D16y8 HONDA CIVIC 1996 6.G Workshop Manual

Transmission
Installation (cont'dl
9. Attach the torque converter to the drive plate witheight drive plate bolts and torque as follows:Rotate the crankshaft pulley as necessary to tightenthe bolts to 1/2 of the specified torque. then to thefinal torque, in a crisscross pattern.
After tightening the last bolt, check that the crank-shaft rotates freely.
TOROUE: 12 N.m {1.2 kgl.m, 8.7 tbt{r}
10 x 1.25 mm
6x1.0mm12 N.m (1.2 kgt m,8.7 rbt ft)
I 1.25 mm2/t N.m {2.4 kg{.m,17 tbt ftlCONVERTEB
10. Install the torque convener cover and the €nginestiffener.'11. Tighten the crsnkshaft pull€y bolt, if necessary (see
section 61.
12. Connect the ATF cooler hoses to the ATF cooler lines(see page 1,t192).
ATF COOIIRUNE
10 x 1.25 mma,l N.m {4.5 kgl.m,33 rbt.fttRIGHT FRONT 12 x 1.25 mmMOUNT/BRACKET 6.t N.m (6.5 kg{.m,47 tbt ftl
13. Install the right front mounvbracket.
4,r N.m 14.5 kgf.m,33 lbtft)
COVER
L,
14-1A4
SHIFT CABLE
SHIFT CAAE COVER
14. Install the control lever with a new lock washer tothe control shaft, then install the shift cable cover.
CAUION: Taks care not to bend the shift cable.
L(rcK WASHERReplace.
8 x 1,25 r'|m22N-m12.2 tgt m. 16lbnftl
x 1.0 mmtit N.m 11.4 kgt m,10 tbr,ft,
15. lnstall the exhaust pipe A.
NOTE: D16Y8 engine is shown; D16y/ engine is sim_ilar.
Replace.
GASKETReplace.
SELF.LOCKING NUTReplace.10 x 1.25 mm54 N.m (5.5 lgf.m,40 tbt ftl
NUTSELF.LOCKING NUTReplace.8 x 1.25 mm22 N.m {2.2 kgl.m, 16lbtfrl
Replace.8 x 1.25 mm16 N.m {1.6 kgI.m,12 tbf.ft)

Transmission
Installation {cont'd)
Connect the lock-up control solenoid connector. andinstall the transmission ground cable.
6 x '1.0 mm12 N.m {1.2 kgf.m, 8.7 lbl.ft}
LOCK.UP CONTROLSOLENOID CONNECTOR
Connect the staner cables on the staner motor. andinstall the cable holder.
NOTE; When installing the starter cable terminal.make sure that the crimped side of the ring terminalis facing out (see section 23).
6x1.0mm12 N.m 11.2 kg{.m.8.7 tbtftl
{0.9 kg'f.m, 7 lbf.ftl
TRANSMISSIONGROUND CABLE
b
14-186
STARTER CAELE
24. Installthe intake air duct.
D16Y7 engine:
Install the intake air duct and the resonaror.
D16Y8 engine:
lnstall the intake air duct and the air cleaner hous_ang assembly.
25. Refill the transmission with ATF (see page 14_1.18).
26. Connect the positive (+) cable first. then the nega-tive (-) cable to the battery.
27. Check the ignition timing (see section 23).
28. Start the engine. Set the parking brake, and shift thetransmission through all gears. three times. Checkthe shift cable adjustment (see page 14_190).
29, Check the front wheel alignment (see section 1g).
30. Let the engine reach operating temperature (thecooling fan comes on) with the transmission in Nor @ position, then turn it off and check the fluidlevel (see page 14- 7).
31. Road test as described on pages 14-113 thru ,14_116.

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

Gonnector ldentification and Wire Harness Routing
Engine Wire Harness (D16Y5, Dl6Yg engines): ,99 - 00 models
Connectot or
Terminal
Number ot
CavitiesLocationConn€cts toNotes
c'101cl02c103c104c 104c10s
c107c 108c'r09c110c111cl12c113cl14c l15c116cl17c118c119c120cl20c121
c122c123c123cl23cl24c124c125
c127c12Ac129c 130c131cl32c133c 134c135c137c138c 139c 140c142c143c144cl44c145c146c147
103,]
322223332221414322'10
8,l
2484224222120
32
2212223
282
No. 1 luel injector INo.2 fuel injectorNo.3 fuel injector ]No. 4 fuel injector iIAC valve I anThrottle position lTP) sensorManifold absolute pressure {MAP) sensor IIntake air temperature (lAT) sensor IPower steering pressure (PSP)switch USAEVAP purge control solenoid valve ]
Main wire harness 1C303)Crankshaft speed fluctuation (CKF) sensorEngine oil pressure switchAlternatorAlternator
Left side ot engine compartmentlvliddle of engineMiddle of engineLeft side ot engine compartmentLeft side of engine compartmentMiddle of engineMiddle ot engineMiddle of engineMiddle of engineMiddle oI engineMiddle of engineMiddle of engineMiddle of engineMiddle of engineNliddle of engineMiddle of engineMiddle of engineMiddle of engineRight side of engine compartmentMiddle of engineMiddle of engineN4iddle of engineMiddle of engine
Middle of engineMiddle ot engineMiddle ot engineMiddlo of engineMiddle of engineMiddle ot enginelrliddle of engineMiddle of engineMiddle oI engineMiddle ot engineRight side of engine compartmenlBehind right kick panelUnder right side of dashBehind right kick panelBehind right kick panelBehind righr kick panelBehind right kick panelMiddle ot engine[,liddle of engineN4iddle of engineMiddle of engineMiddle oI engineLeft side of engine compartmentMiddle of engineMiddle of engineRight side ol engine compartmentRight side of engine companmentRight side of engine compartment
USACanada
Junction connectorJUnct|On COnnectorVehicle speed sensor lVSS)Countershaft speed sensorEngine coolant temperature {ECT} switch ADistributorDistributorEngine coolant temperature (ECT) sendingunitEngine coolant temperature (ECT) sensorPrimary H02S (sensor 1)Primary HO2S (sensor 1)Primary HO2S lsensor 1)Back-up light switchLock'!p control solenoid valveSecondary HO2S (sensor 2)Mainshaft speed sensorLinear solenoid valveShift control solenoid valveStarter solenoidJunction connectorMain wire harness (C446)ECM/PCMECM/PCMECM/PCMPCtvtKnock sensor (KS)IAC valveVTEC solenoid valveVTEC pressure switchEGR control solenoid valveSecondary gear shaft speed sensorEGR valveEGR valveDrive pulley speed sensorSolenoid connector (CVT)Driven pulley speed sensor
*' (A/TI
*1 (CVT)*, (M/T)
Mfia (A/Tl
" (A,/T)., (4,/r)-' {AlrJ
*1 (M/T)
tvliT
*1 (CVT)*, (cvT)*' (cw)*1 (MiT)*1 {CVT)*1 {CVT)*, (cvr)
T101T102Left side of engine companmentRight side ot engine companmentAlternatorUnder'hood fuse/relay boxG 101Middle of englne IEngine ground, via engine wire harness*1: 016Y5*2: D16Y8*3: Dl6Y5
engineengine(CW), D16Y8 engines
23-14

Connector ldentification and Wire Harness Routing
Main Wire Harness lLeft side ot engine compartment branchl
Connector or
Terminal
Number of
CavitiesLocationConnects toNotes
c301
c302
c303
c304
c305
c305
c306
c307
c308
c309
c309
c310
5
2
10
3
14
8
1
I
10
2
2
Left side of engine compartment
Left side of engine compartment
Left side of engine companment
Left side of engine compartment
Left side of engine compartment
Left side of engine compartment
Left side ot engine companment
Left side of engine companment
Left side of engine compartment
Left side of engine companment
Left side of engine companment
Left side of engine companment
Windsh ield wiper motor
Test tachometer connector
Engine wire harness (C101)
Daytime running lights resistor
Engine wire harness (C136)
Engine wire harness (C136)
Brake fluid level switch (+)
Brake fluid level switch (-)
Engine compartment wire harness (C201)
Engine companment wire harness (C202)
Engine compartment wire harness (C202)
Left front ABS wheel sensor
Canada
;|.'
ABS*lr D'16Y5 engine *5:'96 9g models*2: D16Y8 engine*3: With cruise control*4r Without cruise control
*1: '99 - 00 models
Main Wire Harness (Right side of engine compartment branch)
Connector or
Terminal
Number of
CavitiesLocationConnects toNotes
c353
c354
c355
c356
c357
c359
c360
11
3
I
3
2
2'10
2
2
Right side of engine compartment
Right side of engine companment
Right side of engine companment
Right side of engine compartment
Right side of engine compartment
Right side of engine companment
Right side of engine compartment
Right side of engine compartmentRight side of engine compartment
Right side of engine compartment
Right side of engine compartment
Under-hood fuse/relay box (CgoB)
Under-hood fuse/relay box (C906)
Underhood fuse/retay box (C905)
Under-hood tuse/relay box (C907)
Engine companment wire harness {C214)Under-hood ABS fuse/relay box {C927)Under-hood ABS fuse/retay box (C926)
Right front ABS wheel sensor
ABS solenoid
ABS pump motor
EVAP control canister vent shut valve
USA
ABS
ABS
ABS
ABS
ABS
G403Right side of engine compartmentBody ground, via main wire harness
23-30

Gonnector ldentification and Wire Harness Routing
Floor Wire Harness lCoupe/Haichbackl
Connsclor or
Terminal
Number of
CavitiesLocationConnects toNotes
c551
c552
c553
c554
c556
c556
c557
c558
c560
c561
c562
c564
c56s
16
8'16
14
20
2
25,)
,I
2
1
14
20
2
2?
1
10
Behind underdash fuse/relay box
Behind under-dash fuse/relay box
Above under-dash fuse/relay box
Under left side of dash
Above under-dash fuse/relay box
Above under-dash fuse/relay box
Driver's door
Driver's door
Passenger's door
Passenger's door
Middle of floor
Left side offloor
Left B-pillar
lnside of left rear wheel
Left c-pillar
Left C-pillar
Left C-pillar
Fueltank
Fueltank
Inside of right rear wheel
Right B-pillar
Fueltank
Left side ot dash
Under-dash fuse/relay box {C923)
Under-dash fuse/relay box (C921)
Dashboard wire harness {C503)
Main wire harness (C402)
Main wire harness (C401)
Main wire harness {C401)
Driver's door wire harness (C631)
Driver's door wire harness (C631)
Passenger's door wire harness (C651)
Passenger's door wire harness (C651)
Parking brake switch
Driver's seat belt switch
Driver's door switch
Left rear ABS wheel sensor
Rear wire harness (C601)
Rear wire harness (C601)
Rear wire harness {C602}
Fuel gauge sending unit
Fuel pump
Right rear ABS wheel sensor
Passenger's door switch
Fuel tank pressure sensor sub-harness(c791)
Power mirror switch
ABS
ABS
ABS
G551
G552
Left kick panel
Left side of floor
Body ground, via floor wire harness
Body ground. via floor wire harness
*1r With power windows*2: Without power windows*3: D16Y8 engine {Coupe)
*4: '96 - 98 models*5: '99 - 00 models
23-40

Ground Distribution
Circuit ldentification
(To
I 8an6ry ground cable
: Engine ground caue A
Primary HO2S (M/I) IEGR valve (,tffT) | {Ot6y5 engtne)EGB conrol Isllenoid va ve (vT) lwEc flessure switdr (Bl6A2engine)
vss
PSP swtch
Baaery
BLK -* bqiu"trl'ff lso",ilE o;l?f ;".,L ur,u" "ou.,,r,oo, "*'n",
Trlnsmission ho!gng
BLK
BLK
BLK
BRN/BLK
I
I
Vp?oe 23-76, 77)
'96-98 models'99-00 models 816A2, D16Y7 engines
99-00 modors D16Y5, D16Y8 engines
s,-( -i-t;lBL(- pcM Frman reray' E ) tc" 't*' tn''n''*t'''
wEC pressurc sMch(016Y5, D16Y8 engines : 98-00 models)
@
E
Efal
i Engine grcund cable B
: Engrne wire hamess
(cont'd)
23-75
El , M"in ttire hatn"."

rt
'99-00 models:
(5i%ease)E>4 BRNiBLK
i.,.,].',,-
ERNi BtK
BRIVBLK
BFN/BLK
BRN/BLK
BRN]BLK
BRIl/8LK
BFN/BLK
r * s r;l ao^r,qt r
CKF s€nsor 1t -1ll ELU/FEU
Knoq( sonsor (r15J '-l !l r{EUl6LU
P maryHo2s*?H wHT
Mainshafl speeo ssnsor -1ll fiEU
Coutershall sp€ed sensor -+F ] BLU) ..",r.u,.0n
016Y7, Dl6Y5 (CW) ongines
;;=-"r,i,-l
Ly"::::::::
I Secondary Ho2s :{ WHT/RED-;'4:v-..1
RED/BLU - I
wHT - f rau,rru (an )
pgTpse- J
*1i016Y5, Dl6Y8engines *4:016Y7, Bl6AzerEines lcont'd)*2: Excepl DI6YSengino ([VT) *5: D16Y5, D16Y7, D16Y8Bngines* 3:Dl6Y5 sngine ([VT) *6:B16M, D16Y8,016Y5 (CW)engines
015Y5 (LVT) sngine
41-.1
Dfiv6 prirEy speeo sonsot -1l l hEL,bLU
Driven gr ley sp€ed sensor -- F I WHT
Secondary gea sian sp€ed sensor .-ll WHT/RED
E : Engine w re harness E : Rear h€al6d orygen sensor sLlb harness
IIJ : Main wire harnsss ------ shielding
816A2, Dl6Ygengiftes
23-77

Ground-to-Components I ndex
f.,lONOTE: All ground wires are BLK unless otherwise noted.
GroundPageComponents or Circuit Grounded
Battery (BLKYEL)
Steering pump bracket
t+-rg ITransmission housing
l
G101
(-1)
G101
(-2)
14-2
and
14-3
ano
14-1
Powertrain or engine control module (PG1 and pG2 are BLK: LG1 and LG2 are
BRN/BLK), EGR control solenoid valve (CW, EGR valve and lift sensor (Dt6yS enginewith M,/T), Engine coolant temperature switch, pGM-Fl main relay, power steeringpressure switch (USA), Primary HO2S (D16Y5 engine with l\/,/T), Vehicle speed sensor,VTEC pressure switch (D16Y5/D16Y8 engines), CKF sensor (BRN/BLK), Transmission
control module (CYf) (Pc1 is BLK: LG1 is BRN/BLK)
Shielding betvveen the PCM or ECM and these components (all have BRN/BLK wires):
CKF sensor, TDC/CKP/CYP sensor. Primary and secondary heated oxygen sensors.
Knock sensor (CWDl6YB engine), Mainshaft speed sensor (AiT except CVT),
I Countershaft speed sensor (A/T except CVf)
Shielding between the TCM and these components (CVT) (all have BRN/BLK wires):
Drive pulley speed sensor, Driven pulley speed sensor, Secondary gear shaft
speed sensor
Powertrain or engine control module (PG1 and pG2 are BLK; LG1 and LGz are
BRN/BLK), EGR control solenoid valve (D16Y5 engine), EGR valve (Dt685), Engine
coolant temperature switch, Fuel pressure regulator shut-off solenoid valve (D1685),
PGM-FI main relay, Power steering pressure switch (USA), Vehicle speed sensor, VTECpressure switch (All except D16Y7 engine), CKF sensor (A

except 81642) (BRN/BLK)
Shielding between the PCM or ECM and these components (all have BRN/BLK wires):
CKF sensor, TDC/CKP/CYP sensor, Primary and secondary heated oxygen sensors,
Knock sensor (All except D16Y7 engine), i/ainshaft speed sensor (Arf except CW),
Countershaft speed sensor (A,/T except CVf), Drive pulley speed sensor (CW), Drivenpulley speed sensor (CVT), Secondary gear shaft speed sensor (CVf)
I Badiator fan motor, Right front parking/turn signat tight, Right headtight
G20214-4I Cruise control actuator, Left front parking/turn signal lights, Left headlight, Rear window
I washer motor, Windshield washer motor, Washer fluid level switch (,99-'00 Canada)
G401| +-o
and
14-7
Accessory power socket, Brake fluid level switch, Clutch interlock switch (M/T), Clutchswitch (lillT with cruise/D16Y5 engine with MfD, Combination wiper switch (Z wires),
Cruise control main switch, Cruise control unit, Dash lights brightness controller, Data
link connector, Daytime running lights control unit (Canada), Gauge assembly, Horn('96-'97 models), Integrated control unit, Interlock control unit (ArI), Keyless door lock
control unit ('99-'00 models with keyless), Moonroof close and open relays, Moonroof
switch, Park pin switch (A/r), Power window relay, Rear window defogger relay, Rear
window defogger switch ('96-'98 models), Steering lock, Stereo radio tuner (,96-,98
USA: LX, EX, and HX), Turn signal/hazard relay, Windshield wiper motor.....plus
everything grounded through G402
6-6

'1 = '96 D16Y8 engine: All coupes'97 D16Y7 engine: California Coupe, California Sedan LX'97 D16YB engine: All coupes, California Sedan'98100 models: All except D1685-.t UNDER-DASHI
I
\
'--1 $NEGRATED
| !s$il:'Ptlofo avtEw 67
c42'lPHO|O 63vlEW 50
ct01
vtEw28
FUSE/RELAYBOX
\
I
T
D16Y8
13
c568
ELKAYTIT
BLKAVHT
1
143
EVAP BYPASS : :SOLENOIDVALVE . ,Page 23-9,23-11,23-14,24-7,' '
24-9, ot 24-11
H02SPage 23-11ot 24-11pHoTolo4 ; ; PHoTo 43(See S/lV page 11-9lor'99-'00 models) ,
i1[
":"[-lT:T
l+Tli'::f;:r i"'{' l;;;]fip;:
I Fs'[
**,
I il i I ii !-l s];$:i i Ii t--l
i ! i'*[ iEi.;*Ti lii
'fl*-i
i li itqii-*
i l il[l?ti
lii iiii;:" i:li
i trr i I i.r^.:.'.'.'i::::;j i !' i
: i i , I i ,+e;::"," i : ! i
itI
i! | i | :".*lfigi3li;ts's"";:tg;u'u^.i : ! :
iv7"-- : rA : *'I i i osl :
; CoNTBOL , r--1
i liiit- i i_j i i_j #s,{;'i' i [__j
ffnih'*'
i 23:11,23-t4, , EVAP PURGE I pRtMARy Ho2s : ' powERTRAtN :| 24-7,24-9, ' CONTFOL ; Page 23-8, 23'10, 23'13, , ; CONTROL ,' ot 24-11 ' SOLENOIO , 24-7 .24-8. 24-10. ot 25-8 ' , MOOULE (PCM) ,' pHoTo 3s : VALVE I PHoro 40 ' ' Paqe 39-8 '
| (see s/M : Pase23-s,23'11, : ii3l311l l3;ll Pl?191,.,"^,, : ' orSe-12 :
' PHoTo 39 I vALvE | ' Paqe 39-6
: (See S/M : Page 23-9, 23'11. ' lHqI94?199 99 0.16Y!i - i ' or 5g-tz :i bi-gllt-g i zs:tq, zc-i, zc-g', ' PHoro 733 ree 00 D16Y8/816A2) i '. in6i "i i
:':1T:9' ',91"?i'l; i------ ------j ".-':-*-'1. -----j(cont'd)- - - -::-:-l - - - - t PHO\O 37 to16Y7l
1(}5