vacuum connections HONDA CIVIC 1996 6.G Workshop Manual

!
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

System Description
Vacuum Connections
D16Y5 engin6 ('96 - 97 modelsl:
To EVAPORATIVE EMISSION(EVAPI
TWO WAY VALVE
MANIFOLDABSOLUTEPRESSURE IMAPISENSOR
€VAPORATIVEEMISSION IEVAPIPURGE CONTROL SOLENOIDVALVE
EXHAUST GAS BECIRCULATION(EGR) VALVE end EXHAUST GASRECIRCULATION IEGR) VALVELIFT SENSOR
Qo
FRONT OF VEHICLE
To CRUISECONTROLDIAPHRAGM(wath cruise control)
Qo
O: Vacuum hose No.
11-12
EXHAUST GAS RECIRCULATION(EGR) CONTROL SOLENOID VALVE {CVT}\.'.-' \
I
I
)
FUEL PRESSURE REGULATOR

System Description
Vacuum Connections {cont'd}
Dl6Y8 engine l'96 - 98 models):
To EVAPOBATIVE EMISSIONIEVAPI THREE WAY VALVE{'96 coupe, '97 coupe: all models.'97 sedan: KL model. 'g8-models)
EVAPORATIVE EMISSION (EVAPI
CONTROL CANISTERVENT SHUT VALVE{'96 coupe,'97 coupe: all models,'97 sedan: KL model. 'g8-modelsl
To EVAPORATIVE EMISSION{EVAP)TWO WAY VALVE
{'96 coupe,'97 coupe: all models,sed6n: KL model)
EVAPORATIVEEMISSION {EVAPIPUBGE CONTROLCANISTER
EVAPORATIVE EMISSION{EVAPI PUBGECONTROL CANISIERl'96 sadan, '97 sodan: XA,
FUEL PRESSUREREGULATORMANIFOLD ABSOLUTEPRESSURE (MAP) SENSOR
I
KC mod6l3l
EVAPORATIVEEMISSION {EVAPITo CRUISECONTROLDIAPHRAGM{with cruise control)
PURGE CONTROL SOLENOIDVALVE
FRONT OF VEHICLE
11-14

System Description
Vacuum Connections (cont'dl
D16Y7 engine ('96 models,'97 coupe: KA. Kc models, '97 sedan: KA, Kc, KL lDx) models,'97 hatchback: all modelsl:
EVAPORATIVEEMISSION (EVAPIPURGE CONTROL
FUELPRESSUREREGULATOR
To EVAPORATIVEEMISSION {EVAP}TWO WAY VALVE
MANIFOLD ABSOTUTEPRESSURE (MAP)
To CRUISECONTROLDIAPHRAGMlwith cruise
EVAPORATIVEEMISSION (EVAPI
PURGE CONTROLCANISTERFRONT OFVEHICLE
11-16

System Description
Vacuum Connections (cont'd)
D16Y5 engine ('98 modet):
-: Vacuum hose No,*: CW only
(9 POSITIVE CRANKCASE VENTILATION {PCV} VALVE?!J EXHAUST GAS BECIRCULATION (EGR}CONTROLSOLENOIO VALVE'1 ExHAUST GAs RECIRCULATIoN IEGRI VALVE22 EXHAUST GAS RECIRCULATION {EGR} VALVE LIFISENSOR€J EvApoRATtvE EMtsstoN {EvAp} puRGE coNTRoLSOLENOID VALVEq4 PURGE JOINT@ EVAPoRATIVE EMIssIoN {EVAP) coNTRoL CANISTER@ EVAPORATIVE EMISSION IEVAP} BYPASS SOLENOIDVALVE?? EVAPORATIVE EMISSION {EVAP) THREE WAY VALVEITII EVAPORATIVE EMISSION IEVAP} CONTROL CANISTERVENT SHUT VALVEO FUEL TANK PRESSURE sENsoRQlI EVAPORATIVE EMISSION {EVAP}TWO WAY VALVE8' THREE WAY CATALYTIC CONVERTER {TWCI
il) PRIMAFY HEATED OXYGEN SENSOR IPRIMARY HO2S.SENSOR 1)O SECoNDARY HEATEo oxYGEN sENsoR {sEcoNDARYHO2S. SENSOB 2)iq] MANIFOLD ABSOLUTE PRESSURE (MAPI SENSORO ENGINE COOLANT TEMPERATURE IECT) SENSOR5 INTAKE AIR TEMPERATURE {IATI SENSOR! KNOCK SENSOR tKSlO CRANKSHAFT SPEED FLUCTUATIoN {cKF) sENsoFO IDLE AIR coNTRoL {IAc) vALvE99 THROTTLE BODY ITBI@ FUEL INJECToRO FUEL PULSATION DAMPER@ FUEL F -TER@ FUEL PRESSURE REGULAToR[4 FUEL PUMP IFPI(9 FUEL TANK(D FUEL TANK EVAPoRATIVE EMIssIoN IEVAPI VALVEO' AIR CLEANER(D RESoNAToR
11-20

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
@A)@
11-22

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

System Description
Vacuum Connections (cont'd)
Dl6Y7 angin6 ('97 coup.: KL mod€l, sedan: KL (LX) model,,9g modet):
i1] PRIMARY HEATED OXYGEN SENSOR (PRIMARY HO2S,SENSOR 1)E) SECONDARY HEATED OXYGEN SENSOR {SECONDARYHO2S, SENSOR 2l€l MANTFOLD ABSOT_UTE PRESSUnE tMAp) SENSOR€r ENGINE COOLANT TEMPERATURE |ECT) SENSOR€] INTAKE AIR TEMPERATURE IIAT} SENSOR6 CRANKSHAFT SPEED FLUCTUATION ICKFI SENSOR17 IOLE AIR CONTROL IIACI VALVE@ THRoTTLE BoDY {TBIO FUEL INJEGToR(9 FUE|- FTLTEFO FUEL PRESSURE REGULAToR@ FUEL PUMP {FPI(D FUEL TANK@ FIFL TANK EVAPoRATIVE EMIssIoN {EVAPIVALVE(, AIR CLEANER
(tO RESONATORl? PoSITIVE cRANKcAsE VENTILATIoN IPcv}VALVEIA EVAPORANVE EMISSION TEVAPI PURGE CONTROLSOLENOID VALVE19 EVAPORATIVE EMISSION IEVAPI CONTROL CANISTERE EVAPORATIVE EMISSION (EVAPIBYPASS SOLENOIDVALVE€' EVAPoRATIVE EMIssIoN IEVAPI THREE wAY vALvEQ' EVAPORATIVE EMISSION IEVAPI CONTROL CANISTERVENT SHUT VALVE@ FUEL TANK PRESSURE sENsoR{?1! EVAPORANVE EMISSION IEVAPI TWO WAY VALVE?5 THREE WAY CATALYTIC CONVERTER ITWC'
11-26

I
a
System Description
Vacuum Connections (cont'd)
816A2 engine:
@ EvApoRATtvE EMtsstoN tEvAp) puRGE coNTRoLSOLENOID VALVE@ PURGE JoINT€t EvApoRATtvE EMtsstoN (EVApt coNTRoL caNtsTERQA EVAPORATIVE EMISSION (EVAP) BYPASS SOLENOIDVALVE
@ EVApoRATtvE EMtsstoN lEvApl coNTRoL caNtsrERFILTER@ EvApoRATtvE EMtsstoN {EvApt coNrRoL cANtsrERVENT SHUT VALVE@ FUEL TANK PRESSURE sENsoRGI EVAPORATIVE EMISSION (EVAP} TWO WAY VALVE@ ONBOARD REFUETING VAPOR RECOVERY {ORVR} VENTSHUT VALVE@ oNBoAnD REFUELING vApoR REcovERy (oRvRl vApoR. RECIRCULATION VALVE(c} THREE WAY CATALYTIC CONVERTER {TWCI
(' PRIMARY HEATED OXYGEN SENSOR IPRIMARY HO2S.SENSOR 1l.?) SECONDARY HEATED OXYGEN SENSOR {SECONDARYHO2S, SENSOR 2)13] MANIFOLD ABSoLUTE PRESSURE (MAP) sENsoBi' ENGINE COOLANT TEMPERATURE IECT) SENSORO INTAKE AIR TEMPERATURE ITATI SENSORi6l KNOCK SENSOR {KS}O oRANKSHAFT SPEED FLUCTUATIoN {cKF} sENsoR@ IDLE AIR coNTRoL (IAc} VALVE€) THRoTTLE BoDy trB|(D FUEL INJECToRO FUEL PULSATIoN DAMPER[D FUEL FILTER@ FUEL PRESSURE REGULAToR!I FUEL PUMP IFP)f,' FUEL TANK(iD ArR CLEANERt' RESONAToR'.1]i POSITIVE cRANKcAsE VENTILATIoN {Pcv} VALVE
11-28

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