Seat HONDA CIVIC 1999 6.G Workshop Manual

Gonnector ldentification and Wire Harness Routing
Floor Wire Harness (Sedanl: '97 - 00 models
Connector or
Terminal
Number of
CavitiesLocationConnects toNotes
c552
c553
c554
c555
c556
c557
c557
c558
c559
c560
c56'l
c562
c563
c564
c566
c568
c569
c570
c571
c572
16
8
14
20
25
2
2
1
2
1
20
2
2
2
1
l0
1
1
Behind under-dash fuse/relay box
Behind under dash fuse/relay box
Above under-dash fuse/relay box
Under left side of dash
Above under-dash fuse/relay box
Above under-dash fuse/relay box
Driver's door
Driver's door
Passenger's door
Passenger's door
Middle of floor
Left side of floor
Right B-pillar
Inside of left rear wheel
Left C-pillar
Left C-pillar
Left C-pillar
Fuel tank
Fuel tank
Inside of righr rear wheel
Left B-pillar
Fuel tank
Left side of steering wheel
Righr B,pillar
Left B pillar
I ofr ^,,.riar ^.^al
Right quarter panel
Under-dash fuse/relay box (C923)
Under-dash fuse/relay box (C921)
Dashboard wire harness (C503)
Main wire harness (C402)
Main wire harness (C401)
Main wire harness (C401)
Driver's door wire harness (C631)
Driver's door wire harness {C631}
Front passenger's door wire harness (C651)
Front passenger's door wire harness (C651)
Parking brake switch
Driver's seat belt switch
Front passenger's door switch
Left rear ABS wheel sensor
Rear wire harness (C601)
Rear wire harness (C601)
Rear wire harness (C602)
Fuel gauge sending unit
Fuel pump (FP)
Right rear ABS wheel sensor
Driver's door switch
Fuel tank pressure sensor sub-harness(c791)
Power mirror switch
Right rear door wire harness (C671)
Left rear door wire harness (C661)
Left rear door switch
Right rear door switch
ABS
ABS
ABS
G551Left kick panel
Left side of floor
Body ground, via floor wire harness
Body ground, via floor wire harness
"1r With power windows*2: Without power windows
*3:'97 - '98 models*4: '99 - 00 models
23-44

JBrush Holder Test
1. Check that there is no continuity between the O and
o brush holders.
lf there is continuity, replace the brush holder
assemoly.
O BRUSH HOLDER
@ BRUSH HOLDER€) BRUSH HOLDER
2. Insert the brush into the brush holder, and b.ing the
brush into contact with the commutator, then attach
a spring scale to the spring. Measure the spring ten-
sion at the moment the spring lifts off the brush.
SPRING SCALE
Spring Tension
15.7 - 17.7 N (1.60 - 1.80 kgf. 3.5 - 4.0 lbf)
ERUSH
Brush Inspection
Measure the brush length. lf not within the service limit,
replace the brush (or brush holder assembly).
Brush Length
NOTE: To seat new brushes after installing them in their
holders, slip a strip ot #500 or #600 sandpaper. with the
grit side up, over the commutator and smoothly rotate
the armature. The contact surface of the brushes will be
sanded to the same contour as the commutator.
Overrunning Clutch lnspection
Slide the overrunning clutch along the shaft. Does it
move freely? lf not, replace it.
Rotate the overrunning clutch both ways. Does it
lock in one direction and rotate smoothly in
reverse? lf it does not lock in either direction or it
locks in both directions, replace it.
2.
L
Standard (NEW)Service Limit
15.8 - 16.2 mm
(0.62 - 0.64 in)
1 1.0 mm
{0.43 in)
CLUTCH GEAR
DRIVE GEAR

Starting System
Starter Replacement
1.Make sure you have the anti-theft code for the
radio, then write down the frequencies for the
radio's preset buttons ('99 - 00 models).
Disconnect the battery negative cable.
Disconnect the starter cable from the B terminal on
the solenoid, then disconnect the BLK trHT wire
from the S terminal.
MOUNTING BOLT44 N.m l/t.s kgf.m. 32 lbf.ft)
S TERMINAL
MOUNTING BOLT6,1 N.m {4.5 kstm.32lbtftl
MOUNTING NUT9 N,m {0.9 kgl.m,6.s lbtftl
B TERMINAL
4. Remove the two bolts holding the starter, then
remove the starter.
lnstall in the reverse order of removal.
NOTE: When installing the staner cable, make sure
that the crimped side ofthe ring terminal is facing out.
TERMINAL
Connect the battery positive cable and negative cable
to the battery.
Enter the anti-theft code for the radio, then enter the
customer's radio station presets ('99 - 00 models).
7.
Crimped side of ring
23-100
Starter Reassembly
'1. Pry back each brush spring with a screwdriver, then
position the brush about halfway out of its holder.
and release the spring to hold it there.
Install the armature in the housing. Next, pry back
each brush spring again, and push the brush down
until it seats against the commutator, then release
the spring against the end of the brush.
aw
3. Install the end cover on the brush holder.
ERUSH HOLDER

JRectifier Removal
1. Remove the four through bolts.
Heat the rear bearing seat with a 1,000 W hair drier
tor about five minutes (120 - 140'F, 50 - 60"C).
3. Separate the rear housing from the drive-end hous-
ing by inserting a flst tip screwdriver into the open-
ings and prying them a part. Be careful not to dam-
age the stator with the tip of the screwdraver.
Seoarate the rear housing and drive-end housing
with the stator attached to the rear housing.
DEIVE-END HOUSING
STATOR
{cont'd)
23-121
REAR HOUSING

Gharging System
Rear Bearing Replacement
1. Pull offthe rear bearing,
. Make sure the tips of the bearing puller jaws arethin enough to fit between the bearing and theslip rings.
. Do not reuse the bearing.
SLIP RINGSBEARING PULLER
Use a hand press to install the new bearing. Applypressure only on the inner race to avoid damaging
the bearino.
REAB BEARING
23-124
Alternator Reassembly
1. Push the brushes in, then insert a pin or drill bit(about 1.8 mm diameter) to hold them there.
Heat the rear bearing seat in the rear housing asdescribed on page 23-121. After heating, continueimmediately with assembling before the rear bear-ing seat cools completely,
Put the rear housing/stator assembly and drive-endhousing/rotor assembly together. tighten the fourthrough bolts and pull out the pin.
REARSTATOR ASSEMBLY
After assembling the alternator, turn the pulley byhand to make sure the rotor rotates smoothlv andwithout noise.
BRUSHES
THROUGH BOLT
Iq
%*z
BRUSH AOCESS HOI."E

Gauge Assembly
Bulb Locations (With Tachometer)
GAUGE LIGHT II.' WI
SEAT BELTREMINDER LIGHT I1.4 WI
LOW FUELLIGHT 13 W)
RIGHT TURN SIGNALINDICATOR LIGHT I1.4 WI
A/T GEARGAUGE LIGHTS 13 W)
CI{ARGING SYSTEM LIGHT (1.,1W)
GAUGE I-IGHT {1,4 WI
LOW ENGINE OIL PRESSUREINDICATOR LIGHT (1,' W}
HIGH EEAMINDICATOR LIGHT(1.4 W)
GAUGE LIGHT l3.il Wl
MALFUNCTIONINDICATORLAMP {MIL}BULE (1.{ Wl
WASHER I.'C VELINDICATOR LIGHT{1.4 Wl (Canada)
LEFT TURN SIGNALINDICATOR LIGHT {1.4 WI
sRsTOB (1.4 Wl
{On the printed circuit board)INDICATOR (1.12 x 6l(On the printed
circuit board)
ABS |ND|CATOR (1.. Wl{On the printed circuit board)CRUISE or SHIFT-UP INDICATOR 11.12 11.{On the orinted circuit board)
23-136

JBulb Locations {Without Tachometer)
TRUNK INDICATORLIGHT {1.i1W}
.4 Wl
CHARGING SYSTEM LIGHT 11,4 W}
LTGHT (1.4 W)GAUGE LIGHT
SEAT BELTREMINDER LIGHT (1.4 WI
LOW ENGINE OIL PRESSUBE
INDICATOB LIGHT (1.4 WI
LOW FUEL INDICATORLrGl{T (3 W)
RIGHT TURN SIGNALINOICATOR LIGHT
(1.1Wt
GAUGE LIGHTS {3 WI
WASHER LEVELINDICATOR LIGHT{1.4 W} lcanad.l
HIGH BEAMINDICATOR LIGHTMALFUNCTIONINDICATORLAMP (MIL)
BULB {1.4 WI
{1.ilW)
LEFT TURN SIGNALINDICATOR LIGHT {1.4 WI
A/T GEAR POSITIONINDICATOR (1.12 x 6)(On the printed
circuit board)
sRs TND|CATOR 11.4 W)
{On the Drinted circuit board}
aBs tNDtcAToR t1.4 W)(On the printed circuit board)(3.{ Wt
o/ o \7 o
23-137

Integrated Gontrol Unit
Input Test (cont'dl
A8--------.--all
Key-in/Seat Belt R€mind€r, Lights-on Reminder Systom:
Cavity WireTest condhion
Bulb Check System (Brako System Light):
Cavity WireTest condilion
Tost: D€sirod r€guh
T6st: Dosirad result
Possible cause if result is not obtained
Possibls cause if rasuft b not obtainod
A8
Combination light
switch ON
Check for voltage to ground;
There should be battery voltage.
Blown No.30 (7.5 A)fuse in the
under-dash fuse/relay box
Faulty combination light switch
An open in the wire
B7RED/BLU
lgnition switch ON (ll),
and driver's seat belt
switch unbuckled
Check for voltage to ground:
There should be 1 V or less.
Poor ground (G552)
Faulty seat belt switch
An open in the wire
B9GRNDriver's door openCheck for voltage to ground:
There should be 1 V or less.
. Faulty driver's door switch. An open in the wire
Bl0BLU/RED
lgnition key inserted
into the ignition key
switch
Check for voltage to ground:
There should be 1 V or less.
Poor ground (G401. G402)
Faulty ignition key switch
An open in the wire
A4GRN/RED
lgnition switch ON {ll),
brake fluid reservoir
full, and parking brake
tever oown
Connect to ground: Brake system
light should come on.
Blown No.25 (7.5 Alfuse in the
under-dash fuse/relay box
Blown brake system light bulb
An open in the wire
A13BLUA/1r'HT
lgnition switch at
START (III)Check for voltage to ground:
There should be battery voltage.
Blown No.31 (7.5 A) fuse in the
under-dash fuse/relay box
Faulty starter cut relay
An open in the wire
23-160

Headlights
Adjustment
Eoforo adiu3ting th€ h.adlights:
. Park the vehicle on level surface.
. Make sure the tire prgssures are correct.
a The driver or someone who weighs the same should
sit in the driver's seat.
96 - 98 modols
1. Open the hood.
2. Check the horizontal adjustment indicator.
The "0" mark on the horizontal indicator gear
should be aligned with the mark on the horizontal
indicator.
HORIZONTAL INDICATOR
Check the vertical adjustment indicator. The bubble
should be centered underneath the longest scribe
mark on the gauge.
VERTICAL INDICATOR:
Headlight become very hot in use; do not touch them
or any attaching hardware immediately after they
have been turnsd off.
MARK
23-164
(Bubblol
lf either indicator is not aligned with its "0"mark as
described left column, an adjustment can be made
by using a Phillips screwdriver.
Adjust the headlights to local requirements by turn-
ing the adjusters.
After headlight replacement, it may bs necessary to
readjust the horizontal indicator gear.
. First install the headlioht, and adjust its horizon-
tal and vertical aimings according to local re-
quirements.
. Then check that the arrow on the horizontal indi-
cator gear is aligned with the mark on the hori-
zontal indicator.- lf they are not aligned, remove the screw,
adiust the indicator gear, and retighten the
screw.
NOTE: As the outer lenses are made ot an acryli-
coated, polycarbonated material, do not cover the
headlights when they are turned on.

Description
)
The sRS is a safety device which, when used in coniunction with the seat belt, is designed to help protect the driver land
front passenger) in a frontal impact exceeding a certain set limit. The system consists of the sRS unit {including safing
sensor and impact sensor), the cable reel, the driver's airbag (and front passenger's airbag)
FRONT PASSENGEB'SAIRAAG
DRIVER'S AIRBAG
CABLE REEL
SRS UNtT
t
Operation
The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charge(s) lf
battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power clrcult
resoectivelv will keep voltage at a constant level.
For the SRS to operate:
(1) The impact sensor must activate. and send electric signals to the mlcroprocessor'
(2) The microprocessor must compute the signals' and must send signals to the airbag inflator(s)'
{3) The inflator(s) must ignite and deploy the airbag(s)'
_"-_-l
Ir3B!#h i
!.. I
ffi,*
Self-diagnosis System
A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (ll), the SRS indicator light comes
on and goes off after about six seconds if the system is operating normally
lf the liglt does not come on, or does not go off after six seconds, or if it comes on while driving, it indicates an abnormal-
ity in the system. The system must be inspected and repaired as soon as possible
For better serviceability, the memory will store the cause of the malfunctlon, and the data link circuit passes on the infor-
mation from the memory to the data link connector (DLC). This intormation can be read with the Honda PGM Tesler con-
nected to the DLC (16P).
l,
24-5