Disc HONDA CIVIC 1997 6.G Workshop Manual

Emission Control System
Exhaust Gas Recirculation (EGR) System (D16Y5 engine with GWI (cont'dl
lTl49il T_he scan tool indicates Diagnostic Trouble Code (OTC) P1491: A malfunction in the Exhaust Gas Recirculation- lEgh) svstem.
CvT lM/T see page 1l-2611:
J
EGR VALVELIFT SENSOR#16 HOSE
PUMP/GAUGE,0- 30 in.HsA973X-041-XXXXX
EGRVALVE
The MIL has been reoorted on.DTC P1491 is stoled.
Problem verification:1. Do the ECM/PCM Reset Proce-du re.2. Connect the SCS service con'
3. Start the engine. Hold theengine at 3,000 rpm with noload {in Park or neutral) untilthe radiator fan comes on,4. Drive the vehicle on the roadfor approx. 10 minutes. Try tokeep the engine speed in the1,700 - 2,500 rpm range.
Intermittonl failure, system is OKat this time. Check for Door con-nections or loose wires at, C144{EGR velve} and ECM/PCM.
ls DTC P l49l indicated?
Check fo. vacuum to ihe EGR
1. Disconnect the No. 16 hose fromthe EGR valve.2. Connect a vacuum pump/gauge to the hose.3. Start the engine and let it idle.
ls there any vacuum?
Check tor a malfunction in theEGR control solenoid valve:'1. Disconnect the EGR controlsolenoid valve 2P connector,2. Becheck the No. 16 hose for
Check vacuum hose routing o,the entire EGR svstem. lf hoserouting is OK, replac€ the EGRcontrol solenoidvalv6.
ls there any vacuum?
Substitute a known-good ECM/PCM and recheck. It symptom/indicalion goes away, replacethe original ECM/PCM.
(To page 11 257)
11-256

\EGR VALVELIFT SENSOR#16 HOSE
I
(From page 11-256)
EGR VALVE LIFT SENSOR3P CONNECTOR lC14.l)
zF vcczI- . ] IYEL/BLU)ll 2l3l---l-r_ 7 |
v-,, ISG2IGRN/BLK) I ^ II{Vts
ECM CONNECTOR D {16P)
PUMP/GAUGE,0 - 30 in.Hs4973X-041-XXXXX
sG2(GRN/BLKIvcc2IYEL/BLU}
Wire side ol temale terminals
PCM CONNECTORS C (31P}'
YES
Wire side of female terminals
1
(cont'd)
1-257
Check fo. a mallunction in theEGF valv€:1. ldove the vacuum pump/gauge
to the EGR valve.2. With the engine at idle, apply
26.7 kPa (200 mmHg,8.0 in.Hg)
ofvacuum to the EGR valve.
Does the engine stall or runrough and does the EGR valvehold vacuum?
Check for an open in the wire
IVCC2linel:1. Turn the ignition switch OFF.2. Disconnect the EGR valve liftsensor 3P connector.3. Turn the ignition switch ON (ll).
4. Measure voltage between theEGR valve lift sensor 3P con'
nector terminals No. 3 and
No.2.
ls lhere approx.5 V?
Check for an oDen in the wire
{VCC2 line}:Measure voltage between theECM/PCM connector terminalsD10 and Dl1 (C18 and C28)*.
Rep.ir open in the wire betweenrhe EGR valve snd ECM/PCM
{Dl0 {C28)*).lsthere approx.5 V?
Sub3titute t known-good ECM/PCM end recheck. lt 3ymptom/indication goos eway, replaceth6 original ECM/PCM.(To page 1l-258)*: '99 - 00 models

Emission Control System
Exhaust Gas Recirculation (EGR) System (Dl6Y5 engine with CW) (cont'dl
tJ
(From page 11-259)EGR CONTROL SOLENOIDVALVE 2P CONNECTOR {C142}
Wire sideof lemaleterminals
ECMCONNECTORa t32Pl
Chock lor an open in the wire (E
SOL linsl:1. Turn the ignition switch OFF.2. Disconnect the 2P connectorIrom the EGR control solenoid
3. Disconnect the ECN4/PCM con-nector A (32P) (B (25P))* fromthe EcM/PCM.4. Check tor continuity betweenECM/PCl, connector terminal47 (86)* and the EGR controlsolenoid valve 2P connectorterminal No.2.
Repair opon in th. wir. bstwocntha EGR control 3ol€noid valvoand tho ECM/PCM (A7 186l'1.
ls there continuity?
Check for . rhort in the wire(ESOL linel:Check for continuity between theEGR controlsolenoid valve 2P con-nector terminal No. 2 and bodyground,
R.p.ir ahort in tha wi.c b.twecnthe EGR control iolonoid vllyeand th. ECM/FCM {A7 (46}rl.
Check for an opon in the wiroIGND linel:Check for continuity between theEGR controlsolenoid vaive 2P con-nector terminal No. I and bodyground,
Rcpai. op€n in the wir6 b6'twoenthe EGR control rol.noid valveand G101.
Sub3titule a known-good ECM/PCM and rechock. lf symptom/indication goes away, replac€the original ECM/PCM.
ESOL
IRED)
ESOLIRED)
Wire sideof femaleterminals--_-]
I
EGR CONTROL SOLENOIDVALVE 2P CONNECTOR ICl'2}
Wire sideof femaleilterminals
ECMCONNECTORB l25P)ESOL(REDI
Wire sideof femalerermtnats
*: '99 - 00 models
11-260

\JExhaust Gas Recirculation System (D16Y5 engine with M/T)
M/T:
EGR VALVE 6P CONNECTOB (C14'rl
G10lIBLK}
1
a
PNK
IE.EGRI
Wi16 side of male terminals
I
sG2{GRN/BLK}
vcc2{YEL/BLU)
- Th6 MIL ha3 b€on reponed on.- DTC Pl,{tl is 3tored.
Prcblem verification:1. Do the ECM Reset Procedure.
2. Connect the SCS service con_nector.3. Start the engine. Hold the
engine at 3,000 rpm with no
load (transmission in neutral)
untilthe radiator fan comes on.
4. Drive the vehicle on the road
for approx. 10 minutes. Try to
keep the engine speed in the
1,700 - 2,500 rpm range.
lnlermittont tailure, svalem is OK
at thi3 tim6. Check foi Poor con'
nections or looso wiro3 at Cl/K
IEGR valvsl and ECM.
ls DTC P1491 indicated?
Check tor a malfunction in the
EGR valv6:1. Turn the ignition switch OFF.
2. Disconnect the EGR valve 6P
connector.3. Stanthe engine and let it idle
4. Measure voltage between the
EGR valve 6P connector termi'
nals No.4and No.6.
Check the EGR valve:1. Turn the ignition switch OFF2. Turn the ignition switch ON lll).3. Measure voltage between theEGR valve 6P connector termi
nals No.2 and No.3.
ls there battery voltage?
Substitute a known-good ECM
and recheck. It symptom/indica_tion goes away, replace th€ origi-
nal ECM.
ls there approx.5V?
(To page 11-262)

T
t
lFrom page 11-262)
Chock for rn opon in the wire
{EGR L linel:1. Reconnect the EGR valve connector.2. Tu.n the ignition switch ON (ll).
3. Measure voltage betweon thePCM connector terminals Dgand Dl1.
Check tor th€ wirc (EGR L line):
Check for continuity betweenECM connector terminal Dg andbody ground.
ls there approx. 1.2 V?
Roprir op6n in the wirs botweanthe EGR valvo.nd th. ECM lD9).
Rooair ahort in tho wiro baftr,otn
tho EGR v.lv..nd the ECM lDgl.
Ch€ck the EGR valve:1. Turn the ignition switch OFF.2. Disconnect the EGR valve 6P
connector.3. Connect the battery positive
terminal to EGR valve 6P con-nectorterminal No. 6.4. Stan the engine and let it id'e,then connect the battery nega_
tive terminal to EGR valve 6Pcon nector term inal No, 4,
ECM CONNECTOR D I16P'
Wire side oI female terminals
EGR VALVE 6P CONNECTOR
wire sid6 of lemale te.minals
(cont'd)

Emission Gontrol System
Exhaust Gas Recirculation System (Dl6Y5 engine with M/Tl (cont'dl
lFrom page 11 263)EGR VALVE6P CONNECTOR {C144}
J
Wire sideof femaletermtnals
J
Check lor an op€n in the wire (E-
EGR line):1. Turn the ignition switch OFF.2. Disconnect the ECM connector,A (32P)trom the ECM.3. Check lor continuity betweenECM connector terminal A7and the EGR valve 6P connec-torterminal No. 6.
Repair open in the wiro botweenthe EGR valv6.nd th€ ECM {A71.
Check tor a short in the wire {E-EGR lin6l:Check for continuity betweenECM connector terminal A7 andbody ground.
Reoair shorl in tho wiro belwe€nthe EGn vake rnd the ECM lA7l.ls there continuity?
Check fo. an open in tho wiro
IGND line):Check for continuity between theEGR valve 6P connector terminalNo.4 and body ground.
R6pai. open in th€ wir. betweenth6 EGF control solenoid v6lveand G101.
Substitute 8 known-good ECMand recheck. It symptom/indica-tion goes away, roplace the origi-nalECM.
CONNECTORA l32P)
2
a
I G101
Q) raur
-264

J\
Exhaust Gas Recirculation System
The scan tool indicates Diagnostic Trouble
Recirculation (EGRlvalve lift sensor circuit.
(D16Y5 enginel
Code {DTC) P1498: A high voltage problem in the Exhaust Gas
EGR VALVE LlFf SENSOR 3P {M/T: 6Pl CONNECTOR (C1441
cvT:
vcc2{YEL/BLUI
SG2 IGRN/BLK)
IM/T:sG2{GRN/BLKI
Wir€ side ol lemale terminals
ECM CONNECTOR D (16P)
vcc2(YEL/BLUIsG2(GRN/BLK)
Wir€ side of female terminals
PCM CONNECTORS C 131P)'
Wire side oI female terminals
11-265
- The MIL has been reportod on.- DTC P1498 is storod.
Probl€m verification:1. Do the ECM/PCM Reset Proce
dure.2. Stan the engine.
Intermittent tailure, sy3lem is OK
at lhis time. Check tor poor con'
nections or loose wire3 at C144
|EGR valvel and ECM/PCM.
ls DTC P1498 indicated?
Check for an open in tho EGRvalv6 lift sen3or:1. Turn the ignition switch OFF.
2. Disconnect the EGR valve lift
sensor 3P (M/T: 6Pl connector.
3. Turn the ignition switch ON (ll).
4. Measure voltage between the
EGR valve litt sensor 3P lM/T:6P) connector terminals No. 3and No.2.
ls there approx.5 V?
Check lor op€n in th€ wire (SG2
line):Measure voltage between ECM/PCM connector terminals 010 andD1l (C18 and C28)*.
Repair open in tho wiro betwoen
ECM/PCM lDl1 (Cl8)r) and EGR
valvo lift sensor.ls there approx. 5 V?
Substitute . known-good ECM/PCM and recheck. ll symptom/indicrtion goes away, replacothe original ECM/rcM.
*:'99 - 00 D16Y5 engine with CVT

\J
\
,96 D16Y5 engine,,96 D16r,gngino,,96 Dt6Y8 engine {3edan)' 37 D16Y5 engino..97 D16r, engine {coupe: KA, Kc mod-
els. sedan: KA, KC, KL {DX} models. hatchback: all modols}''97 Dl6Y8 ongine (s€dan: KA' KC mod€lsl:
The scan tool indicates Diagnostic Trouble code (DTC) P0441: Evaporative Emission (EVAP) control system
insufficient purge flow.
Description
By monitoring the purge line vacuum with the MAP sensor, the ECM/PCM can detect insufficient EVAP control system
purge flow.
Possible Cau3e
. EVAP Purge Control Solenoid Valve
. EVAP Purge Control Solenoid Valve Circuit
. EVAP Control Canister
. Vacuum Lines
. ECM/PCM
Troubl93hooting Flowchart
Wire side of femaleterminals
EVAP PURGE CONTROI-sottNotD vALvE 2P
CoNNECTOR (Cl1al
r-+-r
I'l'l
lG-ro.*l'rr"r
O)
Y
(cont'd)
11-271
- The MIL has bsGn.eportad on.- DTC milal k rtored.
Pioblem vsrificJtion:1. Start the engine. Hold the
engine at 3,000 rPm with no
load {in Park or noutral) until
the radiator fan comes on.
2. Do the ECM/PCM Reset Proce'
dure,3. Connect the SCS service con-
nector.4. Test-drive under following con-
ditions on the road- Without any electrical load- A/T in E or E Position(M/T in 3rd-sth gear)- Engine sPeed betweon
1,200 - 2.400 rpm.- Decelerate {rom 50 mph (80
knl/h)to 15 mph (24 km/h)lntormittont lailuro, sFtorn b OK
at thi. timo. Ch€ck tor Poor con'
ncction3 or looac wir.3 at C144
{EVAP purgo control tolonoid
vrtv.l .nd ECir/FCttl.
ls DTC P0441 indicatod?
Ch.ck fo. !n op€n in the wiro l|(illinel:1. Turn the ignition switch OFF.
2. Disconnect the EVAP Purgecontrol solenoid valve 2P con_
neclor,3. Turn the ignition switch ON (ll)
4. Measur€ voltage between bodyground and the EVAP Purgecontrol solenoid valve 2P con-
nector terminal No 1.
Rop.ir opor in tho wir6 b€two€n
the EVAP purgo codtiol tolonoid
v.lvo rnd tho No 15 ALIERNA'
TOR SP SENSOR 17.5 A)lu.o.
{To page 11-272)

Emission Gontrol System
Evaporative Emission (EVAPI Controls (cont'dl
(From page 11-271)
I
ECM/PCM CONNECTOR D I32P}
PGl IBLKI
Check the EVAP purge controlsolenoid valvei1. Reconnect the EVAP purge
control solenoid valve 2P con-nector.2. Connect ECM/PCM connectorterminals A15 and 410 with a
Check for an open or short in thewire (PCS line):Measure voltage between ECM/PCM connector terminal A15 andbody gro!nd.
Does the solenoid valve clickwhen the jumper is connected?
Che'ck for a short in the wir6 {PCSline):1. Turn the ignition switch OFF.2. Disconnect the ECM/PCM con-nector A (32P).
3. Disconnect the EVAP purgecontrol solenoid valve 2P connector.4. Check lor continuity betweenbody ground and ECM/PCMconnector terminal A15.
Repai. short in the wir6s betwoonthe EVAP purge control solanoidvalve and ECM/rcM lA15l.
R€pair op€n in the wir$ betwo€ntho EVAP purge control solenoidvalve and ECM/rcM lA15l.
Check the vacuum lin€3:Check the vacuum lines ol EVAPsystem for misrouting, leakage,breakage and clogging.
Are the vacuum lines OK?
PCS {REO/YEL)
t389t0'tt
12l3'I'tt5t5'11IE1920232a
?5212A2930
PCS {RED/YEL)
23a67E9t0It
12t3'ta't5l617ta1920222321
2a2728A30
0) Pcs {REo/YELI
-272

J\
(From page 11-272)D16Y5 engine:
JUMPER WIRE
D16Y7, D16Y8 engine
VACUUMPUMP/GAUGE,
VACUUMPUMP/GAUGE,0 - 30 in.HgAs73x - 0il1 -
xxxxx
0 - 30 in.HgA973X -
otl -
xxxxx
I
EVAP CONTROLCANISTER
ECM/PCM CONNECTOH D I32PI
VACUUM/PBESSUREGAUGE0-4in.Hg07JAZ - 0010008
Wire side otfemale terminals
D16Y7, Dl6Y8 engine:
t
VACUUM/PRESSUREGAUGE0-4 in.Hgo?JAZ - 001fl)OB(cont'd)
11-273
PGl IBLKI
Check lhe EVAP Purge control
solsnoid valve:
1. Disconnect the vacuum hose
from the EVAP controlcanister'
2. Connect the vacuum PumP to
the hose and aPPIY vacuum
Does it hold vacuum?
Check the EVAP control canister:
1. Reconnect the vacuum hose to
the EVAP control canlster.
2. Connect the vacuum/Pressuregaugeto the Purge aar hose
3. Connect ECM/PCM connector
terminals A15 and A10 with a
iumper wire.4. Start the engine5. Check the vacuum
Check the EVAP two way valve(see page 11-193)
Does the EVAP two waY valveReplace the EVAP two wsY valve.
Sub3titute a known-good ECM/
PCM .nd recheck. lt symPtom/
indicrtion go6s away, rePlace the
original ECM/PCM.
D16Y5 sngin€: