Engine harness HONDA CIVIC 1999 6.G User Guide

ldle Control System
lgy"t9!"_"ring Pressure (PSPI Switch Signal
('96 - 98 Models, '99 - 00 DlGy5 engine witn fU/f) (USAI
This signals the ECM/ PCN4 when the power steering load is high.
ECM/PCM CONNECTORS
PSP SWITCH 2P CONNECTOR
PSP SW IGRNI
JUMPER l--L I IwfRE -2/
GND (BLKI
Wire side ol female terminais
Inspection o{ PSP switch signal.
Check for an opon in the wire {PSPSW linelr1. Turn the ignition switch ON (ll).2. Measure voltage betweenECM/PCM connecror termi-nals A9 and C16.
Check lor an open in the wire (PSPSW line):1. Turn the ignition switch OFF.2. Disconnecl the PSP switch 2p
3. Turn the ignition switch ON (ll).4. At the harness side, connectthe PSP switch 2P connectorterminals No. l and No.2with a jumper wire.5. Measure voltage betweenECM/PCM connector terminalsAg and C16.
ls there lessthan 1.0 V?
- Repair open in the wirobetween the ECM/PCM lc16land the PSP switch.- Repair open in BLK wirebetwoen the PSP switch andG101.
ls there less than 1.0 V?Check the operation of the PSPswitch:'1. Start the engine2. Turn steering wheel to full
3- Measu re voltage betweenECM/PCM connector terminalsA9 and C16.
ls there battery voltage?
PSP switch signel is OK.
Wire side oI temale terminals
11-212
(To page 11'2'13)

I
PGM-FlMain Relay
Description
The PGM-Fl main relav actuallv contains two individual
relays. This relay is located at the right side of the cowl.
One relay is energized whenever the ignition is on which
supplies the battery voltage to the ECM/PCM, power to
the luel iniectors, and power for the second relay. The
second relay is energized lor two seconds when the igni-
tion is switched ON (lll, and when the engine is running,
to supply power to the luel pump.
PGM-FIMAIN RELAY
J
I
t
FUEL PUMP
Relay Testing
NOTE:
. It the engine starts and continues lo run. the PGM Fl
main relay is OK.
. Use the terminal numbers below;
ignore the terminal numbers molded into the relay,
1. Remove the PGM Fl main relay.
2. Attach the battery positive terminal to the No. 2 ter-
minal and the battery negative terminal to the No 1
terminal of the PGM-Fl main relay. Then check for
continuity between the No.5 terminal and No 4ter-
minal of the PGM Fl main relay.
. lf there is continuity, go on to step 3.
. lf there is nocontinuity, replacethe PGM-Fl main
relay and retest.No. 3No. 1
To lGN. 1
To GROUND
To ST. SWITCH
To ECM/PCM {A161
To 8AT O
To ECM/PCM{(a11, A241, (81. B9l*l
To FUEL PUMP.r '99 model
3.Altach the batterv positive terminal to the No.5 ter-
minal and the battery negative terminal to the No. 3
terminal of the PGM-Fl main relay. Then check that
there is continuity between the No. 7 terminal and
No. 6 terminal of the PGM-Fl main relay.
. lf there is continuity, go on to step 4
. lf there is nocontinuity, replacethePGM-Fl main
relay and retest.
Attach the battery positive terminal to the No. 6 ter-
minal and the battery negative terminal to the No. 1
terminal of the PGM Fl main relay. Then check that
there is continuity between the No. 5 terminal and
No. 4 terminal of the PGM-Fi main relay.
. lf there is continuity, the PGM-Fl main relay is OK.
lf the fuel pump still does not work, go to Harness
Testing on the next page.
. lf there is no continuity, replace the PGM Fl main
4.
(cont'd)
11-237
relay and retest.

\
'99 - 00 models excepi Dl6Y5 engine with M/T:
The scan tool indicates Diagnostic Trouble Code (DTC) P0452: A low voltage problem in the Fuel Tank Pressure
sensor.
The fuel tank pressure sensor converts fuel tank absolute pressure into electrical signals and inputs the ECM/PCM
OUTPUTVOLTAGE(vlt.5
0.5-7 kP.(-g) mmHg,-2 in.Hgl
+7 kP.
150 mmHg,2 in.Hgl
PRESSURE
I
Wire side of lemale terminals
FUEL TANKPRESSURE SENSORSUB.HARNESS6P CONNECTOR (C574 (C568)rl
vcc2(YEL/BLUIsG2{GRN/BLK}
Wire side o{ temale terminals
The MIL has been .eported on.
DTC P0452 is stored
Check the vacuum lines:
Check the vacuum lines of the
fuel tank pressure sensor lor mis-
routing, leakage, breakage and
cloggrng.
Are the vacuum hnes OK?
Problem veritication:1. Do the ECM/PCM Reset Proce-
du re,2. Bemove the fuel fill caP.
3. Turn the ignition switch ON {ll)
4. Monitorthe FTP Sensor voltage
with the Honda PGM Tester' or
measure voltage between body
groLrnd and ECM/PCM connec_
tor terminalA29.
lntermitlent tailure, 3Ystem b OK
at this time. Check for Poor con'
nections or loose wire3 at C131
{located under right side of dash},
C401 {located above under'dash
tuse/relay box), C574 (C568)*
llocdted under access Panel),C792 (tuel rank Prcssure sensorl
and ECM/PCM.
ls there approx.2 5 V?
Check for an open in wire {VCC2
line):1. Turn the ignition switch OFF.
2. Reinstall the ltrel fill caP
3, Remove the access Panel from
the floor.4. Disconnect the fuel tank Pres'sure sensor sub-harness 6P
5. Turn the ignition switch ON (ll).
6. At the access Panel side, mea_
sure voltage between the fuel
tank Pressure sensor sub-nar-
ness 6P connector No 5termi
nal and No. 6 termlnal.
Repair open in tho wire between
th6 fu€l tank Prossuro sen3oa and
the ECM/PCM lc28).ls there approx 5 V?
ECM/PCM CONNECTOR A (32P)
PTANK {LT BLUI
I
ll
(To page '11-278)
(cont'd)

\
'99 - 0O modols except Dl5Y5 engine with M/T:
rFo45'::n":"tooIindicatesDiagnosticTroub|ecode(DTc)P0453:Ahighvo|tageprob|emintheFUelTankPressure
Wire side of temale terminals
FUEL TANKPRESSUNE SENSOR
SUB.HARNESS6P CONNECTOR {C574 (C568)}}
vcc2{YEL/BLUI
sG2IGRN/BLK)
Wire side of female terminals
PTANK{LT GRNI
(cont'd)
11-281
ECM/PCM CONNECTOR A {32P)
PTANK {LT GRN)
The MIL has been reported on.
DTC P0453 is stored.
Check the vacuum lines:
Check the vacuum lines ot the
fuel tank pressure sensor for mis-
routing, leakage, breakage and
clogging.
Are the vacuum lines OK?
Problem verilication:1. Do the ECM/PCM Reset Proce-
du re,2. Remove the fuel fill caP
3. Turn the ignition switch ON (ll).
4. Monitor the FTP Sensor volt'
age with the Honda PGM
Tester, or measure voltage
between body ground and
ECM/PCM connector terminalA.29.
lntermittent failuro. svstem b OK
at this time. Check for Poor con_
noctions or loo3€ wire3 at C131
{located under tight side of dash),
C4Ol {located above underdash
fuse/relay boxl, C57{ (C5681'
llocaled unde. access Panell,C792 {fuel tank Pressure sensorl
aod ECM/PCM.
ls there approx.2.5 V?
Ch€ck for an open in the wira
{SG2line):1. Turn the ignition switch OFF.
2. Reinstall the fuel fill caP
3. Remove the access Panellrom the floor.
4. Disconnect the fuel tank Pres-sure sensor sub-harness 6P
5. Turn the ignition switch ON (ll)
6, At the access Panelside, mea-
sure voltage between the fuel
tank pressure sensor sub_har-
ness 6P connector termlnals
No.5 and No.6.
Repair open in the wire between
the fueliank Pres3ure 3ensor and
ECM/PCM {Cl8).ls there approx.5 V?
Check lor an oPen in the wire
{PTANK linel:At the access Panel side, mea
sure voltage between the fuel
tank pressure sensor suo_harness
6P connector No. 2 terminal and
No. 6 terminal.
ls there approx. 5 V?
(To page 11.282)

\
\
(From page 11-284)
\(cont'd)
11-285
EVAP PURGE CONTROL SOI.INOID
VALVE 2P CONNECTOR IC114I
Wire side otfemaleterminals
?,
I,l,lil?"",,,u
EL,TWYEL)
Check the EVAP pirrge controlsolenoid valvei1. Disconnect the 2P connector
lrom the EVAP purge control
solenoid valve.
2. Ouickly raise the engine speed
to 3,000 rpm.
ls there vacuum?
InsDect vacuum ho56 routing.ll OK, replace the EVAP Purgecontrol solenoid valve.
Chock for a short in the wire(PCS linel:1. Turn the ignition switch OFF
2. Disconnect ECM/PCM connec'
tor A (32Pi.
3. Check for continuity between
the 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 set
the parking brake.3. Jack up the front o{ the vehi-
cle and support it with safety
stands,4. Start the engine. Hold the
engine al 3,000 rpm wlth no
load (in Park or neutral) until
the radiator fan comes on, then
let it idle.5, Check for vacuum at the vac-
uum hose with transmissaonin gear (A/T in B Position,M/T in lst gear) after starting
the engrne.6. Ouickly raise the engine speed
to 3,000 rpm.
Reoair short in the wire botween
the EVAP purg€ cor|t]ol solenoid
valve and the ECM/pcM lA15l.ls there continuity?
Substitute a known-good ECM/
PCM and recheck. lf sYmPtom/indication goes eway. repl.c€ the
original ECM/PCM.
Check the EVAP Purg€ control
solenoid valve:1. Turn the ignition switch OFF
2. Disconnect the 2P connector
from the EVAP Purge control
solenoid valve and warm lt
up to normal operating tem_perature again if necessary
3. Stan the engine.4. At the harness side, measure
voltage between the EVAP
Purge control solenoid valve
2P connector terminal No. 1
and No. 2 with the transmission in gear (A,/T in E Posi-tion, M/T in 1st gear).
In3pect vacuum ho3€ touting.
ll OK, replace EVAP Purge con-
lrol aolenoid vtlv€.
Check lo. an open in the wire
llGl linel:At the harness side, measure volt
age between the EVAP Purge con-
trol solenoid valve 2P connectorterminal No. 1 and body groundRepeir open in tho wire between
EVAP purge conttol solenoid valv€
and the No. 15 ALTERNATOR SP
SENSOR (7.5 A fu3e
IBLK/YELI
lTo page 11 286i(To page 11-286)

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)

Torque Value
A - 15 N.m (1.5 kgf.m, 1'1 lbf.ft)
B - 27 N.m (2.8 kgf.m. 20 lbift)
C - 31 N.m {3.2 kgnm, 23 lbift)
\
O BALL BEARING (*T)
ANGULAR
BALL BEARING {*2I
O 5TH SYNCHRO HUB
O 5TH SYNCHRO SLEEVE
€) SYNCHRO SPRING
o SYNCHRO B|NG
@ 5TH GEAR
@ gz xgt x 23.5 mm
NEEDLE BEARING
@ SPACER COLLAR
@34x39x23mm
NEEDLE BEARING
(D 4TH GEAR
O SYNCHRO RING
C) SYNCHRO SPRING
CO 3RD/4TH SYNCHRO SLEEVE
@ 3RD/4TH SYNCHRO HUB
(} 3RD GEAR
@34x39x27.5mmNEEDLE BEARING
G) MAINSHAFT
G) WASHER
@ SPRING WASHER
@ BALL BEARING
Check for wear and
operation.(E 26x42x7 mm OIL SEAL
Replace.
@ 28 mm PLUG BOLT
5,1 N.m {5.5 kgf'm, /t0 lbt'ft)
@ lsT/zND SELECT SPRING
L. 36.26 mm (1./P8 in)
@ SHIFT ARM SHAFT
@ CLUTCH HOUSING
@ INTEELOCK GUIDE BOLT
39 N.m (4.0 kgf.m, 29 lbf.ftl
@ REVERSE SHIFT HOLDER
@ REVERSE IDLER GEAR
@ REVERSE IDLER GEAR SHAFT
@ 5 x 22 mm SPRING PIN
Replace.
@ 3RD/4TH SHIFT PIECE
@ 5TH/REVERSE SHIFT PIECE
@ MBS SHIFT PIECE
@ 1ST/2ND SHIFI FORK
*1:D16Y7 engine*2: D16Y5, D16Y8 engines
@ 3RD//|TH SHIFT FORK
@ 5TH/REVERSE SHIFT FORK
@ 52 mm SNAP RING
@ 65 mm THRUST SHIM (*11
70 mm THRUST SHIM (*21
Selection, page 13-36
@ OIL GUIDE PLATE
@ wASHER Replace.
@ BACK.UP LIGHT SWITCH
25 N.m (2.5 kgf'm, 18 lbf'ft)
@ sET SCREW
22 N.m {2.2 kgf.m, 16 lbl.ft}
@ WASHER Replace.
@D SPRING 1.31.6 mm (1.2,1inl
@ STEEL BALL 15/16 in)
@ BACK-UP LIGHT
SWITCH HARNESS BRACKET
@ TRANSMISSION HANGER
@ 32 MM SEALING BOLT
25 N.m (2.5 kgf.m, 18 lbt'ft)
@ OIL SEAL
Replace.
@ OIL DRAIN PLUG
39 N.m (4.0 kgf.m, 29 lbf.ft)
@ WASHER Replace.
@} OIL FILLER PLUG
44 N.m (4.5 kgf.m, 33 lbf'ftl
@ WASHER Replace.
@) TRANSMISSION HOUSING
€) CLUTCH LINE BRACKET
@ OIL GUTTER PLATE
@ REVERSE LOCK CAM
@ REVEBSE SELECT SPRING
L. 63.4 mm {2.,196 in)
@ REVERSE SELECT RETAINER
@ SHIFT ARM C
@ SHIFT ARM B
@ INTERLoCK
@ COLLAR
@ SHIFT ARM A
@ SPRING WASHER
@ MAGNET
@ sET BALL SPRING BOLT
22 N.m (2.2 kgf.m, 16 lbf.ftl
@ 14 x 20 mm DOWEL PIN
@ 72 mm THRUST SHIM l*11
80 mm THRUST SHIM (*21
Selection, page '13-33
@ DIFFERENTIAL ASSEMBLY
See page 13-30
@ 14 x 25 x 17.5 mm OIL SEAL
Replace.
@ 35 x 56 x 8 mm OIL SEAL
Replace.
@ SHIFT ROD
@ BOOr
@ OIL GUIDE PLATE
@30x47x21 mm
NEEDLE BEARING (* 1}
30x55x21 mm
NEEDLE BEARING {'2)
@ COUNTERSHAFT
@36x41 x 25.5 mm
NEEDLE BEARING
Check for wear and
operatron.
@ lsT GEAR
@ FRICTION DAMPER
@ SYNCHRO RING
@ SYNCHRO SPRTNG
@ lST/2ND SYNCHRO HUB
@ REVERSE GEAR
@ SYNCHRO SPRING
@ SYNCHRO RING
@ FRICTION DAMPER
@ SPACER
@39x4lx27mm
NEEDLE BEARING
@ 2ND GEAR
@ 3RD GEAR
@ 4TH GEAR
@ sTH GEAR
@) BALL BEARING {* 1}
NEEDLE BEARING (*2}
@ BALL BEARING
@) SPRING WASHER
@ LoCKNUT Replace.
108 - 0- 108 N.m
ftt.o* o- 1r.o kst.m,l
179.6- 0- 79.6 rbtft I

13-1 1

Electrical Troubleshooting ('96 - 98 Models)
Troubleshooting Flowchart - Start Clutch Control System
NOTE: Record all freeze data before you troubleshoot.
Po$ible Ceuaa
Frulty start clutch cont.ol 3ys-tem
14-260
OBO ll Scan Tool indic.le3 Cod6P1891.Solt-diagnosis E indicator lightindicates Code (1.
Check for Another Codo:Check whether the @ indicatorlight indicates another code.
Poiform tho TroublcahootlngFlowchrrt lor the indicat.dCode(sl.
ls the E indicator light indi-cate another code?
Test Strrt Clutch Oper.tion:1. Turn the ignition switch OFF.2. Disconnect the 8P connectorfrom the solenoid harness con,nector.3. Start the engine, and shift toE position.4. Check whether the vehiclemoves.
Rcplaca th. strrt dudt r$amt ly.
Check Creeping Spe€d:1. Turn the ignition switch OFF.2. Reconnect the 8P connector tothe solenoid harness connec-tor,3. Start the engin6, and shift toE position.4. Check whether the vehiclecreeps, and chock the creep-Ing speed.
Does the vehicle move and isthe creeping speed approx.3mph (5 km/h)?
To page 14-261
E

Electrical Troubleshootang ('gg - 00 Models)
Troubleshooting Flowchart - Start Clutch Control System
Possibl€ Cause
Faultv start clutch control sys-lem
NOTE: Record allfreeze data before you troubleshoot.
fo page 14 287
. OBD ll Scan Tool indicates CodeP1891.. Self-diagnosis E indicator tightindicates Code 43.
Check for Another CodelCheck whether the E indicatorlight indicates another code.
Perform the TroubleshootingFlowchart tor the indic.tedCodelsl.
ls the E indicator light indi-cate another code?
Test Stsn Clutch Operation:1. Turn the ignition switch OFF.2. Disconnect the 8P connectorfrom the solenoid harness connector.3. Start the engine, and shift toE position.4. Check whether the vehiclemoves.
Repl.c€ the stan clutdt rasemHy.
Check Croeping Sp€6d:1. Turn the ignition switch OFF.2. Reconnect the 8P connector tothe solenoid harness connec
3. St€rt the engine, and shift toE posation.4. Check whether the vehiclecreeps, and check the creeping speed.
Does the vehicle move and isthe creeprng speed approx, 3mph (5 km/h)?
14-2A6

Transmission
Removal
@. Mako suro lifts. iacks, and satety stands are placod
properly, and hoi3t bracket are attached to lhe cor-
rect position on the engine {see soction 1}.
. Apply parking brake and block r€ar wheels so tha
vehicle will not roll off stands and fall on you while
working undor it.
CAUTION: Use tender covers to avoid damaging painted
surfaces.
Disconnect the battery negative (-) terminal from
the battery, then remove the positive (+)terminal.
Remove the intake air duct and air cleaner housing
1.
assembly.
3. Remove the starter cables and cable holder from
the starter motor.
STARTER CABLE
STARTER MOTOR
14-304
4, Disconnect the solenoid harness connector, the drivepulley speed sensor connector, and the ground cable
terminals.
DRIVE PULI.-EYSPEED SENSORCONNECTOR
SOLENOIO HARNESSCONNECTOR
Remove the clip, then separate the shift cable from
the control lever,
CAUTION: Take care not to bend the shift cable.
WASHER
WASHER
GROUND CABLE
GROUND CAELE
CONTROL LEVER
S}IIFT CABLE