removal HONDA CIVIC 1997 6.G Repair Manual

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816A2 engine:
AIR CLEANER (ACLI
Replacement, Page 11-244
THROTTLE BODY {T8)Inspection. page 11-247Removal, page 1 '1-248
Disassembly, page 1 1-249THROTTLE CABLElnspection/Adiustment, page 1 1 -244
lnstallation, page 1 1-245
POSITIVE CRANKCASEVENTILATION IPCVI VALVEInspection, page 1 1-266
11-11

Fuel Supply System
Fuel Pressure Regulator
Te3ting
@ Do not smoke during the tast. Keep open
flamcs away from your work arsa.
1. Attach the special tool(s) to the service port on the
fuel filter (see pages 1 1-230, 231).
Pressure should bo:
except 81642 engine
260 - 310 kPa |'2.7 - 3.2 kgllcrn2,38 - /t6 psil
816A2 engine:
27O - 320 kPa 12.8 - 3.3 kgf/cm,, 40 - 47 psi)
{with the tuel pressure regulator vacuum hose
disconnested and pinched)
Reconnect the vacuum hose to the fuel pressure
regulator.
Check that the fuel pressure rises when the vacuum
hose from the fuel pressure regulator is disconnected
again.
lf the fuel pressure did not rise, replace the fuel
pressure regutalor.
CLAMP
REGULATOR
11-234
Reolacement
@@ Do not smoke while working on luel sys-
tem. Keep open flame away from your work area,
1. Place a shop towel under the fuel pressure regulator,
then relieve fuel pressure (see pages 11-230,231l..
2. Disconnect the vacuum hose and fuel return hose.
3. Remove the two 6 mm retainer bolts and the fuel
pressure regurator.
Apply clean engine oil to a new O-ring. and carefully
install it into its proper position.
Install the fuel pressure regulator in the reverse
order of removal.

I
FuelFilter
Replacement
r@. Do not smoke whilc working on fuel system. Keep
open flame away from your work arsa.
. While replacing the tuel filter, be catelul to koep a
sale distance betwoen battery torminals and any
tools.
The fuel filter should be replaced whenever the fuel
pressure drops below the specified value [260 - 310 kPa
12.7 - 3.2 ksl/cm',38 - 46 psi), |270 - 320 kPa (2.8 - 3 3
kgf/cm,, 40 - 47 psi))* with the fuel pressure regulator
vacuum hose disconnected and pinchedl after making
sure that the fuel pump and the fuel pressure regulator
are OK. *: 81642 engine
1. Place a shop towel under and around the fuelfilter.
2. Relieve fuel pressure (see pages 11-230,231]-
Remove the 12 mm banjo bolt and the fuel feed
pipe from the fuel filter, while supporting it with the
another wrench, as shown.
Remove the fuel filter ciamp and fuel filter'
lnstall the new fuel filter in the reverse order
removal, and note these items:
a When assembling, use new washers as shown
. Clean the flared joint of high pressure hoses
thoroughly before reconnecting them.
I
,96 MODELS:
(3.4 kgl.m,25 rbf.ftl
,97 AND LATER MODELS:
12 mmBANJOBOLT33 N.m
12 mmBANJOBOLT33 N.mt3.4 kgf m,25 lbf.fr)
\i(o-r
)
11-235

Fuel Supply System
Fuel Pump
Testing
!@ Do not smoke during the test, Keep open
flame away from your work atea,
lf you suspect a problem with the fuel pump, check that the
fuel pump actually runs; when it is ON (ll), you will hear
some noise if you hold your ear to the fuel fill port with the
fuel fill cap removed. The fuel pump should run for two
seconds when ignition switch is first turned ON (ll). lf the
fuel pump does not make noise, check it as follows:
L Remove the seat cushion {see section 20).
2. Remove the access panel from the floor.
3. Make sure the ignition switch is OFF, then discon-
nect the Iueltank 2P connector.
4. Connect the PGM-FI main relay 7P connector termi-
nal No. 4 and No. 5 with a jumper wire.
PGM-R MAIN RELAY 7P CONNECTOR lC4,(|l
FUEL PUMP
IYEL/GRN}
IGN 1(YEL/GRNI
tcs6s)
FUEL PUMP(YEL/GRNI
Wire side oftemale torminals
JUMPER WIRE
Wire side of temale terminals
Check that battery voltage is available between the
fuel pump connector terminal No. 1 and body ground
when the ignition switch is turned ON (ll).
CONNECTOR
=
[t
L3l .i)
T
lf battery voltage is available, check the fuel pump
ground. lf the ground is OK, replace the fuel pump.
lf there is no voltage, check the wire harness (see
page 11-238).
11-236
Replacement
@E Do not smoke while working on tuel svs-
tem. Keep open llames away from your work area.
1. Remove the seat cushion (see section 20).
2. Remove the access panel trom the floor.
3. Disconnect the 2P connector from the fuel pump.
4. Remove the fuel pump mounting nuts.
5. Remove the fuel pump from the fuel tank.
6. Install pans in the reverse order of removal.
ACCESS PANEL
i

IFuelTank
'96 - 98 models:
Replacement
I
1. Relieve the fuel pressure (see pages \1-230' 23'll'
2. Remove the seat cushion (see section 20).
3. Remove the access panel from the floor'
4. Disconnect the 2P (C565) and 3P (C564) connectors ('96 D]6Y8 engine (coupe) '97 D16Y/ engine(coupe: KL model'
sedanKL(LX)model).'97D'l6YSengine(coupe:allmodels'sedan:KLmodel'98-allmodels):and6P(C568)connec-
tor),
5. Disconnect the hose and quick-connect fittings (see pag es'l'l-225' 2271
6. Jack up the vehicle, and support it with jackstands'
7. Removethefuel tank cover ('96,'97 model) orthefuel hose joint protector'
8. Bemovethedrain bolt,and drainthefuel into an approved container'
9. Disconnect the hoses {see page r i-izst. Sria" nu"i ihe clamps, then twist hoses as you pull, to avoid damaging them'
10. Place a jack. or other support, under the tank'
11. Remove the strap nuts, and let the straps fall free'
12. Removethefuel tank lf it sticks on the undercoat applied to its mount' caref u lly pry it off the mount'
13.|nsta||thedrainbo|twithanewwasher.thencoatthedrainbo|twithNoxrustl24B,A||owtheNoxrustdryfor20min-
ules.
14. Installthe remaining pans in the reverse order of removal'
SASE GASKETReplace.
BASE GASKETReplace.
!@@ Do not smoke while working on fuel system' Keep open flame away from your work ar'a'
TANKSTRAPS
DRAIN BOLT,19 N.m {5.0 kgt m, 36 lbf.ftl(cont'd)
11-241

Fuel Supply System
Fuel Tank {cont'dl
39 - (xt models:
Replac6ment
o
@ Do not smoke whire working on fuer system. Ke€p open frama away trom your work area.
1. Relievethefuel pressure (see pages 11-230,23'll.
2. Remove the seat cushion lsee section 2O).3, Remove the access panel fromthefloor.
4. Disconnectthe2P (C565) and3P(CS64) connectors and 6p (C569) connecror.5. Disconnect the hose and quick-connect fiftings (see pages 1l-226,22j),6. Jack up the vehicle, and support it with jackstands.
7. Removethefuel hose joint protector and heat shield.8. Removethedrain bolt. and drainthefuel intoan aporoved container.9 Disconnect the hoses (see page 11-226). Slide back the clamps. then twist hoses as you pull, to avoid damagtng rnem.10. Place a jack, or other support, under the tank,11. Remove the strap nuts, and let the straps fallfree,'12. Removethefuel tank. lf itsticks onthe undercoat applied to its mount, carefully pry itoffthe mount.13. Install thedfain boltwith a new washer. then coat the d rain bolt with Noxrust 124B,Allowthe Nox.ust drv for 20 min-utes.
14. Installthe remaining parts in the reverse order of removal,
Replace.
DRAIN BOLT,19 N.m (5.0 kgf.m, 36lbf.ft)
11-242

Intake Air System
J
Throttle Body (cont'dl
Removal
D16Y5, Dl6Y8, 81642 engine:
D15Y7 engine:
AIR CLEANER
{ACLI
22 N.m12.2 kgl.m,16 rbf.ftl
NOTE:
. Do not adjust the throttle stop screw.. After reassembly, adjust the throttle cable {see page l l-244).. The TP sensor is not removable.
IAT SENSOR
MAP SENSOR
GASKETReplace.
11-248
THROTTLE CABLE

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7. Connect a second vacuum pump to the OBVR signal
nose.
VACUUM PUMP/GAUGE.0 - 30 in.HgA973X - 041 -
xxxxx
Apply vacuum (1 pump) to the ORVR signal hose,
then check the vacuum on the pump in step 6.
. lf the vacuum holds, replace the ORVR vent shut
valve.
. lf the vacuum is released, the ORVR vent shut
valve is OK.
Disconnect the ORVR quick disconnect from the EVAP
canister, then plug the port on the canister.
Reapply vacuum (80 pumps).
. lf the vacuum holds, reDlace the ORVR vent shut
valve,
. lf the vacuum does not hold, inspect the EVAP can-
ister vent shut valve O-ring. lf the O-ring is OK,
replace the EVAP canister and repeat step 4.
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I
11-297
ORVR Vent Shut Valve Replacement
1. Remove the fuel tank (see page 1 1-242).
2. Remove the ORVR vent shut valve from the fuel tank.
3. lnstall oarts in the reverse order of removal.

J
t
Clutch
Speciaf Tools .......... ...........12-2
f lfustrated Index .......... ......12-3
clutch Pedal
Adjustment .................... 12'4
Clutch Master Cylinder
Removal/lnstallation ..... 12-5
Slave Cylinder
Removal/lnstallation .....12'6
Pressure Plate
Removal/lnspection ...... 12-7
Clutch Disc
Removal/lnspection ...... 12-8
Flywheel
Inspection ....................... 12-9
Replacement ....................................... 12-9
Clutch Disc, Pressure Plate
lnstallation ..................... 12-10
Release Bearing
Removal/lnspection ......12-11
f nstalfation .................,... 12-12
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lllustrated Index
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NOTE:
. Whenever the transmission is removed, clean and grease the release bearing sliding surface
. lf the parts marked with an asterisk (*) are removed, the clutch hydraulic system mustbe bled (seepage 12-6)
. Inspect the hoses for damage, leaks, interference, and twisting
'RESERVOIF TANK
ASSIST SPRING
LOCK PIN
5x1,0mm9.8 N.m (1.0 kgf.m,7.2 tbtftl*CLUTCH LINE15 N.m {1.5 kgJ m,11 tbt.ft)
RELEASE BEARINGRemoval/lnspection, page 12-1 1Installation, page 12-'12
*CLUTCH MASTER CYLINDERRemoval/lnstallation, page 12 5
6x1.0mm9.8 N.m (1.0 kgf.m,7.2 tbf.ft)
FLYWHEELInspectaon, page 12IReplacement, Page 12-9
CLUTCH DISCRemoval/lnspection, page 1 2-8
lnstallation, page 12-'10
'12 x 1.0 mm118 N.m {12.0 kgt'm,86.8lbfft)
PBESSURE PLATEBemoval/lnspection, page 12 7Installation, page 12''10
8 x 1.25 mm22 N m (2.2 kgf.m, 16lbf ft)
ISLAVE CYLINDERRemoval/lnstallation, page 12_6
12-3