ac line HONDA CIVIC 1999 6.G Workshop Manual

Emission Control System
Evaporative Emission {EVAP) Controls (cont'dl
\J
tF1456-l
tP14sz-l
EVAPCONTROLCANISTERVENTSHUTVALVE
O.RINGReplace.
EVAPCONTROLCANISTER
ECM/PCM CONNECTOR A I32PI
(To page 11'289)
'99 - 00 modols except Dl6Y5 engine with M/T:
The scan tool indicates Diagnostic Trouble Code (DTC) P1456: Evaporative Emission (EVAP) control system leak
detected (fuel tank svstem).
The scan tool indicates Diagnostic Trouble Code (DTC) P1457: Evaporative Emission (EVAP) control system leak
detected (EVAP control canister system).
Possible Cause
. Fuel fill cap
. Vacuum Connections
. FuelTank
. EVAP Control Canister Vent Shut Valve
. EVAP Control Canister Vent Shut Valve Circuit
. EVAP Purge Control Solenoid Valve
o EVAP Purge Control Solenoid Valve Circuit
. EVAP Bypass Solenoid Valve
0 -30 in,Hg
. EVAP Bypass Solenoid Valve Circuit
. Fuel Tank Pressure Sensor
. Fuel Tank Pressure Sensor Circuir
. EVAP Control Canister
. ORVR vent shut valve
. ORVR vapor recirculation valve
. Throttle Body
Troubleshooting Flowchart
VACUUMPUMP/GAUGE,A973X - oal -
xxxxx
T-t
t\
The MIL has been reported on.DTC P1456 o. P1457 is stored.
Check the EVAP cont.ol canistervent shul valve:1. Disconnect the vacuum hosefrom the EVAP three wayvalve and connect a vacuumpump to the hose.2. Remove the EVAP controlcanister vent shut valve fromtne canrster.3. Turn the ignition switch ON (ll).
4. Apply vacuum to the hose.Check for a short in the wiro(VSV linel:Disconnect the 2P connector fromthe EVAP control canister ventDoes the vaive hold vacuum?
RoDair 3hort in the wire botwe€nthe EVAP control canilter ventshut valve and the ECM/PCM{A4t.
Does the valve hold vacuum?Check the EVAP cont.ol canisterv€nl shut valve:1. Turn the ignition switch OFF.2. Connect ECM/PCM connectorterminal A4 to body groundwith a jumper wire.3. Turn the ignition switch ON (ll).
4. Apply vacuum to the hose.
Reolace the EVAP control canis-ter veni shut valve.
Does the valve hold vacuum?
Wire side of female terminals
11-288
lTo page 11-289)

\
EVAP CONTROLCANISTER VENT SHUTVALVE 2P CONNECTOR IC141I
Wire side of temale terminals
ECM,/PCM CONNECTORS
tG1IBLK/WHT}
A973X -
0/r1 - XXXXX
Wire side of femaletermrnats
\
?,T-t
fl
VACUUMPUMP/GAUGE, 0 -30 in.Hg
\(cont'd)
11-289
{From page l1 288}
{To page 11-290)
Ch€ck the vac[um when cold:1, Disconnect the vacuum hoseshown from the EVAP controlcanister and connect a vacuumgauge to the hose.2. Start the engine and allow it
to idle.NOTEi Engine coolant temperature must be below 154"F(68'C) or Ay'C switch OFF.3. Ouickly raise the engine speedto 3,000 rpm.
(From page 11-288)
Check for an open in tha wire(lGt linol:1. Turn the ignition switch OFF.2. Disconnect the 2P connectorfrom the EVAP control canis-ter vent shut valve.3. Turn the ignition switch ON lll).4. Measure voltage between theEVAP control canister vent shut
valve 2P connector terminalNo.2 and bodyground.
Repair open in the wire betweenthe EVAP control canister ventshut valve .nd the No. 15 ALTER-NATOR SP SENSOR {7.5 A)fu3e.
ls there battery voltage?
Ch€d( for an op€n in the wiie IVSVlinel:1. Turn the ignition switch OFF.
2. R€connect the 2P connectorto the EVAP control canistervent shut valve,3. Turn the ignition switch ON (ll).
4. Measure vo ltage betweenECM/PCM connector termi-nals A4 and 82.
Repair open in the wire bctweenthe EVAP control canistor ventshut valve and lhe ECM/PCM{44t.
ls there battery voltage?
Rcolaco tho EVAP control canis.t6r vent shut valvo.
a t32P)
-

Emission Control System
Ch€ck the EVAP purge controlsolenoid valv6:1. Disconnect the 2P connectorfrom the EVAP purge controlsolenoid valve.2. Ouickly raise the engine speedto 3,000 rpm.
Insped vacuum hose routing.lf OK. roplace the EVAP purge
control solonoid valve.
Chock tor r short in the wir€
{PCS line):1. Turn the ignition switch OFF.2. Disconnect ECM/PCM connec-tor A (32P).
3- Check tor continuity betweenthe EVAP purge control sole-noid valve 2P connector termi-nal No. 2 and body ground.
Check the vacuum when hot:1. Turn the ignition switch OFF.2. Block the rear wheels and setthe parking brake.3. Jack up the lront of the vehi-cle and support it with safetystands.4. Start the engine. Hold theengine at 3,000 rpm with noload (in Park or neutrali until
the radiator fan comes on, thenlet it idle.5. Check for vacuum at the vac-uum hose with transmissionin gear (A/T in E position,
lvl/T in 1st gear) after startingthe engine.6. Ouickly raise the engine speedto 3,000 rpm.
Rooair shoft in the wire belwegnthe EVAP pulg6 control solenoidvalvs and tho ECM/PCM {A61.ls there continuity?
Substitute a known-good ECM/PCM and rech6ck. lt 3ymptom/indicrtion 90e3 rway, r6plac6 th€o.iginal ECM/FCM.
Check th€ EVAP purge controlsolenoid valve:1. Turn the;gnition switch OFF.2. Disconnect the 2P connectorfrom the EVAP purge controlsolenoid valve and warm itup to normal operating tem-perature again if necessary.3. Start the engine.4- At the harness side, measurevoltage between the EVAPpurge control solenoid valve2P connector terminal No. 1and No.2 with the transmis-sion in gear {A/T in E posi-tion, M/T in lst geari.
In3pect vacuum hoae routing.lf OK, repl.ce EVAP purge con-trol solonoid valve.ls there battery voltage?
Chock for an open in the wire(lG1 lina):At the harnoss side, measure volt-age beNveen the EVAP purge con-trol solenoid valve 2P connectorterminal No. 1 and body ground.
Repair open in the wire b€lwe€nEVAP purge contrl 3olenoid valv6and lhe No. 15 ALTERNATOR SPSENSOR 17.5 A, fu3e.
ls there battery voltage?
Evaporative Emission (EVAPI Controls (cont'dl
(From page 11-289)
(To page 11-291)
11-290
IJ
EVAP PURGE CONTROL SOLENOIDVALVE 2P CONNECTOR IC114I
PCS
IRED/YEL)
temaletermrnars
of
PCS(RED/YEL)
tGlIBLK/YEL)
{To page 11 291)

Emission Control System
Evaporative Emission (EVAPI Gontrols (cont'd)EVAP BYPASSSOLENOID VALVEY
(From page l1'291)
Check for a short in the wire{2WBS linel:Disconnect the 2P connector {romthe EVAP bypass solenoid valve.
Does the valve hold vacuum?
Repair short in the wire betweenEVAP bypass solenoid velve andrhe ECM/PCM {A3).
Ooes the valve hold vacuum?
Check the EVAP bvpr$ 3olenoid
1. Turn the ignition switch OFF.2. Connect ECM/PCM connectorterminal A3 and body groundwith a jumper wire.3. Turn the ignition switch ON (ll).Ch€ck lor an op.n in the wirellcl linol:1. Turn the ignition switch OFF.2. Disconnect the 2P connectorfrom the EVAP bypass sole-noid valve.3. Turn the ignition switch ON (lll.
4, Measure voltage between theEVAP bypass solenoid valve2P connector terminal No. 1and body ground.
Does the valve hold vacuum?
Repair open in the wir6 b€tw€€nEVAP purg6 control 3olanoid valveand the No. 15 ALTERNATOR SPSENSOR {7.5 A) Iuse.
Wire side ol female terminals
EVAP SYPASS SOLENOIOVALVE 2P CONNECTOR IC793}
tG1{BLK/WHT)
Wire side offemaleterminals
{To page 11 293)
11-292
(To page 11 293i

Emission Control System
Evaporative Emission (EVAPI Controls (cont'd)
Evaporative Emission (EVAPI Two Way Valve Testing
l'96 DIGYS engine lcoupel,'97 Dl6Y7 engine (coupe: KL
model, sedan: KL (LX) modoll,'97 Dl6Y8 engine {coup€:
alt models, sedan: KL model, '98-all modelsll:
1. Remove the fuel fill cap.
2. Remove the vapor line from the EVAP two way
valve. and connect it to a T-fitting from a vacuum
gauge and a vacuum pump as shown.
VACUUM/PRESSURE
IJ
f96 D16Y5 engine,'96 D16Y7 engine,'96 D16Y8 ongine
(sedanl,'97 D16Y5 engine,'97 Dl6Y7 engine {coupe: KA,
KC models, sedan: KA, KC, KL {DX} models, hatchback:
all modsls),'97 D16Y8 engine {sedan: KA, KC models}l:
1. Remove the fuel fill cap,
2. Remove the vapor line from the EVAP two way
valve on the fuel tank, and connect it to a T-fitting
from a vacuum gauge and a vacuum pump as
snown.
VACUUM/PRESSURE GAUGE,0 - 4 in.Hg07JAZ - 0010008VACUUMPUMP/GAUGE.0 -30 in.HgA973X-041 -XXXXX
Apply vacuum slowly and continuously while watch-
ing the gauge. The vacuum should stabilize momen-
tarily at 0.8 - 2.1 kPa (6 - 16 mmHg, 0.2 - 0.6 in.Hg).
lf the vacuum stabilizes (valve opens) below
0.8 kPa {6 mmHg, 0.2 in.Hg) or above 2.1 kPa
(16 mmHg, 0.6 in.Hg), install a new valve and retest.
Move the vacuum pump hose from the vacuum fit-
ting to the pressure fitting, and move the vacuum
gauge hose from the vacuum side to the pressure
side as shown.
Slowlv pressurize the vapor line while watching the
gauge. The pressure should be stabilize momentari
ly above 1.0 kPa (8 mmHg. 0.3 in.Hg).
. lf the pressure momentarily stabilizes (valve
opens) above '1.0 kPa (8 mmHg, 0.3 in.Hg), the
valve is OK.
. lf the pressure stabilizes below 1.0 kPa (8 mmHg,
0.3 in.Hg), install a new valve and retest.
Apply vacuum slowly and continuously while
watching the gauge. The vacuum should stabilize
momentarily at 0.7 - 2.0 kPa (5 - 15 mmHg, 0.2 - 0.6
in.Hg ).
lf the vacuum stabilizes (valve opens) below
0.7 kPa (5 mmHg,0.2 in.Hg) or above 2.0 kPa
(15 mmHg, 0.6 in.Hg), install a new valve and retest.
Move the vacuum pump hose from the vacuum fit-
'l'
4.
5.
ting to the pressure fitting, and move the
gauge hose from the vacuum side to the
side as shown.
PRESSURESIDE
Slowly pressurize the vapor line while watching the
gauge. The pressure should stabilize at 1.3 - 4.7 kPa
(0 - 35 mmHg, 0.4 - 1.4 in.Hg).
. It the pressure momentarily stabilizes (valve
opens) at 1.3 - 4.7 kPa (10 - 35 mmHg, 0.4 - 1.4
in. Hg), the valve is OK.
. lf the pressure stabilizes below 1.3 kPa (10 mmHg,
0.4 in.Hg) or above 4.7 kPa (35 mmHg. 1.4 in.Hg),
install a new valve and retest.
vacuum
pressure
GAUGE0- 4 in.Hg
T-FITTINGT-FITTING
11-294
\,

\
Evaporative Emission (EvAPl Two Way Valve T6ting
'99 - 00 modols:
'L Remove the fuel tank (see page 11-242).
2. Remove the vapor line {rom the EVAP two way
valve (located above the EVAP control canister), and
connect it to a T-fitting from vacuum gauge and
vacuum pumo as snown,
VACUUM/PRESSUREGAUGE0 - il in.Hg07JAZ - 001(x)08
ry(L
"*'"""_,";f1
T.FITTING
Apply vacuum slowly and continuously while watch-
ing the gauge.
The vacuum should stabilize momentarily at 0.8 -
2.1 kPa {6 - 16 mmHg, 0.2 - 0.6 in.Hg).
lf the vacuum stabilizes (valve opens) below
0.8 kPa (6 mmHg, 0.2 in.Hg) or above 2.1 kPa
(16 mmHg, 0.6 in.Hg), install a nsw valve and retest.
Move the vacuum pump hose from the vacuum fit-
ting to the pressure fitting, and move the vacuum
gauge hose from the vacuum side to the pressure
side as shown.
GAUGE,0 - 30 in.Hg4973X - (Xl -
xxxxx
J.
5. Slowly pressurize the vapor lin€ while watching the
gauge.
The pressure should be stabilize momentarily
above 1.0 kPa (8 mmHg, 0.3 in.Hg).
. lf the pressure momentarily stabilizes (valve
opens) above 1.0 kPa (8 mmHg, 0.3 in.Hg), the
valve is OK.
. ll the pressure stabilizes below 1.0 kPa (8 mmH9,
0,3 in,Hg), install a new valve and retsst.
(cont'd)
11-295

lllustrated Index
\
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

Glutch Master Gylinder
IRemovaUlnstallation
CAU'NON:
. Do not sDill brake lluid onthevehicle;it may damage
the paint; if brake fluid does contact the paint, wash
it off immediatelY with water.
. Plug the end ofthe clutch line and reservoir hos€ with
a shop towelto prevent brake tluid from coming out
1. The brake tluid can be removed from the clutch
master cylinder reservoir with a syringe
2. Disconnect the clutch line and reservoir hose from
the clutch master cylinder.
19N.m 11.9 kgf.m,14 tbf.ttl
[.
3. Pry out the lock pin, and pull the pedal pin out
the yoke. Remove the nuts
NUTS8 x 1 .25 mm13 N.m {'1.3 kgt.m,9.4lbf ft)
)
of
CLUTCH LINE
iffi,
4. Remove the clutch master cylinder.
CLUTCH MASTER CYLINDER
lnstall the clutch master cylinder in the reverse
order of removal.
NOTE: Bleed the clutch hydraulic system {see page
12-61,
12-5

Slave Gylinder
Removal/lnstallation
CAUTION:
. Do not spill brake tluid on the vehicle; it may damage
the paint; if brake fluid does contact th€ paint, wash
it off immodiatoly with water,
. Plug the end ot the clutch line with a shop towel to
prevsnt brake fluid from coming oul.
-61'srp", High Temp Urea crease (p/N
08798 - 90021.
: Brake Assembly Lube or equivalent rubber
grease.
1. Disconnect the clutch line from the slave cvlinder.
2. Remove the slave cylinder from the clutch housing.
12-6
3. Install the slave cylinder in the reverse order of
removal.
NOTE: Make sure the boot is installed on the slave
cvlinder.. CLUTCH LINE15 N.m (1 .5 kgf.m, 1 1 lbf.It)
SLAVE CYLINDER
-G4(P/N 08798- 90021
8 x 1.25 mm22 N.m 12.2 kgl.n,16 lbl.lt)
:^..:i!!!!! :l
(Brak€ AssemblyLubol
Bleed the clutch hydraulic system.
a Attach a hose to the bleeder screw, and suspend
the hose in a container of brake fluid.
. Make sure there is an adequate supply of fluid at
the clutch master cylinder, then slowly pump the
clutch pedal until no more bubbles appear at the
bleeder hose.
. Refill the clutch master cylinder with fluid when
done.
. Always use Genuine Honda DOT 3 Brake Fluid.
Using a non-Honda brake fluid can cause corro-
sion and decrease the life of the system.
. Confirm clutch operation, and check for leaking
flu id.

Transmission Assembly
I
Removal
@. Make sure iacks and safety stands are placed prop€dy,
and hoist brackets are atlach€d to correct position on
the enginc.
. Apply parking brake and block rear whosls so car will
nol roll olf stands and lall on you while working under
it.
CAUTION: Use fender covers to svoid damaging painted
surfaces.
1. Disconnect the negative {-) cable first, then the pos-
itive (+) cable from the battery'
Drain transmission oil {see page 13-3).
Remove the intake air tube. intake air duct and air
cleaner housing assembly (see section 5).
Disconnect the starter motor cables, transmission
ground wire and back-up light switch connector.
6x1.0 mm BACK-UP LIGHT
9.8 N.m (1.0 ksf.m, 7.2 lbI.ft) swlTcH CoNNECTOR
8x 1 .25 mm8.8 N.m {0.9 kgt.m,6.5 lbf.ftl
\
ARTER
5. Remove the wire harness clamps.
vssCONNECTOR
6. Disconnect the vehicle speed sensor (VSS) connec-
ror.
Remove the clutch line bracket, clutch line clamp,
and slave cvlinder.
CAUTION:
. Do not opsr.te tho clutdh pedal once the 3lavc
cylindor has b6on romoved.
. Tske care not to bend tha clutch lin6.
7.
(cont'd)
13-5