cooling HONDA CIVIC 1996 6.G Workshop Manual

MEASUREMENTSTANDARD INFWIEngine oilCapacityf (uS qt, lmp qt)
Inner-to outer rotor radial clearancePump body-to outer rotor radialclearancePump body to-rotor axial clearance
4.8 (5.1, 4.2) for eng;ne overhaul4.0 (4.2, 3.5) for oil change, ;ncludin3.7 (3.9.3 3)for dil .h,nde '^,irh^,,rg oilfilter
Oil pump0.04 - 0.16 {0.002 - 0.006)0.10 - 0.19 (0.004-0.007)0.02 0.07 10.001 ,0.003)
0.20 (0.008)
0.20 {0.008)0 15 {O OO6iRelief valvePressure setting 176"F (80.C)kPa (kgflcm,, psi) at;dteat 3,000 rpm70 (0.7, 10) min.340 (3.5,50) min.
Standards and Service Limits
Engine Lubrication (B16A2 engine) (cont,d) - Section 8
Cooling - Section 10
L,
L.
MEASUREMENTSTANOARO {NEW)RadratorCoolant capacity t 1US qt, tmp qt)including engine, heater, cooling line andreservotr
Beservoir capacity:0.4 f {0.42 US qt, 0.35 lmp qt)
81642 engine5.0 {5.3, 4.4) for overhaul4.5 (4.8, 4.0) for cootant changeD16Y5, D16Y7, D16Y8 engines:M/T: 4.2 (4.4, 3.7)for overhaul3.1 (3.3, 2.7) for coolant changeA"/T: 016Y74.1 (4.3, 3.6) for overhaul3.0 (3.2, 2.6) for cootant changeDl6Y84.3 {4.5, 3.8)for overhaul3.2 (3.3, 2.8) for cootant changeCW: 4.3 (4.5,3.8)for overhaul3.2 (3.3, 2.8)for cootant chanqeRadiator capOpeningpressure kPa(kgl/cm,,psi)
Start to open .F (.C)Fully open "F ('C)Valve lift at fulty open
93 123 (0.95- 1.25, 14 18)
169 - 176 (76 80)194 (90)
8.0 (0.31)min.
196 - 203 191 95)Subtract 5 - 15 {3 - 8) from actual ,,ON,, temperature
Thermostat
Cooling fanThermoswilch 'ON" temperature F r.C,Thermoswitch "OFF' lemperature .F ( C)
L
3-6
L,

trEM I merntc ENGLISH NorEs
SfAnff n i*nt-i- W"'gf,t MllSUBA r.u, l.z kw r'4 rg
CLUTCHClutch Type
Clutch Facing Area
M/T
CVTM/T
Single plate dry, diaphragm springTorque converterMulti plates wet sanP, hYdraulic160 cm,25 sq in
Synchronized 5-speed forward, 1 reverse
4 speed automatic, 1 reverse
Non stage speed forward, 1 reverse
Direct 1 : 1
TRANSMISSIONTransmission Type
Primary Reduction
M/TArrCW
Manualtransmission
Gear Ratio 1st2nd3rd4th5thReverse
Final Reduction Gear ratio
Gear tYPe
Engine type
D16Y5 | D16Y7 D16Y8 I 81642
3.2501.1821.1120.9090.7023.153
3.2501.1821.1120.9090.7023.153
3.2501.9091.2500.9090.1023.153
3.2302.1051.4581.1070.8753.000
*1:2 doorHatch back+2r 2-door Coupe,and 4 doorSedan
3.122 13.122"11.053" 1 4.250 | 4.266
Single helicalgear
Engine type
D16Y7 | D16Y8Automatic transmission
Gear Ratio 'lst
2nd3rd4thReverse
Final Reduction Gear ratio
Gear tYPe
2.6001.4680.9260.6381.954
2.122
0.9750.6381.954
1.3514.357
cwGear Ratio Low - O.D.Reverse
Secondary Reduction Gear Ratio
Final Reduction Gear Ratio
2.466 0.4492.4661.3334.357
AIRCONDITIONING
Cooling Capacity3,530 Kcal/h14,000 BTU/h
Compressor Type/MakeNo. of CYlindersCaPacitYMax. SpeedLubricant CaPacitY
Scroll/SANDEN
85.7 m//rev 5.22 cu inkev10,000 rpm130 mf 41l3tl oz.
| 4.6 imp ozsP,10
Compressor Type/ManufacturerNo. of CylinderCapacityMax. SpeedLubricant CaPacitY
Lubricant TYPe
Swash-plate/DENso10155.3 mf /rev 9.4 cu_in/rev76,000 rpm140 mf | 4 2l3fl oz,I 4 9lmp ozND'OIL8
Condenser TypeCorrugated fin
Evaporator TyPeCorrugated fin
Elower TyPeMotor InputSPeed ControlMax. CaPacity
Sirocco fan200w112v4 speed variable460 m3/h 16,200 cu ft/h
Temperature Control
Compressor Clutch TyPePower ConsumPtionDry, single plate, PolY-V'belt drive40 W max./12 V at 68'F (20'C)
Refrigerant TyPeouantity
HFC 134a (R'134a)
650 gos | 22.9 isoz
(cont'd )
4 . J-Z I

Engine
Engine Removal/lnstallation ................ 5-1
Gylinder Head/Valve Train ................... 6-1
Engine Bfock .......... ...........7-1
Engine Lubrication ........... 8-1
Intake Manifold/Exhaust System ........ 9'1
Cooling ......... 10-1

Engine Removal/lnstallation
Installation (cont'd)
Except CVT:
12 x 1.25 mm64 N.m (6.5 kgd.m,
Tighten the bolts/nut on the left front mount in thenumbered sequence shown {O - @).
(t 12 x 1.25 mm83 N'm (8.5 kgf.m,61 tbt.trl
/+4 N.m 14.5 kgf.m,33 lbt.trl
O 12 r 1.25 mm59 N.m 16.0 kgt.m,43 tbt.rtlSeplace.
5-16
\
7. Perform the following:
. Clean the areas where the driveshaft(s) and theintermediate shaft contact the transmission (dif_ferential) thoroughly with solvent or carburetorcteaner, and dry with compressed air.. Check that the set rings on the ends of the drive_shaft and intermediate shaft click into place.CAUTION: Use new set rings,. Adjust the shift cable (see section 14).. Adjust the throttle cable (see section 11).. Adjust the cruise control cable (see section 23).. Refill the engine with engine oil (see page 8-6).. Refill the transmission with fluid (see section 13,14).
. Refill the radiator with engine coolant (see page10-7).
. Bleed air from the cooling system with the heatervalve open (see page j0-7).
. Clean the battery posts and cable terminals withsandpaper, assemble them, then apply grease toprevent corrosaon.. Inspect for fuel leakage (see section j l).After assembling the fuel line, turn on l) the igni_tion switch (do not operate the starter) so that thefuel pump runs for approximately two secondsand the fuel line pressurizes. Repeat this opera_taon two or three times, then check for fuel leak_age at any point in the fuel line,

Cooling
fllustrated Index ."..."... ""' 10-2
Radiator
Replacement .'....'...."..."
Engine Coolant Refilling and
Bleeding
Cap Testing
Testing
Thermostat
Replacement .............'....
Testing
10-6
10-7
10-9
10-9
10-10
10-10
Engine Goolant TemPerature
(ECT) Switch
Testing """ 10-11
Water PumP
fffustrated Index ......'... " 10-12
Inspection ' 10'14
Replacement ..'..'...."...'.'....'..'.....'.""" 10-14
!

lllustrated Index
@@ system is under high pressure when theengine is hot. To avoid dangsr of rsleasing scaldingengine coolant, removo the cap only when the engine iscoot.
Total Cooling System Capacity flncluding heater andfoservoir (0.4 f (0.42 US qt, 0.35 tmp qt)ll:
*2: 81642 engine*3: D16Y7 engine*4: D16Y8 engine
CAUTION: lf any engine coolant spills on painted por-tions of the body, rinse it off immediately.
NOTE:
. Check all cooling system hoses for damage, leaks ordeterioration and replace if necessary.. Check all hose clamps and retighten if necessary.. Use new O-rings when reassembling.
RADIATOR CAPPressure test, page '10 86x1.0mm9.8 N.m {1.0 kgtm,7.2 tbt.ltl
UPPERRADIATORHOSE
UPPER BRACKETAND CUSHION
COOLANT
RAOIATOREngine coolant refilling and bleeding,page 10 7Leak test, page 10-9Inspect soldered joints andseams for leaks,Blow out dirt Irom betweencore fins with compressed air.lf insects, etc,, are cloggingradiator, wash them off withrow pressure water.
RESERVOIR
5x0.8mmA: ,1.4 N.m {0.45 kgf.m, 3.3 tbtftlg: 5.4 N.m (0.55 kgtm.4.0 tbf.ft)
6x1.0mm7.2 N.m (0.73 kgt.m,5.3 tbtftl
LOWERCUSHION
RADIATOR FANBADIATORFAN
DRAINPLUG
O-RINGReplace.
LOWEBRADIATORHOSE
FAN MOTOR SHROUD
Ar TOYO RADIATOR manufactured radiatorB: NIPPONDENSO manufacfared raoraror
10-2
Refer to section 14when installing.
Mt-|-4.2 f (4.4 US qt,3.7 tmp qt)*j
5.0 / (5.3 U$ q1, 4.4 16p q11*z
4.1 f (4.3 US qt, 3.6 lmp q0*3
4.31 (4.5 US qt, 3.8 tmp qt)*a
CVT4.3 f (4.5 US qt,3.8 Imp qt)
*1i D16Y5, D16Y7, D16Y8 engines
iil

Radiator
Engine Coolant Refilting and Bleeding (cont,dl
8. Mix the recommended antifreeze with an eoualamount of water in a clean container.
NOTE:
o Use only genuine Honda antifreeze/coolant.. For best corrosion protection. the coolant con_centration must be maintained year_round at50% minimum. Coolant concentrations less than50% may not provide sufficient protectionagainst corrosion or freezing.. Coolant concentrations greater than 60010 willimpair cooling efficiency and are not recom_mended.
CAUTION:
. Do not mix difforont brands ofar ilreeze/coolants.. Do not use additional rust inhibiiors or anti_rustproduqt3; they may not be compatible with thecoolant.
Engine Coolent Refi

Capacity Iincluding reservoir{0.4 f 10.42 US qr, 0.35 lmp qt),I;
*1: D16Y5, D16Y/, O16Y8 engines*2: 81642 engine*3; Dl6Y7 engine*4: Dl6Y8 engine
M/r3.8 f {4.0 US qt, 3.3 lmp qt)*1
4.5 / (4.8 US qt. 4.0 tmp qt)*,
Att3.7, (3.9 US qr,3.3 tmp qt).3
3.9 / (4.1 US qt,3.4lmp qt)*.
CW3.9 / (4.1 US qt,3.4 tmp qtl
10-8
\.-I
9. Pour coolant into the radiator up to the base of thefiller neck. and install the radiator cap looselv.
Start the engine and let it run until it warms up (theradiator fan comes on at least twicer.
Turn off the engine. Check the level in the radiator.add coolant if needed.
Put the radiator cap on tightly, then run the engineagain and check for leaks.
10.
11.

EGT Switch
-f
Testing
Replace the thermostat if it is open at room temperature'
To test a closed thermostat:
1, Suspend the thermostat in a container of water as
shown.
THEBMOMETER
THERMOSTAT
Heat the water, and check the temperature with a
thermometer. Check the temperature at which the
thermostat first opens, and at which it is fully open
CAUTION: Do not let the thermometer touch the
bottom of the hot Gonlainel.
Measure lift height of the thermostat when fully
open.
STANDARD THERMOSTAT
Lift height above 8.0 mm (0.31 inl
Starts opsning: 169' - 176'F (76' - 80'Cl
Fully open: 194'F {90"C1
!'o
10-1 1
Testing
!!@ Romoving the EcT swhch while lhs engine
i!-ot can cause the coolant to sPray out, seriously scald-
ing you. Always lst th€ ongine and rediator cool down
before removing ihe ECT switch.
NOTE: Bleed air from the cooling system after installing
the ECT switch (see Page 10-7)
1. Remove the ECT switch from the thermostat hous-
ing (see Page'10-10).
2. Suspend the ECT switch in a container of water as
shown.
Heat the water, and check the temperature with a
thermometer.
CAUTION: Do not let the thermomoter touch tho
bottom of the hot container'
Measure the resistance between the A and B termi-
nals according to the table.4.
Terminal
Oo"rffi
swlTcH
ON196' - 203"F
(91" - 95'C)o--o
OFF
5" - 15'F {3" - 8'C)
lower than the temPera-
ture when t goes on

Diagnostic Trouble Code (DTCI Chart
connector is connecteda1: Dl6Y5 engine (CVT)*2: Except D16Y5 engine (M/T)*14:'97 model*15:'96 model*16: '98 model
(cont'd)
11-97
DTC
{MlL indication*lDelection liemProbable CausePage
Manifold Absolute
Pressure Circuit
Range/Performance Problem
. Vacuu m connection. MAP sensor11115
P0107 (3)
Manifold Absolute
Pressure Circuit
Low Input
Open or short in MAP sensor circuit
MAP sensor
ECMiPCM
TCM*1
11't1'l
P0108 (3)Manifold Absolute
Pressure Circuit
High Input
Open in MAP sensor circuit
MAP sensor
ECtvt/PCM
't 1 121
P0.111*14. *15 (10)
lntake Air Temperature
Circuit
Range/Performance Problem
. IAT sensor11-124
PO112 {10}
Intake Air
Temperature Circuit
Low Input
Short in IAT sensor circuit
IAT sensor
ECMiPCM
11-125
P0113 (10)lntake Air
Temperature Circuit
High Input
Open in IAT sensor circuit
IAT sensor
ECM/PCM
't1-126
P0116 (86)Engine Coolant
Temperature Circuit
Range/Performance Problem
. ECT sensor. Cooling system11-124
PO't't7 {6)
Engine Coolant
Temperature Circuit
Low Input
Short in ECT sensor circuit
ECT sensor
ECM/PCM
11-129
P0118 (6)Engine Coolant
Temperature Circuit
High lnput
Open in ECT sensor circuit
ECT sensor
ECM/PCM
11-130
?0122 t1l
Throttle Position
CircuitLow Input
Open or short in TP sensor circuit
TP sensorECM/PCM
TCM*1
11-132
P0123 (7)Throttle Position
Circuit
High Input
Open in TP sensor circuit
TP sensor
ECM/PClvl
11-136
P0131*' (1)
Primary Heated Oxygen Sensor
Circuit Low Voltage(Sensor 1)
Short in Primary HO2S (Sensorl ) circuit
Primary HO2S {Sensor 1)
Fuel supply system
ECM/PCM
1 1-139
P0132*' ('r)
Primary Heated Oxygen Sensor
Circuit High Voltage(Sensor 1)
Open in Primary HO2S {Sensor 1} circuit
Primary HO2S (Sensor 1)
ECM/PCM
1 1- 143
P0133*' (61)
Primary Heated Oxygen Sensor
Slow Response(Sensor 1)
. Primary HO2S (Sensorl). Exhaust system11-145
P0135*? (41)
Primary Heated Oxygen
Sensor Heater
Circuit Malfunction(Sensor 1)
. Open or short in Primary HO2S(Sensor 1) heater circuit. ECM11-151
*: The DTCS in parenthesis will be indicated by the blinking of the Malfunction Indicator Lamp (MlL) when the SCS service
! ta

3.
5.
6.
1.
Fuel Cut-off Control
. During deceleration with the throttle valve closed, current to the fuel injectors is cut off to improve fuel economy at
speeds over the following rpm:. D16Y5 engine (M/T):850 rpm. D]6Y5 engine (CVT), D'16Y8 engine (USA M/T): 920 rpm
. Dl6Y8 engine (USA A,/I), D16Y7 engine (USA A,/T);910 rpm
. D16Y8 engine (Canada M/T), D16Y7 engine (canada): 990 rpm
' D16Y8 engine (Canada M/T): 1,000 rpm
. 816A2 engine: 970 rpm
. Fuel cut-off action also takes place when engine speed exceeds 6,900 rpm (D16Y5, D16Y7 engine; D'16Y8 engine:
7,000 rpm. 816A2 engine: 8.100 rpm), regardless of the position of the throttle valve, to protect the engine from
over-rewing. With '99 Dl6Y7 engine (A,/T) and '99 D16Y8 engine (A./T), the PCM cuts the fuel at engine speeds over
5,000 rpm when the vehicle is not moving.
IVC Compressor Clutch Relay
When the ECM/PCM receives a demand for cooling from the air conditioning system, it delays the compressor from
being energized, and enriches the mixture to assure smooth transition to the A,/C mode
Evaporative Emission (EVAP) Purge Control Solenoid Valve*'
When the engine coolant temperature is above 154'F (68'C). the ECM/PCM controls the EVAP purge control solenoid
valve which controls vacuum to the EVAP purge control canister.
Evaporative Emission (EVAP) Purge Control Solenoid Valve*a
When the engine coolant temperature above 154"F (68"C), intake air temperature above 32"F (0'C) and vehicle speed
above 0 mile (0 km/h) or [Ay'C compressor clutch on and intake air temperature above 160"F (41'C)], the ECM/PCM
controls the EVAP purge control solenoid valve which controls vacuum to the EVAP purge control canister.
Exhaust Gas Recirculation (EGR) Control Solenoid Valve*?
When EGR is required for control of oxides of nitrogen (NOx) emissions. the ECM controls the EGR control solenoid
valve which supplies regulated vacuum to the EGR valve
Alternator Control
The system controls the voltage generated at the alternator in accordance with the electrical load and driving mode,
which reduces the engine load to improve the fuel economy.
ECM/PCM Fail-safe/Back-up Functions
1. Fail safe Function
When an abnormality occurs in a signal from a sensor, the ECM/PCM ignores that signal and assumes a pre-pro-
grammed value for that sensor that allows the engine to continue to run.
2. Back-uD Function
When an abnormality occurs in the ECM/PCM itself, the fuel injectors are controlled by a back-up circuit independent
of the system in order to permit minimal driving.
3. Self diagnosis Function lMalfunction Indicator Lamp (MlL)l
When an abnormality occurs in a signal from a sensor, the ECM/PCM supplies ground for the lvllL and stores the DTC
in erasable memory. When the ignition is initially turned on, the ECM/PCM supplies ground for the MIL for two sec-
onds to check the MIL bulb condition.
4. Two Trip Detection Method
To prevent false indications, the Two Trip Detection Method is used for the HO2S, fuel metering-related. idle control
system, ECT sensor, EGR system and EVAP control system self-diagnostic functions. When an abnormality occurs,
the ECM/PCM stores it in its memory. When the same abnormality recurs after the ignition switch is turned OFF and
ON 0l) again, the ECM/PCM informs the driver by lighting the MlL. However, to ease troubleshooting, this function is
cancelled when you jump the service check connector. The MIL will then blink immediately when an abnormality
occurs,
5. Two (or Three) Driving Cycle Detection Method
A "Driving Cycle" consists ot starting the engine. beginning closed loop operation, and stopping the engine. lf misfir-
ing that increases emissions is detected during two consecutive driving cycles, or TWC deterioration is detected dur-
ing three consecutive driving cycles, the ECM/PCM turns the MIL on. However, to ease troubleshooting, this function
is cancelled when you jump the service check connector. The MIL will then blink immediately when an abnormality
occurs.
(cont'd)
1 1-1 05
.1.