Valve clearance HONDA CIVIC 1999 6.G Owner's Manual

Cylinder Head
Installation (cont'dl
10. Align the marks on the cylinder head plug to thecylinder head upper surface, then install the cylin,
der head plug in the cylinder head.
PLUGReplace.
Install the timing belt (see page 6-63).
Adjust the valve clearance (see page 6-61).
Install the head cover gasket in the groove of the
cylinder head cover. Seat the recesses for the
camshaft first, then work it into the groove around
the outside edges,
NOTE:
. Before installing the head cover gasket, thorough-ly clean the head cover gasket and the groove.
. When installing, make sure the head cover gasket
is seated securely in the corners of the recesses
wrrn no gap.
11.
13.
1'
CYLINDEB HEAD
HEAD COVEB
6-86
(\
14. Apply liquid gasket to the head cover gasket at theeight corners of the recesses.
NOTE:
. Use liquid gasket, Part No. 08718 - 0001 or 08718- 0003.
. Check that the mating surfaces are clean and drybefore applying liquid gasket
. Do not install the parts if five minutes or morehave elapsed since applying tiquid gasket.
Instead, reapply liquid gasket after removing oldrestdue.
. After assembly. wait at least 30 minutes before
filling the engine with oil.

Troubleshooting
DTClMlL indicationlDatection hsmProbablo CausePage
P0137(63)Secondary Heated Oxygen SensorCircuit Low Voltage(Sensor 2)
Short in Secondary HO2S lSensor 2) circuitSecondary H02S {Sensor 2)ECM/PCI\41 1-153
P0r38 {63)Secondary Heated Oxygen SensorCircuit High Voltage(Sensor 2)
Open in Secondary HO2S (Sensor 2) circuitSecondary HO2S (Sensor 2)EC[I/PCM11-154
P0'139 (63)Secondary Heated Orygen SensorSlow Response(Sensor 2)
Secondary H02S lSensor 2)1l-156
P0141 (65)
Secondary Heated Oxygen SensorHeaterCircuit Malfunction(Sensor 2)
. Open or short in Secondary HO2S (Sensor2) heater circuit. ECM/PCM11-157
P0171 (45)
System Too LeanFuel supply systemPrimary HO2S (Sensor 1)MAP sensorContaminated fuelValve clearanceExhaust leakage
11,164
P0172 (45)
System Too RichFuel supply systemPrimary HO2S (sensor l)MAP sensorContaminated fuelValve clearance
11-164
P0300*16' }l?
andsome ofPo3o1 /r'' \P0302 l72lP0303 l73lP0304 \7 4l
Random Misfirelgnition systemFuel supply systemMAP sensorEGR systemIAC valveContaminated fuelLack of fuel
r1-r66
P0301P0302P0303P0304
/rt\172ll73l\7 4l
- Cylinder 1- Cylinder 2- Cylinder 3- Cylinder 4Misfire Detected
Fuel InjectorFuel Injector circuitlgnition systemLow compressionValve clearance
11 167
P0325*3 (23)Knock Sensor (KS) CircuitMalfunctionOpen or short in Knock Sensor (KS) circuitKnock Sensor {KS)ECM/FCtvl11-170
P0335(4)Crankshaft PositionSensor CircuitMalfunction
Crankshaft Position SensorCrankshaft Position Sensor circuitECM/PCM11-172
P0336(4)Crankshaft PositionSensorRange/Performance
. Crankshaft Position Sensor. Timing belt skipped teeth11-172
P040'r*r (80)Exhaust GasRecirculationInsufficient Flow Detected
' EGR valve. EGR line
P0420(67)Catalyst SystemEfficiency BelowThreshold
. Th.ee Way Catalytic converter. Secondary HO2S11 253
Diagnostic Trouble Code (DTCI Chat (cont'dl
*3: D16Y5 engine (CVT), D16Y8 engine and B1642 engine*4: D'16Y5 engine*16: '98 model+17: '99 - 00 models
,Jla
1 1-98

PGM-FI System
Fuel Supply System
D017-il Th""""ntool indicates Diagnostic Troubte Code {DTC) p0171;Thefuet system istoo lean.
1P0172 | fne scan tool indicates Dlagnostic Trouble Code (DTC) P0172:Thefuel system istoo rich.
Description
By monitoring the Long Term Fuel Trim, long term malfunctions in the fuel system will be detected.lf a malfunction has been detected during two consecutive trips, the MIL will come on and DTC P0171 and/or P0172 will bestored.
NOTE: lf some of the DTCS listed below are stored at the same time as DTC P0171 andlot P0172, ltouhleshoot those DTCSfirst. then recheck for DTC P0l7l andlot P0172.
P0106-8, P1128*3. *5, P1129*3 *5 MAP Sensor
P0135; Primary HO2S Heater
P0137. P0138: Secondary HO2S
P0'141: Secondary HO2S Heater
P0401: EGR Flow Insufficient*1
P0441: EVAP System Insufficient Purge Flow*6
P1259: VTEC System*,
P1491:EGR Valve Lift Insufficient*r
P1498: EGR Valve Lift Sensor Hjgh Voltage*r
*r: D16Y5 engines*': Dl6Y5, D16Y8, 81642 engine*3: '97 models*a:'96 modelsf 5: '98 - 00 models*6: '96 D16Y5 engine,'96 D16Y7 engine,'96 D16Y8 engine (sedan),'97 D16y5 engine,,97 D16y7 engine (coupe: KA, KC mo+els, sedan KA. KC, KL (DX) models. hatchback; all models),'97 D16Y8 engine (sedan: KA, KC models)
Possible Cause
DTC P0'171
loo lean
DTC P0172
too rach
Fuel Pump insuff icient f lovpressure
Fuel Feed Line clogged, leaking
Fuel Pressure Regulator stuck open
Fuel Filter clogged
Fuel Injector clogged, air inclusion
Gasoline doesn't meet Owner's Manual spec.
Primary HO2S (Sensor 1) deteriorated
MAP Sensor range/performance*.
EGR System malfunction (too much flow)*1
Valve Clearance
Exhaust leak
Fuel Pressure Regulator clogged, stuck closed
Fuel Return Pipe clogged
Fuel Injector leaking
Gasoline doesn't meet Owner's Manual spec.Primary HO2S (Sensor 1) deteriorated
MAP Sensor range/performance*a
EGR System insufficient flow*1
EVAP Purge Control Solenoid Valve leaking, stuck opened
Valve Clearance
11-164

PGM-FI System
Random Misfire
lFoioo l*u o, [FTioo l*' *' and
The scan tool indicates Diagnostic Trouble Code (DTC)
P0300*5 or P1300*3 *1 and some of P0301 - P0304:Random misfire.Description
Misfire detection is accomplished by monitoring the crankshaft speed with the crankshaft speed fluctuation (CKF) sensorwhich is attached to the crankshaft.
lf misfiring strong enough to damage the catalyst is detected. the MIL will blink during the time of its occurrence, and DTCP0300*5 or P1300*3'*' and some of DTCs P0301 through P0304 will be stored. Then, after misfire has ceased, the MIL willcome on.
lf misfiring that increases emissions is detected during two consecutive driving cycles, the MIL will come on, and DTCP0300*5 or P1300*3 *a and some of DTCS P0301 through P0304 will be stored.NOTE: lf some of the DTCS listed below are stored at the same time as a misfire DTC. troubleshoot those DTCS first, thenrecheck for the misfire DTC.
P0106*4. P0107. P0108, P1128*3 *5, Pl129*3 *5; MAP sensorP0131. P0132: HO2S
P0171, P0112i Fuel metering
P0401, P 1491, P1498: EGR svstem*1P0505: ldle Control SystemP1253: VTEC System*,P1361, P1362: TDC sensorP1381, Pl382: CYP sensorP1508: IAC valve
Possible Cause. Fuel pump insufficient fuel pressure, amount of flow. Fuel line clogging, blockage, leakage. Fuel filter clogging. Fuel pressure regulator stuck open. EGR system malfunction*1. Distributormalfunction. lgnition coil wire open. leakage *l: D16Y5 engine. lgnition control module malfunction *2: D16Y5, D16Y8, Bt6A2 engine. MAP sensor range/performance, poor response*r *3: '97 models. Valves carbon deposit *4;'96 models. Compression low *5: '98 - 00 models. IAC valve malfunctionr.. VTEC system malfunction*,. Fuel does not meet Owner's Manual spec., lackoffuel. HO2S. HO2S circuit
Troubleshooting
By test-driving, determine the conditions during which misfire occurs, Depending on these conditions, test in the orderdescribed in the table below.
Possible
- --^ ---
rage
causeEGR*1
system
Crankshaft
position (CKP)
sensor
Fuel
pressure
Distributor and
lgnition wirestcMClearance
tAc
ValveMAP
sensor
section 611-230,
231section 23section 23section 611-19411
Only low rpm and
loado@@oo
Only accelerating@o@@
Only high rpm and
toaooo@
Not specificoo@
NOTE: lf misfire doesn't recur, some possible causes are fuel that doesn't meet owne/s manualspec, lack of fuel, carbon deposits on spark plug, etc.
1 1-1 66
I
P0304

I
Misfire Detected in One Cylinder
P0301 | The scan tool indicates Diagnostic Trouble Code (DTC) P0301: Cylinder 1 misfire detected.
[F03O2l 16"""untool indicates Diagnostic Trouble code (DTc) P0302: Cylinder2 misfire detected.
[FO3Ofl 16" ".un toot indicates Diagnostic Troubte Code (DTC) P0303; Cylinder 3 misfire detected.
I P0304 I ths..rr tool indicates Diagnostic Trouble Code (DTC) PO3O4: Cylinder 4 misfire detected.
D€scription
lMisfire detection is accomplished by monitoring the crankshaft speed with the crankshaft speed fluctuation (CKF) sensor
which is attached to the crankshaft,
lf misfiring strong enough to damage the catalyst is detected, the MIL will blink during the time of its occurrence, and DTC
PO3O1, P0302, PO3O3 or P0304 will be stored. Then, after the misfire has ceased, the MIL will come on.
lf misfiring that increases emissions is detected during two consecutive driving cyclss, the MIL will come on, and DTC
P0301, P0302, P0303 or P0304 will be stored.
NOTE: lf some of the DTCS listed below are stored at the same time as a misfire DTC, troubleshoot those DTCS first, then
recheck for the misfire DTC.
PO106*1, P0107, P0108. P1128*3'*5, P1129*3'*5: MAP sensor
P0131, P0132: HO2S
P0171, P0172iFuel suppiy system
P0335, P0336: CKF sensor
P0401. P1491, P1498: EGR system
P0441: EVAP system Insufficient purge flow*6
Pl359. P1361. Pl362: TDC sensor
P1381. Pl382: CYP sensor*o: '96 models*6: '96 D16Y5 engine,'96 D16Y/ engine,'96 D16Y8 engine {sedan),'97 D16Y5 engine,'97 D16\4, engine (coupe: KA,
KC models, sedan KA. KC, KL (DX) models, hatchback:all models),'97 D16Y8 engine (sedan: KA, KC models)
Possible Cause
. Fuel injector clogging, fuel leakage, air leakage
. Fuel injector circuit open or shorted
. Spark plug carbon deposits, fouling, malfunction
. lgnition wires open. leaking
. Distributor malfunction
. ComDression low
. Valve clearance out of spec
. VTEC system malfunction (D16Y5, D16Y8. 81642 engine)
. HO2S
. HO2S circuit
(cont'd)
11-167
r'a

Intake Air System
Throttle Cable (cont'dl
4. Set the locknut on the cable bracket. Adjust theadjusting nut so that its free play is O mm.
5. Bemove the cable sheath from the throttle bracket,reset the adjusting nut and tighten the locknut.
O16Y5, D16Y8 engino:
ADJUSTING NUT
9.8 N.m{1.0 kgl.m,1.2 tbt.ttl
DtGYT 6ngine:
11-246
816A2 engine:
1. Open the throttle valve fully, then install the throttlecable in the throttle linkage. and install the cablehousing in the cable bracket,
THROTTLE LINK
LOCKNUTADJUSTINGNUT
Start the engine. Hold the engine at 3.000 rpm withno load (in Park or neutral) until the radiator fancomes on, then let it idle.
Hold the throttle link to the throttle lever; thereshould be no clearance.
Hold the cable sheath, removing all slack from thecable.
Turn the adjusting nut untit it is 3 mm {1/8 in.) awayfrom the cable bracket,
LOCKNUT9.8 N.m(1.0 kgt m,7.2 tM.ttl
ADJUSTING NUT
Tighten the locknut. The cable deflection shouldnow be 10 - 12 mm l3/B - 1/2 in.). lf nor. seeInspection/Adjustment.
3 mm 11/8 in.)

IThrottle BodY
Description
The throttle bodY is either a single-barrel side-draft type
(D16Y5, D16Y8, 816A2 engine) or a down-draft type
(D16Y/ engine). The lower portion ot the throttle valve is
heated by engine coolant from the cylinder head' The
idle adjusting screw which regulates the bypass air is
located on the top of the throttle body
THROTTLEPOS|T|ON lTPlSENSOR
IDLE AD.'USTINGSCREW
t
In3pection
1. Check that the throttle cable operates smoothly
without binding or sticking.
lf there are any abnormalities, check for:
. Excessive wear or play in the throttle valve shaft'
. StickY or binding throttle lever at the fully closed
Position.. Clearance between throttle stop screw and throt-
tle lever at the fully closed position'
D16Y5, Dl6Y8 engine:
THROTTLE STOP SCREW
{Do not adjust.)
Dl6Y7 ongine:
816A2 engins:
THROTTLE LINK
STOP SCREW
THROTTTE STOP SCREW(Do not adjust.)
Replace the throftle body if thsre is excessive play in the
throttle valve shaft or iJ the shaft is binding or sticking'
(cont'd)
11-247
{Do not adjust.)

Automatic Transmission
Special Tools ......... .....'."".'-.-.' 14'2
Description .,....................-...... 14-3
power Flow ......,................. 14"6
Elestronic Control System .... . ................'..'.'.. 14-13
Hvdraulic Control .....'......" 1'l-19
Hydraulic F|ow...... .'.'.".'....11-21
Lock-up System '............ ... t/t'33
Electrical System
Component Locations....,.............'......'.............'.,. 14'39
PCM Circuit Diagram
lA/T Control Syst€m: '96 - 98 Models) .........'.. 1/t-40
PCM Tarminal Volt8ge/Measuring Condhions
{'96 - 98 ModeblA/T Control System ............
PCM Circuit Disgram(A/T Conlrol System: '99 - 00 Modsls) '..........' 14-44
PCM Terminal Voltage/Measuring Conditions('99 - 00 Models)A/T Control System ...
Troubleshooting Proceduros ....
Symptom-to-ComPonent Chari
Efectricaf SFiem - '96 - 98 Models '..-.-..."'.'..11-52
Eloqtrical System -'99 - 00 Modols ... .........". 1+54
EleclricatTroubl$hooting ('96 - 98 Models)
Valve Body
Repair .................... ........'.... 14-139
Valve
Assembly
ATF Pump
1,1-1i10
Inspection ...........'.......... 14-141
Main Valvs Body
Disass€mbf y/lnspoction/R.sssembly .'.'.'.'.. -. -. 1 1-1 12
Secondsry Valve BodY
Disa$embfy/lnspoction/Rsassembly ......'.'.'.'. 11-111
Regulator Valve Body
Disa$embly/lnspoction/Rea3sembly ..........'... 14-1{5
Servo Body
Disassombly/lnsp€ction/Reassembly .".'........ 14-146
Lock-up Valv6 Body
Dis$s.mbf y/ln3poction/Rea$embly .'.. -. -..'.'.' 1 1-1 17
Mainsh!ft
Dkassembly/lnep€ction Reassembly ..'...'........ 14'148
Inspoction .............'..........'. l it-149
Countsrshaft
Disa$embly/lnspeqtion/Rea3sembly .......'...'.. 1a-l51
Dba$ombly/Re$s.mblY11-152
til-46
I rl-48
Troubleshooting Flowcharts
Electrical Troubleshooting ('9!t - 00 Models)
Troublsshooting Flowchart3
Lock-up Control Solenoid vslvo A/B AssemblY
RePlacoment
Shift Cont.ol Solenoid Valve A/B A3sembly
Inspestion
Ona-way Clutch
Disassembh/lrupoction/Rca$embly .. "'........ l4-155
Clutch
lllustlttcd Ind.x {A48A, B4RA Transmlssion) ..' 14-156
tustr.tod Index (MrnA Transmi$ionl ............ til-158
...................... 14-153
L
14-56
1+81'
14-105
1+105
Replacoment ......
Mainshaft/Countorshaft Spo€d Sonsors
Replacemsnt ......'."'........... lit'108
Hydraulic System
Symptom-to-Componeni Chart
Hydraulic Sydemr+109
t4-113
1+116
11-117
Rea$emblY
14-106 Difforrr ial
llhdraied Index........ t4-156
B.ckhrh ln3poction. 14-167
Boaring Roplacemont..-..........11-167
..... 14-108 Diftrrsniial Carrior Repl8cemeni .'.-.............'...' lil-168
Oil Sall Romovalt4-t 59
Oil Soal ln3tallstion/Sidc Clearance'......'.....'... 1'l'169
Torqua Convertcr Housing Boarings
Mlin3haft Besring/Oil Scal Roplac.ment ."..'.. lil-172
Counio6hatt Betring R.plscem.nt ..'...... ....... 14-173
Test.....,......14-106
14-107
14-160
11-162
11-171
11-175
Replacement
Test .....,.,..........
Road Te3t
Linear Solenoid AsssmblY
Stall Speed
lllustrated Indax
Transmission/End Cover'. ....
Transmission Hou3ing,.............'.'......'....""..-.-.. 11-128
Torque Conve.ter Housing/Valvo Body ........... 14-130
End Cover
14-itB Park Stop
1+119 In3pection/Adiustmsnt...'......'.'............'...."""'14-175
Transmbgion
Reassombly
11-122 Torquo Convertet/Drivr Plsie ............'.'............'.. . l4-182
Transmission
11.726 Inrtallation
Tranlmission Housing Boarings
Msinsh.ft /CounteEhaft Bearings
B!pltcomgnt
Rcvo.3s ldlor Gear
lnrtallation
Cooler Flushing ..
Shift Cabls
Test
Fluid Level
Checkin9 .........."..'.'.....
Changing
Pressure Testing
Transmission
Transmission
Rgmoval ..
lil-176
.'..........'.'.'..... 1'l-183
.... lil-187
11-132Adiustmont
RemovaUlnttallation1,1-190
lit-191Transmisgion Housing
Removal ... '.'...... ......'..... 14-l3il
Tolque Convgrter Housing/valvs Body
Rsmoval .........,...... ............. 14-136
Valve CaDs
Description .......'................. t 4'138
Shift lndicator Panel
Adiu3tmant ..'.................. 14-192
ATF Coolor Hoses
Connection ..,............,.,....... l'l-192
Shift Lever .,........

The following symptoms can be caused
by improper repair or assembly
Check these items,on th€^ ltems on thePROBABLE CAUSE DUE TO NOTES ListIMPROPER REPAIR List
Vehicle creeps in N position.R1, R2
Vehicle does not move in &l or Pll position.R4
Transmission locks up in E position.R3, R11
Excessive drag in transmission.R6K,R
Excessive vibration, rpm related.R7
Noise with wheels moving onlY.R5
Main seal pops out.R8
Various shifting problems.R9, RlO
PROBABLE CAUSE DUE TO IMPROPER REPAIR
lmproper clutch clearance.
lmproper gear clearance.
Park lever installed upside down.
one-way {sprag) clutch installed upside down.
Reverse selector hub installed upside down.
ATF pump binding.
Torque converter not fully seated in ATF pump.
Main seal improperly installed.
Springs improperly installed.
Valves improperly installed.
Shift fork bolt not installed.
14-11

ATF Pump
Inspection
1. Install the ATF pump gears and ATF pump driven
gear shaft in the main valve body
NOTE:
. Lubricate all parts with ATF during inspection.
. Install the ATF pump driven gear with its grooved
and chamfered side facing up as shown.
MAIN VALVE BODY
ATF PUMP ORIVEN GEAR
Grooved and chamfe.ed side
2. Measure the side clearance of the ATF pump drave
and driven gears.
ATF Pump Gears Side {Radial) Clearance:
Standard (New):
ATF Pump Drive Gear
0.105 - 0.1325 mm {0.004 - 0.q)5 in}
ATF Pump Drivsn Gear
0.035 - 0.0625 mm (0.0014 - 0.0025 inl
MAIN VALVE SOOY
YZ]
o?
ATF PUMPDRIVE GEAR
ATF PUMPDRIVEN GEARInspect teeth for wear and damage
lnspect teeth for wear and damage.
3. Remove the ATF pump driven gear shaft. Measure
the thrust clearance of the ATF pump driven gear-
to-valve bodY.
ATF Pump Drive/Drivon Gear Thrust {Axial} Cloarance:
Standard (Now): 0.03 - 0.05 mm 10'001 - 0.002 inl
Sorvice Limit: 0.07 mm (0.003 in)
1+141