starter system HONDA CIVIC 1996 6.G User Guide

Starting System
Component Location Index
A/T GEAR POSITION SW|TCHTest, page 23'154Replacement, page 23-155
STARTER CUT RELAY (M/T}
Test, page 23-86, 87
oo
ool
CLUTCH INTERLOCK
swlTcH
BATTERYTest, page 23-91
STARTERTest, page 23'95Solenoid Test, Page 23 96
Replacement, Page 23-100
Performance Test, Page 23-101
23-93

Starting System
Component Location lndex
GNIT ONSW TCH
t,U,-*€,-l
&T GEARPOSITION SWITCH(Cosed n posilion N or E)
ELKMHT
I
tl81X,4{HT BLKIWHT
STARTERCUT FELAY
STAPTER(Permaneit nragnel type)
N0 4l (80A) N0 42 (40A)
UNDEF.HOOO FUSEiFELAY BOX
-
__l
23-94

-Starter Test
NOTE; The air temoerature must be between 59 and
100'F (15 and 38"C) before testing.
Recommended Procedure:
. Use a staner system tester.
. Connect and operate the equipment in accordance
with the manufacturer's instructions.
. Test and troubleshoot as described,
Alternate Procedurg:
. Use the following equipment:- Ammeter, 0 - 400 A
- Voltmeter, 0 - 20 V (accurate within 0.1 volt)
- Tachometer, 0 - 1,200 rpm
. Hook up a voltmeter and ammeter as shown.
NEGATIVETERMINAL
NOTE: After this test, or any subsequent repair. reset
the ECM/PCM to clear any codes (see section l1)
Check the Start€r Engagemont:
1. Remove the No. 44 (15 A) fuse from the under-hood
fuse/relay box,
2. Turn the ignition switch to START (llll with the shift
lever in E or E position (rVT) or with the clutch pedal
depressed {M/T). The starter should crank the engine.
. lf the starter does not crank the engine, go to
step 3.
. lf itcranksthe engineerraticallyortooslowly, go
to "Check for Wear and Damage" on the next
page.
Check the battery. battery positive cable, ground,
starter cut relay, and the wire connections for loose-
ness and corrosion, Test again.
lf the starter still does not crank the engine, go to
step 4,
Unplug the connector (BLK,/WHT wire and solenoid
terminal) from the starter,
Connect a jumper wire from the battery positive (+)
terminal to the solenoid terminal.
The starter should crank the engine.
. lf the starter still does not crank the engine,
remove it, and diagnose its internal problem
. lf the startercranksthe engine, goto step 6.
Check the ignition switch (see page 23-891.
Check the starter cut relay and clutch interlock switch
(see page 23-86,87).
Check the A/f gear position switch (see page 23-154).
Check for an open in the wire between the ignition
switch and starter.
7.
(cont'd)
23-95
9.

Starting System
Starter Test lcont'dl
Ch€ck tor Wear and Damage
The starter should crank the engine smoothly and
steadily, lf the starter engages. but cranks the engine
erratically, remove it, and inspect the starter drive gear
and torque converter or flywheel ring gear for damage.
. Check the drive gear overrunning clutch for binding
or slipping when the armature is rotated with the
drive gear held,- lf damaged. replace the gears.
Check Cranking Voltsge and Curr€nt Draw
Cranking voltage should be no less than 8.5 volts.
Current draw should be no more than 350 amperes.
lf cranking voltage is too low, or current draw too high,
check for;
. dead or low batterv.
. open circuit in starter armature commutator seg-
ments,
. starter armature dragging.
. shorted armature winding.
o excessive drag in engine.
Check Cranking rpm
Engine speed during cranking should be above 100 rpm,
lf speed is too low, check for:
. loose battery or stanerterminals.
. excessively worn starter brushes,
. open circuit in commutator segments.
o dirty or damaged helical spline or drive gear.
. defective drive gear overrunning clutch.
Check Siarter Disengag€ment
With the shift lever in El or @ position (A/T) or with the
clutch pedal depressed (M/T), turn the ignition switch to
START (lll), and release to ON (ll).
The starter drive gear should disengage from the torque
converter or flywheel ring gear when you release the
Key.
lf the drive gear hangs up on the torque converter or fly-
wheel ring gear, check for:
. solenoid plunger and switch malfunction,
. dirty drive gear assembly or damaged overrunning
clutch.
Starter Solenoid Test
1. Check the hold-in coil for continuitv between the S
terminal and the armature housing (ground). The
coil is OK if there is continuitv,
ARMATUREHOUSING(GROUND)
S TERMINAL
M TERMINAL
B TERMINAL
STARTERCAELE B TERMINALMOUNTING NUTI N.m {0.9 kgf.m,7 tbf.ft)
Check the pull-in coil for continuity between the S
and M terminals. The coil is OK if there is continuity.

Starting System
Starter Replacement
1.Make sure you have the anti-theft code for the
radio, then write down the frequencies for the
radio's preset buttons ('99 - 00 models).
Disconnect the battery negative cable.
Disconnect the starter cable from the B terminal on
the solenoid, then disconnect the BLK trHT wire
from the S terminal.
MOUNTING BOLT44 N.m l/t.s kgf.m. 32 lbf.ft)
S TERMINAL
MOUNTING BOLT6,1 N.m {4.5 kstm.32lbtftl
MOUNTING NUT9 N,m {0.9 kgl.m,6.s lbtftl
B TERMINAL
4. Remove the two bolts holding the starter, then
remove the starter.
lnstall in the reverse order of removal.
NOTE: When installing the staner cable, make sure
that the crimped side ofthe ring terminal is facing out.
TERMINAL
Connect the battery positive cable and negative cable
to the battery.
Enter the anti-theft code for the radio, then enter the
customer's radio station presets ('99 - 00 models).
7.
Crimped side of ring
23-100
Starter Reassembly
'1. Pry back each brush spring with a screwdriver, then
position the brush about halfway out of its holder.
and release the spring to hold it there.
Install the armature in the housing. Next, pry back
each brush spring again, and push the brush down
until it seats against the commutator, then release
the spring against the end of the brush.
aw
3. Install the end cover on the brush holder.
ERUSH HOLDER

Integrated Gontrol Unit
Input Test (cont'dl
A8--------.--all
Key-in/Seat Belt R€mind€r, Lights-on Reminder Systom:
Cavity WireTest condhion
Bulb Check System (Brako System Light):
Cavity WireTest condilion
Tost: D€sirod r€guh
T6st: Dosirad result
Possible cause if result is not obtained
Possibls cause if rasuft b not obtainod
A8
Combination light
switch ON
Check for voltage to ground;
There should be battery voltage.
Blown No.30 (7.5 A)fuse in the
under-dash fuse/relay box
Faulty combination light switch
An open in the wire
B7RED/BLU
lgnition switch ON (ll),
and driver's seat belt
switch unbuckled
Check for voltage to ground:
There should be 1 V or less.
Poor ground (G552)
Faulty seat belt switch
An open in the wire
B9GRNDriver's door openCheck for voltage to ground:
There should be 1 V or less.
. Faulty driver's door switch. An open in the wire
Bl0BLU/RED
lgnition key inserted
into the ignition key
switch
Check for voltage to ground:
There should be 1 V or less.
Poor ground (G401. G402)
Faulty ignition key switch
An open in the wire
A4GRN/RED
lgnition switch ON {ll),
brake fluid reservoir
full, and parking brake
tever oown
Connect to ground: Brake system
light should come on.
Blown No.25 (7.5 Alfuse in the
under-dash fuse/relay box
Blown brake system light bulb
An open in the wire
A13BLUA/1r'HT
lgnition switch at
START (III)Check for voltage to ground:
There should be battery voltage.
Blown No.31 (7.5 A) fuse in the
under-dash fuse/relay box
Faulty starter cut relay
An open in the wire
23-160

Power Distribution
- From Battery to lgnition Switch, Fuses, and Relays
STARTERPage 21,21-1, ot 21-2
.d1.ro"rr" i
I lsoLENorD I
FUSE 42tG1
BATTERY
To UndeFhood ABSFuse/RelayBox onpage 10-14.
FUSE 47EACK UP
T1
FUSE 41AATTEiY&A
I OETECTOR (ELD) UNIT
tii::.':
UO
PHOfO U
,
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t.------J
ELECTRICAL LOAD
i--i rL---- J ELKml
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FUSE 4e
0ro{ Urod)FUSE '13Ir|]EAtOAUGHT?.:ta
FUSE 46POWEaWll'IDOW
FUSE /t4
r| E/M1{rA204 (DrGa5)
FUS€ 48TtEADL|a}fT9|'A
FUSE 50NEAAOEFOCGER304
+------, f| ',
I ruse sr I oooa I
J LOC|( uNrr \
il-.4WHT/BLK
Itr '\
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vlEW 27
c415Se€ Pow€r Distribution,pag6s 10-10 and 10-11.See Power Distribution,page 10-12.
I
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L------BLK/VI/HT
1
--------Jc415
Vehiclespre-wired foraccessorysecuritysystem
c913PHOTO 6A
FUSE 16AR DEFFEIAY
FUSE 17HEATEA!'/C FEIAY
FUSE 18{RUNNINOL|GHlFET.AY)7.54
FUSE 27CIGAFETTEL|oHTEAACC SOCKET ta
arse ra fBADIO \
?o?"* \15A ('94 raodcr)
ff".acc0)
llL--------J
See Power Distribution,pages 10-8 and 10-9.
STARTERCUT RELAYPage 21-2
P/lolo 135 (99 00)
See PowetDistribution,page 10-7.
Vehicles pre-wired for acces-sory security system
To Fuse 3'|, for delails, see StartrnqSystem, page 21,21-1 , ot 21-2. -
10

- Automatic Transmission (All except Dl685)
NOTE: For cars equipped with optional security system, see Security System, page 133-3, .133-7, or 133-12
for starting system circuit schomatic.
Starting System
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ftxiE "2E1404
WHT/BLK
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lta":
c415
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pag€ 10.
slan?(ll)
c415
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Ji.I ELECTRICALI roAoI DETECTOR
I Gt ol ulra Ptfifo I
IJ
BLKAIVHT1
ELK./YEL
au(|vEL
BL'(4I/HT
4
c416PHOTO 53
c4t 6PHO|O 53PHO|O 56 f98 'oo)vtEw t2
c433
Vehiclss pre-wired foraccessory securaty system(Not Used)
R'SE 4IlA??tNY,olALXAVHY'10
Allsxcsptow aLKlvHrcwSoe Pow6r IDistibution, !page 10. a- ----JT1PHOTO 9
BATTERY
BLKAVHT
7
L-----L---JBLKFED
13:;-1ifl;ft?R
!-
)2 'lPHoto tg
a
BLI(RED
1I
ELIVBED
ALKNED
c433PHOTO 76
Soe PowrDslributbn,Pa€o 10.
9 a c101
er.xiwxr I ffo,rtfl't
c4rIPHO|O 63
Ft gg 3r5? F En 3E ^r7.94
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r'STARTERPHO|O 34UNDER.DASHFUSE/RELAYBOX
A13
tl
II{TEGRATEDco|{TnoLUT{ITPHOfOUvtEw 67,--==--J
Sso PGM-FI, page&1 ot 24-1.
21
lGl

- Manual Transmission
NOTE: For cars equipped with optional security system, see Security System, page 133-3, or 133-7, or 133-12
for starting system circuit schematic.
Starting System
c3s2PHOTA 8vtEw 27
WHT/BLKc415
FUSE 42to!a0a
UNDER-HOODFUSE/RELAYBOXI
I
I
_l
IELECTBICALIOADDETECTOR(ELO) UN|TPtloro I
Sae Po'/Y€rDislibution,pag€ 10.------JT1
Se6 GroundDislribution,page 14-6.
BATTERY
STARTERCUTRELAY
PHO|A 129198)PllO|O r35 f99 00)
a
BLK/FED
9
BLKAVHT
ct01
vlEW 2A
c4't9
vtEw 49
FUSE 31STAATER SICIIAL7.5A
STARTER
4
Sse PGM-FI,page 231ot 2+1.
UNDER-DASHFUSE/RELAYBOX
At3
tl
tl
INTEGRATEDcol{tRoLut{llPHO|O U
r.------T-------------=;-*^:-lsrEERtNG
I i 1'----> R*.|?xf: iiiliffi' t"t%?I,,I Distribulion.1j;cx y' page 10.(0)
it-jtr'tl i
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r---_-_€rx^,:jF;f
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;--;*;.-f -- ^.:---.---1--
,'rr-'OO .o0"," 3,rffiEj,
---;;;;i[
cLUrcH TNTERLOCK tClosed wrlh clutch pedal Ifully depressed. llPHoro 1ra I"**"
!
Se€ PowerDistibution,page 10.
4('98100 models 3)ALU/BLK
f2 lE--r.---?q_l srAFrEn
21-2
I- G1

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ii^ / _;l"d:lt':"i i:ll*cK ( - t*.r.$r Ii!tff^.I^-.-f fl''i" I r
i! ti't|l ! rL---------J-{,5=;==---)"'*TA
"o'uetxret I Pflllodo
l:'iISECURITYSTARTERCUT RELAYPHOTO 53PTOIO 56 ( 98 modsls)vlEW 12
STEERINGLOCK
a
lll except CW
!'G";1cutouiput
SECURIryCONTROLUNIT
vtEw 58
MrrCVT
;BLKTTVHT
('98 model 5)
"a*-", Io
.I A/T GEARI POSTflONa swtTcHPHOfO 78STARTERCUTRELAYfrc433Bt( vHT
10aL|( vHr('98 model 3)4
BLU/BLK
--T6-';'d"r tlf3l
".,u".o I
T
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cLUrcH llTNTERLoCK I
Slig:i* J,clutchpedalfullyoepresseo.
8LK/FED11t A/T GEARI POSTTTONa swrTcH
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c433ot-r\
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BLKRED
".o"ro! BLvFEo.@
"'o"'r"f,
"'ot
ro'ffzr----,
SeeStartingSystemSe€ G.oundDistribution,page l4$.
BLKAVHTTY
II
L____l+.: G401PHOTO 57
STARTER
r::1 STARIER
I uo'r I soLE orD
tl
;-
".orr.i tr-
- -
to :l cat t
*"1.;
[;z*e'
an
L---J---ALI(RED
",#"It#f;,.+,"
rl r
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133-3