ac system HONDA CIVIC 1999 6.G Workshop Manual

Charging System
Rectifier Removal (cont'd)
Separate the rear housing from the stator/rectifier
assembly by removing the four screws and the ter-minal nut.
TERMINAL NUT
Unsolder the rectifier from the stator leads,. To avoid damaging the diodes with heat, pinch
the stator leads between pliers to carry heat off,and apply the soldering iron only long enough toseparate the leads from the rectifier.. Use a 100 W soldering iron.
STATOR SOLDERING
7. Install the new rectifier in the reverse order of removal.. Apply the soldering iron only long enough toensure a good connection so the heat will notdamage the diodes.
a Use only a rosin core type solder or solder joints
will corrode.
6.
SOLDERING
23-122
Rectifier Test
NOTE: The diodes are designed to allow current to pass
in one direction while blocking it in the opposite direc-tion. Since the alternator rectifier is made up of ninediodes, each diode must be tested for continuity in bothdirections with an ohmmeter that has diode checkinocapability; a total of 18 checks.
1. Check for continuity in each direction between- the B and P terminals.- the B'and P terminals.- E {ground) and the P terminals.
All diodes should have continuity in only one direc-UOn.
lf any of the diodes fails, replace the rectifier assem-bly, (Diodes are not available separately.)

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

IJNOER,DASHFUSE/RELAY BOX
GAUGELIGHTS
l3wx4 l
CHARGINGSYSTEMLIGHT0.4w)
Gircuit Diagram
UNDEN HOOD FUSE/RELAY BOXIJ
N0.30 (7.54)FUSE
f7
I
tlRED/BLK BEO/BLK
l"l"8LK BLU
IJ
l'"^*
I
t-
G401G402
__l
tE2
IFED/BLU
CRUISECONTROTUNIT
fl ,,1:
tH
I c12
IFFD
VDASH LIGHTSBRIGHTNESSCONTROLLEF
l"'WHT/BLU
vALTERNATOR
(With shifi-up indicatd lighl)(wi1h cruise conlrcl system)

BRAKESYSTEMLIGHI(1.4w)
RED/GRN GFN/RED
TA
Yimi+" Yo
l[3&1" ;i:l"la',.l l,,1!:,iT "*,,
I lrb'ff" ;i#il;-"1
I'i
_,L J-:-l
G401G()2
GRN/REO
I
TCM
(cont'd)
23-133
8LK
I
G552

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

Fuel Gauge
Gauge/Sending Unit Test
!@ Do not smoke while working on tho fuel
system. Keep open tlame away trom your wotk atea.
NOTE: Refer to page 23-133 for the fuel gauge system
circuit.
'1. Check the No. 25 (7.5 A) fuse in the under-dash fuse/
relay box before testing.
2. Remove the access panel from the floor.
ACCESS PANEL
Disconnect the 3P connector from the fuel gauge
sending unit.
Connect the voltmeter positive probe to the No. 2
terminal and the negative probe to the No. I termi-
nal, then turn the ignition switch ON (ll).
There should be between 5 and 8 V.
. lf the voltage is as specified, go to step 5.
. lf the voltage is not as specified. check for:- an open in the YEUBLK or BLK wire.- poor ground (G552).
Turn the ignition switch OFF.
Attach a jumper wire between the No. 1 and No. 2
terminals, then turn the ignition switch ON (ll).
)\
23-142
1.Check that the pointer of the fuel gauge starts mov-
ing toward the "F" mark.
CAUTION: Turn the ignition switch OFF before thepoinier reaches "F" on ihe gauge dial. Failure to do
so may damage the fuel gauge.
NOTE: The fuel gauge is a bobbin (cross-coil) type,
hence the fuel level is continuously indicated even
when the ignition switch is OFF, and the pointer
moves more slowly than that of a bimetaltype.
. lf the pointer of the fuel gauge does not move at
all, replace the gauge.
. lf the gauge is OK. inspect the fuel gauge send-
ing unit.
Remove the fuel gauge sending unit as shown.
Japan-produced
USA, Canada-produced

Interlock System
Component Location Index
INTERI.OCK
UNITInput Test, page 23-'146
KEY INTEBLOCK SOLENOIDrnd KEY INTERLOCK SWITCH(ln the steering lock assemblylTest, page 23-147
PARK PIN SWITCHTest, page 23-148
SHIFT LOCK SOLENOIDTest, page 23-147
23-144

Interlock System
Control Unit Input Test
1. Disconnect the 8P connector from the interlock con-trol unit.
2. Inspect the connector and socket terminals to besure they are all making good contact.. lf the terminals are bent, loose or corroded, repairthem as necessary, and recheck the system.. lf the terminals look OK, make the followinginput tests at the connector.- lf a test indicates a problem, find and correctthe cause, then recheck the system.- lf all the input tests prove OK, substitute aknown-good control unit, and recheck the sys-tem. lf the check is OK, the control unit mustbe faulty; replace it.
NOTE: lf the shift lock solenoid clicks when theignition switch is turned ON {ll) and you step on thebrake pedal (with the shift lever in E), the shift locksystem is electronically normal; if the shift leve.cannot be shifted from E], test the Aff gear position
switch, park pin switch, and see section 14.
Key Interlock System:
CavityWireTest condition
Reconnect the 8P connector to the interlock control unit.
Shift Lock System:
Cavity WifsTest condition
INTERLOCKCONTROL UNIT
Test: Desired result
Test: Dgsired result
Wire side offemale terminals
Possible cause if result is not obtained
Possible cause if result is not obtained
WHT/BLU
lgnition switch turned toACC (lland key pushed inCheck for voltage to groundiThere should be baftery voltage.Blown No. 48 (30 A) fuse in the underhood fuse/relay boxBlown No. 33 (7.5 A) fuse in the underdash fuse/relay boxFaulty steering lock assemblylkey interlock solenoid)An open in the wire
5WHT
BLKUnder all conditionsCheck for continuity to ground:There should be continuity.
' Poor ground (G401, G402). An open in the wire
6BLK./BLUShift lever in ElCheck for continu;ty to ground:There should be continuity.Poor ground (G401, G402)Faulty Ay'T gear position switchAn open in the wire
2YELlgnition switch ON lll)Check for voltage to ground:There should be banery voltage.
. Blown No. 25 (7.5 A) fuse in the under,dash fuse/relay box. An open in the wire
3YEUBLK
lgnition swirch ON (ll)Check for voltage to ground:There should be baftery voltage.Blown No. 25 (7.5 A) fuse in the under-dash fuse/relay boxFaulty shift lock solenoidAn open in the wire
6BLI(BLUShift lever in ICheck for voltage to ground:There should be 1 V or less.Poor ground (G401, G402)Faulty A,/T gear position switchAn open in the wire
7WHT/RED
lgnition switch ON lll)Brake pedaldepressedCheck for voltage to ground:There should be 1 V or less.Blown No. 52 (15 A) Iuse in the underhood fuse/relay boxFaulty PCMFaulty brake switch (see section 1l)Faulty throttle position {TP) sensor(see section 1'l )An open in the wire
lgnition switch ON (ll)Brake pedalandaccelerator depressed atthe same time
Check for voltage to ground:There sho(Jld be battery voltage.
23-146

Interlock System
Park Pin Switch Test
1, Remove the front console (see section 2Ol.
Disconnect the 4P connector from the park pinswitch.
Check for continuity between the No. 3 and No. 4terminals with:- the shift lever any position other than E, or- the push button pushed in E.There should be continuity.
Check for continuity between the No. 3 and No. 4terminals with the shift lever in E and the push but-ton released. There should be no continuiw. lf nec-essary, replace the park pin switch.
NOTE: Park pin switch 4p connector No. 1 and No.2terminals are lor Ay'T gear position console light.refer to the circuit diagram on page 23-1S0.
23-14A