Power HONDA CIVIC 1999 6.G User Guide

Removal
Engine removal is not required for this procedure.
!@@ Make sure jacks and safety stands are placed
properly and hoist brackels are attached to correst posi-
tion on the engine,
CAUTION:
o Use fender covers to avoid damaging painted sur-
faces.
To avoid damage, unplug the wiling connectors
carelully while holding the connector portion.
To avoid damaging the cylinder head, wait until the
engine coolant temperature drops below 100"F {38'Cl
before loosening the retaining bolt.
NOTE:
. Unspecified items are common.
. Mark all wiring and hoses to avoid misconnection.
AIso, be sure that they do not contact other wiring or
hoses or interfere with other parts.
o Inspect the timing belt before removing the cylinder
n eao.
. Turn the crankshaft pulley so that the No. 1 piston is
at top dead center (see page 6-64).
1. Disconnect the negative terminal from the battery.
Drain the engine coolant {see page 10-7).
. Remove the radiator cap to speed draining.
Remove the strut brace (see page 5-2).
Remove the intake air duct and air cleaner housing
(see page 5-3).
Remove the adjusting bolt and mounting bolt, then
remove the power steering (P/S) pump belt and pump
(see page 5 5).
2.
3.
4.
\
ADJUSTING
6. Loosen the idler pulley bracket bolt and adjusting
bolt, then remove the air conditioning (A/C) com-
pressor belt.
IDLER PULLEY BRACKETBOLT10 x 1.25 mm44 N.m {4.5 kg,l.m, 33 lbt.ft}
7. Loosen the mounting nut and lock bolt, then remove
the alternator belt.
LOCK BOLT8 x 1.25 mm24 N.m {2.4 kgf.m,17 tbtftl
ALTERNATORBELT10 x 1.25 mm,l,l N.m {4.5 kgf.m,33 tbf.ft,
(cont'd)
6-67

4.
Removal/lnspection/lnstallation
2.
3.
1.
5.
6.
1.
8.
Drain the engine oil.
Turn the crankshaft and align the white groove on
the crankshaft pulley with the pointer on the lower
cover.
Remove the cylinder head cover and upper cover'
Remove the power steering pump belt, air condi-
tioner beit and the alternator belt
Remove the crankshaft pulley and remove the lower
cover.
Remove the timing belt.
Remove the drive pulley.
Remove the oil pan and oil screen.
O.RINGReplaceOOWEL PIN
OIL SCREEN
9. Remove the oil PumP.
!'a
10.Remove the screws from the pump housing, then
separate the housing and cover'
Check the inner-to-outer rotor radial clearance on
the pump rotor. lf the inner-to outer rotor clearance
exceeds the service limit, replace the inner and
outer rotors.
lnner Rotor-to-Outer Rotor Radial Clearance
Standard {New}: 815A2 engine 0.04 - 0.16 mm
(0 002 - 0'006 in)
D16Y5, D16Y7, D16Y8 engines
0.02 - 0.14 mm 10.001 - 0.006 in)
Service Limit: 0.20 mm (0 008 inl
OUTER ROTOR
INNER ROTOR
Check the housing-to-rotor axial clearance on the
pump rotor. lf the housing-to rotor axial clearance
exceeds the service limit, replace the set of inner
and outer rotors and/or the pump housing
Housing-to-Rotor Axial Clearance
Standard (N€w): 816A2 engine 0.02 - 0.07 mm
(0.001 - 0.003 inl
D16Y5, D16Y7, D16Y8 engines
0.03 - 0.08 mm (0.001 - 0.003 inl
S€rvice Limit: 0.15 mm 10.006 in)
11.
't2.
(cont'd)
8-13

!
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

Gomponent Locations
L
lndex
D16Y5 engine:
{IATISENSORTroubleshooting,
ELECTRICAL LOADDETECTOR IELD) (USA mod6l)Troubleshooting, page 11 179
THROTTLE POSITION ITP)SENSORTroubleshooting, page 1 1-132
MANIFOLD ABSOLUTEPRESSURE IMAPI SENSORTroubleshooting, page 1'l-115
EXHAUST GAS RECIRCULATION
IEGRI VALVE and EXHAUST GAS
RECIRCULATION IEGRI VALVE
LIFT SENSORTroubleshooting, page'l 1-254
INTAKE AIR TEMPERATUR€
IDLE AIR CONTROL (IAC) VALVE
{M/T)Troubleshooting, page 1 1-194
EXHAUST GAS RECIRCULATION{EGRI CONTROL SOLENOIDVALVE ICW)Troubleshooting. page 1 1-254
EVAPORATIVE EMISSIONIEVAPI PUNGE CONTROLSOLENOID VALVETroubf eshooting, Page 1 1'21 1, 243
CRANKSHAFTPOS|TTON/TOP DEAD CENTER/CYLINDERPOS|T|ON
POWER STEERING PRESSURE(PSP) SWITCH (USAI
Troubleshooting, Page 1 1-212
KNoCK SENSoR (Ks)
(cwl
Troubleshooting, Page 1 1'170ICKP/TDC/CYP} SENSOR(Built into the distributor)Troubleshooting, Page 1 1'172
VEHICLE SPEED SENSORTroubleshooting, Page 1 1-176
FLUCTUATION (CKF} SENSOR
Troubleshooting, Page 1 1 -183
ENGINE COOLANTTEMPERATUREIECT) SENSORTroubleshooting, Page 11 128
IDT.ECONTROL IIACI VALVE
{cw)Troubleshooting, Page 11 198
WAY CATALYTICCONVERTER ITWCITroubleshooting, Page 1 1-252PRIMARY TIEATEDSENSOR {PNIMARY HO2SI
tsENsoR 1t {M/TlTroubleshooting, Page'l 1-146
PRIMARY HEATED OXYGENSENSOR (PRIMARY HO2SI
tsENsoR 1l {cw}Troubleshooting, Page 1 1-139
SECONDARY HEATED OXYGENSENSOR {SECONDARY HO2S){SENSOR 2)Troubleshooting, page 11 153
(cont'd)
1 1-3

Component Locations
Index (cont'd)
D16Y8 enginc:
THROTTLE POSITION {TPISENSORTroubleshooting, page 1 1-132
ELECTRICAL LOADDETECTOR IELDI {USAI
INTAKE AIR TEMPERATUREIIATISENSORTroubleshooting, page 1 1,124
MANIFOLO ABSOLUTEPRESSURE {MAPI SENSORTroubleshooting, page 1 1-1 15
IDI.E{A/T)
IDI.E AIR CONTROL IIACI VALVElMtflTroubleshooting, page 1 1-194
Troubleshooting, page 1 1-179EVAPORATIVE EMISSIONIEVAPI PURGE CONTROLSOLENOIO VALVETroubleshooting, page 1 1 27 1. 283CRANKSHAFTPOSTTTON/TOP DEAD CENTER/CYLINDERPOStTtON
POWER STEERING PRESSURE(PSPI SWTTCH |USA)Troubleshooting, page 1 1-212{CKP/TI'C/CYPI SENSOR(Built into the distributor)Troubleshooting. page 1 1-172KNOCK SENSOR IKSITroubleshooting, page 11 170
CRANKSHAFT SPEEDFLUCTUANON ICKFI SENSORTroubleshooting, page 1 1,183
CONTROL {IACI VALVE
ENGINE COOLANTTEMPERATURE{ECTI SENSORTroubleshooting, page 11 128
Troubleshooting, page 11 198
PRIMARY HEATED OXYGEN SENSOR{PRIMARY HO2S} (SENSOR 1l {'96 - 98 modolslTroubleshooting, page 1 1-139
'9!t - 00 modols:'96 - 98 modols:
THREE WAY CATALYNCCONVERTER ITWCITroubl6shooting, page 1 1-252
THREE WAY CATALYNCCONVERTER ITWCITroubleshooting. page 1 1-252
SECONDARY HEATED OXYGENSENSOn(SECONDARY HO2SI (SENSOR 2ITroubleshooting, page 1 1-153
SECONDARY HEATED OXYGENSENSOBISECONDARY HO2S} ISENSOR 2ITroubloshooting, page 1 1-155
PRIMARY HEATEO OXYGEN SENSORIPRIMARY HO2SI ISENSOR 1ITroubleshooting, page 1 1-141
11-4

D16Y7 engine:
ELECTRICAL LOAO
DETECTOR (ELD) IUSA}Troubleshooting, Page 11'179
THROTTLE POSITION ITPISENSOR
MANIFOLD ABSOLUTEPRESSURE (MAPI SENSORTroubleshooting, Page 1 1-1 15r1-132
CRANKSHAFTPOSTTTON/TOP DEAD CENTER/
CYLINDERPOSITION
POWER STEERll\lG PRESSURE
{PSP' SWTTCH {USA)Troubleshooting, Page 11 212
IDLE AIR CONTROL (IAC) VALVE
Troubleshooting, page 1 1-198
Troubleshooting,
VEHICLE SPEED SENSOR (VSSI
Troubleshooting, Page 1 1-176
INTAKE AIR TEMPERATURE
IIATI SENSORTroubleshooting, page 11 124
l
/i
CRANKSHAFT SPEED
{CKP/TDC/CYPI SENSOR(Built into the distributorlTroubleshooting, Page 't 1-172
FLUCTUATION ICKFI SENSORTroubleshooting, Page 1 1-183
PRIMARY HEATED OXYGEN
SENSOR (PRIMARV HO2S)
{SENSOR 1lTroubleshooting, page 1 1'139
ENGINE COOLANTTEMPERATURE(ECTI SENSORTroubleshooting, page 11 128
EVAPOBATIVE EMISSION(EVAPI PURGE CONTROLSOLENOID VALVE
THNEE WAY CATALYTICCONVERTER ITWCITroubleshooting, page 1 1-252
Troubf eshooting, page 1 1 27 1, 283
SECONDARY HEATED OXYGENSENSOR (SECONDARY HO2S)(SENSOR 2lTroubleshooting, Page 1 1-1 53
(cont'd)
,l .ltr| | -r,

Component Locations
Index (cont'dl
Bl6A2 engine:
INTAKE AIR TEMPERATURE{IAT} SENSORTroubleshooting, page 1'1-125
MANIFOLO AESOLUTEPRESSURE IMAPI SENSORTroubleshooting. page 11-1 19IOLE AIR CONTROL {IAC) VALVETroubleshooting, page 1 1,196
ELECTRICAL LOADDETECTOR IELDI (USA)
Troubleshooting, page 1 1-180
THROTTLE POSITION ITPISENSORTroubleshooting, page 11-134
CRANKSHAfiPOStTtON/TOP DEAD CENTER/CYLINDERPOStTtON{CKP/TDC/CYPI SENSOR(Bualt into the distributor)Troubleshooting,page 11-174
POWER STEERING PRESSURE{PSPI SWTTCH (USA)
Troubleshooting, page 1 1-214
VEHICLE SPEED SENSOR {VSS}Troubleshooting, page 1 1-177
ENGINE
CRANKSHAFT SPEEDFLUCTUATION (CKFI SENSORTroubleshooting, page 11- t85TEMPERATUREIECTI SENSORTroubleshooting, page I 1-128
THREE WAY CATALYTICCONVERTER ITWC)Troubleshooting, page 1 1,252
S€CONOARY HEATED OXYGENsf rlsoR
sfCoNDARY HO2SI {SENSOR 2): ?shootrng, page 11 155
-6
PRIMARY HEATED OXYGEN SENSORIPRIMARY HO2S) ISENSOR 1ITroubleshooting, page 1 1-141
11

I
CLUTCH SWITCH lDl6Y5 onginoM,/TITroubleshooting, page 1 1-218
'96 - 98 modsls:
Sell-diagnostic Procedures.page 11 81
ENGINC CONTROL MOOUI.T(FCMI/POWERTRATN
CONTROL MODULE IPCMITroubleshooting, page 1 1-107
'9!, - 0o modol3:
PGM.FI MAIN RELAYRslay Testing, page 11-237Troubleshooting, page 1 1-238PGM.FI MAIN RELAYRelay Testing, page l1 237Troubleshooting, pago 1'! 238
SERVICEl2Pl
CONNECTOR
ENGINE CONTROL MODU1T(ECM}/POWERTRAIN
CONTROL MODULE IPCMITroubleshooting, page 11 111SERVICE CHECK CONNECTORtzPlSelf-diagnostic Procedures,page 11-81
Self-diagnostic Procedures,page 11-81
{cont'd)
11-7

Troubleshooting
Troubleshooting Procedures
How To Begin Troubleshooting
When the Malfunction Indicator Lamp (MlL) has been reported on, or there is a driveability problem, use the appropr'-
ate orocedure below to diagnose and repair the problem'
A. When the MIL has come on:
,1. connect the Honda PGM Tester or an oBD ll scan tool to the 16P Data Link connector (DLC) located near the left
kick panel.
2. Turn the ignition switch ON (ll)
3. Check the DTC and note it. Also check and note
the freeze trame data
Refer to the Diagnostic Trouble Code Chart and
begin troubleshooting.
NOTE:
.SeetheoBD||scantoolorHondaPGMTesteruser,smanua|sforspecificoperatinginstructions..
.Thescantoo|oltestercanreadtheDiagnosticTroub|ecodes(DTc},freezeframedata,currentdata,andother
Engine Control Module (ECM)/Powertrain Control Module (PCM) data'
oFreezeframedataindicatestheengineconditionswhenthefirstma|function,misfireorfue|trimma|function
was detected. lt can be useful information when troubleshooting'
B. When the MIL has not come on , out there is a d riveability problem, refer to the Symptom Chart on page 1 1-84'
c.DTcswi|lbeindicatedbytheb|inkingoftheMa|function|ndicatorLamp(M|L)withthescsserviceconnectorcon.
nected.
Connect the SCS service connector to Service Check Connector as shown (The 2P Service Check Connector is
|ocatedunderthedashonthepassenger,ssideofthevehic|e')TurntheignitionswitchoN{||)'
OBO ll SCAN TOOL olHONOA PGM TESTER
SERVICE CHECKCONNECTOR I2P)
scs sERvlcE(cont'd)
MALFUNCTIONINDICATORLAMP
DATA LINK CONNECTOR Il6PI
07PAZ - (x)l0100
11-81

Troubleshooting
Troubleshooting Procedures (cont,dl
ll, Engine Control Module (ECM)/powertrain Control Module (pCM) Reset procedure
NoTE: Resetting the EcM/PcM will erase any stored DTcs and any freeze data. lt will also restart all readiness codemonitors.
Either of the following actions will reset the ECM/PCM.
. Use the OBD ll scan tool or Honda pGM Tester to clear the EClM,s/pCM,s memory.
NorE: see the oBD ll scan tool or Honda PGM Tester user's manuals for specific operating instructions.
' Turn the ignition switch oFF. Remove the BACK uP (7.5 A) fuse from the under-hood fuse/relay box for 10 sec-onds.
NorE: Bemoving the BACK uP (7 5 A) fuse cancels the clock and the radio presets. Make note of the customer,spresets so you can reset then
lll. Final Procedure (this procedure must be done after any troubleshoottng)
1. Remove the SCS Service Connector if it is connected.
NoTE: If the Scs service connector is connected and there are no DTcs stored in the EcMipcM, the MtL will stayon when the ignition switch is turned ON 0l).
2. Do the ECM/PCM Reset procedure.
3. Turn the ignition switch OFF.
1-82