opening HONDA CIVIC 1997 6.G User Guide

Road Test
NOTE: Warm up the engine to normal operating temperature (the radiator fan com6s on).
1. Apply the parking brake and block the wheels. Start the engine, then shift to the E position while depressing the
brake pedal. Depress the accelerator pedal and release it suddenly. The engine should not stall.
2. Test in E position
Park the vehicle in a slope (approx. 16'). apply the parking brake, and shift into E position. Release the brake; the
vehicle should not move.
3. Test-drive the vehicle on a flat road in the position shown in the table. Check that the engine speeds meet the approx-imate vehicle speeds shown in the table.
NOTE: Throttle position sensor voltage represents the throttle opening. To monitor the throttle position sensor volt-age, use one of the following methods:
A. Connect the Honda PGM Tester, and go to the PGM-FI Data List.
A1For road testing on '96 - 98 models, remove the drive/s side kick panel to expose the TCM; on '99 - OO models,remove the passenger's side kick panel to expose the PCM (see page l,[-236),
Set the digital multimeter to check throttle position sensor voltage between terminals:. '96 - 98 modols: TCM 84 {+} and Aa (-) or A17 (-1.. '99 - 0O models: FCM C27 {+l and 820 (-l ot 822 l-1.
DIGITAL MULTIMETER(Commerci.lly rvrilabl.lKS-AHM-32-003or oquivalant
BACKPROBE ADAPTER
BRN/BLK
A {26P1
TPS {BED/BLK}
'96 - 98 Models:
BRN/BLK
14-296
OBD ll SCAN TOOL orHONOA PGM TESTER
D{16Pt
Ware side ot female terminals
Wire side of female terminals

o @ position: Engino Speed rPm
Throttle Opening
Vehiclo Speed
-25 mph l/() km/h) | 37 mph {60 km/h) | 62 mph {100 km/h}
Throttle position sensor voltage: 0.75 V1,250 - 1,650
Throttle position sensor voltage: 2'25 V2,500 - 3,1002,650 - 3,2502,700 - 3,300
Throttle position sensor voltage; 4 5 V
Full throttle position3,950 - 4,5504,650 - 5,2505,200 - 5,800
o $l position: Engine Speed rPm
Throttle Oponing
Vehicle Spoed
2s mph (40 km/hl | 37 mph (60 km/hl | 62 mph {r00 km/h}
Throttle position sensor voltage: 0.75 V1,800 - 2,2002,200 - 2,8003,550 - 4,150
Throttle Dosition sensor voltage: 2.25 V2,950 - 3.5503,250 - 3,8504,050 - 4,650
Throftle position sensor voltage: 4.5 v
Full throftle position4,100 - 4,7005,100 - 5,7005,900 - 6,500
o E position: Engin€ Sp6ed rPm
Throttle Oponing
Vehiclo Spoed
25 mph (40 km/hl | 37mPh{60km/h) J 62 mph 1100 km/h}
Throttle Dosition sensor voltage: 0.75 V3,100 - 3,7003,650 - 4,2504,450 - 5,050
Throttle position sensor voltage; 2.25 V3,500 - 4,1004,050 - 4,6504,800 - 5,400
Throttle position sensor voltage: 4.5 V
Fullthrottle position4,100 - 4,7005,100 - 5.7005,900 - 6,500
14-297

l.
'1.
2.
5.
6.
7.
Remove the ATF cooler inlet iine bracket bolt'
Remove the ATF cooler outlet line
Remove the ATF pan (fourteen bolts).
Remove the ATF strainer {two bolts)
Remove the one bolt securing the solenoid harness
connector, then push the connector.
Remove the lower valve body (eight bolts)
Clean the inlet opening of the ATF strainer thoroughly
with compressed air, then check that it is in good
condition, and the inlet opening is not clogged'
ATF STRAINER
INLET OPENING
Replace the ATF strainer if it is clogged or damaged
NOTE: The ATF strainer can be reused it it is not
clogged.
2c'
c;2 ar\
14-315

Power Steering Pump
RemovaUlnstallation
NOTE: Eefore disconnecting the hoses from the pump,
Dlace a suitable container under the vehicle.
1. Remove the belt by loosening the pump mounting
bolts and adjusting bolt ('99 -'00 models: 81642
Engine Type only).
OUTLET LINE11 N.m {1.1 kgf'm,8
L
PUMP MOUNTING BOLT24 N.m (2.4 kgl.m, 17 lbf ft)
2. Cover the Ay'C compressor with several shop towels
to protect it from spilled power steering fluid.
3. Disconnect the inlet hose and the outlet line from
the pump, and plug them.
NOTE: Take care not to spill the fluid on the body
or parts, Wipe off any spilled fluid at once.
4. Remove the pump mounting bolts and adjusting
bolt ('99 -'00 models: 816A2 Engine Type only),
then remove the pump.
NOTE:
. Do not turn the steering wheel with the pump
removeo.
. Wrap the opening of the pump with a piece of
tape to prevent foreign material from entering
the pump.
17-40
1.
8.
Connect the inlet hose and the outlet line. Tiqhten
the pump fittings securely.
Loosely install the pump in the pump bracket with
mounting bolts and adjusting bolt ('99 -'00 models:
81642 Engine Type only).
Installthe pump belt.
CAUTION:
. Make sure that the power steering belt is prop-
orly positioned on the pulleys.
. Do not get power stoering tluid or grease in the
power steering bsh or pulley faces. Clean off any
fluid or grease before installrtion.
Adjust the pump belt (see page 17-32).
Fill the reservoir to the upper level line (see page

\:Outer Handle Replacement
NOTE: Raise the glass fully.
'1. Remove:
. Door panel
. Plastic cover (see page 2o-21
2. Pull out the retainer cliP.
6x1.omm Ii.e N.. tr.o rgf.-, I7.2 rbr.fi) ,2
C3.
CYLINDER PROTECTOR
LOCK CYLINDEB
RETAINERCLIP
Remove the bolts, then remove the cylinder protec-
tor, lock cylinder and outer handle.
>: Bolt locaiions,2
CYLINDER
LOCK CYLINDER
CYLINDER ROD
20-5
4. Pull out the outer handle. Pry the outer handle rod
out of its joint using diagonal cutters
NOTE:
a To ease reassembly, note location @ of the outer
handle rod on the joint before disconnecting it.
. Take care not to bend the outer handle rod.
o Use a shop towel to protect the opening in the
ooor.
OUTER HANDLEROD
DIAGONALCUTTERS
SHOPTOWEL
lnstallation is the reverse of the removal procedure
NOTE: Make sure the door locks and opens properly.
BUSHINGReplace.
\
,w.
5.
i4'

tOuter Handle Replacement
NOTE: Raise the glass fullY.
1. Remove:
. Door panel
. Plastic cover (see page 20-8)
2. Remove the screws.
>: Screw locations, 3
6x1.0mm6 N.m {0.6 kgf m,4 tbf.ftl
a\
3. Move the latch down, and remove the bolts.
>: Bolt locations,2
6x1.0mm9.8 N,m )11.O kst.n,7.2lbiftl //
4. Pull out the outer handle. Pry the outer handle rod
out of its joint using diagonal cutters.
NOTE:
. To ease reassembly, note location O of the outer
handle rod on the joint before disconnecting it.
. Take care not to bend the outer handle rod.
. Use a shop towel to protect the opening in the
door.
BUSHINGReplace.
OUTERHANDLEROD
5.
o
DIAGONAL \
:"'* ,w,
lnstallation is the reverse of the removal procedure
NOTE: N4ake sure the door locks and opens properly.
SHOP TOWEL
20-11

bOuter Handle Replacement
NOTE: Raise the glass fully.
1. Remove:
. Door panel
. Plastic cover (see page 20-14)
2. Pull out the retainer clip.
3.e\
CYLINOER PROTECTOR
LOCK CYLINDER
RETAINERCLIP
Remove the bolts, then remove the cylinder protec-
tor, lock cylinder and outer handle.
>: Bolt locations,2
6x1.omm ]9.8 N.m {1.0 kgf.m,1.2tbl,ttl )_, _-_-,/
CYLINDERPROTECTOR
LOCK CYLINOER
CYLINOER ROD
20-17
4. Pull out the outer handle. Pry the outer handle rod
out of its joint using diagonal cutters.
NOTE:
. To ease reassembly, note location @ ot the outer
handle rod on the joint before disconnecting it.
. Take care not to bend the outer handle rod.
. Use a shop towel to protect the opening in the
door.
DIAGONALCUTTERS
SHOPTOWEL
5. Installation is the reverse of the removal procedure.
NOTE: Make sure the door locks and opens properly.
EUSHINGReplace.
\
,pr,

tInstallation
Using a knife, scrape the old adhesive smooth to a
thickness of about 2 mm (0.08 in.) on the bonding
surface around the entire windshield opening flange.
NOTE:
. Do not scrape down to the painted surface of the
body; damaged paint will interfere with proper
bonding.
. Remove the rubber dams and tasteners from the
body.
. Mask off surrounding surfaces before painting.
Clean the body bonding surface with a sponge damp-
ened in alcohol.
NOTE: After cleaning, keep oil, grease and water
from getting on the surface.
lf the old windshield is to be reinstalled, use a putty
knife to scrape off all traces of old adhesive, then
clean the windshield surface with alcohol where
new adhesive is to be applied.
NOTE: Make sure the bonding surface is kept free
of water, oil and grease.
CAUTION: Avoid setting the windshield on its edges;
small chips may later deyelop into cracks.
NOTE:
. Clean the shadowed area.
o Clean area @ as shown.
lnside
&
'1.
2.
3.
Ct
a4)
)
WINDSHIELD
JWINDSHIELD
20-29
Glue the rubber dam and fasteners to the inside
face of the windshield as shown.
NOTE: Be careful not to touch the windshield where
adhesive will be applied.
ALIGNMENTMABK
13.5 mm(0.53 in.)
LOWER RUBBERDAM
WINOSHI€LD
5. Align and glue the molding to the edge of the wind-
shield.
NOTE: Be caretul not to touch the windshield where
>: Faslener localions, 2
FASTENER
ALTGNMENT, -oMARK
MOLOINGWINDSHIELO
100 mm{3.94 in.l
Apply primer (3M N'200, or equivalent) to edSe (cont'd)of the windshield.

Windshield
Installation (cont'd)
Installthe glass brackets and fasteners as shown.
NOTE: The numbers after the part names show thequantities of the oarts used.
GLASS BRACKETS, 2
Set the windshield on the glass brackets, then cen-
ter it in the opening. Make alignment marks across
the windshield and body with a grease pencil at the
four points shown.
NOTE: Be careful not to touch the windshield where
adhesive will be aDolied.
7.
8. Remove the windshield.
20-30
>: Fastoner locations, 2FASTENER ^ I
I
SCREW
9. With a sponge, apply a light coat of glass primer
around the edge of the windshield as shown. then
lightly wipe it off with gauze or cheesecloth.
NOTE:
. Do not apply body primer to the windshield. and
do not get body and glass primer sponges mixed
up.
. Never touch the primed surfaces with your hands.
lf you do. the adhesive may not bond to the wind-
shield properly, causing a leak after the windshield
is installed.
. Keep water. dust, and abrasrve
from the primed surface.t/////,'/////l I Apply glass p.imer here.
materaals away
Apply glass primerto the molding.
WINDSHIELD
10. With a sponge. apply a light coat of body primer to
the original adhesive remaining around the wind-
shield opening flange. Let the body primer dry for
at least 10 minutes.
NOTE:
. Do not apply glass primer to the body, and be care-
ful not to mix up glass and body primer sponges.
. Never touch the primed surfaces with your hands.
. Mask off the dashboard before painting the flange.7////l/////l I Apply body p mer hcre.
6mm16mm 5mm(0.6:| in.) (0.2 in.l16 mm
{0,63 in.}
/
MOLDING

3
11.Thoroughly mix the adhesive and hardener together
on a glass or metal plate with a putty knife.
NOTE:
. Clean the plate with a sponge and alcohol before
mixing.
. Follow the instructions that come with the adhe-
stve.
Before filling a cartridge. cut the end of the nozzle
as shown.
Cut nozzle end
tu
10 mm 10.39 in.)
7 mm (0.27 in.l
13. Pack adhesive into the cartridge without air pockets
to ensure continuous delivery. Put the cartridge in a
caulking gun, and run a bead of adhesive around
the edge of the windshield as shown.
NOTE: Apply the adhesive within 30 minutes after
applying the glass primer.
12 mm (0.47 in.)
l_Z oo*.t,ut
8 mm 10.31 in.l
UPPERRUBBERDAM
Make a slightly thickerbead at each corner.
5mm(0.2 in )='+
A\uloto^o. -.\
/wWINDSHIELD
LOWEBRUBBERDAM
lmm10.04 in.l
FASTENER
LOWERRUBBERDAM
)
MOLDING
WINDSHIELD
20-31
15.
16.
14. Use suction cups to hold the windshield over the
opening, align it with the alignment marks made in
step 7, and set it down on the adhesive. Lightly
push on the windshield until its edge is fully seated
on the adhesive all the way around.
NOTE: Do not open or close the doors until adhesive
ri vI Y ALTGNMENT MARK
Scrape or wipe the excess adhesive off with a putty
knife or towel.
NOTE: To remove adhesive from a painted surface or
the windshield, wipe with a soft shop towel dampened
with alcohol.
Let the adhesive dry for at least one hour, then spray
water over the windshield and check for leaks. Mark
the leaking areas, let the windshield dry, then seal
with sealant.
NOTE:
. Let the car stand for at least four hours after wind-
shield installation. lf the car has to be used within
the first four hours, it must be driven slowly.
. Keep the windshield dry for the first hour after
installation.
. Check that the ends of the side molding are set
under the cowl cover.
Reinstall all remaining removed parts.
NOTE:
. Install the rearview mirror rubber damper after
the adhesive has dried thoroughl',.
. Advise the customer not to do the following things
for two to three days:- Slam the doors with all the windows rolled
up.- Twist the body excessively (such as when
going in and out of driveways at an angle or
driving over rough, uneven roads).
't7.