Crank no start HONDA CIVIC 1997 6.G Workshop Manual

Main Bearings
4.
Glearance
1.To check main bearing-to-journal oil clearance.
remove the main caps and bearing halves.
Clean each main journal and bearing half with a
clean shop towel.
Place one strip of plastigage across each main jour-
na l.
NOTE: lf the engine is still in the car when you bolt
the main cap down to check clearance, the weight
of the crankshaft and flvwheel will flaften the plasti-
gage further than just the torque on the cap bolt.
and give you an incorrect reading. For an accurate
reading, support the crank with a jack under the
counterweights and check only one bearing at a
time,
Reinstall the bearings and caps, then torque the
bolts.
lst step: 25 N'm (2.5 kgl'm. 18 lbf'ft)
FinalsteD:
B16A2 engine:
76 N.m (7.8 kgf.m, 56 lbf'ft)
D16Y5, Dl6Y7, D16Y8 engines:
51 N.m (5.2 kgf'm, 38 lbf'ft)
NOTE: Do not rotate the crankshaft during inspec-
tron.
Remove the cap and bearing again, and measure the
widest part ot the plastigage.
Main Boaring-toJournal Oil Clearance:
816A2 engine:
Standald {New}:
No. l, 2, 4, 5 Journals:
O.O2,l - 0.042 mm 10'00(B - 0.0017 in)
No. 3 Journals:
0.030 - 0.048 mm {0'0012 - 0'0019 in)
Servico Limit: 0.06 mm {0.002 in,
Dl6Y5, Dl6
r, Dl6Y8 engines:
Standard (Nsw):
No. 1,5 Journals:
0.018 - 0.035 mm {0.0007 - 0'001'[ in)
No. 2. 3, 4 Journals:
0.02,1 - 0.0,(2 mm {0'0009 - 0.0017 in}
Service Limit: 0.05 mm (0.002 in)
\
7-9
7.
lf the plastigage measures too wide or too narrow,
(remove the engine if it's still in the car), remove the
crankshaft, and remove the upper half of the bear-
ing. Install a new. complete bearing with the same
color code {select the color as shown on the next
page), and rechsck the clearance.
CAUTION: Do nol fil€, shim, or scrape the bearings
or tho cap3 to adiust cleatanc€.
lf the plastigage shows the clearance is still incor-
rect, try the next larger or smaller bearing (the color
listed above or below that one), and check again
NOTE: lf the proper clearance cannot be obtained
by using the appropriate larger or smaller bearings,
replace the crankshaft and start over.

Connecting Rod Bearings
Clearance
Remove the connecting rod cap and bearing half
Clean the crankshaft rod iournal and bearing half
with a clean shop towel.
Place plastigage across the rod journal.
Reinstall the bearing half and cap, and torque the nuts.
Torque
Bl6A2 engine:
40 N.m (4.1 kgl.m, 30 lbf'ft)
Dr6Y5, D16Y7, D16Y8 enginss:
31 N'm (3.2 kgf.m, 23 lbf ftl
NOTE| Do not rotate the crankshaft during inspection.
Remove the rod cap and bearing half and measure
the widest part of the plastigage.
Connecting Rod Bearing-to.Journal Oil Glearance:
816A2 engine:
Standard lNewl: 0.032 - 0.050 mm
10.0013 - 0.0020 in)
Service Limit: 0.06 mm 10.002 inl
D16Y5, D16Y7, D16Y8 engines:
Standard lNew): 0.020 - 0.038 mm
(0.0008 - 0.0015 in)
Service Limit 0.05 mm 10.002 inl
'1.
4.
lf the plastigage measures too wide or too narrow'
remove the upper half of the bearing, install a new,
complete bearing with the same color code (select
the color as shown in the right column), and
recheck the clearance.
CAUTION: Do not lile, shim, or scrape the bearings
or the caps to adiust clgarance.
lf the plastigage shows the clearance is still incorrect.
try the next larger or smaller bearing (the color listed
above or below that one), and check clearance again.
NOTE: lf the Droper clearance cannot be obtained
by using the appropriate larger or smaller bearings,
replace the crankshaft and start over.
PLASTIGAGE STRIP
\
7.
7-11
Selection
CAUTION: lf the codes are indecipherable because of
an accumulation of dirt and dust, do not sclub them
with a wile brush or scraper. Clean them only with sol-
vent or detergent,
Connecting Rod Code Location
Numbers have been stamped on the side of each con
necting rod as a code for the size of the big end Use
them, and the letters stamped on the crankshaft (codes
for rod journal size), to choose the correct bearlngs
Half of number ls
stamped on bearingcap and the otherhalf is stamped onrod.
Bearing ldentilication
Color code is on theedge ofthe bearing.
lfA--;T] |
lle"'tt l;llcorlll ll
I lD;;ilril |l-l
Larger brg end bore
Smaller Smallerrod bearlngjournal (thicker)
---------------- Smallerbearing{thrcker)
RedPinkGreen
PinkGreen
GreenErownBlack
GreenBrownBlackBlue
1234
Connecting Rod Journal Code Locations (Lettels)

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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

PGM-FI System
System Description (cont'dl
Lean Burn Control {D16Y5 engine: CvT)
The lean burn control system is based on the characteristic increase in crankshaft angular acceleration which occurs inwhen the air-fuel ratio gets leaner.
The CKF sensor, which is mounted on the crankshaft, monitors sngine speed, lf crankshaft angular acceleration falls belowa certain level (target air-fuel ratio level), the amount of injected fuel is reouceo.
lf crankshaft angular acceleration exceeds this level. the amount of fuel is increased.
This system improves fuel economy and driveability by controlling the amount of injected fuel in the lean burn rangeimmediatelv before combustion starts to deteriorate.
1 1-1 06
TOC/CKP/CYP SENSOR
MAP SENSOR
CKF SENSOR
ECM
Comparison oI current airfuel ratio to target ratio

PGM-FI System
tFos3sl
tFffi6l
tPr361 I
fPfi62l
fFr38il
tF13s2-l
Crankshaft Position/Top Dead Genter/Gylinder Position (CKP/TDC/CYP) Sensor
('96 - 98 Models, '!n - 00 D16Y5 engine with M/Tl
The scan tool indicates Diagnostic Trouble Code (DTC) P0335: A malfunction in the Crankshaft position (CKp)
sensor circuit.
The scan tool indicates Diagnostic Trouble Code (DTC) P0336: A range/performance problem in the CrankshaftPosition (CKP) sensor circuit.
The scan tool indicates Diagnostic Trouble Code (DTC) P1361: Intermittent interruotion in the Too Dead Center(TDC) sensor circuit.
The scan tool indicates Diagnostic Trouble Code {DTC) P1362: No signal in the Top Dead Center (TDC} sensorcircuit.
The scan tool indicates Diagnostic Trouble Code (DTC) P1381: Intermittent interruption in the Cvlinder Position{CYP) sensor circuit.
The scan tool indicates Diagnostic Trouble Code {DTC) Pl382: No signal in the Cylinder Position (CYP} sensorcircuit.
Description
The CKP Sensor determines timing for fuel injection and ignition of each cylinder and also detects engine speed. The TDCSensor determines ignition timing at start-up (cranking) and when crank angle is abnormal. The Cyp Sensor detects theposition of No. 1 cylinder for sequential fuel injection to each cylinder. The CKP/TDC/CYP Sensor is built into the distribu-ror.
NOTE: lf DTC P1359 is stored atthesametime as DTC P0335. P0336, P1361, Pl362, P1381 and/or P1382, troubteshoor DTCP1359 first, then recheck for those DTCS. Ot6y5 6ngine: Dt6y7, ot6y8 enqin6s:
SENSORBOTOR
TDCSENSORCKPSENSORSENSORROTORSENSORROTORSENSORROTORROTORROTOR
DISTRIBUTOR 1OPcoNNECTOR tC120tTDC P
- The MIL hrs been reported on.- DTC P0335, P0336, P1361,P1362, P1381 and/or Pl382 6restored,
Problem verification:1. Do the ECM/PCM Reset Proce-dure.2. Stan the engine.
Intermittent hilu.e, system b OKat this time. Check tor poor con-n€ctions or 10036 wiros at C120{distributor} and ECM/PCM.
ls DTC P0335, P0336, P1361, P1362,P1381 and/or P'l382 indicated?
Check for an open in the CKP/TDC/CYP sensor:1. Turn the ignition switch OFF.2. Disconnect the distributor 10P
3. Measure resistance betweenthe terminals of the indicatedsensor (*see table).
Replace the distributor ignitionhousing (soe section 23).ls there 350 - 700 0?
CYP M {BLK}
SENSORDTCSENSORIERMINATECMfCMTERMINATCOLOR
CKPP033s
m336
2c2BLU
6c12
TDCP1361
P1362
3GRN
7cl3RED
CYPP!381
P't382
c4YEL
8c148LK11-172

PGM-FI System
l-Fos3sl
tFos36l
tF1361 l
Fr362-1
tF13sil
Crankshaft Position/Top Dead Center/Cylinder Position (CKP/TDC/CYPI Sensor
f99 - 00 Models except D16Y5 engine with M/T)
The scan tool indicates Diagnostic Trouble Code (DTC) P0335: A malfunction in the Crankshaft Position (CKP)
sensor circuit.
The scan tool indicates Diagnostic Trouble Code (DTC) P0336: A range/performance problem in the Crankshaft
Position (CKP) sensor circuit.
The scan tool indicates Diagnostic Trouble Code (DTC) P1361: Intermittent interruption in the Top Dead Center
{TDC) sensor circuit.
The scan tool indicates Diagnostic Trouble Code {DTC) P1362: No signal in the Top Dead Center (TDC) sensor
circuit.
The scan tool indicates Diagnostic Trouble Code (DTC) P1381: Intermittent interruption in the Cylinder Position(CYP) sensor circuit.
lTiaSt The scan tool indicates Diagnostic Trouble Code (DTC) P1382; No signal in the Cylinder Position (CYP) sensor: circuil.
DoscriDtion
The CKP Sensor determines timing for fuel injection and ignition of each cylinder and also detects engine speed. The TDC
Sensor determines ignition timing at start-up (cranking) and when crank angle is abnormal. The CYP Sensor detects the
position of No. 1 cylinder for sequential fuel injection to each cylinder. The CKP/TDC/CYP Sensor is built into the distribu-
tor.
NOTE; lf DTC P1359 is stored at the same time as DTC P0335, P0336, P1361. P1362, P1381 and/or P1382, troubleshoot DTC
P1359 first, then recheck for those DTCS. D16Y5 engino:
SENSORROTOR
TDGSENSORCKPSENSOBTDCSENSOBCKPSENSOBCYPs€NsonBOTORROTORBOTONROTOR ROTOR
D16Y7, D16Y8 ongine:
(To page 11-175)
1-174
- The MIL has been reportod on.- DTC P0335, P0336. P1361,P1362, P1381 rnd/or P1382.restored.
Problem verific{tion:1. Do the ECM/PCM Reset Proce-dure.2. Start the engine.
Intormittcnt failure, systom b OKat thb time. Check to. poor con-nections or loose wires at C120(dktributorl and ECM/PCM.
ls DTC P0335, P0336, P1361, P1362,P1381 and/or Pl382 indicated?
Check tor an open in the CKP/TDC/CYP 3enior:1. Turn the ignition switch OFF.2. Disconnect the distributor 10Pconnector,3. Measure resistance betweenthe terminals of the indicatedsensor (*see table).
Replrce the distributor ignitionhou3ing (!ee section 231.ls there 350 700 0?
SENSORDTCSENSORTEBMINAIECM/PCMTERI\,4INAICOLOR
CKPP0335
P0336
2c88LU
6c9
TDCP1361
P1362
3c20GRN
7c21BED
CYPP1381
P1342
c29YEL
Ic30BLK

tCrankshaft Speed Fluctuation (CKF) Sensor -
('99 - 00 Mociels except D16Y5 engine with M/T)
The scan tool indicates Diagnostic Trouble code (DTC) P1336: Intermittent interruption in the crankshaft speed
Fluctuation (CKF) sensor circuit
The scan tool indicates Diagnostic Trouble Code (DTC) P1337: No signal in the Crankshaft Speed Fluctuation (CKF)
sensor circuat,
Description
Thediagnosticsystemhasapulserrotoronthecrankshaftandapu|sepick-upsensorontheengineb|ock.TheEcM/PcM
monitors the crankshaft speed fluctuation based on the cKF sensor signal. and judges that an engine misfire occurred if
the fluctuation goes beyond a predetermined limit'
I
Ftu6l
tF13g7l
CKF SENSOR 3P CONNECTOR
r--r t|-.r-r'--]llll l2l3ll.l---'.-T_
CKFM I I CKFP
twHTl |/Ai i lBlul--\9-
Terminal side oI male terminals
CKF M(WHT)CKF P(BLU)
t(cont'd)
1 1-185
- The MIL has b€on reportad on.- DTC P1336 and/or P1337 are
stored.
Problem verification:1. Do the ECM/PCM Reset Proce'
dure.2. Start the enginelntermittcnt failuro, sydcm is OK
ai this time. Check lot Poor con_
noctions or loo3e wiros at C102
ICKF s€nsor) and ECM/FCM, and
make suro CKF sansor mounting
bolt b tight.
Check tor an open in the CKF sen_
1. Turn the ignition switch OFF
2. Disconnect the CKF sensor 3P
3. Measure the resistance
between the CKF sensor 3P
connector terminals No. 1 and
No.3.
ls there 1.6 3.2 kO?
Check for a short in ihe CKF sen_
sot:Check for continuity betweenbody ground and the CKF sensor
3P connector terminals No 1 and
No.3 individuallY.
(To page 11-186)

l,a
Crankshaft Position/Top Dead Center/Cylinder Position (CKP/TDC/CYPI Sensor
Thescantoo|indicatesDiagnosticTroub|ecode(DTc)P1359:Aprob|eminthecrankshaftPosjtion/TopDead
Center/Cvlinder Position (CKP/TDC/CYP) sensor circuit'
- The MIL has been reported on- DTC P1359 is stored
Problem veritication:1. Do the ECM Reset Procedure
2. Stan the engine lftheengine
won't start, crank it for at least
10 seconds-
lntermittent failure, sYstem is OK
Check for poor connecllon3 or
loose wires at C120 {distributor}and ECM,/PCM.
ls DTC P1359 indicated?
Check for poor connections or
loose wires between the distribu
tor and the ECM/PCM
Substitute a known'good ECM/
PCM, and rccheck. lt 3ymPtom/
indication goes awtY, rePlace
the original ECM/PCM.
r ta
11-1A7

ldle Control System
Starter Switch Signal ('96 - 98 Models,'99 - 00 D16Y5 engine with M/Tl
Thjs signals the ECM/PCM when the engine is cranking.
NOTE:. A/T: Transmission in E or E position. M/T: in neutral
a l32PlLGl
Wire side ot female lerminals
Check tor an open or short in thewire ISTS linel:Measure voltage between ECM/PCM connector terminals A9 andC6 with the ignition switch in thestart lllli position.
Inspect the No. 31 STARTER SIG-NAL (7.5 A) fuse in the underdashfuse/relay box.
- Repair .hort in the wirebotwoen tha ECM {C6l andtho No, 31 STARTER SIGNAL{7.5 Al tuss or the PGM-FImain relay,- Roolac. the No. 3'l STARTERSIGNAL l?.5 Al tu3€.
Staner 3witch signal is OK.
Repair opon in th6 wiro botweanih. ECII4/PCM (C6) and the No.31STARTER SIGNAL {7.5 Al tulo.
ECM/PCM CONNECTORS
{BRN/BLKISTS IBLU/ORNI
216910It3567a9l0
l2l3la15!6171a1920222att12t3l4t5t6171E
252l2A7t30232a2930
11-202

\
Starter Switch Signal ('99 - 00 Models except Dl6Y5 engine with M/T)
NOTE:. M/f: Clutch pedal must be depressed.. A,/T: Transmission in E or E position
ECM,/PCM CONNECTORS
I
This signals the ECM/PCM when the engine is cranking
Ch€ck for an open or short in the
wire {STS linel:Measure voltage between ECM/PC[/| connector terminals A24
and 820 with the ignition switch
in the start position (lll).
Inspect the No.31 STARTER SIG-NAL (7.5 Alluse in the under-dash
- Repair 3hort in tho wire be'
tween tho ECM/PCM lA24)and tho No. 31 STARTER SIG-NAL 17.5 Al fuse or the PGM-FImein relay.- ReDlaco the No. 31 STARTERSIGNAL 17.5 Al fuse.
Staner 3witch signal is OK.
Repair open in the wirc betwean
the ECM/PCM lA24) and the No.
31 STARTER SIGNAL {7.5 Alfuse.
W;re side of female terminals