starter HONDA CIVIC 1999 6.G Service Manual

Starting System
Component Location lndex
GNIT ONSW TCH
t,U,-*€,-l
&T GEARPOSITION SWITCH(Cosed n posilion N or E)
ELKMHT
I
tl81X,4{HT BLKIWHT
STARTERCUT FELAY
STAPTER(Permaneit nragnel type)
N0 4l (80A) N0 42 (40A)
UNDEF.HOOO FUSEiFELAY BOX
-
__l
23-94

-Starter Test
NOTE; The air temoerature must be between 59 and
100'F (15 and 38"C) before testing.
Recommended Procedure:
. Use a staner system tester.
. Connect and operate the equipment in accordance
with the manufacturer's instructions.
. Test and troubleshoot as described,
Alternate Procedurg:
. Use the following equipment:- Ammeter, 0 - 400 A
- Voltmeter, 0 - 20 V (accurate within 0.1 volt)
- Tachometer, 0 - 1,200 rpm
. Hook up a voltmeter and ammeter as shown.
NEGATIVETERMINAL
NOTE: After this test, or any subsequent repair. reset
the ECM/PCM to clear any codes (see section l1)
Check the Start€r Engagemont:
1. Remove the No. 44 (15 A) fuse from the under-hood
fuse/relay box,
2. Turn the ignition switch to START (llll with the shift
lever in E or E position (rVT) or with the clutch pedal
depressed {M/T). The starter should crank the engine.
. lf the starter does not crank the engine, go to
step 3.
. lf itcranksthe engineerraticallyortooslowly, go
to "Check for Wear and Damage" on the next
page.
Check the battery. battery positive cable, ground,
starter cut relay, and the wire connections for loose-
ness and corrosion, Test again.
lf the starter still does not crank the engine, go to
step 4,
Unplug the connector (BLK,/WHT wire and solenoid
terminal) from the starter,
Connect a jumper wire from the battery positive (+)
terminal to the solenoid terminal.
The starter should crank the engine.
. lf the starter still does not crank the engine,
remove it, and diagnose its internal problem
. lf the startercranksthe engine, goto step 6.
Check the ignition switch (see page 23-891.
Check the starter cut relay and clutch interlock switch
(see page 23-86,87).
Check the A/f gear position switch (see page 23-154).
Check for an open in the wire between the ignition
switch and starter.
7.
(cont'd)
23-95
9.

Starting System
Starter Test lcont'dl
Ch€ck tor Wear and Damage
The starter should crank the engine smoothly and
steadily, lf the starter engages. but cranks the engine
erratically, remove it, and inspect the starter drive gear
and torque converter or flywheel ring gear for damage.
. Check the drive gear overrunning clutch for binding
or slipping when the armature is rotated with the
drive gear held,- lf damaged. replace the gears.
Check Cranking Voltsge and Curr€nt Draw
Cranking voltage should be no less than 8.5 volts.
Current draw should be no more than 350 amperes.
lf cranking voltage is too low, or current draw too high,
check for;
. dead or low batterv.
. open circuit in starter armature commutator seg-
ments,
. starter armature dragging.
. shorted armature winding.
o excessive drag in engine.
Check Cranking rpm
Engine speed during cranking should be above 100 rpm,
lf speed is too low, check for:
. loose battery or stanerterminals.
. excessively worn starter brushes,
. open circuit in commutator segments.
o dirty or damaged helical spline or drive gear.
. defective drive gear overrunning clutch.
Check Siarter Disengag€ment
With the shift lever in El or @ position (A/T) or with the
clutch pedal depressed (M/T), turn the ignition switch to
START (lll), and release to ON (ll).
The starter drive gear should disengage from the torque
converter or flywheel ring gear when you release the
Key.
lf the drive gear hangs up on the torque converter or fly-
wheel ring gear, check for:
. solenoid plunger and switch malfunction,
. dirty drive gear assembly or damaged overrunning
clutch.
Starter Solenoid Test
1. Check the hold-in coil for continuitv between the S
terminal and the armature housing (ground). The
coil is OK if there is continuitv,
ARMATUREHOUSING(GROUND)
S TERMINAL
M TERMINAL
B TERMINAL
STARTERCAELE B TERMINALMOUNTING NUTI N.m {0.9 kgf.m,7 tbf.ft)
Check the pull-in coil for continuity between the S
and M terminals. The coil is OK if there is continuity.

Starting System
Starter Replacement
1.Make sure you have the anti-theft code for the
radio, then write down the frequencies for the
radio's preset buttons ('99 - 00 models).
Disconnect the battery negative cable.
Disconnect the starter cable from the B terminal on
the solenoid, then disconnect the BLK trHT wire
from the S terminal.
MOUNTING BOLT44 N.m l/t.s kgf.m. 32 lbf.ft)
S TERMINAL
MOUNTING BOLT6,1 N.m {4.5 kstm.32lbtftl
MOUNTING NUT9 N,m {0.9 kgl.m,6.s lbtftl
B TERMINAL
4. Remove the two bolts holding the starter, then
remove the starter.
lnstall in the reverse order of removal.
NOTE: When installing the staner cable, make sure
that the crimped side ofthe ring terminal is facing out.
TERMINAL
Connect the battery positive cable and negative cable
to the battery.
Enter the anti-theft code for the radio, then enter the
customer's radio station presets ('99 - 00 models).
7.
Crimped side of ring
23-100
Starter Reassembly
'1. Pry back each brush spring with a screwdriver, then
position the brush about halfway out of its holder.
and release the spring to hold it there.
Install the armature in the housing. Next, pry back
each brush spring again, and push the brush down
until it seats against the commutator, then release
the spring against the end of the brush.
aw
3. Install the end cover on the brush holder.
ERUSH HOLDER

-Performance Test
NOTE: Before staning the following checks. disconnect
the wire from terminal M. and make a connection as
described below using as heavy a wire as possible (prefer-
ably equivalent to the wire used for the car).
Pull-in CoilTest:
Connect the battery as shown, lf the staner pinion pops
out. it is working proPerly.
CAUTION: Do not leavo tho batterv connost€d for more
than 10 seconds.
Hold-in Coil Test:
Disconnect the battery from the M terminal' lf the pinion
does not retract, the hold-in coil is working properly.
CAUTION: Do not loavc lhe battsry connected for mot6
than 10 ssconds.
Retracting Tosi:
Disconnect the battery also from the body. lf the pinion
retracts immediately, it is working properly.
GAUTION: Do not loave the baftery conn€ctod tor more
than 10 seconds.
Startor No-load Tost:
Clamp the starter firmly in a vise.
Connect the starter to the battery as described in
the diagram below, and confirm that the motor
starts and keeps rotating.
1.
3, lf the electric current and motor speed
specifications when the battery voltage is
the starter is working ProPerly.
Specifications:
80 A or less (Electric current),2,600 rpm or more
(Motor-speed)
meet the
at 11.5 V,
23-101

(A,4)
A,T GEARPosrfloN swlrcH _ _(Closed h posilon l?l ot [!l )
BLU/BLK -> [h'#f- |COMEINATIONLIGHT SWITCH
V
IREO/GRN
UNDEF.DASH FUSEi RELAY BOX
a
E
YEL
I
A iEi,I,B"'T
vll".i,l
| ,rr.nrorro .orrro, ,*,,
tt-
t(
rffi
|
BEMI\DEB crqcurl
lm
| /t I
tffinEoTsru REDTBLU BLIJ/RED clnculr
-neoieru | ,,-,r.0 J
l, "ulTo
/fP /Itr\
YVI onrveqs I or rtor
l3fifl&''' l5frl'.'
l (3'&T' 8iytr") l
(3&Y fiti'fJ"fl )
BLK BLK
TT
c552 G401
I
. BRAKE FLUIDLEVEL SWITCH. PARKING ERAKEswrTcH (usA)
' CEILING LIGHT. KEYLESS RECE VER CIRCUIT(ln lhe audio unil")
..aorr,rro Y
A
Iu$ut,""'
I3fif'3#3trr,)-::
DRIVER'SDOOFswtTcHfolosed : Door open )(Open :Doordosed/
STARTERCUT FELAY
a
-
GFNi RED
23-157

Integrated Gontrol Unit
Input Test (cont'dl
A8--------.--all
Key-in/Seat Belt R€mind€r, Lights-on Reminder Systom:
Cavity WireTest condhion
Bulb Check System (Brako System Light):
Cavity WireTest condilion
Tost: D€sirod r€guh
T6st: Dosirad result
Possible cause if result is not obtained
Possibls cause if rasuft b not obtainod
A8
Combination light
switch ON
Check for voltage to ground;
There should be battery voltage.
Blown No.30 (7.5 A)fuse in the
under-dash fuse/relay box
Faulty combination light switch
An open in the wire
B7RED/BLU
lgnition switch ON (ll),
and driver's seat belt
switch unbuckled
Check for voltage to ground:
There should be 1 V or less.
Poor ground (G552)
Faulty seat belt switch
An open in the wire
B9GRNDriver's door openCheck for voltage to ground:
There should be 1 V or less.
. Faulty driver's door switch. An open in the wire
Bl0BLU/RED
lgnition key inserted
into the ignition key
switch
Check for voltage to ground:
There should be 1 V or less.
Poor ground (G401. G402)
Faulty ignition key switch
An open in the wire
A4GRN/RED
lgnition switch ON {ll),
brake fluid reservoir
full, and parking brake
tever oown
Connect to ground: Brake system
light should come on.
Blown No.25 (7.5 Alfuse in the
under-dash fuse/relay box
Blown brake system light bulb
An open in the wire
A13BLUA/1r'HT
lgnition switch at
START (III)Check for voltage to ground:
There should be battery voltage.
Blown No.31 (7.5 A) fuse in the
under-dash fuse/relay box
Faulty starter cut relay
An open in the wire
23-160

Power Distribution Schematics
Power Distribution schematics show how power is supplied from the positive battery terminal to
various circuits in the car. Refer to the Power Distribution section to get a more detailed picture
of how power is supplied to the circuit you're working on.
From Battery to lgnition Switch, Fuses, and Relays
Individual circuit schematics begin with a fuse. The first half of Power Distribution, however,
shows the wiring "upstream" between the battery and the fuses.
CYLINDERBLOCK
tl
tlL.lt J
",-* f ]fo,o
i BATTERY
IIII
-
----------------Y-?-
ruse so I ruse as I ruse ga | ' ,s. ,a I =u. - srl ruse aai ruse qr I ruse so I ruse sr i ruse iapowEF csw FUsE Bc, \F,.n .;,cren ooon \coounc cor,r. \sun noor powrnw'NDowf50a {* .i1-;.*"1liT""fi3f* f5# fffi'*"f'* fS?'*
- - -L - - -. ... Ji - -.J.- - - -e- - -l. - - -La - J- - - I - - -
"";%,, Y rtr,' .9 l' -%,t",,vtEw47 I ! See Power Dastribution,w - vH-,alr. lt - pages 10,10and 10-11.
' I ---il 9,1?-l--4F--?-
i I
t.urr, 'rrr.,
t i!?'.,,?"" t::=. l ty::.1----.-
-
i
a I r(op-B) .{Noru3€d) J$ifl#ii Jtocl }3fo**."".o'
t -L - - -L - - -: rJ:e'- - -Ei s+s-r -.Fl-J-Jrr.-.
It-STARTER | !Pase 21 ! t FUSE 31I "rn*i
I f
*
i.Jr;-t
i L_i***'" iL-------J
ilr------!
FUSE /I4 ' FUSE 47 ' FUSE 5{' ' FUSE 51' FUSE 52
rlr
OOOB \COOLING CON. \SUN BOOF FOWER
t3f* f5# fffi*" f'* fs?'*
See Power Dastribution,pages 10'10 and 10-11.
T101
34
ALK
4
GAN
I
I
I
I
I\
\I
I
I
FUSE 8DF POWEF SEAT204
FUSE 6ECU204
FUSE 5A/C CLUICH(FN HEATEDSEAD204
C901 C921 {NotPHoro zz OPTION Used)v/EW22 CONNECTOBSee Power Distnbution, page 10-2.
1
FUSE 4
FADIO104
c901
vlEw22
FUSE 12(BUltNrrGLIGHT)
FUSE 19R/C MIRROF
YEL
7
i-f,r-- 't PowERI uon- I Wlt{DOWi racrs i RELAY. t P^da 1tL-J P;dr1ii-
FUSE 3CONOENSEF FAN RELAYCOOLING FAN RELAY
To Fuses 17, 18, 21,and 24, for details,see Power Windowspage 120.a
ll
ll
ALTER-NATORPage 22
f102
c330
See Power Distribution, pages 10-4 and 10-5.

Fuse/Relay Information lcont'd)
- Under-hood Fuse/Relay Box
Front View
T'102(To engine wire harness)
LO
T1Oo starter cables)
*: Not Used
Rear View
c353To main wire harness
DE
tr
tr
tr
t-l
IJ
n
tJ
t-l51
IJ
n
IJ
n5T
IJ
[[o main wire harness)
6-4
ffo main wire harness)fto main wire harness)

Power Distribution
- From Battery to lgnition Switch, Fuses, and Relays
STARTERPage 21,21-1, ot 21-2
.d1.ro"rr" i
I lsoLENorD I
FUSE 42tG1
BATTERY
To UndeFhood ABSFuse/RelayBox onpage 10-14.
FUSE 47EACK UP
T1
FUSE 41AATTEiY&A
I OETECTOR (ELD) UNIT
tii::.':
UO
PHOfO U
,
I
I
I
t.------J
ELECTRICAL LOAD
i--i rL---- J ELKml
!" Gl
FUSE 4e
0ro{ Urod)FUSE '13Ir|]EAtOAUGHT?.:ta
FUSE 46POWEaWll'IDOW
FUSE /t4
r| E/M1{rA204 (DrGa5)
FUS€ 48TtEADL|a}fT9|'A
FUSE 50NEAAOEFOCGER304
+------, f| ',
I ruse sr I oooa I
J LOC|( uNrr \
il-.4WHT/BLK
Itr '\
\
I
I
I
c352
vlEW 27
c415Se€ Pow€r Distribution,pag6s 10-10 and 10-11.See Power Distribution,page 10-12.
I
\
L------BLK/VI/HT
1
--------Jc415
Vehiclespre-wired foraccessorysecuritysystem
c913PHOTO 6A
FUSE 16AR DEFFEIAY
FUSE 17HEATEA!'/C FEIAY
FUSE 18{RUNNINOL|GHlFET.AY)7.54
FUSE 27CIGAFETTEL|oHTEAACC SOCKET ta
arse ra fBADIO \
?o?"* \15A ('94 raodcr)
ff".acc0)
llL--------J
See Power Distribution,pages 10-8 and 10-9.
STARTERCUT RELAYPage 21-2
P/lolo 135 (99 00)
See PowetDistribution,page 10-7.
Vehicles pre-wired for acces-sory security system
To Fuse 3'|, for delails, see StartrnqSystem, page 21,21-1 , ot 21-2. -
10