingbolt loc.tions.
Front:
a.
b.
d.
REGULATOR
Page 1471 of 2189
l'f .
Electrical
Special Toofs .,....................,23-2
Troubleshooting
Tips and Precautions ..............,.................... . 23-3
Five-step Troubleshooting .............. ......... . . 23-5
wire color codes ..........,23-5
Schematic Symbols ........,................... . . .. .... 23-6
Relay and Control Unit Locations
Engine Compartment ...,..................... ... .. . 23'7
Dashboard ......................23-8
Dashboard/Door ......... 23-12*Airbags ................. ....... Section 24
Air Conditioning ......... Section 21
Aftelnator ..........."""" """ 23-112
Anti-lock Brake System {ABS) Section 19*A/T Gear Position Indicator .....................,. .... ... 23-149
Automatic Transmission Svstem .... . ....... Section 14
Batterv ......... . . . ... ...... .......23-91
Blower controls .. . ... Section 2l
Charging System ....'...........23'112
Connector ldentilication and Wire Harness
Routing .................. ......23'13
Cruise Control ............,........23-240
Dash Lights Brightness Controller ............. ....... 23-180
Fan controfs "" 23'126
Fuel PumD ........ . ........ section 11
Fuses/Refay ...............,..,,.. 23'62
PGM-FI Control System ......................,....... Section 1 1
*Gauges
Circuit Diagram ....,.,.......23-131
Fuef Gauge ...........'.'.......23-142
Gauge/lndicator .. . .. 23-129
Ground Distribution .. . 23-75
Heatei controls .. . ..... Section 21*Horn................. ...............23-196
*tgnition Switch ....................23-89
lgnition System .......,.... 23-102
*lntegrated Control Unit ....................................... 23-156
fnterlock System ,........ . . , ,23-144
Lighting System . . . .. ......... 23-161
Lights, Exterior
Back-up Lights ..'............23'171
Brake Lights .................. 23'174
Daytime Bunning Lights (Canadal ............... 23'166
Front Parking Lights ......,................ .'. .......... 23-167
Front Turn Signal Lights .......... . . ............ ..,.23-167
Headtights ....".'....-... ..... 23'167
High Mount Brake Light ...................... ... .23'179
License Plate Lights ...... 23'176
Taitfights ................ .......23'171
lnterior Lights ..-.......,, . 23-142
Moonroof ..,.................,........ 23-235
Power Distribution ....... . . .23-61
Power Door Locks .......,,,. .23'251
Power Mirrors ,..............,.,...23'206
Power Relays ....... . ...... . . .. 23-86
Power Windows ............,,....23-220
Rear Window Defogger .......................... . . ... . . 23-2OO
Spark Plugs . ..... . ........ .....23-111
Slarting System ................23-93*stereo Sound Svstem ,................. ..... ... . ... ,.,.,,23'147'Supplemental Restraint System (SRS) ... . Section 24
Turn Signal/Hazard Flasher System .......'.'....-... 23-173
*Undel-dash Fuse/Relay Box ............,.................. 23-85
vehicfe soeed sensor (VSSI """" ""' 23-140+Wipers/Washers .........,.,.,...23-214
NOTE: Unless otherwise specified, references to auto-
matic transmission (Mf) in this section include the CVT.
Page 1486 of 2189
Connector ldentification and Wire Harness Routing
Engine Wire Harness lD16Y5, D16Y8 enginss): '96 - 98 models
Connector or
Torminal
Numbsr of
CavitissLocationConnects toNot€s
c 101c102c103c104c104c105c106c107c108c 109c110c111c112c113c114c115c116cl17c118c119c120cl21
c122c123cl23c124
c125
c127c12Ac129c130c131c132c 133c134c135
c136
c138c139c140c 141c142c 143c144cl44c145c'146cl47
10
1
22
14l4322l0I
2
2
2
2120
3l
14
14
1222
2
2
22
Left side of engine compartmentMiddle of engineMiddle of engineLeft side of engine companmentLeft side of engine compartmentMiddle of engineMiddle of engineMiddle of engineMiddle of engineMiddle of enginefvliddle of engineMiddle of engineMiddle of engineMiddle of engineMiddle of engineMiddle of engineMiddle of engineLeft side of engine compartmentMiddle of engineMiddle of engineMiddle of engineMiddle of engine
Middle of engineMiddle of engineMiddle of engineMiddle of engineMiddle of engineMiddle of engineMiddle of engineMiddle of engineMiddle of engineRight side of engine companmentBehind right kick panelUnder right side of dashUnder riOht side of dashUnder right side of dashUnder right side of dashUnder right side of dashUnder right side of dash
Under right side of dash
Under right side of dash
Middle of engineMiddle ot enginel iddle of engineMiddle of engineMiddle of ongineMiddle of engineLeft side of engine compartmentMiddle of engineMiddle of engineRight side of engine compartmentRight side of engine compartmentRight side of engine compartment
USACanada
Afi
USA
-' (A/r)
Main wire harness (C303)Crankshaft speed fluctuation (CKF) sensorEngine oil pressure switchAlternatorAlternatorNo. 'l fuel injectorNo. 2 fuel injectorNo.3 fuel injectorNo. 4 fuel injectorIAC valveThrottle position (TP) sensorl\4anifold absolute pressure (MAP) sensorIntake air temperature (lAT) sensorPower steering pressure {PSPI switchEVAP purge control solenoid valveJunction connectorJunction conn€ctorVehicle speed sensor {VSS}Countershaft speed sensorEngine coolant temp€rature (ECT) switch ADistributorEngine coolant temperature (ECT) sendingunrtEngine coolant temperature (ECT) sensorPrimary HO2S (sensor'l)Primary HO2S (sensor 1)Back-up light switchLock-up control solenoid valveSecondary HO2S (sensor 2)Mainshaft speed sensorLinear solgnoid valveShift control solsnoid valveStarter solenoidJunction connectorMain wire harnesE (C446)ECM/PCMPCMECMiPCMECM/PCMMain wire harness (C305)
Main wire harness (C305)
Main wire harness (C305)
Knock sensor (KS)IAC valveVTEC solenoid valveVTEC pressure switchEVAP control canister vent shut valveEGR control solenoid valveSecondary gear shaft speed sensorEGR valveEGR valveDrive pulley speed sensorSolenoid connector {CVT)Driven pulley speed sensor
*, (M/T)M/T*" INT\
*, tAtf)
NT:'96 model*,(A,/T):'97 - 98mooets
moqets
M/T
-1 (l,/T)*, (A,/T)-,(4,/T)*1 {M/T)*, (A,/T)*1 (CW)*, (A,T)
T101r102Left side of engine companmentRight side of engine companmentAlternatorUnder-hood fuse/relay boxG 101Middle of engineEngine ground, via engine wire harness
2
*1: Dl6Y5 engine*2: D16Y8 engine*3: D16Y5 (Ay'T), D16Y8 engines
3-16