Engine control HONDA CIVIC 1996 6.G Workshop Manual

22. Install the shift cable end on the control lever, and
install the shift cable on the shift cable bracket'
CAUTION: Take care not to bend the shift cable'
23. lnstall the clip in the direction shown.
LOCKNUT
SHIFI CABLE 29 N m {3.0 kg{ m, 22lblftl
SHIFT CABLEERACKET
WASHERIPLASTIC)
CONTROL LEVER
24, Connect the solenoid harness connector. the drive
pulley speed sensor connector. and the ground
cable terminals.
6x1.0mm12 N.m {1.2 kgf.m.8,7 rbtft)
GROUND CABLETERMINAL 6x1.0mm
GROUNDTERMINAL
12 N.m {1.2 kgf'm,8.7lbtfrl
DRIVE PULLEYSPEED SENSORCONNECTOR
SOLENOID HARNESS
CONNECTOR
25. Connect the starter motor cable on the starter motor.
and install the cable holder.
NOTE: When installing the staner motor cable. make
sure that the crimped side of the ring terminal is
facing out (see section 23).
STARTEB
BMOUNTING NUT
9 N.m (0.9 kgf m,7 lbf ft)
26. Install all removed connectors and clamps'
27. Install the distributor.
28. Install the intake air duct and air cleaner housing
29.
assemDly.
Refill the transmission with the recommended
Genuine Honda CVT Fluid (see page 14-2991
CAUTION: While filling the CvT Fluid, bs surs not io
allow dust and other fotoign particles to entor into
the transmission.
Connect the battery positive (+) terminal first, then
the negative (-l terminal to the battery'
Check the ignition timing (see section 23).
Start the engine. Set the parking brake, and shift the
transmission through all gears three times Check
shift cable adjustment (see page 14-355).
Check the front wheel alignment (see section 18)
Let the engine reach operating temperature (the
radiator fan comes on) with the transmission in lXl
or E position, then turn it off and check fluid level'
Perform the start clutch calibration procedure on
page 14-293.
Road test as described on pages 14-296 and 14-297
30.
31.
34.
36.
STARTER MOTOR
14-351

System Description
Fluid Flow Diagram
The system is a compact rotary-valve-type power steering, connected to the steering gearbox. The fluid pressure is pro-
vided by a vane-type pump which is driven by the engine crank pulley. The amount of fluid and pressure is regulated by
the flow control valve built into the pump. The fluid pressure from the pump is delivered to the valve body unit around the
pinion of the steering gearbox. The valve inside the valve body unit controls the hydraulic pressure and changes the direc-
tion of the flow. The fluid then flows to the power cylinder. where rack thrust is generated. Fluid returning from the power
cylinder flows back to the reservoir, where the fluid is "filtered" and supplied to the pump again.
RESERVOIR
VALVE BOOY UNIT
SUB.VALVE
FLOW CONTROL VALVESTEERING GEARBOX
17-16

System Description
Steering Pump (cont'dl
The flow control valve and sub-valve in the pump per-
forms the following steps @ through @ to control the
flow of fluid, that is to increase the discharge volume
when engine speed is low, and to decrease it when the
engine speed increases. The assistance thrust of the
steering gearbox changes in compliance with the
change in the discharge volume.
When the engine starts, fluid discharged from the
discharge port starts to flow through oil passage A,
the fixed orifice and the variable orifice to the steer-
ing gearbox. When the engine speed is extremely
low, the return port is closed by the flow control
Fluid pressure discharged from the discharge port
is applied to the top of the sub-valve, and the fluid
pressure that passed through oil passage A is applied
to the bottom of the sub-valve. When this happens,
the pressure difference between the ends of oil pas-
sage A, which is caused by the resistance oil passage
A when the fluid flows through the passage. is
applied to the sub-valve, However, the pressure dif-
ference applied to the sub-valve. that is the force
that pushes the sub-valve down, is too small to
overcome the spring force, and the variable orifice is
fully open when the engine speed is extremely low.
Because the fluid volume flowing through the fixed
orifice and variable orifice increases, a pressure dif-
terence is created between the ends of these ori-
fices, and it increases in proportion to the engine
speed. As the fluid pressure that passed the fixed
orifice and variable orifice is directed to the bottom
of the flow control valve. a pressure difference is
created between the top and bottom of the valve,
which pushes down the flow control valve and
opens the return port. As a result, pan of the fluid
discharged from the discharge port feturns to the
pump suction port, keeping the discharge volume
constant.
In this condition, the sub-valve does not move. and
the variable orifice stays fully open.
lo
trrtrrlo3
J
o
PUMP R.P.M.
To STEERING GEARBOXSUB.VALVE
To STEEnING GEARBOX
FLOW CURVE
!rs+/f/ffih\
o,,-i^"l^tKzYt)91y ul3Yl
FLOW CONTNOL VALVE
su8-vALvE
ORIFICE
ToP
17-18
FLOW CONTROL VALVE

t
To STEERING GEARBOX
To STEERING GEAREOx
@ The fluid volume that flows thorough oil passage A
and the pressure djfference applied to the sub-valve
increase in proportion to the engine speed. The
sub-valve lowers overcoming the spring force, and
it stans to close the variable orifice to regulate the
discharge volume, When this happens, the fluid vol-
ume flowing to the steering gearbox decreases as
the engine speed increases. At the same time, the
flow control valve continues to control the fluid vol-
ume to the return Port,
@ As the engine speed increases funher, the pressure
difference at the sub-valve increases further as well.
The sub-valve then closes the variable orifice com-
pletely, regulating the discharge volume further.
When this happens, the fluid volume discharged
from the pump to the steering gearbox is regulated
and maintained at a given level until the engine
speed reaches the high speed range The flow con-
trol valve functions continues to control the fluid
volume to the return Port.
Pressure Relief
Pressure at the discharge side of the fixed orifice is
directed to the bottom of the flow control valve. When
the pressure builds up, the relief valve in the flow con-
trol valve opens to release the pressure at the bottom of
the valve. This allows the flow control valve to be
pushed back by the pressure difference, and the fluid
volume to the pump return port increases.
As explained above. the system keeps the pump dis-
charge pressure (relief pressure) from exceeding the
given level by controlling the volume of the fluid to the
pump relurn pon,
1.,DAMPING ORIFICE{Docreases excessiv€vibration in the valv6.)
17-19
)
RELIEF VALVE {Opan)
SUB.VALVE
FLOW CONTROL VALVE
/F ft>..\
'-€/K\A/A
o'.'to"5lo'#2"n af11\D7
FLOW CONTROL VALVE

Troubleshooting
General Troubleshooting
Check the following before you begin:. Has the suspension been modified in a way that would affect steering?. Are tire sizes, tire variety and air pressure correct?. lsthe steering wheel original equipment or equivalent?. lsthe powersteering pump belt properlyadiusted?
. ls steeringfluid reservoirfilledto proper level?. ls the engine idle speed correct and steady?
Hard Steering (Check the powor assist. se€ page 17-3o. lfthe torce is over 29 N (3.0 kgf, 6.6lbo, Procede with this troubleshootinq.)
Abnormallluid pressure
{fluid pressureis too high)
Faulty valve body unit
Relief pres-sure too low
Abnormal
Faulty llow control valve(Replace the pump es anassembly)
Ch€ck the feed snd return circuit lin€s ano nosebetw6€n the gearbox and pump for clogging andd€lormation.
Normal line and hose
Check the pump fluid pressure(soe page 17-34).l/easure steady-state tluid pres-s!re while idling with the bothvalves tully open.It should be 1.500 kPa (15 kgf/cmr,213 psi) or below.
Normal
Check th€ flow control vslve (see page 17-42).. Chock the valvo lor smooth movement in the hous-ing.. Check the reliefvalve for leaks.
Check the pump fluid pressure
{see page 17-34).Measure pump relief pressurewhile idling with the pressure con-trol valve Iully closed.It should be 6,400 - 7,400 kPa (65 -
75 kgflcm,,920 - 1,070 psi)
Normal relisf pressure
17-22
Go to page 17-23Faulty pump assembly

/
Uneven or rough steering
Steering wheel kicks back
during wide t!rns.
ll,
)
Adjust the rac* guide (see page 17-3).
lf the problem is not corrected bY
adjusting the rack guide, replace
the gearbox.
Adiust the belt tension. Feplace the
belt, il necessary (see Page 17 32).
lfthe engine stalls when the wheel
is turned while car is stopped or
moving at low speed, adjust the
idle spe€d (see section 11)
ldle speed low or erratic.
Check power sleering fluid level lf
the level is excessively low, check
lor leaks in the system. Add lluid
to the specified level.
Air in reservoir, or check Powersteering Iluid level.
lf ltuid level is OK, check O-rings
and seals on both ends of thepump inlet hose, and the P/Spump housing mating surfaces
and the pumP shaft oil seal for
suction leaks. RePlace Parts as
nocessary.
Adjust the belt tension (see Page17 32)or replace belt.Pump belt sliPPing on PLrlleY(pump stops momentarilY)
Check if pump press{rre is normal
and the gauge needle travel is 500
kPa (5 kgl/cm?, 7l Psi) or less.
Chock the flow control valve if the
needle travel exceeds 500 kPa (5
kgflcm', 71 Psi). l{ the flow control
valve is normal, replace the PumPas an assemoly.
Install the power steering pressure
gauge, Close the Pressure contrcl
valve fully and m6ssure the PumPpressure {s€e page 17-34}.
17 -25,

lnspection and Adjustment
Pump Pressure Check
Check the fluid pressure as follows to determine
whether the trouble is in the pump or gearbox.
NOTE: First check the power steering fluid level andpump belt tension.
CAUTION: Disconnect the high pr$sure hos€ with care
so as not lo spill the power sieering tluid on tha frame
and other parts.
1. Disconnect the outlet line from the Dumo outlet fit-
ting, then installthe P/S joint adaptor (pump) on the
Dumo outlet.
2. Connect the P/S joint adaptor (hose) to the power
steering pressure gauge, then connect the outlet
hose to the adaptor.
3. Install the power steering pressure gauge to the P/Sjoint adaptor (pump) as shown.
ourlEr HosE FnrNo ,t"ll lrilu"ott
P/S JOINT ADAPTOB IHOSEI07RAK - S0i10l2rol07RAK- 50{{)120
P/S PRESSURE GAUGE07406 - 001000Aor07406 - 0010001
4. Open the shut-off valve fully.
5. Open the pressure control valve fully.
17-34
(Pa.t of tooll11 N.m11.1 kgt m, 8 lbf.ftl
PRESSURECONTROL VALVE
SHUT.OFFVALVE
PUMP OUTLETFITTING
6 x 1.0 mm BOLTlPart of tool)11 N.m11.1 kgf m, 8 lbtftl
7.
Start the engine and let it idle.
Turn the steering wheel from lock-to-lock several
times to warm the fluid to operating temperature.
Measure steady-state fluid pressure while idling. If
the pump is in good condition, the gauge should
read less than 1500 kPa (15 kgf/cmr, 213 psi).
lf it reads high, check the outlet line or valve body
unit (see General Troubleshooting 17-22).
Close the pressure control valve, then close the
shut-off valve gradually until the pressure gauge
needle is stable. Read the oressure.
lmmediately open the pressure control valve fully.
GAUTION: Do not keep lhe prossure control valve
clos€d more then 5 soconds or the pump could be
damagod by over-heating.
lf the pump is in good condition, the gauge should
read at least 6,400 - 7,400 kPa (65 - 75 kgflcm,, 920 -
1,070 psi). A low reading means pump output is too
low for full assist. Repair or replace the pump,
9.
P/S PBESSURE GAUGE07{16 -@1@OA
oi
SI{UT.OFF VALVE

Master Cylinder/Brake Booster
IRemovaUlnstallation
CAUTION:
. Be care{ul nol to bend or damage the brake lines when
rsmoving the mastsr cYlinder.
. Do not soill brakefluid on the vehicle; it may damage
the paint; if brake fluid does contact the paint, wssh
it off immediatelY with water'
. To prevent spill3, cover the hose ioints with rags or
shop towels.
9. Remove the four booster mountlng nuts
10. Pull the brake booster forward until the clevis is
clear of the bulkhead.
11. Remove the brake booster from the engine com-
panmenr.'12. Install the brake booster and master cylinder in the
reverse order of removal.
CAUTION:
. When connecting the brake lines. make sure
that there is no inte erence between the brake
lines and oth6r Parts.
r Be careful not to bend or damage the brake lines
when installing the master cylinder.
NOTE: lf replacing the master cylinder or brake
booster, check and adiust the pushrod clearance
be{ore installing the master cylinder (see page 19-221'
Fill the master cylinder reservoir, and bleed the
brake svstem (see Page 19-7).
After installation. check the brake pedal height and
brake pedal tree play (see page l9-5) and adjust if
necessary.
BRAKE BOOSTER(With ABS: 7" + 8" tandem brake booster)
BRAKE FLUIO LEVELSWITCH CONNECTORS
MASTER CYLINDER
VACUUM HOSE
1.
2.
3,
5.
Disconnect the brake fluid level switch connectors'
Remove the reservoir cap from the master cylinder'
The brake fluid may be sucked out through the top
of the master cylinder reservoir with a syrlnge.
Disconnect the brake lines from the master cylinder'
Remove the master cylinder mounting nuts and
washers.
\l/
6. Remove the master cylinder from the brake booster'
7. Disconnect the vacuum hose trom the brake booster'
8. Remove the cotter pin and clevis pin from the clevis'
CAUTION: Do not disconnect the clevb by remov-
ing it from the operating rod of the brako booster' lf
the clevis is loosened, adiust the pushrod length
before installing th€ brake booster (see page 19-221'
COTTER PINReplace.
To Rear Wheel Cylinders
14.
-6.4CLEVIS PIN
To Front Caliper(Without ABS)$
t'N't'ttrnt'-''
To Front CaliperlWithout ABSi
PBOPORTIONING CONTROL VALVE
15 N.m {1.5 kgl m,11 tbtft)
15 N.m {1.5 kgif.m, 11 lbtft}(With ABS: To modulator unit)lr
19-21

Brake Booster InsPection
FunctionalTest
1. With the engine stopped, depress the brake pedal
several times to deplete the vacuum reservoir, then
depress the pedal hard and hold it for 15 seconds lf
the pedal sinks' either the master cYlinder is
bypassing internally, or the brake system (master
cylinder. lines. modulator, proportioning control
valve, or caliPer) is ieaking.
2. Start the engine with the pedal depressed lf the
pedal sinks slightly, the vacuum booster is operating
normally. lf the pedal height does not vary, the
booster or check valve is faultY.
3. With the engine running. depress the brake pedal
lightly. Apply just enough pressure to hold back
automatic transmission creep. lf the brake pedal
sinks more than 25 mm (1.0 in.) in three minutes,
the master cvlinder is faulty. A slight change in
pedal height when the A'lC compressor cycles on
and off if normal. (The A/C compressor load
changes the vacuum available to the booster')
Leak Test
1. Depress the brake pedal with the engine running.
then stop the engine. lf the pedal height does not
vary while depressed for 30 seconds, the vacuum
booster is OK. lf the pedal rises. the booster is
faulty.
2, With the engine stopped, depress the brake pedal
several times using normal pressure When the
Dedal is first depressed, it should be low On con-
secutive applications, the pedal height should grad-
uallv rise. lf the pedal position does not vary, checK
the booster check valve.
l./
19-23
Booster Check Valve Test
1. Disconnect the brake booster vacuum hose at the
booster.
2. Stan the engine and let it idle. There should be vac-
uum. lf no vacuum is available, the check valve is
not working properly. Replace the brake booster
vacuum hose and check valve, and retest.
BRAKE BOOSTERVACUUM HOSE(Check valve
built-in)

Troubleshooting Precautions
ABS Indicator Light
I The ABS indicator light comes on when the ABS control unit detects a problem in the system. However, even thoughthe system is normal, the ABs indicator light can come on, too, under the following conditions. To determine theactual cause of the problem, question the customer about the problem, taking the following conditions into consider-ation.
. Signal disturbance
. Wheel soin
. Only drive wheels rotate. Battery voltage fluctuates
2. When a problem is detected and the ABS indicator light comes on, the indicator light can stay on untat the ignitionswitch is turned off, or it can automatically go off, depending on the mode.. Lightstayson until the ignition switch isturned off;When the system is inthesvstem down mode.o Light automatically goes off:When the system is in the control inhibition mode.(refer to symptom-to-system chart)3 The ABS indicator light stays on when the system is reactivated without erasing the DTC, but it goes off after startingthe car.
when the wheel sensor system is faulty and the ABS indicator light comes on, the algorithm of the system automaticallyturns off the ABS indicator light after the wheel speed signal returns to the normal speed. while, when the DTC is erased,the CPU is reset and the ABS indicator light goes off when the system check€d out normal by the initial diagnosis.Therefore, test-drive the car after servicing the wheel sensor system, and be sure that the ABS indicator light does notcome on.
4. When the ABS control unit outputs battery voltage to the gauge assembty, the ABS indicator light goes off.
Diagnostic Trouble Code (DTC)
1. The diagnostic trouble code (DTC) is memorized when a problem is detected and the ABS indicator light does not gooff, or when the ABS indicator light comes on.The DTC is not memorized when the ABs indicator right comes on unress the cpU is activated.2. The memory can hold any number of DTCs. However, when the same DTc is detected twice or more, the later one iswritten over the old one.
Therefore. when the same problem is detected repeatedly, it is recorded as one DTC.3. The DTCS are indicated in the order of ascending number, not in the order thev occur.4. The DTCS are memorized in the EEpROM {non-volatile memorv}.Therefore, the memorized DTCS cannot be canceled by disconnecting the battery. perform the specified orocedures toerase.
Solf-diagnosis
1. The self-diagnosis can be classifield into these four categories:' Initial diagnosis; Performed right after the engine sta rts and untiltheABs indicator light goes off.o Except ABS control: Performed when the ABS is not functioning,. During ABS control: Performed when the ABS is functioning.. During warning: Performed when the ABS indicator light is ON.2 The system performs the following controls when a problem is detected by the self-diagnosis:. ABS indicator light ON. Memory of DTC
. Mode change to the "system down mode,, or the "control inhibition mode,,.
MODEABS INDICATOR LIGHTMAIN
RELAY
SOLENOID
VALVECPURestart conditionDTC
SYSTEM
DOWNONNo
operal|on
Drive
inhibitionOperation+rlgnition
switchOFF - ONMemory
CONTROL
INHIBITIONONNo
operat|on
Orive
inhibitionOperationAutomaticMemory
*1: Except CPU failure
19-54