D16y8 intake manifold HONDA CIVIC 1996 6.G Workshop Manual

13. Remove the upper radiator hose' heater hose and
water bYPass hose
WATEREYPASSHOSEUPPERRADIATORHOSE
14.
HEATERHOSE
Remove the engine wire harness connectors and
wire harness clamps from the cylinder head and the
intake manifold.
o Four fuel injector connectors
. Engine coolant temperature (ECT) sensor con-
nector
a
a
a
ECT switch connector
ECT gauge sending unit connector
Throttle position sensor connector
Manitold absolute pressure (MAP) sensor con-
nector
Primary heated oxygen sensor (primary HO2S)
connector
Secondary heated oxygen sensor (secondary
HO2S) connector (D16Y7 engine)
Exhaust gas recirculation (EGR) valve lift sensor
connector (D16Y5 engine)
. VTEC solenoid valve connector (Dl6Y5, D16Y8
engrnes)
. VTEC pressure switch connector (D16Y5. D16Y8
engrnes,
. ldle air control (lAC) valve connector
15.Remove the spark plug caps and distributor from
the cylinder head.
Remove the uPPer bracket.
NOTE:
. Use a jack to support the engine before the
upper bracket is removed.
. Make sure to place a cushion between the oil
pan and the jack.
12 x 1.25 mm
74 N.m {7.5 kgf m.
sil lbl.ftl
UPPERBRACKET
'17. Remove the cylinder head cover'
CYLINDERHEAD COVER
(cont'd)
6-29

lntake Manifold
Replacement (cont'dl
NOTE: Use new O,rings and gaskets when reassembling.
CAUTION:
. Check lor folds or scratches on the surface of the gasket.. Replace with a new gasket il damaged.
D16Y8 engine:
INTAKE MANIFOLDReplace if cracked orif mating surfaces areoamageo,
INTAKE AIR CONTROL{ract vAt_vE {M/Tl
GASKETReplace.
8 x 1.25 mm24 N.m {2.{ kgtm.17 tbtftt
THROTTLEBODY
8 x 1.25 mm22 N.rn |.2.2 kgl.rn,16 tbtft)INTAKE MANIFOLDBRACKET
9-4

System Description
Vacuum Connections (cont'd)
D16Y8 engine ('96 sedan, '97 sedan: KA, KC modelsl:
PRIMARY HEATED OXYGEN SENSOR (PRIMARY HO2S.SENSOR SECONOARY HEATED OXYGEN SENSOR {SECONDARYHO2S, SENSOR 2lMANIFOLD ABSOLUTE PRESSUBE {MAPI SENSORENGINE COOLANT TEMPERATURE {ECTI SENSORINTAKE AIR TEMPERATUFE IIATI SENSORKNOCK SENSOR IKSICRANKSHAFT SPEED FLUCTUATION {CKFI SENSORIDLE AIR CONTROL IIACI VALVETHROTTLE EODY (T8)FUEL INJECTORFUEL FILTER
FUEL PRESSURE REGULATORFUEL PUMP {FPIFUEL TANKFUEL TANK EVAPORATIVE EMISSION IEVAP} VALVEAIR CLEANERRESONATORPOSITIVE CRANKCASE VENTILATION {PCV} VALVEEVAPORATIVE EMISSION IEVAP) PURGE CONTROLSOLENOID VALVEEVAPORATIVE EMISSION IEVAPI CONTROL CANISTEREVAFORATIVE EMISSION IEVAP} TWO WAY VALVETHREE WAY CATALYTIC CONVERTER (TWC'
{M/T}
i@l: F@i
HiiFl
(A/T)
I ENGINE I
I coor-rruri
i@ i+ il/A. nfi |(Or)l /U[ |)l#t,/,6
0)
t;
-l
@
!o,(t
@@@
@@@(9
@@@(D
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11-22

D16Y8 engine l'96 coupe.'97 coup6: all models.'97 sodan: KL modol.'98 modell:
?
3-
a67.a
9,!
1?
!1{r5
PRIMARY HEATEO OXYGEN SENSOR IPRIMARY HO2S,
SENSOR 1)SECONDARY HEATED OXYGEN SENSOR ISECONDARY
HO2S. SENSOR 2l
MANIFOLD ABSOLUTE PRESSURE IMAPI SENSOR
ENGINE COOLANT TEMPERATURE IECTI SENSOR
INTAKE AIR TEMPERATURE (IATI SENSOR
KNOCK SENSOR {KS)CRANKSHAFT SPEED FLUCTUATION ICKFI SENSOR
IOLE AIR CONTROL {IAC) VALVE
THROTTLE BODY ITBIFUEL INJECTORFUEL FILTERFUELPRESSURE REGULATOR
FUEL PUMP IFPIFUEL TANKFUEL TANK EVAPORATIVE EMISSION IEVAP)VALVE
AIR CLEANERRESONATORPOSITIVE CRANKCASE VENTILATION (PCV) VALVE
EVAPORATIVE EMISSION IEVAPI PURGE CONTROL
SOLENOID VALVEEVAPORATIVE EMISSION {EVAPI CONTROL CANISIER
EVAPORATIVE EMISSION IEVAPI BYPASS SOLENOIO
VALVEEVAPORATIVE EMISSION {EVAPI THREE WAY VALVE
EVAPORATIVE EMISSION IEVAPI CONTROL CANISTER
VENT SHUT VALVEFUEL TANK PRESSUFE SENSOREVAPORATIVE EMISSION IEVAP) TWO WAY VALVE
THREE WAY CATALYTIC CONVERTER ITWCI
@o@@
@@
@@
@@@
(cont'd)
11-23

System Description
Vacuum Connections (cont'dl
D16Y8 engine l'99 - 00 modetsl:
(]-i PAIMARY HEATEO OXYGEN SENSOR {PRIMARY HO2S,SENSOR 1)..2r SECONOARY HEATEO OXycEN SENSOB ISECONDARYHO2S, SENSOR 2li3) MANIFOLD ABSOLUTE PBESSURE {MAPI SENSORO ENGINE cooLANT TEMPERATURE (ECTI sENsoR(5) INTAKE AIR TEMPERATURE {IAT} sENsoRG] KNOCK SENSOR IKSI?r CRANKSHAFT SPEEo FLUCTUATTON {CKF) SENSOR.O IDLE AIR coNTRoL {IAc)vALvEi-9] THROTTLE BOOY {TB)(O FUEL INJECToRI]'i FUEL FILTER.O FUEL PRESSURE REGULAToR[t FUEL PUMP {FPl.D FUEL TANKil' AIR CLEANERTD RESONATORO FUEL TNJEC oN AtR tFtA) coNTRoL vAt_vE.19 POSITIVE CRANKCASE VENTILATION {PCVI VALVE
.19) EVAPORATIVE EMIssIoN {EVAP) PURGE coNTBoLSOLENOID VALVE€g PURGE JorNTtj EVApoRATtvE EMtsstoN {Evap} coNTRoL cANtsTERC4 EVAPONANVE EMISSION (EVAP) BYPASS SOLENOIDVALVE
?3 EVAPORATIVE EMISSION {EVAP} CONTROL CANISTERFILTERA4 EVAPoBATIVE EMIssIoN (EVAP) coNTRoL CANISTERVENT SHUT VALVEC! FUEL TANK PRESSURE sENsoREO EVAPOBATIVE EMISSION (EVAP) TWO WAY VALVEe? oNBoARD REFUELtiIG vApoR REcovERy {oRvR} VENTSHUT VALVE@ oNBoARD REFUELTNG vapoR REcovERy (oRvR) vapoRRECIRCULATION VALVEiP THREE WAY CATAI.YTIC CONVEBTER {TWCI
'- *o'*- -
COOLANT
]L
nrl
L
ii8'x'", *
--j IIM TTI ^n 14 [l(2i)-fr l-1ry|
11-24

ECM/PCM CONNECTOR D I16P)
Wire side ot female terminals
ECM/PCM CONNECTOR D l16P)NOTE: Standard battery voltage is 12 V
Te.minalnumb€r
Wirecolor
Terminaln!meDor.riptionSignal
RED/BLKTPS (THROTTLE POSITION
SENSOR}
Detects TP sensor signal.With throttle fully open: about 4.8 V
With throttle fully closedl about 0.5 V
REDA/VHTECT {ENGINE COOLANTTEMPERATURE SENSORDetects ECT sensor signalWith ignition switch ON{ll): about 0.1 - 4 8 v
(depending on engine coolant lempe ratu re)
3RED/G RNMAP {MANIFOLD ABSO'LUTE PRESSURE SENSOR}Detects MAP sensor signal.With ignition switch ON(ll): about 3 V
At idle: about 1.0 V
{depending on engine speed)
YEUREDVCCl (SENSOR VOLTAGE)Power source lor MAP sensor.With ignition switch ON (ll): about 5 v
With ignition switch OFF: 0 V
5GRNMHTBKSW {BRAKE SWITCHIDetects brake switch signalWith brake pedal released: 0 v
With brake pedal depressed: baftery voltage
6*?RED/BLUKS {KNOCK SENSOR}Detects KS signal.With engine knocking: Pulses
1
PHO2S (PRIMARY HEAT-ED OXYGEN SENSOR,SENSOR 1)
Detects Primary heated oxygen
sensor (sensor 1l signal
With throttle fullv opened from idle with
Iully warmod up engine: above 0.6 V
With throttle quickly closed: below 0.4 v
LABELDetects LABEL resistanceWith engine r!nning:about 0.3 - 4.9 V
8RED//ELIAT (INTAKE AIR TEM-PERATURE SENSOR)
Detects IAT sensor signal.With ignition switch ON (ll): about 0 1 -
4.8 V {depending on intake air temperature)
9*lWHT/BLKEGRL iEGR VALVE LIFT
SENSOR)
Detects EGR valve lift sensor signalAt idle without vacuum: about'1 2 V
With 27 kPa (2OO mmHg,8 in. Hg): about 4 3 V
10YEUBLUVCC2 (SENSOR VOLTAGE)Provides sensor voltage,With ignition switch ON(ll): about 5 V
With ignition switch OFF:0 V
11GRN/BLKSG2 (SENSOR GROUND}Sensor ground.Less than 1.0 V at alltimes
12G RN,4/1r'HTSG1 (SENSOR GROUND)Ground for MAP sensor.Less than 1.0 V at alltimes
GRN/BLK*1?SHO25G (SECONDARY
HEATED OXYGEN SEN'
SOR, SENSOR 2 GROUND)
Ground for secondary heated oxy-
gen sensor (sensor 2).
14WHT/REDSH02S (SECONDARY
HEATED OXYGEN SEN'soR, sENsoR 2)
Detects secondary heated oxygen
sensor (sensor 2) signal.With throftle fully opened lrom idle with
fully warmed up engine: above 0.6 V
With throttle quickly closed: below 0.4 V
15|3. *15LT GRNPTANK {FUEL TANK PRES.
SURE SENSOR)
Detects fueltank prgssure sensor'With fuelfill caD opened: about 2.5 V
16*1GRN/RED
EL (ELD)Detects ELD signal.With parking lights turned on at idle: about
2.5 - 3.5 VWith low beam headlights turned on at
idle: about 1.5 - 2.5 V
*1: USA model*2r A/T (D16Y7, D16Y8 engine)*3: CVT (D16Y5 engane)*4: A,/T and Dl6Y7 engine*5: Except A/T and D16Y7 engine*6: A"/T (D16Y8 engine)i7: CVT (Dl6Y5 engine) and Dl6Y8 engine*8: .96 D16Y8 engine (coupei,'97 D16Y8 engine
models, sedanr KL model),'98 016Y5 engine,
engine, '99 - 00 D16Y5 (M/T) engine
*9: D16Y5 engine*10: M/T (D16Y5 engine)*11: Except M/T (Dl6Y5 engine)* 12r D16Y5. D16YB engine*13: D16Y8 engine*14: Dl6W engine*15: '97 D16Y7 engine (coupe: KL model, sedan: KL lLX) model),'98D16Y7 engine:(coupe: all'98 D16Y8
(cont'd)
1 1-91

ldle Control System
System Description
The idle speed ot the engine is controlled by the ldle Air Control (lAC) Valve.The valve changes the amount of air bypassing into the intake manifold in response to electric current controlled bv theECM/PCM. When the IAC Valve is activated, the valve opens lo maintain the proper idle speed.
D16Y5, D16Y8, Br6A2 engine (M/T):
(ROTARYItac vat-vEEI{GINEcooLAI{T
VARIOUSsEI{SORS
VARIOUSSENSORS
INTAKE MANIFOTDDl6Ys {CVTl, D16Y8 engine lA/T):
D16Y7 engine:
{ROTABY)
;iy--, - --- INTAKEMANIFOLD
11-190

Fuel Supply System
Fuel Injectors
Replacement
@ Do not smoke when working on the tuel systgm, Keep gp6n flames away from your work area
'f. Relieve the fuel pressure (see pages 11-230,231J.
2. Disconnect the connectors from thefuel injectors (D16Y7 engine: Remove the air cleaner).
3. Disconnect the vacuum hoses from thefuel pressure regulator. Placeashoptowel overthefuel return hose, then dis-connect it from the fuel pressure regulator. Disconnect the vacuum hoses and 2P connector from the EVAp purgecontrol solenoid valve.
4. Remove the retainer nuts on the fuel rail.
5. Disconnect the fuel rail.
6. Removethefuel injectors from the intake manifold.
D16Y5, D16Y8 engine:
NOTE: lllustration shows D16Y8 engine.
D16Y5 engine is similar.
12 N.m11.2 kgl.m,8.7 rbt.ft)
12 N.m11.2 lgl.m,8.7 rbt.ftl
.q
wE4
Y
Ve
ffi}Yg
E
O.RINGReplace.
CUSHIONRINGReplace.
O.RINGReplace.
cusl{toNRINGReplace.
SEALRINGReplace.
ffi
E
EV
R
w
t
YEVAPPURGE CONTNOLSOLENOID VALVE
FUEL
11-232

Intake Air System
\JSystem DescriPtion
The system supp|ies air for a|| engine needs' |t consists of the intake air pipe' Air C|eaner (ACL}, intake air duct, Thrott|e
Body (TB), ldle Air control (lAc) valve and intake manifold. A resonator in the intake air pipe provides additional silencing
as air is drawn into the system.
D16Y5, D16Y8, 816A2 engine {M/Tl
YEL/ - From PGM-FIaLK - MA|N RELAY
BLK/BLU
-- ORN
INTAKEAIRDUCT
IROTARYIIAC VALVE
Iaru
ENGINECOOLANT
BLK/
INTAKEAIR DUCT
I
D16Y5 engine (CVT), D16Y8 engine (A/T)' f'ttlxr ,tla"tpoto
D16Y7 engine:
{ROTARY)IAC VALVE
VARIOUSSENSORS
INTAKEAIRPIPE
tr
RESONATOR
!r,
IAC VALVE
BLK
11-243

Emission Control System
Positive Crankcase Ventilation IPCVI System
Descripiion
The Positive Crankcase Ventilation (PCV) system is
designed to prevent blow-by gas from escaping to the
atmosphere. The PCV valve contains a spring-loaded
plunger. When the engine starts, the plunger in the PCV
valve is lifted in proportion to intake manifold vacuum
and the blow-by gas is drawn directly into the intake
manifold.
D15Y5, D16Y8, 816A2 ongins:
BREATHERHOSE
Dl6'|11 6ngin6:
-: aLOW-BY VAPOR-: FnESH AIF
11-266
tJ
lrcpection
1. Check the PCV hoses and connections for leaks and
clogging.
2. At idle, make sure there is a clicking sound from the
PCV valve when the hose between the PCV valve
and the intake manifold is lightly pinched with your
fingers or pliers,
D16Y5, D16Y8 ongins:
BREATHERHOSE
PCV VALVE
Gently pinch here.
Bl6A2 engins:VALVE
lf there is no clicking sound, check the PCV valve
grommet for cracks and damage. If the grommet is
OK, replace the PCV valve and recheck.
PCV