replace HONDA CIVIC 1996 6.G Workshop Manual

JArmature Inspection and Test
1.Inspect the armature for wear or damage due to con-
tact with the permanent magnet or field winding.
. lf there is wear or damage. replace the armature.
Inspect for damage.
2. Check commutator surface and diameter.
. lf the surface is dirty or burnt. resurface with emery
cloth or a lathe within the following specifications,
or recondition with #500 or #600 sandpaper.
. lf commutator diameter is below the service limit,
replace the armature.
Commutator Diameter
Standard {NEW)Service Limit
28.0 - 28.1 mm
(1.102 - 1.106 in)
27.5 mm
(1.083 in)
VERNIER CALIPEB
3. Measure the commutator runout.
. lf the commutator runout is within the service
limit, check the commutator for carbon dust or
brass chips betlveen the segments.
. lf the commutator runout is not within the ser-
vice limit, replace the armature.
Commutator Runout
Standard (NEW)Service Limit
0 - 0.02 mm(0 - 0.0008 in)
u-u!r mm
(0.002 in)
COMMUTATOR
(cont'd)
23-97

Starting System
Armature Inspection and Test (cont'dl
4. Check tor mica depth. lf necessary, undercut mica
with a hacksaw blade to achieve proper depth. l{ ser-
vice limit cannot be maintained, replace the armature.
MICA D€PTH
Commutator Mica D€pth
5. Check for continuity between the segments of the
commutator. lf an open circuit exists between any
segments, replace the armature.
NOT GOOD
Standard (NEW)Service Limit
0.4 - 0.5 mm
(0.016 - 0.02 in)
0.15 mm
(0.006 in)
23-98
corL coFECOMMUTATOR
6. Place the armature on an armature tester. Hold a
hacksaw blade on the armature core.
ARMATURE TESTER
. lf the blade is attracted to the core or vibrates
while the core is turned, the armature is shorted.
Replace the armature.
7. Check with an ohmmeter that no continuity exists
between the commutator and armature coil core,
and between the commutator and armature shaft. lf
there is continuity, replace the armature.
ARMATURE

JBrush Holder Test
1. Check that there is no continuity between the O and
o brush holders.
lf there is continuity, replace the brush holder
assemoly.
O BRUSH HOLDER
@ BRUSH HOLDER€) BRUSH HOLDER
2. Insert the brush into the brush holder, and b.ing the
brush into contact with the commutator, then attach
a spring scale to the spring. Measure the spring ten-
sion at the moment the spring lifts off the brush.
SPRING SCALE
Spring Tension
15.7 - 17.7 N (1.60 - 1.80 kgf. 3.5 - 4.0 lbf)
ERUSH
Brush Inspection
Measure the brush length. lf not within the service limit,
replace the brush (or brush holder assembly).
Brush Length
NOTE: To seat new brushes after installing them in their
holders, slip a strip ot #500 or #600 sandpaper. with the
grit side up, over the commutator and smoothly rotate
the armature. The contact surface of the brushes will be
sanded to the same contour as the commutator.
Overrunning Clutch lnspection
Slide the overrunning clutch along the shaft. Does it
move freely? lf not, replace it.
Rotate the overrunning clutch both ways. Does it
lock in one direction and rotate smoothly in
reverse? lf it does not lock in either direction or it
locks in both directions, replace it.
2.
L
Standard (NEW)Service Limit
15.8 - 16.2 mm
(0.62 - 0.64 in)
1 1.0 mm
{0.43 in)
CLUTCH GEAR
DRIVE GEAR

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

lgnition System
Component Location Index
IGNITION TIMING CONTROL SYSTEM
. Troubleshooting, section 11
. ldle speed Inspection/Adjustment. section 11
. Inspection and Setting, page 23-105
SERVICE CHECK CONNECTOR {2P}Iwiie colors: 8RN and BLKI
TEST TACI{OMETER CONNECTOB
IGNITION WIRESlnspection and Test, page 23-110
PLUGSInspection, page 23 1 11
Replacement, page 23'106Overhaul, page 23-107lgnition Coil Test, page 23'110lgnition Control Module llCM)Input Test, page 23-109
23-102

lgnition System
Distributor Replacement
Removal:
1. Disconnect the connector from the distributor.
2. Disconnect the ignition wires from the distributor
ignition {Dl) cap.
3. Remove the mounting bolts from the distributor,
then remove the distributor from the cylinder head.
DISTRIBUTOR END CAMSHAFT END
MOUNTING BOLT18 N.m 11.8 kgtm, 13lbf.ltl
lnstallation:
NOTE: Before you install the distributor. bring the No. 1
piston to compression stroke TDC.
1. Coat a new O-ring with engine oil, then install it.
2. Slip the distributor into position
NOTE: The lug on the end of the distributor and its
mating grooves in the camshaft end are both offset
to eliminate the possibility of installing the distribu-
tor 180" out of time.
3. Installthe mounting bolts, and tighten them lightly.
23-106
4, Connect the ignition wires to the distributor ignition
(Dl) cap as shown.
rracfit'
No. 1CYLINDERMARK
No. 1CYLINDER
TEG:
5.
6.
7.
No. 2No. a
Connect the connector to the distributor.
Set the ignition timing (see previous page).
After setting the ignition timing, tighten the mount-
ing bolts.

el -Distributor Overhaul
HITACHI:
TOC/CKP/CYP
DISTRIBUTOR IGNITION {DI} HOUSINGCheck for cracks and damage.
Troubleshooting, section 1 1
Do not disassemble.
CAP SEALCheck for damage.
IGNITION CONTROL MODULE (ICMI
Input Test, page 23'109
IGNITION {DI) CAP
Check for cracks, wear,damage, and fouling.Clean or replace,
{cont'd)
23-107
Test, page 23_110

lgnition System
Distributor Overhaul (cont'dl
TEC:
IGNITION CONTROLMODULE IICM'Input Test, page 23-1
DISTRIBUTOR IGNITION {DI} HOUSINGCheck for cracks and damage.
COVER
DISTRIBUTOR IGNITION IDI) ROTOB
CAP SEALCheck for damage.DISTRIBUTOR IGNITION {DII CAPCheck for cracks, wear,damage, and fouling.Clean or replace,
IGNITION COILTest, page 23-110
O-RINGReplace
\
I
@
TDC/CKP/CYP S€NSORTroubleshooting, section 1 1Do not disassemble.
WHT/BLU
23-104

Jlgnition Control Module (lCMl Input Test
NOTE:
. See section 1'l when the malfunction indicator lamp
(MlL) turned on.
. Perform an input test for the ignition control module
(lCM) after finishing the fundamental tests for the
ignition system and the fuel and emissions systems
1. Remove the distributor ignition (Dl) cap, the distrib-
utor ignition (Dl) rotor and the leak cover (TEC).
2. Disconnect the wires from the lCM.
HITACHI:
BLK/YEL
TEC:
Turn the ignition switch ON (ll). Check for voltage
between the BLK/YEL wire and body ground.
There should be battery voltage.
. lf there is no battery voltage, check the BLK/YEL
wire between the under-dash fuse/relay box and
rhe lcM.
. lf there is battery voltage, go to step 4.
Turn the ignition switch ON (ll). Check for voltage
between the wire*r and body ground
There should be battery voltage.
. lfthere is no battery voltage, check:
- the ignition coil.
- the wire*1 between the ignition coil and the
tcM.
. lf there is battery voltage, go to step 5
*1: BLU'wire (HITACHI)
WHT/BLU wire (TEC)
Disconnect the EcM/PCM connector A (32P). Check
for continuity on the YEUGRN wire between the
ECM/PCM and the lCM.
There should be continuity.
Check for continuity on the YEUGRN wire to body
ground.
There should be no continuity.
Check for continuity on the BLUl wire between the
test tachometer connector and the ICM
There should be continuitY.
Check for continuity on the BLUl wire to body ground.
There should be no continuity.
lf all the tests are normal, replace the ICM
7.
23-109

lgnition System
lgnition Coil Test
Using an ohmmeter, measure resistance between the
terminals. lf the resistance is not within soecifications.
replace the ignition coil.
NOTE: Resistance will vary with the coil temperature;
specifications are at 68'F (20'C).
HITACHI:
Primary Winding Resistance
{Betwesn the A and B lerminalsl;
0.45 - 0.55 0
Secondary Winding Resistanc€
(Between the A and secondary winding terminals):
22.1 - 33.6 kA
TERMINAL B {-)
TERMINAL A
TEC:
Primary Winding Resistsnce
{Between the A and B terminalsl:
0.63 - 0.77 0
Secondary Winding Resistance
(Between the A and secondary winding terminals):
12.8 - 19.2 kO
SECONDARYWINDINGTERMINAL
TERMINAL A
23-110
TERMINAL B (-)
lgnition Wire lnspection and Test
CAUTION: Carelully remove the ignition wires bypulling on the rubber boots, Do not bend the wires; you
might break them inside.
'1. Check the condition of the ignition wire terminals. lf
any terminal is corroded, clean it, and if it is broken
or distorted, replace the ignition wire.
Check for broken,corroded, and bentlermrnals.IGNITION WIRE
Connect ohmmeter probes and measure resistance.
lgnition Wire Resistance:
25 k0 max. at 68"F (20"C)
IGNITION WIRE
3. lf resistance exceeds 25 kO, replace the ignition wire.