engine HONDA CIVIC HYBRID 2004 7.G Repair Manual

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The tow
truck uses two pivoting arms that go
under the tires (f ront or rear) and lif t
them of f the ground. The other two
tires remain on the ground. If your vehicle needs to be towed,
call a prof essional towing service or
organization. Never tow your vehicle
with just a rope or chain. It is very
dangerous.
The operator
loads your vehicle on the back of a
truck. With the f ront wheels on the ground,
it is best to tow the car no farther
than 50 miles (80 km), and keep the
speedbelow35mph(55km/h).
If your vehicle is equipped with a
f ront spoiler, remove it bef ore
towing so it is not damaged.
Therearetwowaystotowyour
vehicle.
If , due to damage, your vehicle must
be towed with the f ront wheels on
the ground, do the f ollowing:
Release the parking brake.
Shif t the transmission to Neutral.
Release the parking brake.
Start the engine.
ShifttoD,thentoN.
Turn of f the engine.
5-speed Manual Transmission:
Automatic Transmission (CVT):
Wheel-lif t Equipment
Flat -bed Equipment
T his is
an acceptable way to tow your
Honda. This is the best way to trans-
port your Honda.
Emergency T owing
T aking Care of t he Unexpect ed199
NOTICE:
NOTICE: Improper towing preparation
will damage the transmission. Follow
the above procedure exactly. If you
cannot shif t the transmission or start
the engine (automatic transmission),
your vehicle must be transported with
the f ront wheels of f the ground.
Trying to lif t or tow your
vehicle by the bumpers will cause
serious damage. The bumpers are not
designed to support the vehicle’s weight.

The Vehicle Identif ication Number
(VIN) is the 17-digit number your
Honda dealer uses to register your
vehicle f or warranty purposes. It is
also necessary f or licensing and
insuring your vehicle. The easiest
placetofindtheVINisonaplate
fastened to the top of the dashboard.
Youcanseeitbylookingthrough
the windshield on the driver’s side. It
is also on the Certification label at-
tached to the driver’s doorjamb, and
is stamped on the engine com-
partment bulkhead. The VIN is also
provided in bar code on the
Certif ication label. Your vehicle has several identif ying
numbers in various places.
Identif ication Numbers
T echnical Inf ormation202
VEHICLE IDENTIFICATION NUMBERCERTIFICATION LABEL

The Engine Number is stamped into
the engine block.
The Transmission Number is on a
label on top of the transmission.
The IMA Motor Number is stamped
on the motor housing.
Identif ication Numbers
T echnical Inf ormation203
ENGINE NUMBER
TRANSMISSION
NUMBER IMA MOTOR
NUMBER

Î
Î
Î
Î
T echnical Inf ormation
Specif ications
204
Dimensions
Weights
EngineCapacities
174.8 in (4,440 mm)
67.5 in (1,715 mm)
56.3 in (1,430 mm)
103.1 in (2,620 mm)
57.9 in (1,470 mm)
57.9 in (1,470 mm)
2.87 x 3.15 in (73.0 x 80.0 mm) 82 cu-in (1.339 cm
)
10.8 13.2 US gal (50
)
11.9 US gal (45)
1.08 US gal (4.1
)
1.06 US gal (4.0)
1.37 US gal (5.2
)
1.35 US gal (5.1)
3.4 US qt (3.2
)
3.2 US qt (3.0)
4.0 US qt (3.8)
1.6 US qt (1.5)
1.7 US qt (1.6)
3.4 US qt (3.2)
5.7 US qt (5.4)
4.8 US qt (4.5
)
2.6 US qt (2.5)
0.11 US gal (0.4
)
Length
Width
Height
Wheelbase
Track
Gross vehicle weight rating See the certification label attached
to the driver’s doorjamb.
Type
BorexStroke
Displacement
Compression ratio
Spark plugs Water cooled 4-stroke SOHC VTEC
4-cylinder gasoline engine
IFR5G-11K
SK16PR-L11 Fuel tank
Engine
coolant
Engine oil
Automatic
transmission
fluid (CVT)
Including the coolant in the reserve tank and that remaining in the
engine.
Reserve tank capacity:
Excluding the oil remaining in the engine.
Front
Rear
Approx.
1:
2:
(NGK)
(DENSO) ULEV
AT-PZEV
Change Manual
CVT
Total Manual
CVT
Change
Without filter
Total
Change
Total
Change
Total
U.S. Vehicles
Canada Vehicles
Manual trans-
mission fluid Including filter
Windshield
washer reservoir
1
2

Î
ÎThe United States Clean Air Act
sets standards f or automobile
emissions. It also requires that
automobile manufacturers explain to
owners how their emissions controls
workandwhattodotomaintain
them. This section summarizes how
the emissions controls work.
Scheduled maintenance is on page . As gasoline evaporates in the f uel
tank, an evaporative emissions
control canister f illed with charcoal
adsorbs the vapor. It is stored in this
canister while the engine is of f . Af ter
the engine is started and warmed up,
the vapor is drawn into the engine
and burned during driving.
The Onboard Ref ueling Vapor
Recovery (ORVR) system captures
the f uel vapors during ref ueling. The
vapors are adsorbed in a canister
f illed with activated carbon. While
driving, the f uel vapors are drawn
into the engine and burned of f .
In Canada, Honda vehicles comply
with the Canadian Motor Vehicle
Saf ety Standards (CMVSS) f or
Emissions valid at the time they are
manuf actured.
The burning of gasoline in your
vehicle’s engine produces several by-
products. Some of these are carbon
monoxide (CO), oxides of nitrogen
(NOx) and hydrocarbons (HC).
Gasoline evaporating f rom the tank
also produces hydrocarbons. Con-
trolling the production of NOx, CO,
and HC is important to the environ-
ment. Under certain conditions of
sunlight and climate, NOx and HC
react to f orm photochemical ‘‘smog.’’
Carbon monoxide does not contri-
bute to smog creation, but it is a
poisonous gas.
Your vehicle has a Positive
Crankcase Ventilation System. This
keeps gasses that build up in the
engine’s crankcase f rom going into
the atmosphere. The Positive Crank-
case Ventilation valve routes themfrom the crankcase back to the
intake manif old. They are then
drawn into the engine and burned.
145
Crankcase Emissions Control
System Evaporative Emissions Control
System
Onboard Ref ueling Vapor
Recovery
The Clean Air Act
Emissions Cont rols
T echnical Inf ormation208

The emissions control systems are
designed and certif ied to work to-
gether in reducing emissions to
levels that comply with the Clean Air
Act. To make sure the emissions
remain low, you should use only new
Honda replacement parts or their
equivalent f or repairs. Using lower
qualitypartsmayincreasethe
emissions f rom your vehicle.
The emissions control systems are
covered by warranties separate from
the rest of your vehicle. Read your
warranty manual f or more informa-
tion.
The exhaust emissions controls
include f our systems: PGM-FI,
Ignition Timing Control, Exhaust
Gas Recirculation and Three Way
Catalytic Converter. These four
systems work together to control the
engine’s combustion and minimize
the amount of HC, CO, and NOx that
comes out the tailpipe. The exhaust
emissions control systems are
separate f rom the crankcase and
evaporative emissions control
systems.
The PGM-FI System uses sequential
multiport f uel injection.
It has three subsystems: Air Intake,
Engine Control, and Fuel Control.
The Engine Control Module (ECM)
uses various sensors to determine
how much air is going into the
engine. It then controls how much
f uel to inject under all operating con-
ditions. This system constantly adjusts the
ignition timing, reducing the amount
of HC, CO, and NOx produced.
The Exhaust Gas Recirculation
(EGR) system takes some of the
exhaust gas and routes it back into
the intake manif old. Adding exhaust
gas to the air/f uel mixture reduces
the amount of NOx produced when
the f uel is burned.
The three way catalytic converter is
in the exhaust system. Through
chemical reactions, it converts HC,
CO, and NOx in the engine’s exhaust
to carbon dioxide (CO ), nitrogen
(N ), and water vapor.
2
2
Exhaust Emissions Controls Replacement Parts
PGM-FI Syst emIgnit ion T iming Cont rol Syst em
Exhaust Gas Recirculat ion (EGR)Syst em
Three Way Catalytic Converter
Emissions Cont rols
T echnical Inf ormation209

The three way catalytic converter
contains precious metals that serve
as catalysts, promoting chemical
reactions to convert the exhaust
gasses without af f ecting the metals.
The catalytic converter is ref erred to
as a three-way catalyst, since it acts
on HC, CO, and NOx. A replacement
unit must be an original Honda part
or its equivalent.
The three way catalytic converter
must operate at a high temperature
for the chemical reactions to take
place. It can set on f ire any com-
bustible materials that come near it.
Parkyourvehicleawayfromhigh
grass, dry leaves, or other f lamma-
bles.A defective three way catalytic
converter contributes to air pollution,
and can impair your engine’s per-
f ormance. Follow these guidelines to
protect your vehicle’s three way
catalytic converter.
Always use unleaded gasoline.
Even a small amount of leaded
gasoline can contaminate the
catalyst metals, making the three
way catalytic converter inef f ective. Keep the engine tuned-up.
Have your vehicle diagnosed and
repaired if it is misf iring, back-
f iring, stalling, or otherwise not
running properly.
Three Way Catalytic Converter
T echnical Inf ormation210
THREE WAY CATALYTIC CONVERTER

Make sure the gas tank is nearly,
but not completely, f ull (around
3/4).
Make sure the ambient
temperature is between 20° and
95°F.Without touching the accelerator
pedal, start the engine, and let it
idle f or 20 seconds.
If you take your vehicle f or a state
emissions test shortly af ter the
battery has been disconnected or
gone dead, it may not pass the test.
This is because of certain ‘‘readiness
codes’’ that must be set in the on-
board diagnostics f or the emissions
systems. These codes are erased
when the battery is disconnected,
and set again only after several days
of driving under a variety of
conditions. If the testing f acility determines that
the readiness codes are not set, you
will be requested to return at a later
date to complete the test. If you must
get the vehicle re-tested within the
next two or three days, you can
condition the vehicle for re-testing
by doing the f ollowing.
Make sure the vehicle has been
parked with the engine of f f or 8
hours or more. Keep the vehicle in Park
(automatic transmission) or
Neutral (manual transmission).
Increase the engine speed to 2,000
rpm and hold it there until the
temperature gauge rises to at least
1/4of thescale(approximately3
minutes).
CONT INUED
T esting of Readiness Codes
St at e Emissions T est ing
T echnical Inf ormation211

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#
) This manual covers maintenance and recommended
procedures f or repair to engine and chassis components.
It is written f or the journeyman mechanic, but is simple
enough f or most mechanically-inclined owners to under-
stand.
This manual describes the procedures involved in the
replacement of damaged body parts. This manual complements the Service Manual by
providing in-depth troubleshooting inf ormation f or each
electrical circuit in your vehicle.
Authorized Manuals
Service Manual:
Electrical T roubleshooting Manual:
Body Repair Manual:
218
NOTE: Dealers and Companies please provide dealer or company name,
and also the name of the person to whose attention the shipment should
be sent. For purchases outside U.S.A. please write to the address shown
below for a quotation.
P.O. BOX 07280·DETROIT, MICHIGAN 48207·1-800-782-4356
Customer Name Attention
Apartment Number
State & Zip Code
City
Daytime Telephone Number
Check or money order enclosed payable to Helm Inc U.S. funds only.
Do not send cash
Master
Card VISA
Check here if your billing address is different
from the shipping address shown above.
Account Number Expiration: Mo. Yr.
CUSTOMER SIGNATURE DATE
Street Address No P.O. Box Number
()
These Publications cannot be returned for credit without receiving advance authorization within 14
days of delivery. On returns, a restocking fee may be applied against the original order.

CONT INUED
....................................
Accessories .121
ACCESSORY (Ignition Key .......................................
Position) .72
...............
Accessory Power Socket . 85
....................
Additives, Engine Oil . 153
.............................
Airbag (SRS) .10, 22
...
Airbags, Additional Information . 22
...
Additional Safety Precautions . 28
.............................
Airbag Service .28
How the Side Airbag Cutof f ......................
Indicator Works .27
..
How the SRS Indicator Works . 26
How Your Front Airbags .........................................
Work .22
...
How Your Side Airbags Work . 25
........................
SRS Components .22
................
Air Conditioning System . 88
.......................
Air Pressure, Tires .170
..................
High Speed Driving . 170
.........................
Normal Driving .170
......................................
Antif reeze .155
Anti-lock Brakes (ABS) ...............................
Indicator .54, 141
...................................
Operation .141 ..............
Anti-thef t, Audio System . 107
Anti-thef t Steering Column ..............................................
Lock .72
..................................
Audio System .94
........................
Auto Idle Stop .131, 137
...
Automatic Seat Belt Tensioners . 20
.............
Automatic Speed Control . 109
..............
Automatic Transmission . 133
..........................
Capacity, Fluid .204
...............
Checking Fluid Level . 158
.......................................
Shif ting .133
.
Shif t Lever Position Indicator . 133
................
Shif t Lever Positions . 133
....................
Shif t Lock Release . 136
Battery Charging System ...........................
Indicator .54, 191
............................
Jump Starting .186
..............................
Maintenance .175
............................
Specif ications .205
..............................
Bef ore Driving .113
....................................
Belts,Seat .8,19
.............................
Beverage Holder .85 ..................................
Booster Seats .43
Brakes ...........
Anti-lock System (ABS) . 141
.............
Break-in, New Linings . 114
....................
Bulb Replacement .161
...........................................
Fluid .160
.........................................
Parking .82
.................
System Indicator . 54,193
........................
Wear Indicators .140
.............................
Braking System .140
.................
Break-in, New Vehicle . 114
..
Brightness Control, Instruments . 67
........................
Brights, Headlights .66
Bulb Replacement ..........................
Back-up Lights .165
..............................
Brake Lights .164
................
Front Parking Lights . 163
........
Front Side Marker Lights . 163
.................................
Headlights .161
.........
High-mount Brake Light . 165
.........
Rear Side Marker Lights . 164
............................
Specif ications .205
Bulb Replacement ....................
Turn Signal Lights . 163
..............................
Bulbs, Halogen .161
Index
A
B
I