fuel pressure HONDA CIVIC 1996 6.G Workshop Manual

Unit of length: mm (in)
Fuel and Emission - Section
MEASUREMENTSTANOARO (NEW)
260 310 (2.7 - 3.2, 38 - 46)
260 - 310 (2.7 - 3.2, 38 - 46i
260 - 310 (2.7 - 3.2, 38 - 46)
210 - 320 Q.A - 3.3, 40 - 47 1
45 {11.9, 9.9)
M/T (neutral) I A/T or C\.T (lE or fd positioni
Fuel paessure
regulator
Pressure wilh fuel pressure regulator vacuum hose
disconnected kPa (kgvcm', Psi)D16Y5D 16Y7D16Y881642
FueltankCapacity I (US gal, lmp gal)
E ngineldle speed rpm
016Y5D16Y7D16Y8816A2
u.s.A.CanadaU,S,A.Canada
670 1 506701 50670150700 t 50
7501 507501 507501 50
700 t 50700 I 507001 50750150750 r 50
ldle CO %0.1 max.
Clutch - Serrtion 12
MEASUREMENTSTANDARD {NEWI I SERVICE LIMIT
Clutch pedalPedal height to floor
StrokePedal play
Disengagement height to floorto carpet
16s (6 1/2)130 140 (5 1/8 5 1/2)
12 -21 t1l2 - 13/16183 (3 1/4)44 (1 3/4) min. Reference
FlywheelClutch surface ruoout
Rivet head depthThickness
0.05 (0.002) max.0.15 (0.006)
Clutch disc1.3- 1.9 (0.05 - 0.07)
8.5 - 9.1 (0.33 - 0.36)
0.2 {0.01)5.5 (0.22)
Pressure plateWarpageDiaphragm spring fingers alignment
0.03 (0.001) max0.6 (0.02) max
0.15 (0.006)
1.0 (0.04)
Lro
3-7
lfllHlllllllllrltllli[

Engine Removal/lnstallation
Removal (cont'dl
10. Relieve fuel pressure (see section l1).
!@ Do not smoke while working on the fuelsystem, Keep open flame or spark away from thewolk area. Drain fuel only inlo an approved container.
11. Remove the evaporative emission (EVAP) controlcanister hose and fuel feed hose.
D16Y7 engine:
BANJO BOLT33 N m ( 3.it lgt m, 25 lbt.ft)
FUEI- FEED HOSE
D16Y5, D16Y8, Bt642 engines:
5-4
I
12. Remove the brake
hose and vacuum
D16Y7 engine:
booster vacuum hose, fuel returnhose.
VACUUM HOSE
Dl6Y5, D16Y8, Bl642 enginos:
BRAKE BOOSTERVACUUM HOSE

Cylinder Head
Removal (cont'd)
9. Relieve fuel pressure (see section 11),
E@E Do not smoke while working on tho fuelsystem. Ke6p opgn flame or gpark away from lhework area, Drain fuel only into an app.oved containgr.
10. Remove the evaporative emission (EVAP) controlcanister hose, fuel feed hose and breather hose.
D16Y7 engine:
BANJO BOLT33 N.m {3.4 kgt m,25 tbf.ftt
BREATHER HOSE
D15Y5, Dl6YB engines:
BANJO AOLT33 N.m (3.4 kgf.rn,25 tbf.ftt
EVAP CONTROLCANISTER HOSE
6-28
(
1 1. Remove the brake booster vacuum hose. fuel returnhose and vacuum hose (see page S_4).
12. Remove the water bypass hose and positive crank_case ventilation (pCV) hose.
016V7 engine:
PCV HOSE
D16Y5, D16Y8 engines:
\a
I
WATER EYPASS
PCV HOSE

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

Cylinder Head
Removal (cont'd)
8. Remove the P/S pump lower bracket.
8 x 1.25 mm24 N.m 12.4 kgf.m,17 tbtftl
9.
T SHIELD
10.
P/S PUMP LOWERBRACKET10 x 1.25 mm44 N.m {4.5 kgf.m,33 tbf.frl
Relieve fuel pressure (see section l1).
@ Do not smok6 while working on fuel
system, keep open flam€ or spark away lrom work
ar€a, Drain fuelonly into an approved cortain€r.
Remove the evaporative emission (EVAP) control
canister hose, fuel feed hose and breather hose.
BANJO BOLT33 N.m (3.4 kgl.m.25 lbf.ftl
BREATHERHOSE
WASHERS
6-68
\.
11. Remove the brake booster vacuum hose, fuel return
hose and vacuum hose (see page 5 4).
12. Remove the water bypass hose and positive crankcase
ventilation (PCV) hose.
WATER BYPASSHOSEWATER EYPASSHOSE
Remove the throttle cable and throttle control cable
by loosening the locknut, then slip the cable end out
of the throftle linkage.
NOTE;
. Take care not to bend the cables when removing
them. Always replace any kinked cable with a new
one.
. Adjust the throttle cable when installing (see sec-
tion I I ),. Adjust the throttle control cable when installing(see section 14).
CONTROLCABLE
1a
PCV HOSE

WATER BYPASS
HOSE
14. Remove the upper radiator hose, heater hose and
water bvpass hose.
HEATER
Remove the engine wire harness connectors and wlre
harness clamps from the cylinder head and the intake
manifold.
Four fuel injector connector
Engine coolant temperature (ECT) sensor connec-
tor
ECT gauge sending unit connector
ECT switch connector
ldle air control (lAC) valve connector
Manifold absolute pressure (MAP) sensor connec-
tor
Throttle position sensor connector
Primary Heated oxygen sensor (Primary HO2S)
connecror
VTEC solenoid valve connector
15.
a
a
a
a
a
\
16.
17.
Remove the spark plug caps and distributor form
the cylinder head.
Remove the upper bracket.
NOTE:
. Use a jack to support the engine before removing
the upp€r bracket is removed.
. Place a cushion between the oil panandthejack.
12 x 1.25 fin74 N.m 17.5 kgtm,
UPPER BRACKET
18. Remove the cylinder head cover.
{cont'd)
6-69

!
Fuel and Emrsslons
SoecialToofs .....,...."..,. 11-2
Component Locations
lndex ....................., ......... 11-3
Svstem Description
Vacuum Connections ................,,..,.. ......... 11-12
Electrical Connections ...............,.,.,... ....... 11-29
System Connectors ........,.,.,.......................... 1 1-51
Troubleshooting
Troubleshooting Procedures ................. .. 11-81
Engine Control Module/PowertrainControl Module TerminalAfiangement ....,.,..... 11-88
Diagnostic Trouble Code Chart .................,., 11.97
How to Read Flowcharts .,.......................... . 11-103
PGM-Fl System
System Description ...... 11-10,1
Troubleshooting Flowcharts
Engine Control Module/PowertrainContlol Module ........ 11-107
Manitold Absolute Pressure Sensor .....'. . ... 11-115
fntake Air Temperatuie Sensor ..... . . ., . 11'121
Engine Coolant Temperatuae Sensol ........., 11-128
Throttle Position Sensor ...................,........... 11-132
Primary Heated Orygen Sensor (Sensor 1l ... 11-139
Secondary Heated Oxygen Sensor(Sensor 21.................................................... 1 1-153
Heated Oxygen Sensor Heater ...................,. 11-157
Fuel Supply System ...... 11-164
Random Mislire ......., ..11-166
Misfire Detected in One Cylindsr ................. 11-167
Knock Sensor .,.,............ 11-170
CKP/TDC/CYP Sensor ................................... 11'172
Vehicle Speed Sensor ...........,......,...,.,........... 1t-176
Barometric Pressure Sensor ...............,......... I 1-178
Electrical Load Detector,.,,............................ 1 1-179
CKF Sensor .................... 11-183
ECM/PCM Internal Circuit ............................. I 1-188
A/T Signal {TMA/TMBI .................................. I 1-189
ldle Control System
System Doscriplion ............ 11-190
Troubleshooting Flowcharts
ldle Control System ...... 11-192
ldle Air Control Va1ve .................................... I 1-19i1
Starter Switch Signal .................................... 1 1'202
Air Conditioning Signal ................................. 11'201
Ahernator FR Signal .................................... . 1 1-208
BrakeSwitch Signal ..................................... f 1"210
Power Sleering Prossure Switch Signal ......11-212
A/T Gear Position Signal ............................... 11-216
Clutch Swiich Signal ................................-.... 11-214
ldte Speed Setting . .............11-220
Fuel Supply System
Fuel Lines .,...................,.,.,.,11-221
Fuef Tube/Ouick-Connect Fittings ..........,.,........ 11 -227
System Description ....'.... 11-230
Fuel Pressure .......,.,,........... 11-230
Fuef fniectors ......................11-232
Fu€f Pressure Regulator .....,.......................'...,. 11-231
Fuef Fifter ............................11-235
Fuel Pump .............'.......'.... 11-236
PGM-FI Main Relay .............11'237
Fuel Tank ................ ....,...'.'.' 11'211
Intake Air System
System Description ....-.-.....11-243
Air Cfeaner ...........,......."". .11-211
Throttle Cable .....................11-211
Throttfe Body ........ ..'... . . .,.11-211
Fuel Iniestion Air Control System ,.,.,....-........... 11-250
Emission Control System
System Description .-..........11-252
Taifpip€ Emission ...............11-252
Three Way Catafytic Convert€r ............,.,,.,.,.,.... 11 -252
Exhaust Gas Racirculaiion System ...,.,,,,.,.,.,.,,. 11'254
Positive Crankcas€ Ventilation System .... . . .. 11-266
Evaoorative Emission Controls ..................,,..,.,. 11 -267

Special Tools
a\-Special Tools
R€f. No. I Tool NumberDsscriptionOty I Pagr Reference
O
@/n
@
@
@
A973X_041 _ XXXXX
07JAZ - 0010008
07PAZ - 0010100
07sAz - 001000A
07406 - 0040001
07406 - 0040304
Vacuum Pump/Gauge, 0 - 30 in.H9
Vacuum/Pressure Gauge, 0 - 4 in.Hg
SCS Service Connector
Backprobe Set
Fuel Pressure Gauge
Fuel Pressure Adapter,6 x 15 mm
I
I
1
2
1
I
11-251,256, 257 ,273,27 4, 283,284,
286, 288, 289, 291,
294,296,297
11-294,295
11-81
11-83
1't-230, 231, 234
11-230
ta
1n\Y
11-2

Component Locations
Index (cont'dl
'96 D16Y8 engine (coupel,'97 D16Y7 engine (coupe: KL model, sedan: KL (LXl model),'97 D16Y8 engine (coupe: all models, sedan: KL modell,'98-all models:
FUEI- VAPOR PIPEFUEL FEED PIPEFUEL GAUGE SENDING UNITTesting, see section 23FUEL PUMPTesting, page 11 236Replacement, page 11 236FUEL FILTERReplacement,
€VAPOFATIVE EMISSION(EVAPI CONTROL CANISTERVENT SHUT VALVETroubleshooting, page l1'283
FUEL FILLCAP
FUEL TANKReplacement, page I l-241
EVAPORATIVE EMISSIONIEVAPI CONTROLCANISTERTroubleshooting, page 11 283
EVAPORATIVE EMISSIONIEVAP) BYPASS SOLENOIDVALVETroubleshooting, page 1 1 -283
FUEL INJECTORSReplacement, page 1 1-232EVAPORATIVE EMISSION(EVAPI TWO WAY VALVETesting, page 11 294
FUELREGULATORTesting, page 11-234
TANK PRESSURESENSORTroubleshooting, page 11-275
Replacement, page 1 1-234
'96 Dt6Y5 engine,'96 D16Y7 engin€, '96 D16Y8 engine (sedanl,'97 D16Y5 engine,'97 Dl6Y7 engins (coupe: l(A, KC models,
sedan: KA, KC, KL (DXl models, hatchback: all models),'97 Dl6Y8 engine (sedan: KA, KC modelsl:
FUEL FEED PIPE
FUELFITTINGSPrecautions, page 1 1-227Disconnection, page 11 227Connection, page 11-228
FUEL VAPOR PIPE
FITTINGS
EVAPORATIVE EMISSIONIEVAPI CONTROL CANISTERTroubleshootiog, page 1 1-271
FUEL FILTERReplacement, page 1 1-235FUEL PUMPTesting, page 11-236Replacement, page 11-236
FUEL TANKBeplacement, page 11 241
TIVE EMISSION{EVAP) TWO WAY VALVETesting, page 11-294
TUBE/OUICK.CONNECT
FUEL PRESSUREREGULATORTesting, page 11'234Beplacement, page 11 234
Precautions, page 1 1-227Disconnection, page 11'227Connection, page 1 1-228
11-8
FUEL RETURN PIPE

'99 - 00 models:
EVAPORATIVE EMISSIONIEVAP} PURGE CONTROLSOLENOID VALVETroubleshooting, page 1 1'288FUEL GAUGE SENDING UNITTesting, see section 23
FUEL VAPOR PIPE
ONBOARD REFUELING VAPORR€COVERY IORVRIVENT SHUT VALVETest, page 11 296
EVAPORATIVE EMISSION
{EVAP) CONTROL CANISTERVENT SHUT VALVETroubleshooting, Page 1 1_288
EVAPORATIVE EMISSION
FUEL FILTERBeplacement, page 11-235
FUEL FEED PIPE
FUEL RETURN PIPE
FUEI- PUMPTesting, page 11 236Replacement, page 11-236
FUEL FILLCAP
{EVAPI CONTROLTroubleshooting, page 1 1_288
FUELPULSATION DAMPEB
FUEL INJECTORSReplacement, page 1 1'232
FUEL PRESSUREREGULATOR
EVAPORATIVE EMISSION
{EVAP) BYPASS SOLENOIDVALVETroubleshooting, page 1 1-288
FUELRAIL
FUEL TANK PRESSURESENSOBTroubleshooting, Page 1 1'274
EVAPORATIVE EMISSIONIEVAPI TWO WAY VALVETesting, page 11 295
Testing, page 11-234Replacement, page 11 234FUEL TUBE/OUICK.CONNECTFITTINGSPrecautions, page 1 l-227Disconnection, page 11 227Connection, page 1 1-228
Replacement, page 1 1-241
I(cont'd)
1 1-9