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SERVICE

MANUAL
CIVIC
CIVIC 4/5D
MAINTENANCE, REPAIR &
CONSTRUCTION 01
How to Use This Manual

How to Use This Manual


This manual is divided into 23 sections. The first page of General Info
each section is marked with a black tab that lines up with its Specifications
corresponding thumb index tab on this page. Maintenance
You can quickly find the first page of each section without Engine Electrical
looking through a full table of contents. The symbols printed
Engine
at the top corner of each page can also be used as a quick
reference system. Cooling
Each section includes: Fuel and Emissions
1. 1. A table of contents, or an exploded view index *Transaxle
showing: *Steering
Parts disassembly sequence. Suspesion
Bolt torques and thread sizes.
*Brakes (Including ABS)
Page references to descriptions in text.
2. 2. Disassembly/assembly procedures and tools. * Body
3. Inspection. *Heating, Ventilation and Air Conitioning
4. Testing/troubleshooting. * Body Electrical
5. Repair.
*Restraints
6. Adjustments.

Safety Messages
Your safety and the safety of others, is very important. To help
you make informed decisions, we have provided safety
messages and other safety information throughout this
manual. Of course, it is not practical or possible to warn you
about all the hazards associated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms
including:
Safety Labels - on the vehicle.
Safety Messages - preceded by a safety alert
symbol and one of three signal words,
DANGER, WARNING or CAUTION.
These signal words mean:

DANGER
You WILL be KILLED or SERIOUSLY HURT if you do
not follow instructions.

WARNING
You CAN be KILLED or SERIOUSLY HURT if you do
not follow instructions.

CAUTION
You CAN be HURT if you do not follow instructions.
Instructions - how to service this vehicle correctly
and safely.

All information contained in this manual is based on the latest


product information available at the time of printing. We
reserve the right to make changes at any time without notice.
No part of this publication may be reproduced, stored in
retrieval system, or transmitted, in any form by any means,
electronic, mechanical, photocopying, recording, or otherwise,
without the prior written permission of the publisher. This
includes text, figures and tables.
How to Use This Manual

As you read this manual, you will find information that is


preceded by a symbol. The purpose of this
message is to help prevent damage to your vehicle, other
property, or the environment.
First Edition 7/2000 2494 HONDA MOTOR CO.,LTD.
pages
All Rights Reserved Service Publication
Office

As sections with *include SRS components;


special precautions are required when servicing.
A Few Words about Safety

IMPORTANT SAFETY PRECAUTIONS


A Few Words about Safety
Service Information

The service and repair information contained in this manual is Make sure you have a clear understanding of all
intended for use by qualified, professional technicians. basic shop safety practices and that you are wearing
Attempting service or repairs without the proper training, tools, appropriate clothing and using safety equipment.
and equipment could cause injury to you or others. It could When performing any service task, be especially
also damage the vehicle or create an unsafe condition. careful of the following:
This manual describes the proper methods and procedures for Read all of the instructions before you begin, and
performing service, maintenance and repairs. Some procedures make sure you have the tools, the replacement or
require the use of specially designed tools and dedicated repair parts and the skills required to perform the
equipment. Any person who intends to use a replacement part, tasks safely and completely.
service procedure or a tool that is not recommended by Honda, Protect your eyes by using proper safety glasses,
must determine the risks to their personal safety and the safe goggles or face shields any time you hammer, drill,
operation of the vehicle. grind, or work around pressurised air or liquids, and
springs or other stored-energy components. If there
If you need to replace a part, use genuine Honda parts with
is any doubt, put on eye protection.
the correct part number or an equivalent part. We strongly
Use other protective wear when necessary, for
recommend that you do not use replacement parts of inferior
example gloves or safety shoes. Handling hot or
quality.
sharp parts can cause severe burns or cuts. Before
FOR YOUR CUSTOMER'S SAFETY you grab something that looks like it can hurt you,
Proper service and maintenance are essential to the stop and put on gloves.
customer's safety and the reliability of the vehicle. Any error or Protect yourself and others whenever you have the
oversight while servicing a vehicle can result in faulty vehicle up in the air. Any time you lift the vehicle,
operation, damage to the vehicle, or injury to others. either with a hoist or a jack, make sure that it is
always securely supported. Use jack stands.
WARNING Make sure the engine is off before you begin any
Improper service or repairs can create an unsafe servicing procedures, unless the instruction tells you
condition that can cause your customer or others to do otherwise. This will help eliminate several
to be seriously hurt or killed. potential hazards:
Follow the procedures and precautions in this Carbon monoxide poisoning from engine exhaust.
manual and other service materials carefully. Be sure there is adequate ventilation whenever you
run the engine.
FOR YOUR SAFETY Burns from hot parts or coolant. Let the engine and
exhaust system cool before working in those areas.
Because this manual is intended for the professional service
Injury from moving parts. If the instruction tells you
technician, we do not provide warnings about many basic shop
to run the engine, be sure your hands, fingers, and
safety practices (e.g., Hot parts - wear gloves). If you have not
clothing are out of the way.
received shop safety training or do not feel confident about
your knowledge of safe servicing practices, we recommend that Gasoline vapours and hydrogen gases from batteries
you do not attempt to perform the procedures described in this are explosive. To reduce the possibility of a fire or
manual. explosion, be careful when working around gasoline
or batteries.
WARNING Use only a non-flammable solvent, not gasoline to
Failure to properly follow instructions and clean parts.
precautions can cause you to be seriously hurt or Never drain or store gasoline in an open container.
killed. Keep all cigarettes, sparks and flames away from
the battery and all fuel-related parts.
Follow the procedures and precautions in this
manual carefully.

Some of the most important general service safety precautions


are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and
repair procedures. Only you can decide whether or not you
should perform a given task.
Introduction - Introduction

   
Introduction
Supplemental Restraint System (SRS)

The Civic SRS includes a driver's airbag in the steering wheel hub and a passenger's airbag in the dashboard above the glove box
and seat belt tensioners in the front seat belt retractors. Information necessary to safely service the SRS is included in this Shop
Manual. Items marked with an asterisk (*) on the contents page include, or are located near, SRS components. Servicing,
disassembling or replacing these items will require special precautions and tools, and should therefore be done by an authorised
Honda dealer.

WARNING
To avoid rendering the SRS inoperative, which could lead to personal injury or death in
the event of a severe frontal collision, all SRS service work must be performed by an
authorised Honda dealer.
Improper service procedures, including incorrect removal and installation of the SRS,
could lead to personal injury caused by unintentional deployment of the airbags.
SRS electrical wiring harnesses are identified by yellow colour coding. Related
components are located in the steering column, front console, dashboard, dashboard
lower panel, and in the dashboard above the glove box. Do not use electrical test
equipment on these circuits.

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General Information - General Information

General Information

Chassis and Engine Numbers - 4-Door KE, KG, KQ Models 1-2


Chassis and Engine Numbers - 4-Door KK, KM, KP, KX 1-4
Models
Chassis and Engine Numbers - 4-Door KB, KH, KU, KV, 1-6
KW, KY Models
Chassis and Engine Numbers - 4-Door KF, KN, KT Models 1-8
Chassis and Engine Numbers - 5-Door Model 1-10
Identification Number Locations 1-12
Warning/Caution Label Locations 1-13
Lift and Support Points 1-15
Towing 1-16
Service Precautions 1-17
Abbreviations 1-24

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General Information - General Information

1-2
General Information
Chassis and Engine Numbers

4-Door KE, KG, KQ Models

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General Information - General Information

1-3
General Information
Chassis and Engine Numbers (cont'd)

Applicable Area Code/VIN/Engine Number/Transmission Number List


MODEL APPLICABLE GRADE TRANSMISSION VEHICLE ENGINE TRANSMISSION
AREA CODE NAME TYPE IDENTIFICATION NUMBER NUMBER
NUMBER
CIVIC KE 1.4S 5MT JHMES45301S200001- D14Z5- SLW-1000001-
1000001-
4AT JHMES46301S200001- D14Z5- SLXA-1000001-
1000001-
1.6SE 5MT JHMES55401S200001- D16W7- SLW-1000001-
1000001-
4AT JHMES56401S200001- D16W7- SLXA-1000001-
1000001-
KG 1.4S 5MT JHMES45301S200001- D14Z5- SLW-1000001-
1000001-
4AT JHMES46301S200001- D14Z5- SLXA-1000001-
1000001-
1.6LS 5MT JHMES55401S200001- D16W7- SLW-1000001-
1000001-
4AT JHMES56401S200001- D16W7- SLXA-1000001-
1000001-
5MT JHMES55501S200001- D16W7- SLW-1000001-
1000001-
4AT JHMES56501S200001- D16W7- SLXA-1000001-
1000001-
1.6ES 5MT JHMES55701S200001- D16W7- SLW-1000001-
1000001-
4AT JHMES56701S200001- D16W7- SLXA-1000001-
1000001-
5MT JHMES55901S200001- D16W7- SLW-1000001-
1000001-
4AT JHMES56901S200001- D16W7- SLXA-1000001-
1000001-
KQ GLI 5MT JHMES15501S200001- D17Z1- SLW-1000001-
1000001-
4AT JHMES16501S200001- D17Z1- SLXA-1000001-
1000001-
VTI 5MT JHMES15901S200001- D17A2- SLW-1000001-
1000001-
4AT JHMES16901S200001- D17A2- SLXA-1000001-
1000001-
5MT JHMES15001S200001- D17A2- SLW-1000001-
1000001-
4AT JHMES16001S200001- D17A2- SLXA-1000001-
1000001-

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General Information - General Information

1-4
General Information
Chassis and Engine Numbers (cont'd)

4-Door KK, KM, KP, KX Models

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1-5
General Information
Chassis and Engine Numbers (cont'd)

Applicable Area Code/VIN/Engine Number/Transmission Number List


MODEL APPLICABLE GRADE TRANSMISSION VEHICLE ENGINE TRANSMISSION
AREA CODE NAME TYPE IDENTIFICATION NUMBER
NUMBER NUMBER
CIVIC KK DX 5MT JHMES85101S200001- D15Y5- SLW-1000001-
1000001-
4AT JHMES86101S200001- D15Y5- SLXA-1000001-
1000001-
5MT JHMES85201S200001- D15Y5- SLW-1000001-
1000001-
4AT JHMES86201S200001- D15Y5- SLXA-1000001-
1000001-
LX 5MT JHMES15501S200001- D17A1- SLW-1000001-
1000001-
4AT JHMES16501S200001- D17A1- SLXA-1000001-
1000001-
5MT 1HGES15501L500001- D17A3- SLW-1000001-
1400001-
4AT 1HGES16501L500001- D17A3- BMXA-5000001-
1400001-
5MT 2HGES155*1H750001- D17A3- SLW-1000001-
1400001-
4AT 2HGES165*1H750001- D17A3- BMXA-5000001-
1400001-
EX 5MT JHMES15701S200001- D17A2- SLW-1000001-
1000001-
4AT JHMES16701S200001- D17A2- SLXA-1000001-
1000001-
5MT 1HGES15701L500001- D17A4- SLW-1000001-
1400001-
4AT 1HGES16701L500001- D17A4- BMXA-5000001-
1400001-
5MT 2HGES157*1H750001- D17A4- SLW-1000001-
1400001-
4AT 2HGES167*1H750001- D17A4- BMXA-5000001-
1400001-
KM LX-B 5MT 93HES15301Z000001- D17A3- SLW-1000001-
1400001-
LX 5MT 93HES15501Z000001- D17A3- SLW-1000001-
1400001-
4AT 93HES16501Z000001- D17A3- BMXA-5000001-
1400001-
EX 5MT 93HES15801Z000001- D17A4- SLW-1000001-
1400001-
4AT 93HES16801Z000001- D17A4- BMXA-5000001-
1400001-
KP LX 5MT 93HES15501Z000001- D17A3- SLW-1000001-
1400001-
4AT 93HES16501Z000001- D17A3- BMXA-5000001-
1400001-
EX 5MT 93HES15801Z000001- D17A4- SLW-1000001-

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General Information - General Information

1400001-
4AT 93HES16801Z000001- D17A4- BMXA-5000001-
1400001-
KX LX 5MT IHGES15501L900001- D17A3- SLW-1000001-
1400001-
4AT IHGES16501L900001- D17A3- BMXA-5000001-
1400001-
EX 5MT IHGES15701L900001- D17A4- SLW-1000001-
1400001-
4AT IHGES16701L900001- D17A4- BMXA-5000001-
1400001-

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General Information - General Information

1-6
General Information
Chassis and Engine Numbers (cont'd)

4-Door KB, KH, KU, KV, KW, KY Models

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General Information - General Information

1-7
General Information
Chassis and Engine Numbers (cont'd)

Applicable Area Code/VIN/Engine Number/Transmission Number List


MODEL APPLICABLE GRADE TRANSMISSION VEHICLE ENGINE TRANSMISSION
AREA CODE NAME IDENTIFICATION NUMBER NUMBER
TYPE NUMBER
CIVIC KB 1.4S 5MT JHMES45301S200001- D14Z5- SLW-1000001-
1000001-
4AT JHMES46301S200001- D14Z5- SLXA-1000001-
1000001-
1.6ES 5MT JHMES55701S200001- D16W7- SLW-1000001-
1000001-
4AT JHMES56701S200001- D16W7- SLXA-1000001-
1000001-
KH EXI 4AT JHMES86801S200001- D15Y2- SLXA-1000001-
VTI 1000001-
JHMES56801S200001- D16W8- SLXA-1000001-
1000001-
KU EXI 5MT JHMES85801S200001- D15Y6- SLW-1000001-
1000001-
4AT JHMES86801S200001- D15Y6- SLXA-1000001-
1000001-
EXI-H 5MT JHMES85801S200001- D15Y6- SLW-1000001-
1000001-
4AT JHMES86801S200001- D15Y6- SLXA-1000001-
1000001-
VHI-H 5MT JHMES85901S200001- D15Y4- SLW-1000001-
1000001-
HMM JHMES86901S200001- D15Y4- MLXA-1000001-
1000001-
VTI 5MT JHMES85901S200001- D15Y4- SLW-1000001-
1000001-
HMM JHMES86901S200001- D15Y4- MLYA-1000001-
1000001-
VTI-S 5MT JHMES15901S200001- D17A2- SLW-1000001-
1000001-
HMM JHMES16901S200001- D17A2- MLYA-1000001-
1000001-
5MT JHMES15001S200001- D17A2- SLW-1000001-
1000001-
HMM JHMES16001S200001- D17A2- MLYA-1000001-
1000001-
KV LXI 5MT JHMES853*1S400001- D15Y3- SLW-1000001-
1000001-
4AT JHMES863*1S400001- D15Y3- SLXA-1000001-
1000001-
EXI 5MT JHMES857*1S400001- D15Y3- SLW-1000001-
1000001-
4AT JHMES867*1S400001- D15Y3- SLXA-1000001-
1000001-
VTI 5MT JHMES158*1S400001- D17A5- SLW-1000001-
1000001-
4AT JHMES168*1S400001- D17A5- SLXA-1000001-

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General Information - General Information

1000001-
KW EXI 5MT JHMES85801S200001- D15Y3- SLW-1000001-
1000001-
4AT JHMES86801S200001- D15Y3- SLXA-1000001-
1000001-
KY LXI 5MT JHMES853*1S400001- D15Y3- SLW-1000001-
1000001-
4AT JHMES863*1S400001- D15Y3- SLXA-1000001-
1000001-
5MT JHMES854*1S400001- D15Y3- SLW-1000001-
1000001-
4AT JHMES864*1S400001- D15Y3- SLXA-1000001-
1000001-
EXI 5MT JHMES857*1S400001- D15Y3- SLW-1000001-
1000001-
4AT JHMES867*1S400001- D15Y3- SLXA-1000001-
1000001-
5MT JHMES858*1S400001- D15Y3- SLW-1000001-
1000001-
4AT JHMES868*1S400001- D15Y3- SLXA-1000001-
1000001-
VTI 5MT JHMES158*1S400001- D17A5- SLW-1000001-
1000001-
4AT JHMES168*1S400001- D17A5- SLXA-1000001-
1000001-
5MT JHMES159*1S400001- D17A5- SLW-1000001-
1000001-
4AT JHMES169*1S400001- D17A5- SLXA-1000001-
1000001-

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1-8
General Information
Chassis and Engine Numbers (cont'd)

4-Door KF, KN, KT Models

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1-9
General Information
Chassis and Engine Numbers (cont'd)

Applicable Area Code/VIN/Engine Number/Transmission Number List


MODEL APPLICABLE GRADE TRANSMISSION VEHICLE ENGINE TRANSMISSION
AREA CODE NAME TYPE IDENTIFICATION NUMBER NUMBER
NUMBER
CIVIC KF LXI 5MT JHMES85301S200001- D15Y3- SLW-1000001-
1000001-
4AT JHMES86301S200001- D15Y3- SLXA-1000001-
1000001-
EXI 5MT JHMES85701S200001- D15Y3- SLW-1000001-
1000001-
4AT JHMES86701S200001- D15Y3- SLXA-1000001-
1000001-
KN 150I 5MT JHMES85401S200001- D15Y3- SLW-1000001-
1000001-
4AT JHMES86401S200001- D15Y3- SLXA-1000001-
1000001-
170I 5MT JHMES15901S200001- D17A5- SLW-1000001-
1000001-
4AT JHMES16901S200001- D17A5- SLXA-1000001-
1000001-
KT LXI 5MT JHMES85301S200001- D15Y3- SLW-1000001-
1000001-
4AT JHMES86301S200001- D15Y3- SLXA-1000001-
1000001-
EXI 5MT JHMES85701S200001- D15Y3- SLW-1000001-
1000001-
4AT JHMES86701S200001- D15Y3- SLXA-1000001-
1000001-

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1-10
General Information
Chassis and Engine Numbers (cont'd)

5-Door Model

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1-11
General Information
Chassis and Engine Numbers (cont'd)

Applicable Area Code/VIN/Engine Number/Transmission Number List


MODEL APPLICABLE GRADE TRANSMISSION VEHICLE ENGINE TRANSMISSION
AREA CODE NAME TYPE IDENTIFICATION NUMBER NUMBER
NUMBER
CIVIC KE 1.4S 5MT JHMEU57201S200001- D14Z5- SLW-1000001-
1000001-
1.4LS 5MT JHMEU57401S200001- D14Z5- SLW-1000001-
1000001-
1.6S 5MT JHMEU67201S200001- D16W7- SLW-1000001-
1000001-
4AT JHMEU68201S200001- D16W7- SLXA-1000001-
1000001-
1.6LS 5MT JHMEU67401S200001- D16W7- SLW-1000001-
1000001-
4AT JHMEU68401S200001- D16W7- SLXA-1000001-
1000001-
1.6ES 5MT JHMEU67701S200001- D16W7- SLW-1000001-
1000001-
4AT JHMEU68701S200001- D16W7- SLXA-1000001-
1000001-
KQ VI 5MT JHMEU37301S200001- D17A2- SLW-1000001-
1000001-
4AT JHMEU38301S200001- D17A2- SLXA-1000001-
1000001-
VTI 5MT JHMEU37501S200001- D17A2- SLW-1000001-
1000001-
4AT JHMEU38501S200001- D17A2- SLXA-1000001-
1000001-
5MT JHMEU37701S200001- D17A2- SLW-1000001-
1000001-
4AT JHMEU38701S200001- D17A2- SLXA-1000001-
1000001-
5MT JHMEU37801S200001- D17A2- SLW-1000001-
1000001-
4AT JHMEU38801S200001- D17A2- SLXA-1000001-
1000001-
KT EXI 5MT JHMEU67401S200001- D16V2- SLW-1000001-
1000001-
4AT JHMEU68401S200001- D16V2- SLXA-1000001-
1000001-

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General Information - General Information

1-12
General Information
Identification Number Locations
1. Build Date and Vehicle Type
Except KK, KX, KY models
2. Vehicle Identification Number (VIN)
3. Engine Number
4. Transmission Number (Manual)
5. Certification Plate
(KK, KX models)
6. Certification Plate
(KY model)
7. Transmission Number (Automatic)
8. Transmission Number (Honda Multi Matic)

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General Information - General Information

1-13
General Information
Warning/Caution Label Locations
1. STEERING COLUMN NOTICE
2. PASSENGER AIRBAG CHILD SEAT
CAUTION
(KE model)
3. SRS INFORMATION
(KG, KK, KX models)
4. SRS INFORMATION
(KE, KN, KQ models)
5. PASSENGER AIRBAG CHILD SEAT
CAUTION
(KG model)
6. FRONT PASSENGER MODULE
DANGER
7. FRONT SEATBELT TENSIONER
WARNING
8. PASSENGER AIRBAG CHILD SEAT
CAUTION
(KQ model)
9. DRIVE MODULE DANGER
10. CABLE REEL CAUTION
11. MONITOR NOTICE
12. SIDE AIRBAG INFORMATION
Located on driver's and passenger's
door jamb (not shown)

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General Information - General Information

1-14
General Information
Warning/Caution Label Locations (cont'd)
1. ENGINE COOLANT INFORMATION AND SERVICE
INFORMATION
(Under-hood Emission Control Label)
2. SRS WARNING LABEL
3. AIR CONDITIONING INFORMATION
4. TYRE INFORMATION
(KQ model)
5. TYRE INFORMATION
(KE, KT models)
6. TYRE INFORMATION
(LH model)
7. RADIATOR CAP CAUTION
8. BATTERY CAUTION

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General Information - General Information

1-15
General Information
Lift and Support Points

NOTE: If you are going to remove heavy components such as Floor Jack
suspension or the fuel tank from the rear of the vehicle, first 1. 1. Block the rear wheels when raising the front of the
support the front of the vehicle with tall safety stands. When vehicle; block the front wheels when raising the rear
substantial weight is removed from the rear of the vehicle, the of the vehicle.
centre of gravity can change and cause the vehicle to tip Place the blocks behind and ahead of the wheels.
forward on the hoist. 2. 2. Raise the vehicle high enough to insert the safety
Frame Hoist stands.
1. 1. Position the hoist lift blocks (A), or safety stands, 3. Adjust and place the safety stands so the vehicle will
under the vehicle's front support points (B) and rear be approximately level, then lower the vehicle onto
support points (C). them.

2. 2. Raise the hoist a few inches and rock the vehicle


gently to be sure it is firmly supported.
Safety Stands
To support the vehicle on safety stands, use the same support
points (B and C) as for a frame hoist. Always use safety stands
when working on or under any vehicle that is supported only by
a jack.

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General Information - General Information

1-16
General Information
Towing

If the vehicle needs to be towed, call a professional towing Wheel Lift Equipment - The tow truck uses 2 pivoting arms
service. Never tow the vehicle behind another vehicle with just that go under the tyres (front or rear) and lift them off the
a rope or chain. It is very dangerous. ground. The other 2 wheels remain on the ground.
Emergency Towing Sling-type Equipment - The tow truck uses metal cables
There are 3 popular methods of towing a vehicle. with hooks on the ends. These hooks go around parts of the
frame or suspension and the cables lift that end of the vehicle
Flat-bed Equipment - The operator loads the vehicle on
off the ground. The vehicle's suspension and body can be
the back of a truck. This is the best way of transporting the
seriously damaged if this method of towing is attempted.
vehicle.
If the vehicle cannot be transported by flat-bed, it should be
To accommodate flat-bed equipment, the vehicle is equipped
towed with the front wheels off the ground. If due to damage,
with a towing hook (A) and tie down hook hooking slots (B).
the vehicle must be towed with the front wheels on the
The towing hook can be used with a winch to pull the vehicle ground, do the following:
onto the truck and the tie down hook hooking slots can be
Release the parking brake.
used to secure the vehicle to the truck.
Start the engine.
Shift to position, then position.
Turn off the engine.
It is best to tow the vehicle no farther than 50 miles (80 km),
and keep the speed below 35 mph (55 km/h).

Improper towing preparation will damage the


transmission. Follow the above procedure exactly. If
you cannot shift the transmission or start the engine
(automatic transmission), the vehicle must be
transported on a flat-bed.
Trying to lift or tow the vehicle by the bumpers will
cause serious damage. The bumpers are not
designed to support the vehicle's weight.

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General Information - General Information

1-17
General Information
Service Precautions

General Mark or place all removed parts in order in a parts


rack so they can be reassembled in their original
CAUTION places.
Observe all safety precautions and notes while
working.

Protect all painted surfaces and seats against dirt


and scratches with a clean cloth or vinyl cover.

Use the special tool when use of such a tool is


specified.

Work safety and give your work your undivided


attention. When either the front or rear wheels are to
be raised, block the remaining wheels securely.
Communicate at frequently as possible when work
involves 2 or more workers. Do not run the engine
unless the shop or working area is well ventilated.
Parts must be assembled with the proper torque
according to the maintenance standards established.
When tightening a series of bolts or nuts, begin with
the centre or large diameter bolts and tighten them in
criss-cross pattern in 2 or more steps.

Before removing or disassembling parts, they must


be inspected carefully to isolate the cause for which
service is necessary. Observe all safety notes and
precautions and follow the proper procedures as
described in this manual.

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General Information - General Information

1-18
General Information
Service Precautions (cont'd)

Use new packings, gaskets, O-rings and cotter pins Brake fluid and hydraulic components
whenever reassembling. When replenishing the system, use extreme care to
Do not reuse parts that must be required to replace. prevent dust and dirt from entering the system.
Always replace them. Do not mix different brands of fluid, as they may
not be compatible.
Do not reuse drained brake fluid.
Because brake fluid can cause damage to painted
and resin surfaces, care should be taken not to
spill it on such materials. If spilled accidentally,
quickly rinse it with water or warm water from
painted or resin surfaces.
After disconnecting brake hoses or pipes, be sure
to plug the openings to prevent loss of brake fluid.
Use genuine HONDA parts and lubricants or their Clean all disassembled parts only in clean BRAKE
equivalent. When parts are to be reused, they must FLUID. Blow open all holes and passages with
be inspected carefully to make sure they are not compressed air.
damaged or deteriorated and are in good usable Keep disassembled parts from air-borne dust and
condition. abrasives.
Check that parts are clean before assembly.

Coat or fill parts with specified grease as specified


(see page 3-2). Clean all removed parts with solvent
upon disassembly.
Avoid oil or grease getting on rubber parts and
tubes, unless specified.
Upon assembling, check every part for proper
installation and operation.

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General Information - General Information

1-19
General Information
Service Precautions (cont'd)

Electrical Troubleshooting Information Some connectors have a clip on their side used to
Before Troubleshooting attach them to a mounting bracket on the body or on
another component. This clip has a pull type lock.
1. 1. Check applicable fuses in the appropriate fuse/relay
Some mounted connectors cannot be disconnected
box.
unless you first release the lock and remove the
Check the battery for damage, state of charge and clean and
connector from its mount bracket (A).
tighten the connections.

Do not quick-charge a battery unless the battery


ground cable has been disconnected, otherwise you
will damage the alternator diodes.
Do not attempt to crank the engine with the battery
ground cable loosely connected or you will severely
damage the wiring.
Check the alternator belt tension.
Handling Connectors
Make sure the connectors are clean and have no
loose wire terminals. Never try to disconnect connectors by pulling on their
Make sure multiple cavity connectors are packed with wires; pull on the connector halves instead.
grease (except watertight connectors). Always reinstall plastic covers.
All connectors have push-down release type locks
(A).

Before connecting connectors, make sure the


terminals (A) are in place and not bent.

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General Information - General Information

1-20
General Information
Service Precautions (cont'd)

Check for loose retainer (A) and rubber seals (B). Handling Wires and Harnesses
Secure wires and wire harnesses to the frame with
their respective wire ties at the designated locations.
Remove clips carefully; do not damage their locks
(A).

The backs of some connectors are packed with


grease. Add grease if necessary. If the grease is
contaminated, replace it.

Slip pliers (A) under the clip base and through the
hole at an angle, then squeeze the expansion tabs to
release the clip.

Insert the connector all the way and make sure it is


securely locked.
Position wires so that the open end of the cover
faces down.

After installing harness clips, make sure the harness


does not interfere with any moving parts.
Keep wire harnesses away from exhaust pipes and
other hot parts, from sharp edges of brackets and
holes and from exposed screws and bolts.
Seat grommets in their grooves properly (A). Do not
leave grommets distorted (B).

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General Information - General Information

1-21
General Information
Service Precautions (cont'd)

Testing and Repairs Use a probe with a tapered tip.


Do not use wires or harnesses with broken insulation.
Replace them or repair them by wrapping the break
with electrical tape.
After installing parts, make sure that no wires are Refer to the instructions in the Honda Terminal Kit
pinched under them. for identification and replacement of connector
When using electrical test equipment, follow the terminals.
manufacturer's instructions and those described in
this manual.
If possible, insert the probe of the tester from the
wire side (except waterproof connector).

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General Information - General Information

1-22
General Information
Service Precautions (cont'd)

When checking any control module(s) or unit(s) connector terminals, gently slide the sharp tester probe from the wire side into the
connector until it comes in contact with the terminal end of the wire.
1. DIGITAL CIRCUIT TESTER
(Commercially available) or 07411-0020000
2. Any CONTROL MODULE or UNIT
3. SHARP TESTER PROBE

CAUTION
Puncturing the insulation on a wire can cause poor or intermittent electrical
connections.
For testing at connectors, bring the tester probe into contact with the terminal from
the connector side of wire harness connectors in the engine compartment. For female
connectors, just touch lightly with the tester probe and do not insert the probe.
1. RUBBER SEAL
2. TESTER PROBE
3. TERMINAL
4. WIRE HARNESS

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General Information - General Information

1-23
General Information
Service Precautions (cont'd)

5-step Troubleshooting Wire Colour Codes


1. 1. Verify The Complaint The following abbreviations are used to identify wire colours in
Turn on all the components in the problem circuit to verify the circuit schematics:
the customer complaint. Note the symptoms. Do not begin
disassembly or testing until you have narrowed down the WHT…………… White
problem area. YEL……………. Yellow
2. 2. Analyse The Schematic BLK……………. Black
Look up the schematic for the problem circuit. Determine BLU……………. Blue
how the circuit is supposed to work by tracing the current
GRN…………… Green
paths from the power feed through the circuit components to
ground. If several circuits fail at the same time, the fuse or RED……………. Red
ground is a likely cause. ORN…………… Orange
Based on the symptoms and your understanding of the PNK……………. Pink
circuit operation, identify one or more possible causes of the BRN……………. Brown
problem.
GRY…………… Grey
3. 3. Isolate The Problem By Testing The Circuit
PUR……………. Purple
Make circuit tests to check the diagnosis you made in step
2. Keep in mind that a logical, simple procedure is the key LT BLU………… Light Blue
to efficient troubleshooting. Test for the most likely cause of LT GRN……….. Light Green
failure first. Try to make tests at points that are easily
accessible. The wire insulation has one colour or one colour with another
4. 4. Fix The Problem colour stripe. The second colour is the stripe.
Once the specific problem is identified, make the repair. Be
sure to use proper tools and safe procedures.
5. 5. Make Sure The Circuit Works
Turn on all components in the repaired circuit in all modes
to make sure you have fixed the entire problem. If the
problem was a blown fuse, be sure to test all of the circuits
on the fuse. Make sure no new problems turn up and the
original problem does not recur.

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General Information - General Information

1-24
General Information
Abbreviations

List of automotive abbreviations, which may be used in shop EPR Evaporator Pressure Regulator
manual.
EPS Electrical Power Steering
ABS Anti-lock Brake System EVAP Evaporative
A/C Air Conditioning, Air Conditioner EX Exhaust
ACL Air Cleaner
A/F Air Fuel Ratio F Front
ALR Automatic Locking Retractor FIA Fuel Injection Air
ALT Alternator FL Front Left
AMP Ampere(s) FP Fuel Pump
ANT Antenna FR Front Right
API American Petroleum Institute FSR Fail Safe Relay
APPROX. Approximately FWD Front Wheel Drive
ASSY Assembly
A/T Automatic Transmission GAL Gallon
ATDC After Top Dead Centre GND Ground
ATF Automatic Transmission Fluid GPS Global Positioning System
ATT Attachment
ATTS Active Torque Transfer System H/B Hatchback
AUTO Automatic HC Hydrocarbons
AUX Auxiliary HID High Intensity Discharge
HO2S Heated Oxygen Sensor
BARO Barometric
BAT Battery IAB Intake Air Bypass
BDC Bottom Dead Centre IAC Idle Air Control
BTDC Before Top Dead Centre IACV Idle Air Control Valve
IAR Intake Air Resonator
CARB Carburettor IAT Intake Air Temperature
CAT Catalytic Converter ICM Ignition Control Module
or CATA ID Identification
CHG Charge ID or I.D. Inside Diameter
CKF Crankshaft Speed Fluctuation IG or IGN Ignition
CKP Crankshaft Position IMA Idle Mixture Adjustment
CO Carbon Monoxide Integrated Motor Assist
COMP Complete IMMOBI. Immobilizer (Immobiliser)
CPB Clutch Pressure Back up IN Intake
CPC Clutch Pressure Control INJ Injection
CPU Central Processing Unit INT Intermittent
CVT Continuously Variable Transmission
CYL Cylinder KS Knock Sensor
CYP Cylinder Position
L Left
DI Distributor Ignition L/C Lock-up Clutch
DIFF Differential LCD Liquid Crystal Display
DLC Data Link Connector LED Light Emitting Diode

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General Information - General Information

1-25
General Information
Abbreviations (cont'd)

MAP Manifold Absolute Pressure SPEC Specification


MAX. Maximum S/R Sun Roof
MBS Mainshaft Brake System SRS Supplemental Restraint System
MCK Motor Check STD Standard
MCU Moment Control Unit SW Switch
MIL Malfunction Indicator Lamp
MIN. Minimum T Torque
MPI Multi Point Injection TB Throttle Body
M/S Manual Steering T/B Timing Belt
M/T Manual Transmission TC Torque Converter
TCM Transmission Control Module
N Neutral TCS Traction Control System
Nox Oxides of Nitrogen TDC Top Dead Centre
TFT Thin Film Transistor
OBD On-board Diagnostic T/N Tool Number
O2S Oxygen Sensor TP Throttle Position
OD or O.D. Outside Diameter TWC Three Way Catalytic Converter

P Park VC Viscous Coupling


PAIR Pulsed Secondary Air Injection VIN Vehicle Identification Number
PCM Powertrain Control Module VSS Vehicle Speed Sensor
PCV Positive Crankcase Ventilation VTEC Variable Valve Timing & Lift Valve Electronic
Proportioning Control Valve Control
PDU Power Drive Unit VVIS Variable Volume Intake System
PGM-FI Programmed-fuel Injection
PGM-IG Programmed Ignition W With
PH Pressure High W/O Without
PL Pilot Light or Pressure Low WOT Wide Open Throttle
PMR Pump Motor Relay
P/N Part Number 2WD Two Wheel Drive
PRI Primary 4WD Four Wheel Drive
P/S Power Steering 2WS Two Wheel Steering
PSF Power Steering Fluid 4WS Four Wheel Steering
PSP Power Steering Pressure 4AT 4-speed Automatic Transmission
PSW Pressure Switch 5MT 5-speed Manual Transmission
6MT 6-speed Manual Transmission
Qty Quantity Park
Reverse
R Right Neutral
REF Reference Drive (1st through 4th gear)
RGB Red, Green, Black Drive (1st through 3rd gear)
RH Right Hand Second
RHD Right Hand Drive First
RL Rear Left Drive

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General Information - General Information

RON Research Octane Number Second


RR Rear Right
Low
O/D Over Drive
SAE Society of Automotive Engineers
1 ST Low (gear)
SCS Service Check Signal
2 ND Second (gear)
SEC Second
Secondary 3 RD Third (gear)
SOHC Single Overhead Camshaft 4 TH Fourth (gear)
SOL Solenoid Fifth (gear)
5 TH
6 TH Sixth (gear)

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Specifications - Specifications

Specifications

Standards and Service Limits


Engine Electrical 2-2
Engine Assembly 2-3
Cylinder Head 2-4
Engine Block 2-6
Engine Lubrication 2-7
Cooling 2-8
Fuel and Emissions 2-9
Clutch 2-10
Manual Transmission and Differential 2-11
Automatic Transmission and A/T Differential 2-13
Honda Multi Matic Transmission and HMM 2-19
Differential
Steering 2-24
Suspension 2-24
Brakes 2-25
Air Conditioning 2-25

Design Specifications
Dimensions 2-26
Weight 2-26
Engine 2-27
Starter 2-28
Clutch 2-28
Manual Transmission 2-28
Automatic Transmission 2-28
Honda Multi Matic Transmission 2-28
Steering 2-28
Suspension 2-28
Wheel Alignment 2-29
Brakes 2-29
Tyres 2-29
Air Conditioning 2-29
Electrical Ratings 2-30

Body Specifications
Illustration 2-31

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Specifications - Standards and Service Limits

2-2
Standards and Service Limits
Engine Electrical

Item Measurement Qualification Standard or New Service Limit


Ignition coil Rated voltage 12 V
Firing order 1-3–4-2
Spark plug Type D14Z5, D15Y6, D15Y4, NGK: ZFR5J-11
D16W7 engines DENSO: KJ16CR-L11
D17A1, D17A2, D17Z1, NGK: ZFR6J-11
D17Z4 engines DENSO: KJ20CR-L11
D17A5, D17Z5 engines NGK: ZFR6J-11
DENSO: KJ20CR-L11
D15Y2, D15Y3, D16W8, NGK: BKR5E-11
D16W9 engines DENSO: K16CR-L11
D17Z2, D17Z3 engines NGK: ZFR6J-11,
ZFR7J-11
DENSO: KJ20CR-L11,
KJ22CR-L11
D14Z6, D16V1 engines NGK:ZFR5J-11,
ZFR6J-11
DENSO: KJ16CR-L11,
KJ20CR-L11
Gap 1.0-1.1 mm (0.039-0.043 in.) -
Ignition timing At idle (check the red mark) M/T (in neutral): 8+2° BTDC at 700+50 rpm (min-1)

A/T HONDA MULTI MATIC (in or ): 8+2°


BTDC at 700+50 rpm (min-1)
Alternator belt Deflection with 98 N (10 kgf, Without A/C (with A/C, see Used belt: 8.5-11.0 mm (0.33-0.43 in.)
NOTE: Adjust a new 22 lbs) applied midway "Compressor belt" in the
New belt: 6.5-8.5 mm (0.26-0.33 in.)
belt to the new belt between pulleys A/C table)
spec., run the engine
Tension (measured with belt Without A/C (with A/C, see Used belt: 340-490 N (35-55 kgf, 77-110 lbs)
for 5 minutes, then
tension gauge) "Compressor belt" in the
readjust it to the used New belt: 540-740 N (55-75 kgf, 120-170 lbs)
A/C table)
belt spec.
Alternator Output At 13.5 V and normal 70 A
engine temperature
Coil (rotor) resistance at 68°F (20°C) 1.84-2.10 ohms
Slip ring O.D. 22.7 mm (0.89 in.) 21.7 mm (0.85 in.)
Brush length 19.0 mm (0.75 in.) 5 mm (0.20 in.)
Brush spring tension 3.3-4.1 N (1.6-1.8 kgf, 3.5-4.0 lbs)
Starter for D15Y2, Output 1.0 kW
D16W7 (KG model),
Commutator mica depth 0.50-0.75 mm (0.020-0.030 0.2 mm (0.008 in)
D16W8, D17Z1
in.)
(Except Malaysia
model), D17A1, Commutator runout 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in)
D17A2 (Except Commutator O.D. 27.9-28.0 mm (1.098-1.102 27.0 mm (1.063 in.)
Malaysia model), in.)
D17A5 (Except
Indonesia model) Brush length 14.0-14.5 mm (0.55-0.57 in.) 9.0 mm (0.35 in)
engines (DENSO) Brush spring tension 13.7-17.7 N (1.4-1.8 kgf,
3.09-4.00 lbf)

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Specifications - Standards and Service Limits

2-3
Standards and Service Limits
Engine Electrical (cont'd)

Item Measurement Qualification Standard or New Service Limit


Starter for D15Y3 Output 0.8 kW
(Philippine model),
Commutator mica depth 0.50-0.75 mm (0.020-0.030 0.2 mm (0.008 in.)
D16W9 (Philippine
in.)
model), D17Z1
(Malaysia model), Commutator runout 0.05 mm (0.002 in.) max 0.4 mm (0.02 in).
D17Z5, D17A2 Commutator O.D. 27.9-28.0 mm (1.098-1.102 27.0 mm (1.063 in.)
(Malaysia model), in.)
D17A5 (Indonesia
model) engines Brush length 9.7-10.3 mm (0.38-0.41 in.) 6.0 mm (0.24 in)
(MITSUBISHI) Brush spring tension 13.7-17.7 N (1.4-1.8 kgf,
3.09-4.00 lbf)
Starter for Except Output 0.8 kW
D15Y2, D15Y3
Commutator mica depth 0.50-0.75 mm (0.020-0.030 0.2 mm (0.008 in.)
(Philippine model),
in.)
D16W7 (KG model),
D16W8, D16W9, Commutator runout 0.05 mm (0.002 in.) max. 0.4 mm (0.02 in.)
D17Z1, D17A1, Commutator O.D. 27.9-28.0 mm (1.098-1.102 27.0 mm (1.063 in.)
D17A2, D17A5 in.)
engines (DENSO)
Brush length 9.7-10.3 mm (0.35-0.41 in.) 6.0 mm (0.24 in.)

Engine Assembly
Item Measurement Qualification Standard or New Service Limit
Compression Pressure check at 250 rpm Minimum 930 kPa (9.5 kgf/cm2, 135 -
(min-1) with wide open psi)
throttle. (See Design Specs Maximum variation 200 kPa (2.0 kgf/cm2, 28 psi) -
for ratio.)

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Specifications - Standards and Service Limits

2-4
Standards and Service Limits
Cylinder Head

Item Measurement Qualification Standard or New Service Limit


Head Warpage - 0.05 mm (0.002 in.)
Height 92.95-93.05 mm (3.659- -
3.663 in.)
Camshaft End Play 0.05-0.15 mm (0.002-0.006 0.5 mm (0.02 in.)
in.)
Camshaft-to-holder oil 0.050-0.089 mm (0.0020- 0.15 mm (0.006 in.)
clearance 0.0035 in.)
Total runout 0.03 mm (0.001 in.) max. 0.04 mm (0.002 in.)
Cam lobe height for D15Y4 VTEC intake, primary 38.427 mm (1.5129 in.) -
engine
VTEC intake, secondary 32.292 mm (1.2713 in.) -
VTEC exhaust 38.784 mm (1.5269 in.) -
Cam lobe height for D16W7 VTEC intake, primary 38.427 mm (1.5129 in.) -
engine
VTEC intake, secondary 32.848 mm (1.2932 in.) -
VTEC exhaust 38.784 mm (1.5269 in.) -
Cam lobe height for D17A2, VTEC intake, primary 38.604 mm (1.5198 in.) -
D17A5 engines
VTEC intake, secondary 32.848 mm (1.2932 in.) -
VTEC exhaust 38.784 mm (1.5269 in.) -
Cam lobe height for D16W8 VTEC intake, primary 36.662 mm (1.4434 in.) -
engine
VTEC intake, mid 38.274 mm (1.5068 in.) -
VTEC intake, secondary 32.885 mm (1.2947 in.) -
VTEC exhaust 38.008 mm (1.4964 in.) -
Cam lobe height for D14Z5 Intake 34.158 mm (1.3448 in.) -
engine
Exhaust 36.488 mm (1.4365 in.) -
Cam lobe height for D15Y2, Intake 35.299 mm (1.3897 in.) -
D15Y3, D15Y5, D15Y6,
Exhaust 37.281 mm (1.4678 in.) -
D17A1, D17Z1 engines

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Specifications - Standards and Service Limits

2-5
Standards and Service Limits
Cylinder Head (cont'd)

Item Measurement Qualification Standard or New Service Limit


Valve Clearance (cold) Intake 0.18-0.22 mm (0.007-0.009 -
in.)
Exhaust 0.23-0.27 mm (0.009-0.011 -
in.)
Stem O.D. Intake 5.48-5.49 mm (0.2157- 5.45 mm (0.215 in.)
0.2161 in.)
Exhaust 5.45-5.46 mm (0.2146- 5.42 mm (0.213 in.)
0.2150 in.)
Stem-to-guide clearance Intake 0.02-0.05 mm (0.0008- 0.08 mm (0.003 in.)
0.0020 in.)
Exhaust 0.05-0.08 mm (0.0020- 0.11 mm (0.004 in.)
0.0031 in.)
Valve seats Width Intake 0.85-1.15 mm (0.033-0.045 1.60 mm (0.063 in.)
in.)
Exhaust 1.25-1.55 mm (0.049-0.061 2.00 mm (0.079 in.)
in.)
Stem installed height Intake 53.17-53.64 mm (2.093- 53.89 mm (2.112 in.)
2.112 in.)
Exhaust 53.17-53.64 mm (2.093- 53.89 mm (2.112 in.)
2.112 in.)
Valve springs Free length for D15Y4, VTEC intake 56.49 mm (2.224 in.) -
D16W7, D17A2, D17A5
VTEC exhaust 58.70 mm (2.311 in.) -
engines
Free length for D16W8 VTEC intake 58.02 mm (2.284 in.) -
engine
VTEC exhaust 58.70 mm (2.311 in.) -
Free length for D14Z5, Intake 58.70 mm (2.311 in.) -
D15Y2, D15Y3, D15Y5,
Exhaust 58.70 mm (2.311 in.) -
D15Y6, D17A1, D17Z1
engines
Valve guides I.D. Intake 5.51-5.53 mm (0.217-0.218 5.55 mm (0.219 in.)
in.)
Exhaust 5.51-5.53 mm (0.217-0.218 5.55 mm (0.219 in.)
in.)
Installed height Intake 17.85-18.35 mm (0.703- -
0.722 in.)
Exhaust 18.65-19.15 mm (0.734- -
0.754 in.)
Rocker arms Arm-to-shaft clearance Intake 0.017-0.050 mm (0.0007- 0.08 mm (0.003 in.)
0.0020 in.)
Exhaust 0.018-0.054 mm (0.0007- 0.08 mm (0.003 in.)
0.0021 in.)

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Specifications - Standards and Service Limits

2-6
Standards and Service Limits
Engine Block

Item Measurement Qualification Standard or New Service Limit


Block Warpage of deck 0.07 mm (0.003 in.) max. 0.10 mm (0.004 in.)
Bore diameter 75.00-75.02 mm (2.9528- 75.07 mm (2.9555 in.)
2.9535 in.)
Bore taper - 0.05 mm (0.002 in.)
Reboring limit - 0.5 mm (0.02 in.)
Piston Skirt O.D. at 13 mm (0.5 in.) 74.98-74.99 mm (2.9520- 74.97 mm (2.9516 in.)
from bottom of skirt 2.9524 in.)
Clearance in cylinder 0.010-0.040 mm (0.0004- 0.05 mm (0.002 in.)
0.0016 in.)
Ring groove width for Top 1.020-1.030 mm (0.0402- 1.05 mm (0.041 in.)
D15Y3, D17A5 engines 0.0406 in.)
Second 1.220-1.230 mm (0.0481- 1.25 mm (0.049 in.)
0.0484 in.)
Oil 2.805-2.820 mm (0.1104- 2.85 mm (0.112 in.)
0.1110 in.)
Ring groove width for Top 1.020-1.030 mm (0.0402- 1.05 mm (0.041 in.)
except D15Y3, D17A5 0.0406 in.)
engines
Second 1.220-1.230 mm (0.0481- 1.25 mm (0.049 in.)
0.0484 in.)
Oil 2.005-2.020 mm (0.0789- 2.05 mm (0.08 in.)
0.0795 in.)
Piston rings Ring-to-groove clearance Top 0.035-0.055 mm (0.0014- 0.13 mm (0.005 in.)
for except D15Y3, D17A5 0.0022 in.)
engines
Second 0.030-0.055 mm (0.0012- 0.13 mm (0.005 in.)
0.0022 in.)
Ring-to-groove clearance Top 0.035-0.060 mm (0.0014- 0.13 mm (0.005 in.)
for D15Y3, D17A5 engines 0.0024 in.)
Second 0.030-0.055 mm (0.0012- 0.13 mm (0.005 in.)
0.0022 in.)
Ring end gap for except Top 0.15-0.30 mm (0.006-0.012 0.60 mm (0.024 in.)
D15Y3, D17A5 engines in.)
Second 0.30-0.45 mm (0.012-0.018 0.60 mm (0.024 in.)
in.)
Oil 0.20-0.80 mm (0.008-0.031 0.90 mm (0.035 in.)
in.)
Ring end gap for D15Y3, Top 0.15-0.30 mm (0.006-0.012 0.60 mm (0.024 in.)
D17A5 engine in.)
Second 0.30-0.45 mm (0.012-0.018 0.60 mm (0.024 in.)
in.)
Oil 0.20-0.70 mm (0.008-0.028 0.80 mm (0.031 in.)
in.)
Piston pin O.D. 18.996-19.000 mm (0.7479- -
0.7480 in.)
Pin-to-piston clearance 0.010-0.020 mm (0.0004- -
0.0008 in.)
Connecting rod Pin-to-rod interference 0.016-0.036 mm (0.0006- -
0.0014 in.)
Small-end bore diameter 18.96-18.98 mm (0.746- -
0.747 in.)
Large-end bore diameter D14Z5 engine 43.0 mm (1.69 in.) -
(Nominal)

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Specifications - Standards and Service Limits

D15Y2, D15Y3, D15Y4, 45.0 mm (1.77 in.) -


D15Y5, D15Y6 engines
D16W7, D16W8, D17Z1, 48.0 mm (1.89 in.) -
D17A1, D17A2, D17A5
engines
End play installed on 0.15-0.30 mm (0.006-0.012 0.40 mm (0.016 in.)
crankshaft in.)

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Specifications - Standards and Service Limits

2-7
Standards and Service Limits
Engine Block (cont'd)

Item Measurement Qualification Standard or New Service Limit


Crankshaft Main journal diameter D14Z5, D15Y2, D15Y3, 44.976-45.000 mm (1.7707- -
D15Y4, D15Y5, D15Y6 1.7717 in.)
engines
D16W7, D16W8, D17Z1, 54.976-55.000 mm (2.1644- -
D17A1, D17A2, D17A5 2.1654 in.)
engines
Rod journal diameter D14Z5 engine 39.976-40.000 mm (1.5739- -
1.5748 in.)
D15Y2, D15Y3, D15Y4, 41.976-42.000 mm (1.6526- -
D15Y5, D15Y6 engines 1.6535 in.)
D16W7, D16W8, D17Z1, 44.976-45.000 mm (1.7707- -
D17A1, D17A2, D17A5 1.7717 in.)
engines
Rod/main journal taper 0.0025 mm (0.0001 in.) 0.005 mm (0.0002 in.)

Rod/main journal out-of- 0.0025 mm (0.0001 in.) 0.005 mm (0.0002 in.)


round
End play 0.10-0.35 mm (0.004-0.014 0.45 mm (0.018 in.)
in.)
Runout 0.03 mm (0.001 in.) max. 0.04 mm (0.002 in.)

Crankshaft bearings Main bearing-to-journal oil No. 1 journal 0.018-0.036 mm (0.0007- 0.05 mm (0.002 in.)
clearance for D14Z5, 0.0014 in.)
No. 5 journal
D15Y2, D15Y3, D15Y4,
D15Y5, D15Y6 engines No. 2 journal 0.020-0.038 mm (0.0008- 0.05 mm (0.002 in.)
0.0015 in.)
No. 3 journal
No. 4 journal
Main bearing-to-journal oil No. 1 journal 0.018-0.036 mm (0.0007- 0.05 mm (0.002 in.)
clearance for D16W7, 0.0014 in.)
No. 5 journal
D16W8, D17Z1, D17A1,
D17A2, D17A5 engines No. 2 journal 0.024-0.042 mm (0.0009- 0.05 mm (0.002 in.)
0.0017 in.)
No. 3 journal
No. 4 journal
Rod bearing clearance 0.024-0.042 mm (0.0009- 0.05 mm (0.002 in.)
0.0017 in.)

Engine Lubrication
Item Measurement Qualification Standard or New Service Limit
Engine oil Capacity D15Y4, D17A2 (KU, KQ 4.2 l (4.4 US qt, 3.7 Imp qt) for engine overhaul
models), D17A5 (KN model) 3.5 l (3.7 US qt, 3.1 Imp qt) for oil change, including
engines filter
3.3 l (3.5 US qt, 2.9 Imp qt) for oil change, without filter
Except D15Y4, D17A2 (KU, 4.2 l (4.4 US qt, 3.7 Imp qt) for engine overhaul
KQ models, D17A5 (KN 3.2 l (3.4 US qt, 2.8 Imp qt) for oil change, including
model) engines filter
3.0 l (3.2 US qt, 2.6 Imp qt) for oil change, without filter
Oil pump Inner-to-outer rotor clearance 0.06-0.18 mm (0.002-0.007 0.20 mm (0.008 in.)
in.)
Pump housing-to-outer rotor 0.10-0.18 mm (0.004-0.007 0.20 mm (0.008 in.)
clearance in.)
Pump housing-to-rotor axial 0.02-0.07 mm (0.001-0.003 0.15 mm (0.006 in.)
clearance in.)
Oil pressure with oil At idle 70 kPa (0.7kgf/cm2, 10 psi) min.
temperature at 80°C (176°F) at 3,000 rpm (min-1) 340 kPa (3.5 kgf/cm2, 50 psi) min.

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Specifications - Standards and Service Limits

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Specifications - Standards and Service Limits

2-8
Standards and Service Limits
Cooling

Item Measurement Qualification Standard or New Service Limit


Radiator Coolant capacity (Includes M/T: engine overhaul 5.1 l (5.4 US qt, 4.5 Imp qt)
engine, heater, hoses and
M/T: coolant change 4.0 l (4.2 US qt, 3.5 Imp qt)
reservoir)
A/T, HONDA MULTI MATIC: 5.0 l (5.3 US qt, 4.4 Imp qt)
engine overhaul
A/T, HONDA MULTI MATIC: 3.9 l (4.1 US qt, 3.4 Imp qt)
coolant change
Reservoir Coolant capacity 0.4 l (0.4 US qt, 0.4 Imp qt)

Radiator cap Opening pressure 93-123 kPa (0.95-1.25 kgf/cm2, 14-18 psi)

Thermostat Opening temperature Begin to open 76-80°C (169-176°F)


Fully open 90°C (194°F)
Valve lift at fully open 8.0 mm (0.31 in.) min.

Radiator fan switch Thermoswitch "ON" 91-95°C (196-203°F)


temperature
Thermoswitch "OFF" Subtract 3-8°C (5-15°F) from actual "ON" temperature
temperature

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Specifications - Standards and Service Limits

2-9
Standards and Service Limits
Fuel and Emissions

Item Measurement Qualification Standard or New Service Limit


Fuel pressure Pressure with fuel pressure 270-320 kPa (2.8-3.3 kgf/cm2, 40-47 psi)
regulator gauge connected
Fuel tank Capacity 45 l (11.9 US gal, 9.9 Imp gal)

Engine idle for D14Z5, Idle speed with headlights M/T in neutral 700+50 rpm
D16W7, D17Z1 and radiator fan off
650+50 rpm
engines (4-door A/T in or
model) Fast idle M/T in neutral 1,300+50 rpm
1,300+50 rpm
A/T in or
Idle CO% 0.1 max.

Engine idle for D15Y3, Idle speed with headlights M/T in neutral 750+50 rpm
D17A5 engines (4- and radiator fan off
750+50 rpm
door model) CVT, A/T in or
Fast idle M/T in neutral 1,300+50 rpm
1,300+50 rpm
A/T in or
Idle CO% 0.5 max.

Engine idle for D15Y5, Idle speed with headlights M/T in neutral 720+50 rpm
D15Y2, D16W8, and radiator fan off
720+50 rpm
D17Z1, D17Z2, A/T in or
D17Z5, D17A2, Fast idle M/T in neutral 1,300+50 rpm
D17Z3 engines (4-
door model) 1,300+50 rpm
A/T in or
Idle CO% 0.1 max.

Engine idle for D14Z5, Idle speed with headlights M/T in neutral 700+50 rpm
D16W7 engines (5- and radiator fan off
650+50 rpm
door model) A/T in or
Fast idle M/T in neutral 1,300+50 rpm
1,300+50 rpm
A/T in or
Idle CO% 0.1 max.

Engine idle for D15Y5, Idle speed with headlights M/T in neutral 720+50 rpm
D15Y2 D16W8, and radiator fan off
720+50 rpm
D17A1, D17Z1, A/T in or
D17Z2, D17Z5, Fast idle M/T in neutral 1,300+50 rpm
D17A2, D17Z3
engines (5-door 1,300+50 rpm
A/T in or
model)
Idle CO% 0.1 max.

Engine idle for D16V2 Idle speed with headlights M/T in neutral 750+50 rpm
engine (5-door model) and radiator fan off
750+50 rpm
CVT, A/T in or
Fast idle M/T in neutral 1,300+50 rpm
1,300+50 rpm
A/T in or
Idle CO% 0.5 max.

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Specifications - Standards and Service Limits

2-10
Standards and Service Limits
Clutch

Item Measurement Qualification Standard or New Service Limit


Clutch pedal Height from the floor 198 mm (7.8 in.) -

Stroke 130-140 mm (5.1-5.5 in.) -

Play 8-18 mm (0.3-0.7 in.) -

Disengagement height from 113 mm (4.4 in.) min. -


the floor
Flywheel Runout on clutch mating 0.06 mm (0.002 in.) max. 0.15 mm (0.006 in.)
surface
Clutch disc Rivet head depth D17A engine 1.65-2.25 mm (0.065-0.089 0.8 mm (0.03 in.)
in.)
Except D17A engine 1.2-1.7 mm (0.047-0.067 in.) 0.2 mm (0.01 in.)
Thickness 8.3-9.0 mm (0.33-0.35 in.) 5.7 mm (0.22 in.)

Pressure plate Warpage 0.03 mm (0.001 in.) max. 0.15 mm (0.006 in.)

Height of diaphragm spring Measure with feeler gauge D16W7, 0.6 mm 0.8 mm (0.03 in.)
fingers and special tool D16W8, (0.02 in.)
D16W9, D16V2 max.
engines
Except D16W7, 0.6 mm 1.0 mm (0.04 in.)
D16W8, (0.02 in.)
D16W9, D16V2 max.
engines

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Specifications - Standards and Service Limits

2-11
Standards and Service Limits
Manual Transmission and Differential

Item Measurement Qualification Standard or New Service Limit


Transmission oil Capacity For fluid change: 1.5 l (1.6
US qt, 1.3 Imp qt)
For overhaul: 1.6 l (1.7 US qt,
1.4 Imp qt)
Mainshaft End play 0.11-0.18 mm (0.004-0.007 Adjust
in.)
Diameter of ball bearing 25.977-25.990 mm (1.0227- 25.92 mm (1.021 in.)
contact area (clutch housing 1.0232 in.)
side)
Diameter of spacer collar 28.980-28.993 mm (1.1409- 28.930 mm (1.1390
contact area 1.1415 in.) in.)
Diameter of needle bearing 34.984-35.000 mm (1.3773- 34.93 mm (1.375 in.)
contact area 1.3780 in.)
Diameter of ball bearing 25.987-26.000 mm (1.0231- 25.93 mm (1.020 in.)
contact area (transmission 1.0236 in.)
housing side)
Run out 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.)

Mainshaft 3rd and 4th I.D. 39.009-39.025 mm (1.5358- 39.070 mm (1.5382


gears 1.5364 in.) in.)
End play 3rd gear 0.06-0.21 mm (0.002-0.008 0.33 mm (0.013 in.)
in.)
4th gear 0.06-0.19 mm (0.002-0.007 0.31 mm (0.012 in.)
in.)
Thickness 3rd gear 27.92-27.97 mm (1.099- 27.85 mm (1.096 in.)
1.101 in.)
4th gear 27.02-27.07 mm (1.064- 26.95 mm (1.061 in.)
1.066 in.)
Mainshaft 5th gear I.D. 39.009-39.025 mm (1.5358- 39.070 mm (1.5382
1.5364 in.) in.)
End play 0.06-0.19 mm (0.002-0.007 0.31 mm (0.012 in.)
in.)
Thickness 28.92-28.97 mm (1.139- 28.85 mm (1.136 in.)
1.141 in.)
Countershaft Diameter of needle bearing 34.000-34.015 mm (1.3386- 33.95 mm (1.337 in.)
contact area (clutch housing 1.3392 in.)
side)
Diameter of ball bearing 24.980-24.993 mm (0.9835- 24.93 mm (0.981 in.)
contact area (transmission 0.9840 in.)
housing side)
Diameter of 1st gear 37.984-38.000 mm (1.4954- 37.934 mm (1.493 in.)
contact area 1.4961 in.)
Run out 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.)

Countershaft 1st gear I.D. 43.009-43.025 mm (1.6932- 43.070 mm (1.6957


1.6939 in.) in.)
Endplay 0.03-0.10 mm (0.001-0.039 0.22 mm (0.009 in.)
in.)
Thickness 26.91-26.94 mm (1.059- -
1.061 in.)
Countershaft 2nd gear I.D. 45.009-45.025 mm (1.7720- 45.070 mm (1.7744
1.7726 in.) in.)
End play 0.04-0.12 mm (0.002-0.005 0.24 mm (0.009 in.)

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Specifications - Standards and Service Limits

in.)
Thickness 27.41-27.46 mm (1.079- 27.36 mm (1.077 in.)
1.081 in.)
Countershaft 2nd gear I.D. 34.000-34.010 mm (1.3386- 34.040 mm (1.3402
spacer collar 1.3390 in.) in.)
O.D. 39.989-40.000 mm (1.5744- 39.930 mm (1.5720
1.5748 in.) in.)
Length 27.53-27.56 mm (1.084- 27.51 mm (1.083 in.)
1.085 in.)

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Specifications - Standards and Service Limits

2-12
Standards and Service Limits
Manual Transmission and Differential (cont'd)

Item Measurement Qualification Standard or New Service Limit


Mainshaft 4th and I.D. 29.002-29.012 mm 29.060 mm
5th gears spacer (1.1418-1.1422 in.) (1.1441 in.)
collar
O.D. 34.989-35.000 mm 34.930 mm
(1.3775-1.3780 in.) (1.3752 in.)
Length A 51.97-52.03 mm -
(2.046-2.048 in.)
B 24.03-24.06 mm -
(0.946-0.947 in.)

Reverse idler gear I.D. 15.016-15.043 mm 15.080 mm


(0.5912-0.5922 in.) (0.5937 in.)
Gear-to-reverse gear shaft clearance 0.032-0.077 mm 0.140 mm (0.0055
(0.0012-0.0030 in.) in.)
Synchro ring Ring-to-gear clearance Ring pushed 0.85-1.10 mm (0.033- 0.4 mm (0.016
against gear 0.043 in.) in.)
Dual cone Outer synchro ring-to-synchro cone clearance Ring pushed 0.5-1.0 mm (0.02-0.04 0.3 mm (0.01 in.)
synchro against gear in.)
Synchro cone-to-gear clearance Ring pushed 0.5-1.0 mm (0.02-0.04 0.3 mm (0.01 in.)
against gear in.)
Outer synchro ring-to-gear cone clearance Ring pushed 0.95-1.68 mm (0.037- 0.6 mm (0.02 in.)
against gear 0.066 in.)
Shift fork Finger thickness 1st-2nd and 3rd- 7.4-7.6 mm (0.29-0.30 -
4th forks in.)
5th fork 6.7-6.9 mm (0.26-0.27 -
in.)
Fork-to-synchro sleeve clearance 0.35-0.65 mm (0.014- 1.00 mm (0.039
0.026 in.) in.)
Reverse shift fork Pawl groove width 13.8-14.1 mm (0.543- 15.5 mm (0.610
0.555 in.) in.)
Fork-to-reverse idler gear clearance 1.6-2.2 mm (0.06-0.09 2.8 mm (0.11 in.)
in.)
Shift arm I.D. 13.973-14.000 mm -
(0.5501-0.5512 in.)
Shift fork diameter at contact area 12.9-13.0 mm (0.508- -
0.512 in.)
Shift arm-to-shift lever clearance 0.2-0.5 mm (0.008- 0.62 mm (0.024
0.020 in.) in.)
Select lever Finger width 14.75-14.95 mm -
(0.581-0.589 in.)
Shift lever Shaft-to-select lever clearance 0.05-0.40 mm (0.002- 0.6 mm (0.024
0.016 in.) in.)
Groove (to select lever) 15.00-15.15 mm -
(0.591-0.596 in.)
Shaft-to-shift arm clearance 0.013-0.07 mm 0.1 mm (0.004
(0.0005-0.003 in.) in.)
M/T differential Pinion shaft contact area I.D. 18.010-18.028 mm -
carrier (0.7091-0.7098 in.)

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Specifications - Standards and Service Limits

Carrier-to-pinion shaft clearance 0.027-0.057 mm 0.100 mm (0.0039


(0.0011-0.0022 in.) in.)
Driveshaft contact area I.D. 26.025-26.045 mm -
(1.0246-1.0254 in.)
M/T differential Backlash 0.05-0.15 mm (0.002- -
pinion gear 0.006 in.)
I.D. 18.042-18.066 mm -
(0.7103-0.7113 in.)
Pinion gear-to-pinion shaft clearance 0.059-0.095 mm 0.150 mm (0.0059
(0.0023-0.0037 in.) in.)

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Specifications - Standards and Service Limits

2-13
Standards and Service Limits
Automatic Transmission and A/T Differential

Item Measurement Qualification Standard or New Service Limit


ATF (Automatic Capacity Use genuine Honda ATF-Z1 For fluid change: 2.7 l (2.9 US qt, 2.4 Imp qt)
Transmission Fluid)
For overhaul: 6.0 l (6.3 US qt, 5.3 Imp qt)
ATF pressure Line pressure 880-930 kPa (9.0-9.5 830 kPa (8.5 kgf/cm2,
At 2,000 rpm (min-1) in
kgf/cm2, 120-130 psi) 120 psi)
or position
4th clutch pressure 850-900 kPa (8.7-9.2 800 kPa (8.2 kgf/cm2,
At 2,000 rpm (min-1) in
kgf/cm2, 120-130 psi) 120 psi)
position
3rd clutch pressure At 2,000 rpm (min-1) in 850-900 kPa (8.7-9.2 800 kPa (8.2 kgf/cm2,
kgf/cm2, 120-130 psi) 120 psi)
position
2nd clutch pressure At 2,000 rpm (min-1) in s 850-900 kPa (8.7-9.2 800 kPa (8.2 kgf/cm2
kgf/cm2, 120-130 psi) 120 psi)
position
1st clutch pressure 880-930 kPa (9.0-9.5 830 kPa (8.5 kgf/cm2,
At 2,000 rpm (min-1) in
kgf/cm2, 120-130 psi) 120 psi)
position
1st-hold clutch pressure At 2,000 rpm (min-1) in s 880-930 kPa (9.0-9.5 830 kPa (8.5 kgf/cm2,
kgf/cm2, 120-130 psi) 120 psi)
position
Torque converter Stall speed Check with D14Z5 engine 2,550 rpm (min-1) 2,400-2,700 rpm (min-
vehicle on level ground 1)
D15Y2, D15Y3, D15Y5, 2,650 rpm (min-1) 2,500-2,800 rpm (min-
D15Y6 engines 1)
D16W7 engine 2,800 rpm (min-1) 2,650-2,950 rpm (min-
1)
D16W8 engine 2,800 rpm (min-1) 2,650-2,950 rpm (min-
1)
D17A1, D17Z1 engine 2,800 rpm (min-1) 2,650-2,950 rpm (min-
1)
D17A2, D17Z5 engine 2,800 rpm (min-1) 2,650-2,950 rpm (min-
1)
Valve body Stator shaft needle bearing Torque converter side 27.000-27.021 mm (1.063- When worn or
contact I.D. 1.064 in.) damaged
ATF pump side 29.000-29.013 mm (1.1417- When worn or
1.1422 in.) damaged
ATF pump gear thrust 0.03-0.06 mm (0.001-0.002 0.07 mm (0.003 in.)
clearance in.)
ATF pump gear-to-body Drive gear 0.105-0.1325 mm (0.004- -
clearance 0.005 in.)
Driven gear 0.0350-0.0625 mm (0.001- -
0.002 in.)
ATF pump driven gear I.D. 14.016-14.034 mm (0.5518- When worn or
0.5525 in.) damaged
ATF pump driven gear shaft 13.980-13.990 mm (0.5504- When worn or
O.D. 0.5508 in.) damaged
Reverse shift fork Fork finger thickness 5.90-6.00 mm (0.232-0.236 5.4 mm (0.213 in.)
in.)
Park gear and pawl When worn or
damaged
Servo body Shift fork shaft bore I.D. 14.000-14.010 mm (0.5512- -
0.5516 in.)
Shift fork shaft valve bore 37.000-37.039 mm (1.4567- 37.045 mm (1.4585
I.D. 1.4582 in.) in.)

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Specifications - Standards and Service Limits

Regulator valve body Sealing ring contact I.D. 35.000-35.025 mm (1.3780- 35.050 mm (1.3799
1.3782 in.) in.)
Stator shaft Diameter of needle bearing ATF pump side 29.000-29.013 mm (1.1417- When worn or
contact area 1.1422 in.) damaged
Torque converter side 27.000-27.021 mm (1.0630- When worn or
1.0638 in.) damaged

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Specifications - Standards and Service Limits

2-14
Standards and Service Limits
Automatic Transmission and Differential

Item Measurement Qualification Standard or New Service Limit


Clutch Clutch end plate-to-top disc 1st and 2nd 0.65-0.85 mm (0.026-
clearance 0.033 in.)
3rd and 4th 0.4-0.6 mm (0.016-
0.024 in.)
1st-hold 0.5-0.8 mm (0.020-
0.031 in.)
Clutch return spring free 1st, 2nd, 3rd and 4th 30.5 mm (1.20 in.) 28.5 mm (1.12 in.)
length
1st-hold 34.6 mm (1.36 in.) 32.6 mm (1.28 in.)
Clutch disc thickness 1.94 mm (0.076 in.) -
Clutch plate thickness 1st, 1st-hold 1.6 mm (0.06 in.) When discoloured
2nd, 3rd and 4th 2.0 mm (0.079 in.) When discoloured
1st, 2nd, 3rd and 4th Mark 1 2.1 mm (0.083 in.) When discoloured
clutches end plate thickness
Mark 2 2.2 mm (0.087 in.) When discoloured
Mark 3 2.3 mm (0.091 in.) When discoloured
Mark 4 2.4 mm (0.094 in.) When discoloured
Mark 5 2.5 mm (0.098 in.) When discoloured
Mark 6 2.6 mm (0.102 in.) When discoloured
Mark 7 2.7 mm (0.106 in.) When discoloured
Mark 8 2.8 mm (0.110 in.) When discoloured
Mark 9 2.9 mm (0.114 in.) When discoloured
1st-hold clutch end plate Mark 1 2.1 mm (0.083 in.) When discoloured
thickness
Mark 2 2.2 mm (0.087 in.) When discoloured
Mark 3 2.3 mm (0.091 in.) When discoloured
Mark 4 2.4 mm (0.094 in.) When discoloured
No Mark 2.5 mm (0.098 in.) When discoloured
Mark 6 2.6 mm (0.102 in.) When discoloured
Mark 7 2.7 mm (0.106 in.) When discoloured

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Specifications - Standards and Service Limits

2-15
Standards and Service Limits
Automatic Transmission and Differential
(cont'd)

Item Measurement Qualification Standard or New Service Limit


Mainshaft Diameter of needle bearing at stator shaft 22.980-22.993 mm (0.9047- When worn or
contact area 0.9052 in.) damaged
at 2nd gear 35.975-35.991 mm (1.4163- When worn or
1.4169 in.) damaged
at 4th gear collar 31.975-31.991 mm (1.2589- When worn or
1.2595 in.) damaged
at 1st gear collar 30.975-30.991 mm (1.2195- When worn or
1.2201 in.) damaged
I.D. of gears 1st gear 35.000-35.016 mm (1.3780- When worn or
1.3786 in.) damaged
2nd gear 41.000-41.016 mm (1.6142- When worn or
1.6148 in.) damaged
4th gear 38.000-38.016 mm (1.4961- When worn or
1.4967 in.) damaged
End play of gears 1st gear 0.08-0.19 mm (0.003-0.007 -
in.)
2nd gear 0.05-0.13 mm (0.002-0.005 -
in.)
4th gear 0.075-0.185 mm (0.003- -
0.007 in.)
4th gear collar length 49.50-49.55 mm (1.9488- -
1.9508 in.)
4th gear collar flange 4.435-4.525 mm (0.1746- -
thickness 0.1781 in.)
1st gear collar length 27.00-27.05 mm (1.063- -
1.065 in.)
36.5 x 55 mm thrust washer No. 1 4.00 mm (0.157 in.) When worn or
thickness damaged
No. 2 4.05 mm (0.159 in.) When worn or
damaged
No. 3 4.10 mm (0.161 in.) When worn or
damaged
No. 4 4.15 mm (0.163 in.) When worn or
damaged
No. 5 4.20 mm (0.165 in.) When worn or
damaged
No. 6 4.25 mm (0.167 in.) When worn or
damaged
No. 7 4.30 mm (0.169 in.) When worn or
damaged
No. 8 4.35 mm (0.171 in.) When worn or
damaged
No. 9 4.40 mm (0.173 in.) When worn or
damaged
No. 10 4.45 mm (0.175 in.) When worn or
damaged
Thrust washer thickness 26 x 45 x 3 mm 2.95-3.05 mm (0.116-0.120 When worn or
in.) damaged
1st gear, 26 mm 2.43-2.50 mm (0.096-0.098 When worn or
in.) damaged

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Specifications - Standards and Service Limits

Clutch feed pipe O.D. 1st clutch feed pipe at 15 8.97-8.98 mm (0.535-0.354 8.95 mm (0.352 in.)
mm (0.6 in.) from end in.)
4th clutch feed pipe at 30 5.97-5.98 mm (0.2350- 5.95 mm (0.234 in.)
mm (1.2 in.) from end 0.2354 in.)
Sealing ring thickness 35 mm sealing ring 1.87-1.97 mm (0.074-0.078 1.8 mm (0.071 in.)
in.)
29 mm sealing ring 1.87-1.97 mm (0.074-0.078 1.8 mm (0.071 in.)
in.)
Clutch feed pipe bushing 1st clutch 9.000-9.015 mm (0.3543- 9.03 mm (0.356 in.)
I.D. 0.3549 in.)
4th clutch 6.018-6.030 mm (0.2369- 6.045 mm (0.2380 in.)
0.2374 in.)
Width of sealing ring groove 2.025-2.075 mm (0.0797- 2.095 mm (0.082 in.)
0.0811 in.)

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Specifications - Standards and Service Limits

2-16
Standards and Service Limits
Automatic Transmission and Differential
(cont'd)

Item Measurement Qualification Standard or New Service Limit


Countershaft Diameter of needle bearing at left end 36.004-36.017 mm (1.4175- When worn or
contact area 1.4180 in.) damaged
at 3rd gear 35.980-35.996 mm (1.4165- When worn or
1.4172 in.) damaged
at 4th gear 27.980-27.993 mm (1.1016- When worn or
1.1021 in.) damaged
at reverse gear collar 31.975-31.991 mm (1.2589- When worn or
1.2595 in.) damaged
at 1st gear collar 31.975-31.991 mm (1.2589- When worn or
1.2595 in.) damaged
I.D. of gears 1st gear 38.000-38.016 mm (1.4961- When worn or
1.4967 in.) damaged
3rd gear 41.000-41.016 mm (1.6142- When worn or
1.6148 in.) damaged
4th gear 33.000-33.016 mm (1.2992- When worn or
1.2998 in.) damaged
Reverse gear 38.000-38.016 mm (1.4961- When worn or
1.4967 in.) damaged
End play of gears 1st gear 0.1-0.5 mm (0.004-0.020 in.) -
3rd gear 0.05-0.17 mm (0.002-0.007 -
in.)
4th gear 0.10-0.18 mm (0.004-0.007 -
in.)
Reverse gear 0.10-0.25 mm (0.004-0.010 -
in.)
28 mm distance collar No. 1 39.00 mm (1.535 in.) -
length
No. 2 39.10 mm (1.539 in.) -
No. 3 39.20 mm (1.543 in.) -
No. 4 39.30 mm (1.547 in.) -
No. 5 39.05 mm (1.537 in.) -
No. 6 39.15 mm (1.541 in.) -
No. 7 39.25 mm (1.545 in.) -
No. 8 38.90 mm (1.531 in.) -
No. 9 38.95 mm (1.533 in.) -
3rd gear collar length 20.65-20.70 mm (0.8130- -
0.8150 in.)
Reverse gear collar length 14.5-14.6 mm (0.571-0.575 -
in.)
Reverse gear collar flange 2.4-2.6 mm (0.094-0.102 in.) When worn or
thickness damaged
1st gear collar length 14.5-14.6 mm (0.571-0.575 -
in.)
1st gear collar flange 2.4-2.6 mm (0.094-0.102 in.) When worn or
thickness damaged
3rd gear splined washer 4.95-5.00 mm (0.195-0.197 When worn or
thickness in.) damaged
3rd clutch feed pipe O.D. At 15 mm (0.6 in.) from end 7.97-7.98 mm (0.3138- 7.95 mm (0.313 in.)
0.3142 in.)

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Specifications - Standards and Service Limits

3rd clutch feed pipe bushing 8.000-8.022 mm (0.3150- 8.03 mm (0.316 in.)
I.D. 0.3158 in.)
Reverse selector hub O.D. 51.87-51.90 mm (2.042- When worn or
2.043 in.) damaged
1st gear I.D. of one-way 83.339-83.365 mm (3.2810- When worn or
clutch contact area 3.2821 in.) damaged
Park gear diameter of one- 66.685-66.698 mm (2.6254- When worn or
way clutch area 2.6259 in.) damaged

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Specifications - Standards and Service Limits

2-17
Standards and Service Limits
Automatic Transmission and Differential
(cont'd)

Item Measurement Qualification Standard or New Service Limit


Reverse idler gear Reverse idler gear shaft 13.990-14.000 mm (0.5508- When worn or
diameter at needle bearing 0.5512 in.) damaged
contact area
I.D. 18.007-18.020 mm (0.7089- When worn or
0.7094 in.) damaged
End play 0.05-0.18 mm (0.002-0.007 -
in.)
I.D. of reverse idler gear 14.416-14.434 mm (0.5676- When worn or
shaft holder 0.5683 in.) damaged
Sub-shaft Diameter of needle bearing at transmission housing 25.991-26.000 mm (1.023- When worn or
contact area 1.024 in.) damaged
at 4th gear collar 23.9935-23.0065 mm When worn or
(0.9446-0.9058 in.) damaged
4th gear I.D. 32.000-32.016 mm (1.2600- When worn or
1.2605 in.) damaged
4th gear end play 0.05-0.17 mm (0.002-0.007 -
in.)
4th gear collar length 24.0-24.1 mm (0.945-0.949 -
in.)
4th gear collar flange 2.95-3.10 mm (0.116-0.122 When worn or
thickness in.) damaged
4th gear thrust washer 2.93-3.00 mm (0.115-0.118 When worn or
thickness in.) damaged
1st-clutch feed pipe O.D. at 15 mm (0.6 in.) from end 7.97-7.98 mm (0.3138- 7.95 mm (0.313 in.)
0.3142 in.)

Item Measurement Qualification Standard or New


Wire O.D. Free No. of Coil
Diameter Length
Main valve body Relief valve spring 1.1 mm 8.6 mm 37.1 mm 13.4
springs (see page (0.043 in.) (0.339 in.) (1.4161 in.)
14-183) Modulator valve spring 1.4 mm 9.4 mm 33.8 mm 10.9
(0.055 in) (0.370 in.) (1.331 in.)
CPB valve spring 1.0 mm 8.1 mm 40.9 mm 16.2
(0.039 in.) (0.319 in.) (1.610 in.)
1-2 shift valve spring 0.9 mm 7.6 mm 41.3 mm 16.3
(0.035 in.) (0.299 in.) (1.626 in.)
2nd orifice control valve 0.7 mm 6.6 mm 34.8 mm 22.0
spring (0.028 in.) (0.260 in.) (1.370 in.)
Servo control valve spring 1.0 mm 8.1 mm 52.1 mm 20.8
(0.039 in.) (0.319 in.) (2.051 in.)
Regulator valve body Stator reaction spring 4.5 mm 35.4 mm 30.3 mm 1.9
springs (see page (0.177 in.) (1.394 in.) (1.193 in.)
14-186) Regulator valve spring A 1.9 mm 14.7 mm 77.4 mm 15.2
(0.075 in.) (0.579 in.) (3.047 in.)
Regulator valve spring B 1.8 mm 9.6 mm 44.0 mm 12.6
(0.071 in.) (0.378 in.) (1.732 in.)
Cooler relief valve spring 1.0 mm 8.4 mm 33.8 mm 8.2
(0.039 in.) (0.331 in.) (1.331 in.)
Torque converter check valve 1.0 mm 8.4 mm 33.8 mm 8.2
spring (0.039 in.) (0.331 in.) (1.331 in.)
Lock-up control valve spring 0.8 mm 6.0 mm 38.4 mm 30.3

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Specifications - Standards and Service Limits

(0.031 in.) (0.236 in.) (1.512 in.)

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Specifications - Standards and Service Limits

2-18
Standards and Service Limits
Automatic Transmission and Differential
(cont'd)

Item Measurement Qualification Standard or New


Wire O.D. Free No. of
Diameter Length Coil
Secondary valve body 3-4 shift valve spring 0.9 mm 7.6 mm 57.0 mm 26.8
springs (see page 14- (0.035 in.) (0.299 in.) (2.244 in.)
187)
2-3 shift valve spring 0.9 mm 7.6 mm 57.0 mm 26.8
(0.035 in.) (0.299 in.) (2.244 in.)
4th exhaust valve spring 0.9 mm 6.1 mm 36.4 mm 19.5
(0.035 in.) (0.240 in.) (1.433 in.)
3-4 orifice control valve 0.7 mm 6.6 mm 37.5 mm 24.6
spring (0.028 in.) (0.260 in.) (1.476 in.)
Servo body springs 1st accumulator spring 2.1 mm 16.0 mm 89.1 mm 16.2
(see page 14-188) (0.083 in.) (0.630 in.) (3.508 in.)
4th accumulator spring A 2.6 mm 17.0 mm 88.4 mm 14.2
(0.102 in.) (0.669 in.) (3.480 in.)
4th accumulator spring B 2.3 mm 10.2 mm 51.6 mm 13.8
(0.091 in.) (0.402 in.) (2.031 in.)
3rd accumulator spring A 2.8 mm 17.5 mm 94.3 mm 15.6
(0.110 in.) (0.689 in.) (3.713 in.)
3rd accumulator spring B 2.1 mm 31.0 mm 38.2 mm 2.4
(0.083 in.) (1.220 in.) (1.504 in.)
2nd accumulator spring C 2.2 mm 14.5 mm 68.0 mm 13.9
(0.087 in.) (0.571 in.) (2.677 in.)
2nd accumulator spring A 2.4 mm 29.0 mm 39.0 mm 2.9
(0.094 in.) (1.142 in.) (1.535 in.)
3rd sub accumulator spring 2.7 mm 17.0 mm 39.0 mm 6.3
(0.106 in.) (0.669 in.) (1.535 in.)
Lock-up valve body Lock-up shift valve spring 0.9 mm 7.6 mm 73.7 mm 32.0
springs (see page 14- (0.035 in.) (0.299 in.) (2.902 in.)
189)
Lock-up timing valve spring 0.9 mm 8.1 mm 80.7 mm 54.2
(0.035 in.) (0.319 in.) (3.177 in.)

Item Measurement Qualification Standard or New Service Limit


A/T differential carrier Pinion shaft contact area I.D. 18-010-18.028 mm (0.709- -
0.710 in.)
Carrier-to-pinion shaft 0.023-0.057 mm (0.001- 0.1 mm (0.004 in.)
clearance 0.002 in.)
Driveshaft contact area I.D. 26.025-26.045 mm (1.0246- -
1.0254 in.)
Carrier-to-driveshaft 0.045-0.086 mm (0.002- 0.12 mm (0.005 in.)
clearance 0.003 in.)
Set ring-to-carrier bearing 0-0.15 mm (0-0.006 in.) Adjust
outer race clearance
A/T differential pinion Backlash 0.05-0.15 mm (0.002-0.006 -
gear in.)
I.D. 18.042-18.066 mm (0.7103- -
0.7113 in.)
Pinion gear-to-pinion shaft 0.055-0.095 mm (0.0022- 0.15 mm (0.006 in.)
clearance 0.0037 in.)

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Specifications - Standards and Service Limits

2-19
Standards and Service Limits
Honda Multi Matic Transmission and HMM
Differential

Item Measurement Qualification Standard or New Service Limit


HMM Transmission Capacity Use genuine Honda ATF-Z1 For fluid change: 3.1 l (3.3 US qt, 2.7 Imp qt)
Fluid
For overhaul: 5.6 l (5.9 US qt, 4.9 Imp qt)
Hydraulic pressure Forward clutch pressure 1.4-1.75 MPa (14.3-17.8 kgf/cm2, 203-253 psi)
At 1,500 rpm (min-1) in
position
Reverse brake pressure 1.4-1.75 MPa (14.3-17.8 kgf/cm2, 203-253 psi)
At 1,500 rpm (min-1) in
position
Drive pulley pressure At 1,500 rpm (min-1) in 0.2-0.7 MPa (2.0-7.1 kgf/cm2, 28-101 psi)
position
Driven pulley pressure At 1,500 rpm (min-1) in 1.5-2.3 MPa (15.3-23.5 kgf/cm2, 218-334 psi)
position
Lubrication pressure At 3,000 rpm (min-1) in Above 0.2 MPa (Above (0.2 kgf/cm2, 30 psi)
position
Torque converter Stall speed Check with 2,500 rpm (min-1) 2,350-2,650 rpm (min-
D15Y4 engine in
vehicle on level ground 1)
position
3,000 rpm (min-1) 2,800-3,100 rpm (min-
D15Y4 engine in ,
1)
and positions
2,500 rpm (min-1) 2,350-2,650 rpm (min-
D17A2 engine in
1)
position
2,800 rpm (min-1) 2,600-2,900 rpm (min-
D17A2 engine in ,
1)
and positions
ATF pump ATF pump drive gear shaft 9.98-9.99 mm (0.3929- When worn or
O.D. 0.3933 in.) damaged
ATF pump driven gear shaft 9.98-9.99 mm (0.3929- When worn or
O.D. 0.3933 in.) damaged
ATF pump body bushing Drive gear shaft 10.0-10.015 mm (0.3937- When worn or
I.D. 0.3944 in.) damaged
Driven gear shaft 10.0-10.015 mm (0.3937- When worn or
0.3944 in.) damaged
ATF pump gear side 0.015-0.035 mm (0.0006- -
clearance 0.0014 in.)
ATF pump gear-to-body Drive gear 0.035-0.0505 mm (0.0014- -
clearance 0.0020 in.)
Driven gear 0.035-0.0505 mm (0.0014- -
0.0020 in.)

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Specifications - Standards and Service Limits

2-20
Standards and Service Limits
Honda Multi Matic Transmission and HMM
Differential (cont'd)

Item Measurement Qualification Standard or New Service Limit


Clutch Clutch end plate-to-top disc Forward clutch 0.6-0.8 mm (0.024-0.031 in.) -
clearance
Start clutch 0.5-0.7 mm (0.020-0.028 in.) -
Reverse brake 0.45-0.75 mm (0.018-0.030 -
in.)
Clutch return spring free Forward clutch 30.5 mm (1.20 in.) 28.5 mm (1.12 in.)
length
Start clutch 40.9 mm (1.61 in.) 38.9 mm (1.53 in.)
Reverse brake 29.4 mm (1.16 in.) 27.4 mm (1.08 in.)
Clutch disc thickness Forward clutch 1.94 mm (0.076 in.) -
Start clutch 1.94 mm (0.076 in.) -
Reverse brake 2.00 mm (0.079 in.) -
Clutch plate thickness Forward clutch 2.00 mm (0.079 in.) When discoloured
Start clutch 2.3 mm (0.091 in.) When discoloured
Reverse brake 1.35 mm (0.053 in.) When discoloured
Forward clutch end plate Mark 14 3.4 mm (0.134 in.) When discoloured
Mark 15 3.5 mm (0.138 in.) When discoloured
Mark 16 3.6 mm (0.142 in.) When discoloured
Mark 17 3.7 mm (0.146 in.) When discoloured
Mark 18 3.8 mm (0.150 in.) When discoloured
Mark 19 3.9 mm (0.154 in.) When discoloured
Mark 20 4.0 mm (0.157 in.) When discoloured
Mark 21 4.1 mm (0.161 in.) When discoloured
Mark 22 4.2 mm (0.165 in.) When discoloured
Mark 23 4.3 mm (0.169 in.) When discoloured
Mark 24 4.4 mm (0.173 in.) When discoloured
Mark 25 4.5 mm (0.177 in.) When discoloured
Mark 26 4.6 mm (0.181 in.) When discoloured
Mark 27 4.7 mm (0.185 in.) When discoloured
Reverse brake end plate Mark 1 3.6 mm (0.142 in.) When discoloured
Mark 2 3.8 mm (0.150 in.) When discoloured
Mark 3 4.0 mm (0.157 in.) When discoloured
Mark 4 4.2 mm (0.165 in.) When discoloured
Mark 5 4.4 mm (0.173 in.) When discoloured
Mark 6 4.6 mm (0.181 in.) When discoloured
Mark 7 4.8 mm (0.189 in.) When discoloured
Mark 8 5.0 mm (0.197 in.) When discoloured

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Specifications - Standards and Service Limits

2-21
Standards and Service Limits
Honda Multi Matic Transmission and HMM
Differential (cont'd)

Item Measurement Qualification Standard or New Service Limit


Input shaft Diameter of needle bearing Flywheel side 19.987-20.000 mm (0.7869- When worn or
contact area 0.7874 in.) damaged
Forward clutch side 19.987-20.000 mm (0.7869- When worn or
0.7874 in.) damaged
Thrust clearance ATF pump driven sprocket 0.37-0.65 mm (0.015-0.026 -
hub in.)
Planetary carrier 0.05-0.11 mm (0.002-0.0043 -
in.)
Feed pipe O.D. Drive pulley feed pipe 6.97-6.98 mm (0.274-0.275 6.95 mm (0.274 in.)
in.)
Forward clutch feed pipe 11.47-11.48 mm (0.4516- 11.45 mm (0.451 in.)
0.4520 in.)
Feed pipe bushing I.D. Drive pulley feed pipe 7.00-7.015 mm (0.2756- 7.030 mm (0.277 in.)
0.2762 in.)
Forward clutch feed pipe 11.5-11.518 mm (0.4528- 11.533 mm (0.454 in.)
0.4535 in.)
Sealing ring groove width 2.00-2.10 mm (0.079-0.083 2.105 mm (0.083 in.)
in.)
Thrust shim, 22 x 28 mm C 1.15 mm (0.045 in.) When worn or
thickness (ATF pump driven damaged
sprocket hub)
D 1.40 mm (0.055 in.) When worn or
damaged
E 1.65 mm (0.065 in.) When worn or
damaged
F 1.90 mm (0.075 in.) When worn or
damaged
G 2.15 mm (0.085 in.) When worn or
damaged
H 2.40 mm (0.095 in.) When worn or
damaged
Thrust shim, 25 x 31 mm A 1.050 mm (0.041 in.) When worn or
thickness (Planetary carrier) damaged
B 1.12 mm (0.044 in.) When worn or
damaged
C 1.19 mm (0.047 in.) When worn or
damaged
D 1.26 mm (0.050 in.) When worn or
damaged
E 1.33 mm (0.052 in.) When worn or
damaged
F 1.40 mm (0.055 in.) When worn or
damaged
G 1.47 mm (0.058 in.) When worn or
damaged
H 1.54 mm (0.061 in.) When worn or
damaged
I 1.61 mm (0.063 in.) When worn or
damaged
J 1.68 mm (0.066 in.) When worn or
damaged

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Specifications - Standards and Service Limits

K 1.75 mm (0.069 in.) When worn or


damaged
L 1.82 mm (0.072 in.) When worn or
damaged
M 1.085 mm (0.0427 in.) When worn or
damaged
N 1.155 mm (0.0454 in.) When worn or
damaged
O 1.225 mm (0.0482 in.) When worn or
damaged
P 1.295 mm (0.0510 in.) When worn or
damaged
Q 1.365 mm (0.0537 in.) When worn or
damaged
R 1.435 mm (0.0565 in.) When worn or
damaged
S 1.505 mm (0.0593 in.) When worn or
damaged
T 1.575 mm (0.0620 in.) When worn or
damaged
U 1.645 mm (0.0648 in.) When worn or
damaged
V 1.715 mm (0.0675 in.) When worn or
damaged
W 1.785 mm (0.0703 in.) When worn or
damaged

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Specifications - Standards and Service Limits

2-22
Standards and Service Limits
Honda Multi Matic Transmission and HMM
Differential (cont'd)

Item Measurement Qualification Standard or New Service Limit


Drive pulley shaft Diameter of needle bearing Flywheel side 24.007-24.020 mm (0.945- When worn or
contact area 0.946 in.) damaged
Forward clutch side 24.007-24.020 mm (0.945- When worn or
0.946 in.) damaged
I.D. at sealing ring 24.007-24.020 mm (0.945- When worn or
0.946 in.) damaged
Driven pulley shaft Diameter of needle bearing Start clutch side 43.981-43.991 mm (1.7315- When worn or
contact area 1.7319 in.) damaged
Thrust clearance Start clutch side 0-0.13 mm (0-0.005 in.) -
Cotter, 25.5 mm thickness A 2.90 mm (0.114 in.) When worn or
(Start clutch hub) damaged
B 3.00 mm (0.118 in.) When worn or
damaged
C 3.10 mm (0.122 in.) When worn or
damaged
D 3.20 mm (0.126 in.) When worn or
damaged
Starter clutch feed pipe End cover side 6.97-6.98 mm (0.274-0.275 6.95 mm (0.274 in.)
O.D. in.)
Flywheel housing side 8.97-8.98 mm (0.353-0.354 8.95 mm (0.352 in.)
in.)
Driven pulley shaft feed pipe 11.47-11.48 mm (0.4516- 11.45 mm (0.451 in.)
O.D. 0.4520 in.)
Start clutch feed pipe End cover side 7.00-7.015 mm (0.2756- 7.030 mm (0.277 in.)
bushing I.D. 0.2762 in.)
Flywheel housing side 9.0-9.015 mm (0.354-0.355 9.03 mm (0.356 in.)
in.)
Driven pulley shaft feed pipe 11.50-11.518 mm (0.4528- 11.533 mm (0.454 in.)
bushing I.D. 0.4535 in.)
Start clutch end plate I.D. 88.90-88.935 mm (3.500- When worn or
3.501 in.) damaged
Secondary gear shaft Thrust clearance 0-0.15 mm (0-0.006 in.) -

Thrust shim, 25 x 35 mm A 2.80 mm (0.110 in.) When worn or


thickness damaged
B 2.90 mm (0.114 in.) When worn or
damaged
C 3.00 mm (0.118 in.) When worn or
damaged
D 3.10 mm (0.122 in.) When worn or
damaged
E 3.20 mm (0.126 in.) When worn or
damaged
F 3.30 mm (0.130 in.) When worn or
damaged
G 3.40 mm (0.134 in.) When worn or
damaged
H 3.50 mm (0.138 in.) When worn or
damaged
I 3.60 mm (0.142 in.) When worn or
damaged

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Specifications - Standards and Service Limits

J 3.70 mm (0.146 in.) When worn or


damaged
K 3.80 mm (0.150 in.) When worn or
damaged
Sealing ring groove width 2.50-2.65 mm (0.098-0.104 2.655 mm (0.105 in.)
in.)
Park gear and pawl When worn or
damaged

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Specifications - Standards and Service Limits

2-23
Standards and Service Limits
Honda Multi Matic Transmission and HMM
Differential (cont'd)

Item Measurement Qualification Standard or New Service Limit


HMM differential Pinion shaft contact area 18.010-18.028 mm (0.709- -
carrier I.D. 0.710 in.)
Carrier-to-pinion shaft 0.023-0.057 mm (0.001- 0.1 mm (0.004 in.)
clearance 0.002 in.)
Driveshaft contact area I.D. 26.025-26.045 mm (1.0246- -
1.0254 in.)
Carrier-to-driveshaft 0.045-0.086 mm (0.002- 0.12 mm (0.005 in.)
clearance 0.003 in.)
Set ring-to-carrier bearing 0-0.15 mm (0-0.006 in.) Adjust
outer race clearance
HMM differential Backlash 0.08-0.15 mm (0.003-0.006 -
pinion gear in.)
I.D. 18.042-18.066 mm (0.7103- -
0.7113 in.)
Pinion gear-to-pinion shaft 0.055-0.095 mm (0.0022- 0.15 mm (0.006 in.)
clearance 0.0037 in.)

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Specifications - Standards and Service Limits

2-24
Standards and Service Limits
Steering

Item Measurement Qualification Standard or New Service Limit


Steering wheel Rotational play measure at With engine running 0-10 mm (0-0.39 in.) -
outside edge
Starting load measured at With engine running 29 N (3.0 kgf, 6.6 lbs) -
outside edge
Gearbox Angle of rack guide screw 20° Max.
loosened from locked
position
Pump Output pressure with shut- Engine speed at 3,000 rpm 7,600-8,300 kPa (78-85 kgf/cm2, 1,110-1,210 psi)
off valve closed (min)
290-1,100 kPa (3-11 kgf/cm2, 43-156 psi)
Power steering fluid Capacity Use Genuine Honda power For reservoir capacity: 0.3 l (0.32 US qt, 0.26 Imp qt)
steering fluid
For system capacity: 1.0 l (1.06 US qt, 0.88 Imp qt)
Power steering pump Deflection with 98 N (10 kgf, Used belt: 13.0-16.5 mm (0.51-0.65 in.)
belt NOTE: Adjust a 22 lbs) applied mid-way
New belt: 9.0-11.0 mm (0.35-0.43 in.)
new belt to the new between pulleys
belt spec, run the
Tension (measured with belt Used belt: 390-540 N (40-55 kgf, 88-121 lbs)
engine for 5 minutes,
tension gauge)
then readjust it to the New belt: 740-880 N (75-90 kgf, 165-198 lbs)
used belt spec.

Suspension
Item Measurement Qualification Standard or New Service Limit
Wheel alignment Camber Front 0°00'+45°
Rear -0°45'+45'
Caster Front 1°33'+1°
Total Toe Front 0+3 mm (0+0.12 in.)
Rear Adjust: IN 2+2-1 mm (0.08+0.08-0.04 in.)
Inspect: IN 2+3 mm (0.08+0.12 in.)
Front wheel turning angle Inside wheel
D15B engine 40°00'+2°
D17A engine 38°00'+2°
Outside wheel
D15B engine 31°00' (Reference)
D17B engine 30°00' (Reference)
Aluminium wheel Runout Axial 0-0.7 mm (0-0.03 in.) 2.0 mm (0.08 in.)
Radial 0-0.7 mm (0-0.03 in.) 1.5 mm (0.06 in.)
Steel wheel Runout Axial 0-1.0 mm (0-0.04 in.) 2.0 mm (0.08 in.)
Radial 0-1.0 mm (0-0.04 in.) 1.5 mm (0.06 in.)
Wheel bearings End play Front 0-0.05 mm (0-0.002 in.)
Rear 0-0.05 mm (0-0.002 in.)

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Specifications - Standards and Service Limits

2-25
Standards and Service Limits
Brakes

Item Measurement Qualification Standard or New Service Limit


Parking brake lever Distance travelled when 4-door Rear drum brake 6-7 clicks, Rear disc brake 7-8 clicks
pulled with 196 N (20 kgf,
5-door 8-9 clicks
44 lbs) of force
Brake pedal Pedal height (Carpet M/T 4-door 184 mm (7.24 in.), 5-door 180 mm (7.09 in.)
removed)
A/T 4-door 188 mm (7.40 in.), 5-door 184 mm (7.24 in.)
Free play 0.4-3.0 mm (0.016-0.118 in.)
Master cylinder Piston-to-pushrod 0-0.4 mm (0-0.02 in.)
clearance
Brake disc Thickness Front 20.9-21.8 mm (0.82-0.86 in.) 19.0 mm (0.75 in.)
Rear 8.9-9.1 mm (0.350-0.358 in.) 8.0 mm (0.31 in.)
Runout - 0.10 mm (0.004 in.)
Parallelism - 0.015 mm (0.0006 in.)
Brake pads Thickness Front KX model 9.5-10.5 mm (0.37-0.41 in.) 1.6 mm (0.06 in.)
Except KX model 9.0-10.0 mm (0.35-0.39 in.) 1.6 mm (0.06 in.)
Thickness Rear 8.5-9.5 mm (0.33-0.37 in.) 1.6 mm (0.06 in.)
Brake drum I.D. 4-door 199.9-200.0 mm (7.870-7.874 201 mm (7.91 in.)
in.)
5-door 219.9-220.0 mm (8.657-8.661 221 mm (8.701 in.)
in.)
Brake shoes Lining thickness 4-door 4.0 mm (0.16 in.) 2.0 mm (0.08 in.)
5-door 4.5 mm (0.18 in.) 2.0 mm (0.08 in.)
Brake booster Vehicle Characteristics at 196 N (20 Vacuum N (kgf, lbf) kPa (kgf/cm2, psi)
with ABS kgf, 44 lbf) pedal force
kPa (mmHg, inHg) (1) (2)
0 (0, 0) 98 (10, 22) 0 (0, 0) 0 (0, 0)
294 (30, 66) 1700 (17, 1600 (16,
240) 230)
66.7 (500, 19.7) 98 (10, 22) 4600 (47, 4200 (43,
670) 610)
294 (30, 66) 10500 10300
(107, (105, 1500)
1500)
Brake booster Vehicle Characteristics at 196 N (20 Vacuum N (kgf, lbf) kPa (kgf/cm2, psi)
without ABS kgf, 44 lbf) pedal force
kPa (mmHg, inHg) (3) (4) (5)
0 (0, 0) 98 (10, 22) 0 (0, 0) 0 (0, 0) 0 (0, 0)
294 (30, 66) 1700 (17, 1600 (16, 1800 (18,
240) 230) 260)
66.7 (500, 19.7) 98 (10, 22) 4400 (45, 4100 (42, 4800 (49,
640) 600) 700)
294 (30, 66) 10500 10300 (105, 9800 (100,
(107, 1500) 1400)
1500)

(1) Except 4-door KQ models


(2) 4-door KQ model
(3) Except 4-door KQ, PA models and KK (VIN) model
(4) 4-door KQ model and KK (VIN) model
(5) 4-door PA model

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Specifications - Standards and Service Limits

Air Conditioning
Item Measurement Qualification Standard or New
Refrigerant Type HFC-134 a (R-134 a)
Capacity or system 500-550 g (17.6-19.4 oz)
Refrigerant Oil Type SANDEN: SP-10 (P/N 38897-P13-003 or38899-P13-
A01)
Capacity of components Condenser 25 ml (5/6 fl oz, 0.9 Imp oz)
Evaporator 45 ml (1 ½ fl oz, 1.3 Imp oz)
Each line and hose 10 ml (1/3 fl oz, 0.4 Imp oz)
Receiver 10 ml (1/3 fl oz, 0.4 Imp oz)
Compressor 130-150 ml (4 1/3 fl oz, 3.7 Imp oz-5 fl oz, 4.5 Imp oz)
Compressor Starter coil resistance at 68°F (20°C) 3.05-3.35 ohms
Pulley-to-pressure plate 0.5+0.15 mm (0.02+0.006 in.)
clearance
Compressor belt Deflection with 98 N (10 kgf, Used belt: 8.5-11.0 mm (0.33-0.43 in.)
NOTE: Adjust a new 22 lbs) applied mid-way New belt: 5.0-6.5 mm (0.20-0.26 in.)
belt to the new belt between pulleys
spec., run the engine Tension (measured with belt Used belt: 440-590 N (45-60 kgf, 100-130 lbs)
for 5 minutes, then tension gauge) New belt: 930-1,125 N (95-115 kgf, 210-255 lbs)
readjust it to the used
belt spec.

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Specifications - Design Specifications

2-26
Design Specifications

Item Measurement Qualification Specification


DIMENSIONS Overall length 4-door 4,460 mm (175.6 in.)*1
4,450 mm (175.2 in.)*2
4,435 mm (174.6 in.)*3 *4
5-door 4,285 mm (168.7 in.)
Overall width 4-door 1,715 mm (67.5 in.)
1,720 mm (67.7 in.)*3
1,695 mm (66.7 in.)*4
5-door 1,695 mm (66.7 in.)
Overall height 4-door 1,445 mm (56.9 in.)
1,440 mm (56.7 in.)*2 *3 *4
5-door 1,495 mm (58.9 in.)
1,585 mm (62.4 in.)*5
Wheelbase 4-door 2,625 mm (103.3 in.)
2,620 mm (103.1 in.)*2 *3 *4
5-door 2,680 mm (105.5 in.)*6
2,685 mm (105.7 in.)*7
Track Front (4-door) 1,471 mm (57.9 in.)
1,470 mm (57.9 in.)*2 *3 *4
Front (5-door) 1,470 mm (57.9 in.)*6
1,472 mm (58.0 in.)*7
Rear (4-door) 1,478 mm (58.2 in.)
1,470 mm (57.9 in.)*2 *3
1,465 mm (57.7 in.)*4
Rear (5-door) 1,470 mm (57.9 in.)*6
1,489 mm (58.6 in.)*7
Ground clearance 104 mm (4.10 in.)
Seating capacity Five
WEIGHT Curb Weight 4-door (M/T) 1,077-1,144 kg (2,374-2,522 lbs)
1,100-1,135 kg (2,425-2,502 lbs)*2
4-door (A/T) 1,106-1,170 kg (2,438-2,579 lbs)
1,125-1,160 kg (2,480-2,557 lbs)*2
4-door (HMM) 1,140-1,145 kg (2,513-2,524 lbs)
5-door (M/T) 1,130-1,195 kg (2,491-2,634 lbs)
1,160-1,190 kg (2,557-2,623 lbs)*2
5-door (A/T) 1,164-1,221 kg (2,566-2,692 lbs)
1,185-1,215 kg (2,612-2,679 lbs)*2
Max. permissible Weight 4-door
4-door (KY model) 1,555 kg (3,428 lbs)
Max. loaded Vehicle Weight 4-door 1,580 kg (3,483 lbs)
(ADR)*2
5-door (M/T) 1,640 kg (3,616 lbs)
5-door (A/T) 1,660 kg (3,660 lbs)

*1: European model


*2: Australian model

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Specifications - Design Specifications

*3: Saudi Arabia model


*4: Hong Kong model
*5: With Roof Antenna
*6: European model (MPW Condition)
*7: Except European model

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Specifications - Design Specifications

2-27
Design Specifications
(cont'd)

Item Measurement Qualification Specification


ENGINE Type D17A5, D17A4, D17A2, Water-cooled, 4-stroke SOHC VTEC engine
D16V2, D16W8, D16W7,
D15Y4 engines
D17A3, D17A1, D17Z1, Water-cooled, 4-stroke SOHC engine
D15Y6, D15Y5, D15Y3,
D15Y2, D14Z5 engines
Cylinder arrangement Inline 4-cylinder, transverse
Bore and stroke D14Z5 engine 75 x 79 mm (2.95 x 3.11 in.)
D15Y6, D15Y5, D15Y4, 75 x 84.5 mm (2.95 x 3.33 in.)
D15Y3, D15Y2 engines
D16V2, D16W8, D16W7 75 x 90 mm (2.95 x 3.54 in.)
engines
D17A5, D17A4, D17A3, 75 x 94.4 mm (2.95 x 3.72 in.)
D17A2, D17A1, D17Z1
engines
Displacement D14Z5 engine 1,396 cm3 (85 cu in.)
D15Y6, D15Y5, D15Y4, 1,493 cm3 (91 cu in.)
D15Y3, D15Y2 engines
D16V2, D16W8, D16W7 1,590 cm3 (97 cu in.)
engines
D17A5, D17A4, D17A3, 1,668 cm3 (102 cu in.)
D17A2, D17A1, D17Z1
engines
Compression ratio D14Z5 engine 10.4
D15Y5, D15Y3, D15Y2 9.0
engines
D15Y6 engine 9.4
D15Y4 engine 9.9
D16V2, D16W8 engines 9.4
D16W7 engine 10.4
D17A3, D17A1, D17Z1 9.5
engines
D17A4, D17A2 engines 9.9
D17A5 engine 9.5
Valve train D17A5, D17A4, D17A2, Belt driven, SOHC VTEC 4 valves per cylinder
D16V2, D16W8, D16W7,
D15Y4 engines
D17A3, D17A1, D15Y5, Belt driven, SOHC 4 valves per cylinder
D15Y3, D15Y2, D14Z5
engines

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Specifications - Design Specifications

2-28
Design Specifications
(cont'd)

Item Measurement Qualification Specification


ENGINE Lubrication system Forced, wet sump, with trochoid pump
Oil pump displacement at 6,000 engine rpm 36.4 l (38.5 US qt, 32.0 imp qt)/minute
Water pump displacement at 6,000 engine rpm 130 l (137 US qt, 114 imp qt)/minute
Fuel required KQ, KK, KX, KP, KV, KH, UNLEADED gasoline with 86 research octane number
KN, KU models or higher
KE, KG, KB models Premium UNLEADED gasoline with 93 research
octane number or higher
KY, KF, KW, KT models LEADED gasoline with 86 pump octane number or
higher (RON of 86 UNLEADED gasoline may also be
used)
STARTER Type Gear reduction
Normal output M/T 1.0 kW
A/T 1.2 kW
Hour rating 30 seconds
Direction of rotation Clockwise as viewed from gear end
CLUTCH Clutch M/T Single plate dry, diaphragm spring
A/T Torque converter
Clutch friction material M/T 176 cm3 (102 sq in.)
surface area
MANUAL Type Synchronised, 5-speed forward, 1 reverse
TRANSMISSION
Primary reduction Direct 1:1
Gear ratio 1st D14/D17 engines 4-door and D16 engine 3/4-door
3.142 Other engines 3.461
2nd D14 engine 4-door 1.750 other engines 1.869
3rd 1.241
4th KU D15 engine 0.911 other engines 0.969
5th KU D15 engine 0.756 other engines 0.805
Reverse 3.230
Final reduction Type Single helical gear
Gear ratio 4.411
AUTOMATIC Type Electronically controlled automatic, 4-speed forward, 1
TRANSMISSION reverse
Primary reduction Direct 1:1
Gear ratio 1st 2.722
2nd KU D17A2 engine model: 1.516, other model: 1.468
3rd KU D17A2 engine model: 1.078, other model: 0.975
4th KU D17A2 engine model: 1.516, other model: 0.674
Reverse 1.955
Final reduction Type Single helical gear
Gear ratio KU D15Y6 engine model: 4.066, other model: 4.357
HONDA MULTI Type Electronically controlled continuously variable
MATIC transmission
TRANSMISSION
Primary reduction Direct 1:1
(CVT)
Gear ratio Low-high 2.466-0.449
Reverse 2.466
Final reduction Type Single helical gear

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Specifications - Design Specifications

Gear ratio 4.562


STEERING Type 4-door Rack and pinion, with electrical power
assistance/hydraulic power assistance
5-door Rack and pinion, with electrical power assistance
Overall ratio 14.49
Turns, lock-to-lock 2.83
Steering wheel diameter 380 mm (15.0 in.)
SUSPENSION Type Front (4-door) Strut
Front (5-door) Strut
Rear Double wishbone
Shock absorber Front and rear Telescopic, hydraulic, nitrogen gas-filled

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Specifications - Design Specifications

2-29
Design Specifications
(cont'd)

Item Measurement Qualification Specification


WHEEL ALIGNMENT Camber Front 0°
Rear -0°45'
Caster Front 1°33'
Total toe Front 0 mm (0 in.)
Rear In 2 mm (1/16 in.)
BRAKE Type of service brake Front Power-assisted self-adjusting ventilated disc
Rear Power-assisted self-adjusting solid disc or drum
Type of parking brake Mechanical actuating, rear wheels
Pad friction surface area Front 35 cm2 x 2 (5.4 sq in. x 2)
Shoe friction surface area Rear 67 cm2 x 2 (10.3 sq in. x 2)
TYRES Size of front and rear tyre KE (1.4S), KG (1.4S, 1.6 184/70R14 88H
(4-door) LS), KB, KQ (GLI), KH
(EXI), KN (150I), KU (EXI),
KY, KF, KV, KT models
KK, KX models 185/70R14 86H M + S
KM, KP models 185/65R15 88H
KE (1.6SE), KG (1.6LS, 195/60R15 88H
1.6ES) KQ (VTI), KH (VTI),
KN (170I) KU (VTI, VTI-S)
models
Size of front and rear tyre KE (1.4S, 1.4LS), KT 185/70R 14 88H
(5-door) models
KE (1.6S, 1.6LS, 1.6ES), 195/60R 15 88H
KQ models
Size of spare tyre KQ, KN, KU, KX models T125/70D15 95M
AIR CONDITIONING Cooling capacity 3,870 kcal/h (15,400 BTU/h)
Compressor Type/manufacturer Scroll/SANDEN
Number of cylinders -
Capacity 85.7 ml/rev. (5.23 cu in./rev.)
Maximum speed 12,000 rpm
Lubricant capacity 130 ml (4 1/3 fl oz)
Lubricant type SP-10 (P/N 38897-P13-A01AH or 38899-P13-A01)
Condenser Type Corrugated fin
Evaporator Type Corrugated fin
Blower Type Radial fan
Motor type 190 W/12 V
Speed control 9-speed
Maximum capacity 480 m3/h (16,900 cu ft/h)
Temperature clutch Air-mix type
Compressor clutch Type Dry, single plate, poly-V belt drive
Electrical power 42 W maximum at 12 V
consumption at 20°C (68°F)
Refrigerant Type HFC-134a (R-134a)
Quantity 500-550 g (17.5-19.5 oz)

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Specifications - Design Specifications

2-30
Design Specifications
(cont'd)

Item Measurement Qualification Specification


ELECTRICAL Battery 12 V-36 AH/5 hours
RATINGS
12 V – 45 AH/20 hours
12 V – 38 AH/5 hours*1
12 V – 47 AH/20 hours*1
Starter DENSO 12 V – 1.0 kW
MITSUBA 12 V – 1.2 kW
Alternator 12 V – 70 A
Fuses Under-hood fuse/relay box 80 A, 40 A, 30 A, 20 A, 15 A, 7.5 A
Under-dash fuse/relay box 20 A, 15 A, 10 A, 7.5 A
Light bulbs Headlight high beam 12 V – 60 W
Headlight low beam 12 V – 55 W
Front turn signal/Front side 12 V – 21 W/5 W
marker lights
Front position lights 12 V – 5 W/3 CP*2 (candlepower)
Front parking lights 12 V – 5 W
Side turn signal lights 12 V – 21 W*2
Rear turn signal lights 12 V – 21 W
Brake/Taillights/Rear side 12 V – 21W/5 W
marker light
Rear for light 12 V – 21 W
Inner taillight 12 V – 5 W
High mount brake light 12 V – 21 W
Back-up light 12 V – 21 W
License plate light 12 V -3 CP
Ceiling light 12 V – 8 W
Trunk light (4-door) 12 V – 5 W
Luggage area light (5-door) 12 V – 5 W
Individual map light 12 V – 8 W
Spotlights 14 V – 8 W
Gauge light 14 V – 1.4 W
Indicator light 12 V – 1.12 W

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Specifications - Body Specifications

2-31
Body Specifications

Unit: mm (in.)

*1: European model


*2: Australian model
*3: Saudi Arabia model
*4: Hong Kong model

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Specifications - Body Specifications

2-32
Body Specifications
(cont'd)

Unit: mm (in.)

*1: With Roof Antenna


*2: European model (MPW condition)
*3: Except European model

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Maintenance - Maintenance

Maintenance

Lubricants and Fluids 3-2


Maintenance Schedule for Normal Conditions (For European 3-4
Model)
Maintenance Schedule for Severe Conditions (For European 3-6
Model)
Maintenance Schedule for Normal Conditions (For Australia and 3-8
New Zealand Models)
Maintenance Schedule for Severe Conditions (For Australia and 3-10
New Zealand Models)
Maintenance Schedule for Normal Conditions (Except European, 3-12
Australia and New Zealand Models)
Maintenance Schedule for Severe Conditions (Except European, 3-14
Australia and New Zealand Models)

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Maintenance - Lubricants and Fluids

3-2
Lubricants and Fluids

For the details of lubrication points and type of lubricants to be applied, refer to the illustrated index and various work procedures
(such as Assembly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section.
NO. LUBRICATION POINTS LUBRICANT
1 Engine Always use fuel-efficient that says "API service SG, SH or SJ"
SAE Viscosity See chart below.
2 Transmission Manual Genuine Honda Manual Transmission Fluid (MTF) *1
Automatic Genuine Honda ATF-Z1 (ATF) *2
Honda Multi Matic
3 Brake system (includes ABS line) Brake fluid DOT 3 or DOT 4 *3
4 Clutch line Brake fluid DOT 3 or DOT 4 *3
5 Power steering gearbox Steering grease P/N 08733-B070E
6 Release fork (manual transmission) Super High Temp Urea Grease (P/N 08798-9002)
7 Shift and select cable ends (Manual transmission)
8 Throttle cable end (dashboard lower panel hole) Silicon grease
9 Throttle cable end (throttle link) Multi-purpose grease
10 Brake master cylinder pushrod
11 Clutch master cylinder pushrod
12 Shift lever
13 Pedal linkage
14 Battery terminals
15 Fuel fill lid
16 Rear brake shoe linkage Honda White Lithium Grease
17 Hood hinges and latch
18 Trunk hinges and latch (4-Door model)
Tailgate hinges and latch (5-Door model)
19 Door hinges, upper and lower
20 Door opening detent
21 Calliper piston boot, calliper pins and boots Silicone grease
22 Brake line joints (front and rear wheelhouse) Rust preventatives
23 Power steering system Honda Power Steering Fluid *4
24 Air conditioning compressor Compressor oil: SANDEN: SP-10 (P/N 38897-P13-003 or
38899-P13-A01)
For refrigerant: HFC-134a (R-134a)

Recommended Engine Oil


Engine oil viscosity for ambient temperature ranges

CAUTION
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged
periods. Although this is unlikely unless you handle used oil on a daily basis, it is still

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Maintenance - Lubricants and Fluids

advisable to thoroughly wash your hands with soap and water as soon as possible after
handling used oil.

*1: Always use genuine Honda Manual Transmission Fluid (MTF). Using motor
oil can cause stiffer shifting because it does not contain the proper additives.
*2: Always use genuine Honda ATF-Z1 (ATF). Using a non-Honda ATF can
affect shift quality.
*3: We recommend Genuine Honda Brake Fluid. Using a non-Honda brake fluid
can cause corrosion and decrease the life of the system.
*4: Always Honda Power Steering Fluid. Using any other type of power steering
fluid or automatic transmission fluid can cause increased wear and poor
steering in cold weather.

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Maintenance - Lubricants and Fluids

3-3
Lubricants and Fluids
(cont'd)

4-door

5-door

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Maintenance - Maintenance Schedule for Normal Conditions

3-4
Maintenance Schedule for Normal
Conditions
(European Model)

Listed by Distance/Time
Follow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe Conditions
Maintenance Schedule on 3-6 and 3-7 do not apply.
Service at the indicated distance or time km x 1,000 20 40 60 80 100 120 140 160 180 200
whichever comes first.
miles x 1,000 12 24 36 48 60 72 84 96 108 120
months 12 24 36 48 60 72 84 96 108 120
Replace engine oil z z z z z z z z z z
Replace engine oil filter z z z z z z z z z z
Replace air cleaner element z z z z z
Inspect valve clearance z z z z z
Replace fuel filter z
Replace spark plugs z z z z z
Replace timing belt, and inspect water pump Every 120,000 km (72,000 miles) or 96 months
Inspect and adjust drive belts z z z z z
Inspect idle speed z
Replace engine coolant 200,000 km (120,000 miles) or 120 months, thereafter
every 100,000 km (60,000 miles) or 60 months
Replace transmission fluid Manual Transmission Every 120,000 km (72,000 miles) or 96 months
Automatic Transmission 120,000 km (72,000 miles) or 96 months, thereafter every
80,000 km (48,000 miles) or 48 months
Inspect front and rear brakes z z z z z z z z z z
Replace brake fluid Every 36 months
Check parking brake adjustment z z z z z z
Replace air conditioning filter Every 30,000 km (18,000 miles) or 12 months
Check light alignment z z z z z z z z z z
Test drive (noise, stability, dashboard operation) z z z z z z z z z z
Visually inspect the following items:
Tie rod ends, steering gearbox and boots z z z z z z z z z z
Suspension components
Driveshaft boots
Brake hoses and lines (including ABS)
All fluid levels and condition of fluid
Exhaust system
Fuel line and connections
Tyre condition

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Maintenance - Maintenance Schedule for Normal Conditions

3-5
Maintenance Schedule for Normal
Conditions
(European Model) (cont'd)

NOTES SECTION and PAGE


(see page 8-5)
(see page8-6)
(see page 11-147) (see page 11-147)
Check the valve clearance. (see page 6-14)
(see page 11-138) (see page 11-296)
(see page 11-438) (see page 11-571)
(see page 4-25)
Check water pump for signs of seal leakage. (see page 6-18) (see page 6-22) (see
page 10-7)
Check for cracks and damage. (see page 17-23)
Check deflection and tension.
(see page 11-125) (see page 11-285)
(see page 11-425) (see page 11-560)
Check specific gravity for freezing point. (see page 10-8)
Use genuine Honda MTF (Manual Transmission Fluid). (see page 13-3)
Use genuine Honda AFT-Z1 (ATF). (see page 14-122)
Check the brake pad and disc thickness. Check for damage or (see page 19-3)
cracks.
Check the wheel cylinder for leaks.
Check the brake linings for cracking, glazing, wear or
contamination.
Check the callipers for damage, leaks and tightness.
Use only DOT 3 brake fluid. (We recommend Genuine Honda Brake Fluid.) Check (see page 19-7)
that Brake fluid level is between the upper and lower marks on the reservoir.
Check the parking brake operation. (see page 19-6)
-
Check the position of the headlight. (see page 22-114)
Check for road stability, noise, vibrations and dashboard operation. -
Check for correct installation and position, check for cracks, -
deterioration rust and leaks.
Check tightness of screws, nuts and joints. If necessary, retighten.
Check rack grease and steering linkage. Check the boot for (see page 17-5)
damage and leaking grease.
Check the fluid line for damage and leaks.
Check the bolts for tightness. (see page 18-3)
Check all the dust covers for deterioration and damage.
Check the boot and boot band for cracks (see page 16-3)
Check rack grease.
Check the master cylinder, proportioning control valve and ABS modulator and (see page 19-48)
leakage.
Check for leaks. -
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, (see page 9-5)
leaks and tightness.

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Maintenance - Maintenance Schedule for Normal Conditions

Check fuel lines for loose connections, cracks and deterioration. Retighten loose (see page 11-132) (see page 11-290)
connections and replace any damaged parts (see page 11-432) (see page 11-565)
Check for pressure, puncture or cuts and irregular tread wear. -

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Maintenance - Maintenance Schedule for Severe Conditions

3-6
Maintenance Schedule for Severe
Conditions
(European Model)

Listed by Distance/Time
Service at the indicated distance or time km x 1,000 20 40 60 80 100 120 140 160 180 200
whichever comes first.
miles x 1,000 12 24 36 48 60 72 84 96 108 120
months 12 24 36 48 60 72 84 96 108 120
Replace engine oil Every 10,000 km (6,000 miles) or 6 months
Replace engine oil filter z z z z z z z z z z
Replace air cleaner element z z z z z z z z z z
Inspect valve clearance z z z z z
Replace fuel filter z
Replace spark plugs z z z z z
Replace timing belt and inspect water pump z
Inspect and adjust drive belts z z z z z
Inspect idle speed z
Replace engine coolant 200,000 km (120,000 miles) or 120 months,
thereafter every 100,000 km (60,000 miles) or
60 months
Replace transmission fluid Manual Transmission Every 60,000 km (36,000 miles) or 48 months
Automatic 60,000 km (36,000 miles) or 48 months,
Transmission thereafter every 40,000 km (24,000 miles) or
24 months
Inspect front and rear brakes Every 10,000 km (6,000 miles) or 6 months
Replace brake fluid Every 36 months
Check parking brake adjustment z z z z z z z z z z
Replace air conditioning filter Every 30,000 km (18,000 miles) or 12 months
Check light alignment z z z z z z z z z z
Test drive (noise, stability, dashboard operation) z z z z z z z z z z
Visually inspect the following items:
Tie rod ends, steering gearbox and boots Every 10,000 km (6,000 miles) or 6 months
Suspension components
Driveshaft boots
Brake hoses and lines (including ABS) z z z z z z z z z z
All fluid levels and condition of fluid
Exhaust system
Fuel line and connections
Tyre condition
Follow the Severe Conditions Maintenance Schedule if the customer's vehicle is driven MAINLY under one or more of the following
conditions:

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Maintenance - Maintenance Schedule for Severe Conditions

Driving less than 8 km (5 miles) per trip or, in freezing temperatures, driving less than 16 km (10 miles) per trip.
Driving in extremely hot over 35°C (95°F) conditions.
Extensive idling of long periods of stop-and-go-driving.
Trailer towing, driving with a car-top carrier, or driving in mountainous conditions.
Driving on muddy, dusty, or de-iced roads.

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Maintenance - Maintenance Schedule for Severe Conditions

3-7
Maintenance Schedule for Severe
Conditions
(European Model) (cont'd)

NOTES SECTION and PAGE


(see page 8-5)
(see page 8-6)
(see page 11-147) (see page 11-447)
Check the valve clearance. (see page 6-14)
(see page 11-138) (see page 11-296)
(see page 11-438) (see page 11-571)
(see page 4-25)
Check water pump for signs of seal leakage. (see page 6-18) (see page 6-22) (see
page 10-7)
Check for cracks and damage. (see page 17-23)
Check deflection and tension.
(see page 11-125) (see page 11-285)
(see page 11-425) (see page 11-560)
Check specific gravity for freezing point. (see page 10-8)
Use genuine Honda MTF (Manual Transmission Fluid). (see page 13-3)
Use genuine Honda AFT-Z1 (ATF). (see page 14-122)
Check the brake pad and disc thickness. Check for damage or (see page 19-3)
cracks.
Check the wheel cylinder for leaks.
Check the brake linings for cracking, glazing, wear or
contamination.
Check the calipers for damage, leaks and tightness.
Use only DOT 3 brake fluid. (We recommend Genuine Honda Brake Fluid.) Check (see page 19-7)
that Brake fluid level is between the upper and lower marks on the reservoir.
Check the parking brake operation. (see page 19-6)
-
Check the position of the headlight. (see page 22-144)
Check for road stability, noise, vibrations and dashboard operation. -
Check for correct installation and position, check for cracks, -
deterioration rust and leaks.
Check tightness of screws, nuts and joints. If necessary, retighten.
Check rack grease and steering linkage. Check the boot for (see page 17-5)
damage and leaking grease.
Check the fluid line for damage and leaks.
Check the bolts for tightness. (see page 18-3)
Check all dust covers for deterioration and damage.
Check the boot and boot band for cracks (see page 16-3)
Check rack grease.
Check the master cylinder, proportioning control valve and ABS modulator and (see page 19-48)
leakage.
Check for leaks. -
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, (see page 9-5)
leaks and tightness.

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Maintenance - Maintenance Schedule for Severe Conditions

Check fuel lines for loose connections, cracks and deterioration. Retighten loose (see page 11-132) (see page 11-290)
connections and replace any damaged parts (see page 14-232) (see page 11-565)
Check for pressure, puncture or cuts and irregular tread wear. -

NOTE: If the customer's vehicle is driven OCCASIONALLY under severe condition, you should follow the Normal Condition
Maintenance Schedule on pages 3-4 and 3-5.

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Maintenance - Maintenance Schedule for Normal Conditions

3-8
Maintenance Schedule for Normal
Conditions
(Australian and New Zealand Models)

Listed by Distance/Time
Follow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe Conditions
Maintenance Schedule on 3-10 and 3-11 do not apply.

Service at the indicated distance or km x 1,000 20 40 60 80 100 120 140 160 180 200
time whichever comes first.
miles x 1,000 12 24 36 48 60 72 84 96 108 120
months 12 24 36 48 60 72 84 96 108 120

Replace engine oil Every 10,000 km (6,000 miles) or 12 months

Replace engine oil filter z z z z z z z z z z


Replace air cleaner element z z z z z
Inspect valve clearance z z z z z
Replace fuel filter z z z z z
Replace spark plugs z z z z z
Replace timing belt and inspect water pump z
Inspect and adjust drive belts z z z z z
Inspect idle speed z z
Replace engine coolant 200,000 km (120,000 miles) or 120 months, thereafter every
100,000 km (60,000 miles) or 60 months

Replace transmission fluid Manual Transmission z


Automatic Transmission 120,000 km (72,000 miles) or 96 months, thereafter every
80,000 km (48,000 miles) or 48 months

CVT z z z
Inspect front and rear brakes z z z z z z z z z z
Replace brake fluid Every 36 months

Check parking brake adjustment z z z z z z


Check light alignment z z z z z z z z z z
Test drive (noise, stability, dashboard operation) z z z z z z z z z z
Visually inspect the following items:

Tie rod ends, steering gearbox and boots z z z z z z z z z z


Suspension components

Driveshaft boots

Brake hoses and lines (including ABS)

All fluid levels and condition of fluid

Exhaust system

Fuel line and connections

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Maintenance - Maintenance Schedule for Normal Conditions

Tyre condition

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Maintenance - Maintenance Schedule for Normal Conditions

3-9
Maintenance Schedule for Normal
Conditions
(Australian and New Zealand Models) (cont'd)

NOTES SECTION and PAGE


(see page 8-5)
(see page 8-6)
(see page 11-147) (see page 11-447)
Check the valve clearance. (see page 6-14)
(see page 11-138) (see page 11-296)
(see page 11-438) (see page 11-571)
(see page 4-25)
Check water pump for signs of seal leakage. (see page 6-18) (see page 6-22) (see
page 10-7)
Check for cracks and damage. (see page 17-23)
Check deflection and tension.
(see page 11-125) (see page 11-285)
(see page 11-425) (see page 11-560)
Check specific gravity for freezing point. (see page 10-8)
Use genuine Honda MTF (Manual Transmission Fluid). (see page 13-3)
Use genuine Honda AFT-Z1 (ATF). (see page 14-122)
Use genuine Honda AFT-Z1 (ATF). (see page 14-320)
Check the brake pad and disc thickness. Check for damage or (see page 19-3)
cracks.
Check the wheel cylinder for leaks.
Check the brake linings for cracking, glazing, wear or
contamination.
Check the calipers for damage, leaks and tightness
Use only DOT 3 brake fluid. (We recommend Genuine Honda Brake Fluid.) Check (see page 19-7)
that Brake fluid level is between the upper and lower marks on the reservoir.
Check the parking brake operation. (see page 19-6)
Check the position of the headlight. (see page 22-114)
Check for road stability, noise, vibrations and dashboard operation. -
Check for correct installation and position, check for cracks, -
deterioration rust and leaks.
Check tightness of screws, nuts and joints. If necessary, retighten.
Check rack grease and steering linkage. Check the boot for (see page 17-5)
damage and leaking grease.
Check the fluid line for damage and leaks.
Check the bolts for tightness. (see page 18-3)
Check all dust covers for deterioration and damage.
Check the boot and boot band for cracks (see page 16-3)
Check rack grease.
Check the master cylinder, proportioning control valve and ABS modulator and (see page 19-48)
leakage.
Check for leaks. -
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, (see page 9-5)
leaks and tightness.

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Maintenance - Maintenance Schedule for Normal Conditions

Check fuel lines for loose connections, cracks and deterioration. Retighten loose (see page 11-132) (see page 11-290)
connections and replace any damaged parts (see page 11-432) (see page 11-565)
Check for pressure, puncture or cuts and irregular tread wear. -

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Maintenance - Maintenance Schedule for Severe Conditions

3-10
Maintenance Schedule for Severe
Conditions
(Australian and New Zealand Models)

Listed by Distance/Time

Service at the indicated distance or time km x 1,000 20 40 60 80 100 120 140 160 180 200
whichever comes first.
miles x 1,000 12 24 36 48 60 72 84 96 108 120
months 12 24 36 48 60 72 84 96 108 120

Replace engine oil Every 5,000 km (3,000 miles) or 6 months

Replace engine oil filter Every 10,000 km (6,000 miles) or 6 months

Replace air cleaner element z z z z z z z z z z


Inspect valve clearance z z z z z
Replace fuel filter z z z z z
Replace spark plugs z z z z z
Replace timing belt, and inspect water pump z z
Inspect and adjust drive belts z z z z z
Inspect idle speed z z
Replace engine coolant 200,000 km (120,000 miles) or 120 months,
thereafter every 100,000 km (60,000 miles) or 60
months

Replace transmission fluid Manual Transmission z z z


Automatic Transmission z z z z
CVT z z z
Inspect front and rear brakes Every 10,000 km (6,000 miles) or 6 months

Replace brake fluid Every 36 months

Check parking brake adjustment z z z z z z


Check light alignment z z z z z z z z z z
Test drive (noise, stability, dashboard operation) z z z z z z z z z z
Visually inspect the following items:

Tie rod ends, steering gearbox and boots Every 10,000 km (6,000 miles) or 6 months

Suspension components

Driveshaft boots

Brake hoses and lines (including ABS) z z z z z z z z z z


All fluid levels and condition of fluid

Exhaust system

Fuel line and connections

Tyre condition
Follow the Severe Conditions Maintenance Schedule if the customer's vehicle is driven MAINLY under one or more of the following

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Maintenance - Maintenance Schedule for Severe Conditions

conditions:
Driving less than 8 km (5 miles) per trip or, in freezing temperatures, driving less than 16 km (10 miles) per trip.
Driving in extremely hot over 35°C (95°F) conditions.
Extensive idling of long periods of stop-and-go-driving.
Trailer towing, driving with a car-top carrier, or driving in mountainous conditions.
Driving on muddy, dusty, or de-iced roads.

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Maintenance - Maintenance Schedule for Severe Conditions

3-11
Maintenance Schedule for Severe
Conditions
(Australian and New Zealand Models) (cont'd)

NOTES SECTION and PAGE


(see page 8-5)
(see page8-6)
(see page 11-147) (seepage 11-147)
Check the valve clearance. (see page 6-14)
(see page 11-138) (see page 11-296)
(see page 11-438) (see page 11-571)
(see page 4-25)
Check water pump for signs of seal leakage. (see page 6-18) (see page 6-22) (see
page 10-7)
Check for cracks and damage. (see page 17-23)
Check deflection and tension.
(see page 11-125) (see page 11-285)
(see page 11-425) (see page 11-560)
Check specific gravity for freezing point. (see page 10-8)
Use genuine Honda MTF (Manual Transmission Fluid). (see page 13-3)
Use genuine Honda AFT-Z1 (ATF). (see page 14-122)
Use genuine Honda AFT-Z1 (ATF). (see page 14-320)
Check the brake pad and disc thickness. Check for damage or (see page 19-3)
cracks.
Check the wheel cylinder for leaks.
Check the brake linings for cracking, glazing, wear or
contamination.
Check the calipers for damage, leaks and tightness.
Use only DOT 3 brake fluid. (We recommend Genuine Honda Brake Fluid.) Check (see page 19-7)
that Brake fluid level is between the upper and lower marks on the reservoir.
Check the parking brake operation. (see page 19-6)
Check the position of the headlight. (see page 22-144)
Check for road stability, noise, vibrations and dashboard operation. -
Check for correct installation and position, check for cracks, -
deterioration rust and leaks.
Check tightness of screws, nuts and joints. If necessary, retighten.
Check rack grease and steering linkage. Check the boot for (see page 17-5)
damage and leaking grease.
Check the fluid line for damage and leaks.
Check the bolts for tightness. (see page 18-3)
Check all dust covers for deterioration and damage.
Check the boot and boot band for cracks (see page 16-3)
Check rack grease.
Check the master cylinder, proportioning control valve and ABS modulator and (see page 19-48)
leakage.
Check for leaks. -
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, (see page9-5)
leaks and tightness.

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Maintenance - Maintenance Schedule for Severe Conditions

Check fuel lines for loose connections, cracks and deterioration. Retighten loose (see page 11-132) (see page 11-290)
connections and replace any damaged parts (see page 11-432) (see page 11-565)
Check for pressure, puncture or cuts and irregular tread wear. -

NOTE: If the customer's vehicle is driven OCCASIONALLY under severe condition, you should follow the Normal Condition
Maintenance Schedule on pages 3-8 and 3-9.

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Maintenance - Maintenance Schedule for Normal Conditions

3-12
Maintenance Schedule for Normal
Conditions
(Except European, Australian and New Zealand
Models)

Listed by Distance/Time

Service at the indicated distance or time whichever comes km x 1,000 20 40 60 80 100 120 140 160 180 200
first.
miles x 1,000 12 24 36 48 60 72 84 96 108 120
months 12 24 36 48 60 72 84 96 108 120

Replace engine oil Unleaded type: Every 10,000 km (6,000


miles) or 12 months

Leaded type: Every 5,000 km (3,000 miles)


or 6 months

Replace engine oil filter Unleaded type: Every 20,000 km (12,000


miles) or 12 months

Leaded type: Every 10,000 km (6,000


miles) or 6 months

Clean or replace air cleaner element Every 20,000 km (12,000 miles)

Inspect valve clearance with catalytic Every 40,000 km (24,000 miles)


converter

without catalytic Every 20,000 km (12,000 miles)


converter

Replace fuel filter z z z z z


Replace spark plugs Non-Platinum with catalytic Every 40,000 km (24,000 miles)
type converter

without catalytic Every 20,000 km (12,000 miles)


converter

Platinum type Every 100,000 km (60,000 miles)

Replace timing belt and inspect water pump z z


Inspect and adjust drive belts z z z z z
Inspect idle speed with catalytic z
converter

without catalytic z z z
converter

Replace engine coolant 200,000 km (120,000 miles) or 120 months,


thereafter every 100,000 km (60,000 miles)
or 60 months

Replace transmission fluid Manual Transmission z z


Automatic Transmission z z
Honda Multi Matic z z z
Inspect front and rear brakes Every 100,000 km (60,000 miles) or 6
months

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Maintenance - Maintenance Schedule for Normal Conditions

Replace brake fluid Every 36 months

Check parking brake adjustment z z z z z z


Rotate tyre (Check tyre inflation and condition at least once per month) Every 100,000 km (60,000 miles)

Visually inspect the following items:

Tie rod ends, steering gearbox and boots Every 10,000 km (6,000 miles) or 6 months

Suspension components

Driveshaft boots

Brake hoses and lines (including ABS) z z z z z z z z z z


All fluid levels and condition of fluid

Exhaust system

Fuel line and connections


Follow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe Conditions
Maintenance Schedule on 3-14 and 3-15 do not apply.

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Maintenance - Maintenance Schedule for Normal Conditions

3-13
Maintenance Schedule for Normal
Conditions
(Except European, Australian and New Zealand
Models) (cont'd)

NOTES SECTION and PAGE


(see page 8-5)
(see page 8-6)
(see page 11-147) (see page 11-447)
Check the valve clearance. (see page 6-14)
(see page 11-138) (see page 11-296)
(see page 11-438) (see page 11-571)
(see page 4-25)
Check water pump for signs of seal leakage. (see page 6-18) (see page 6-22) (see
page 10-7)
Check for cracks and damage. (see page 17-23)
Check deflection and tension.
(see page 11-125) (see page 11-285)
(see page 11-425) (see page 11-560)
Check specific gravity for freezing point. (see page 10-8)
Use genuine Honda MTF (Manual Transmission Fluid). (see page 13-3)
Use genuine Honda AFT-Z1 (ATF). (see page 14-122)
Use genuine Honda AFT-Z1 (ATF). (see page 14-320)
Check the brake pad and disc thickness. Check for damage or (see page 19-3)
cracks.
Check the wheel cylinder for leaks.
Check the brake linings for cracking, glazing, wear or
contamination.
Check the callipers for damage, leaks and tightness.
Use only DOT 3 brake fluid. (We recommend Genuine Honda Brake Fluid.) Check (see page 19-7)
that Brake fluid level is between the upper and lower marks on the reservoir.
Check the parking brake operation. (see page 19-6)
The suggested rotation method is shown in the diagram of the Owner's Manual. -
Check for correct installation and position, check for cracks, -
deterioration rust and leaks.
Check tightness of screws, nuts and joints. If necessary, retighten.
Check rack grease and steering linkage. Check the boot for (see page 17-5)
damage and leaking grease,
Check the fluid line for damage and leaks.
Check the bolts for tightness (see page 18-3)
Check all the dust covers for deterioration and damage.
Check the boot and boot band for cracks (see page 16-3)
Check rack grease.
Check the master cylinder, proportioning control valve and ABS modulator and (see page 19-48)
leakage.
Check for leaks. -
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, (see page 9-5)
leaks and tightness.
Check fuel lines for loose connections, cracks and deterioration. Retighten loose (see page 11-132) (see page 11-290)

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Maintenance - Maintenance Schedule for Normal Conditions

connections and replace any damaged parts. (see page 11-432) (see page 11-565)

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Maintenance - Maintenance Schedule for Severe Conditions

3-14
Maintenance Schedule for Severe
Conditions
(Except European, Australian and New Zealand
Models)

Listed by Distance/Time

Service at the indicated distance or time whichever km x 1,000 20 40 60 80 100 120 140 160 180 200
comes first.
miles x 1,000 12 24 36 48 60 72 84 96 108 120
months 12 24 36 48 60 72 84 96 108 120

Replace engine oil Every 5,000 km (3,000 miles) or 6 months

Replace engine oil filter Every 10,000 km (6,000 miles) or 6 months

Clean or replace air cleaner element Every 20,000 km (12,000 miles)

Inspect valve clearance with catalytic converter Every 40,000 km (24,000 miles)

without catalytic converter Every 20,000 km (12,000 miles)

Replace fuel filter z z z z z


Replace spark plugs Non-Platinum type with catalytic converter Every 40,000 km (24,000 miles)

without catalytic converter Every 20,000 km (12,000 miles)

Platinum type Every 100,000 km (60,000 miles)

Replace timing belt and inspect water pump z z


Inspect and adjust drive belts z z z z z
Inspect idle speed with catalytic converter z
without catalytic converter z z z
Replace engine coolant 200,000 km (120,000 miles) or 120 months,
thereafter every 100,000 km (60,000 miles) or 60
months

Replace transmission fluid Manual Transmission z z z


Automatic Transmission z z z z
Honda Multi Matic z z z z z
Inspect front and rear brakes Every 100,000 km (60,000 miles) or 6 months

Replace brake fluid Every 36 months

Check parking brake adjustment z z z z z z


Rotate tyre (Check tyre inflation and condition at least once per month) Every 100,000 km (60,000 miles)

Visually inspect the following items:

Tie rod ends, steering gearbox and boots Every 10,000 km (6,000 miles) or 6 months

Suspension components

Driveshaft boots

Brake hoses and lines (including ABS) z z z z z z z z z z


All fluid levels and condition of fluid

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Maintenance - Maintenance Schedule for Severe Conditions

Exhaust system

Fuel line and connections


Follow the Severe Conditions Maintenance Schedule if the customer's vehicle is driven MAINLY under one or more of the following
conditions:
Driving less than 8 km (5 miles) per trip or, in freezing temperatures, driving less than 16 km (10 miles) per trip.
Driving in extremely hot over 35°C (95°F) conditions.
Extensive idling of long periods of stop-and-go-driving.
Trailer towing, driving with a car-top carrier, or driving in mountainous conditions.
Driving on muddy, dusty, or de-iced roads.

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Maintenance - Maintenance Schedule for Severe Conditions

3-15
Maintenance Schedule for Severe
Conditions
(Except European, Australian and New Zealand
Models) (cont'd)

NOTES SECTION and PAGE


(see page 8-5)
(see page 8-6)
(see page 8-6) (see page 11-447)
Check the valve clearance. (see page 6-14)
(see page 11-138) (see page 11-296)
(see page 11-438) (see page 11-571)
(see page 4-25)
Check water pump for signs of leakage. (see page 6-18) (see page 6-22) (see
page 10-7)
Check for cracks and damage. (see page 17-23)
Check deflection and tension.
(see page 11-125) (see page 11-285)
(see page 11-425) (see page 11-560)
Check specific gravity for freezing point. (see page 10-8)
Use genuine Honda MTF (Manual Transmission Fluid). (see page 13-3)
Use genuine Honda AFT-Z1 (ATF). (see page 14-122)
Use genuine Honda AFT-Z1 (ATF). (see page 14-320)
Check the brake pad and disc thickness. Check for damage or (see page 19-3)
cracks.
Check the wheel cylinder for leaks.
Check the brake linings for cracking, glazing, wear or
contamination.
Check the calipers for damage, leaks and tightness.
Use only DOT 3 brake fluid. (We recommend Genuine Honda Brake Fluid.) Check (see page 19-7)
that Brake fluid level is between the upper and lower marks on the reservoir.
Check the parking brake operation. (see page 19-6)
The suggested rotation method is shown in the diagram of the Owner's Manual. -
Check for correct installation and position, check for cracks, -
deterioration rust and leaks.
Check tightness of screws, nuts and joints. If necessary, retighten.
Check rack grease and steering linkage. Check the boot for (see page 17-5)
damage and leaking grease.
Check the fluid line for damage and leaks.
Check the bolts for tightness. (see page 18-3)
Check all dust covers for deterioration and damage.
Check the boot and boot band for cracks (see page 16-3)
Check rack grease.
Check the master cylinder, proportioning control valve and ABS modulator and (see page 19-48)
leakage.
Check for leaks. -
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, (see page 9-5)
leaks and tightness.
Check fuel lines for loose connections, cracks and deterioration. Retighten loose (see page 11-132) (see page 11-290)

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Maintenance - Maintenance Schedule for Severe Conditions

connections and replace any damaged parts (see page 11-432) (see page 11-565)

NOTE: If the customer's vehicle is driven OCCASIONALLY under severe condition, you should follow Normal Condition
Maintenance Schedule on pages 3-12 and 3-13

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Engine Electrical - Engine Electrical

Engine Electrical

Special Tools 4-2


Starting System
Component Location Index 4-3
Circuit Diagram 4-4
Starter Circuit Troubleshooting 4-5
Clutch Interlock Switch Test 4-7
Starter Solenoid Test 4-7
Starter Performance Test 4-8
Starter Replacement 4-9
Starter Overhaul 4-10

Ignition System
Component Location Index 4-20
Circuit Diagram 4-21
Ignition Timing Inspection 4-22
Ignition Coil Troubleshooting 4-23
Ignition Coil Removal/Installation 4-24
Spark Plug Inspection 4-25

Charging System
Component Location Index 4-26
Circuit Diagram 4-27
Charging Circuit Troubleshooting 4-28
Alternator Replacement 4-31
Alternator Overhaul 4-32
Alternator-Compressor Belt Inspection and Adjustment 4-37
Alternator Belt Inspection and Adjustment 4-38

Cruise Control
Component Location Index 4-39
Circuit Diagram 4-40
Symptom Troubleshooting Index 4-41
Cruise Control Communication Circuit Troubleshooting 4-43
(A/T)
Control Unit Input Test 4-44
Main Switch Test/Replacement 4-46
Set/Resume/Cancel Switch Test/Replacement 4-46
Actuator Test 4-47
Actuator/Cable Replacement 4-48
Actuator Cable Adjustment 4-49
Clutch Pedal Position Switch Test 4-49

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Engine Electrical - Engine Electrical

4-2
Engine Electrical
Special Tools

Number Tool Number Description Qty


1 07JGG-0010100 Belt Tension Gauge 1
2 07746-0010400 Driver Attachment, 52 x 55 mm 1
3 07749-0010000 Handle Driver 1

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Engine Electrical - Starting System

4-3
Starting System
Component Location Index

1. STARTER CUT RELAY


2. Test, page 23-79UNDER-DASH
FUSE/RELAY BOX
3. CLUTCH INTERLOCK SWITCH
(KX model with M/T)
Test, page 4-7
Switch Position Adjustment, page
12-4
4. STARTER
Starter Circuit Troubleshooting, page
4-5
Solenoid Test, Page 4-7
Performance Test, page 4-8
Replacement, page 4-9
Overhaul, page 4-10
5. TRANSMISSION RANGE SWITCH
(A/T)
Test 4-door, page 14-159 or
6. 5-door, page 14-160Replacement,
page 14-161TRANSMISSION
RANGE SWITCH (HONDA
MULTIMATIC)
Test, page 14-342
Replacement, page 14-343

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Engine Electrical - Starting System

4-4
Starting System
Circuit Diagram

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Engine Electrical - Starting System

4-5
Starting System
Starter Circuit Troubleshooting

NOTE: 1. 4. Check the battery condition. Check electrical


connections at the battery and the starter for
Air temperature must be between 15 o and 38 o F (59o looseness and corrosion. Then check the starter
and 100o F) during this procedure. again.
After this test, or any subsequent repair, reset the Did the starter crank the engine?
Engine Control Module (ECM)/Powertrain Control
YES - The starting system is OK.
Module (PCM) to clear any Diagnostic Trouble Codes
(DTCs), 4-door (see page 11-3) or 5-door (see page NO - Go to step 5.
11-3). 2. 5. Make sure the transmission is in neutral, then
Recommended Procedure: disconnect the BLK/WHT wire (A) from the starter
Use a starter system tester. solenoid (B). Connect a jumper wire from the battery
Connect and operate the equipment in accordance positive terminal to the solenoid terminal.
with the manufacturer's instructions.
Alternate Procedure
1. 1. Hook up the following equipment:
Ammeter, 0 - 400 A
Voltmeter, 0 - 20 V (accurate within 0.1 volt)
Tachometer, 0 - 1200 rpm (min -1 )

Did the starter crank the engine?


YES - Go to step 6.
NO - Remove the starter, and diagnose its internal
problems.
3. 6. Check the following items in the order listed until you
find the open circuit.
Check the BLK/WHT wire and connectors
2. 2. Remove the No. 46 (15 A) fuse from the under-dash between the under-dash fuse/relay box and the
fuse/relay box. ignition switch, and between the under-dash
3. 3. With the shift lever in N or P (A/T, HONDA MULTI fuse/relay box and the starter.
MATIC), or the clutch pedal pressed (M/T with KX Check the ignition switch (see page 22-83).
model), turn the ignition switch to start (III). With A/T, HONDA MULTIMATIC, check the
Did the starter crank the engine normally? transmission range switch and connector. With
YES - The starting system is OK. M/T (KX model), check the clutch inter lock switch
and connector.
NO - If the starter will not crank at all, go to step 4. If it Check the starter cat-relay (A/T, HONDA MULTI
cranks the engine erratically or too slowly, go to step 7. If it MATIC, and M/T [KX model]).
will not disengage from the flywheel or torque converter ring
gear when you release the key, check for the following until
you find the cause.
Solenoid plunger and switch malfunction
Dirty drive gear or damaged overrunning clutch

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Engine Electrical - Starting System

4-6
Starting System
Starter Circuit Troubleshooting (cont'd)

1. 7. Check engine speed during cranking.


Is engine speed above 100 rpm (min -1 )?
YES - Go to step 8.
NO - Remove and disassemble the starter, and check for
the following until you find the cause.
Excessively worn starter brushes
Open circuit in commutator brushes
Dirty or damaged helical splines or drive gear
Faulty drive gear clutch
2. 8. Check the cranking voltage and current draw.
Is cranking voltage no less than 8.0 volts (D15Y2, D16W7
(KG model), D16W8, D17Z1 (Except Malaysia model),
D17Z2, D17Z3, D17A1, D17A2 (Except Malaysia model),
D17A5 (Except Indonesia model) engines) or 9.0 volts
(Except D15Y2, D16W7 (KG model), D16W8, D17Z1
(Except Malaysia model), D17Z2, D17Z3, D17A1, D17A2
(Except Malaysia model), D17A5 (Except Indonesia model)
engines) and current draw no more than 200 amps (D15Y2,
D16W7 (KG model), D16W8, D17Z1 (Except Malaysia
model), D17Z2, D17Z3, D17A1, D17A2 (Except Malaysia
model), D17A5 (Except Indonesia model) engines) or 150
amps (Except D15Y2, D16W7 (KG model), D16W8, D17Z1
(Except Malaysia model), D17Z2, D17Z3, D17A1, D17A2
(Except Malaysia model), D17A5 (Except Indonesia model)
engines)?
YES - Go to step 9.
NO - Remove and disassemble the starter, and check for
the following until you find the cause.
Open circuit in starter armature commutator
segments
Starter armature dragging
Shorted armature winding
Excessive drag in engine
3. 9. Remove the starter and inspect its drive gear and the
flywheel or torque converter ring gear for damage.
Replace any damaged parts.

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Engine Electrical - Starting System

4-7 Starter Solenoid Test


Starting System
Clutch Interlock Switch Test

1. 1. Disconnect the clutch interlock switch 2P connector. 1. 1. Check the hold-in coil for continuity between the S
terminal (A) and the armature housing (ground).
There should be continuity.
If there is continuity, go to step 2.
If there is no continuity, replace the solenoid.

2. 2. Remove the clutch interlock switch (A).


3. 3. Check for continuity between the terminals according 2. 2. Check the pull-in coil for continuity between the S
to the table. terminal (A) and M terminal (B). There should be
continuity.
If there is continuity, the solenoid is OK.
If there is no continuity, replace the solenoid.

4. 4. If necessary, replace the switch or adjust the pedal


height (see page 12-4).

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Engine Electrical - Starting System

4-8
Starting System
Starter Performance Test

1. 1. Disconnect the wires from the S terminal and the M 1. 5. Disconnect the battery also from the body. If the
terminal. pinion retracts immediately, it is working properly. To
avoid damaging the starter, do not leave the battery
connected for more than 10 seconds.

2. 1. 12V BATTERY
2. BODY (GROUND)
2. 1. 12V BATTERY
3. 2. Make a connection as described below using as
2. BODY (GROUND)
heavy a wire as possible (preferably equivalent to
the wire used for the vehicle). 3. 6. Clamp the starter firmly in a vice.
3. Connect the battery as shown. If the starter pinion 7. Connect the starter to the battery as described in the
pops out, it is working properly. To avoid damaging diagram below, and confirm that the motor starts and
the starter, do not leave the battery connected for keeps rotating.
more than 10 seconds.
4. Disconnect the battery from the M terminal. If the
pinion does not retract, the hold-in coil is working
properly. To avoid damaging the starter, do not
leave the battery connected for more than 10
seconds.

4. 1. STARTER
2. 12V BATTERY

4. 1. 12V BATTERY 5. 8. If the electric current and motor speed meet the
2. BODY (GROUND) specifications when the battery voltage is at 11.5 V,
the starter is working properly.
Specifications:
Maker Electric current Motor speed
DENSO 90 A or less 3,000 rpm (min -1 )
(1.0 Kw) or more
DENSO 50 A or less 6,000 rpm (min -1 )
(0.8 Kw)
MITSUBISHI 53 A or less 6,000 rpm (min -1 )
(0.8 Kw) or more

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Engine Electrical - Starting System

4-9
Starting System
Starter Replacement

1. 1. Make sure you have the anti-theft code for the radio, 1. 6. Install in the reverse order of removal. Make sure the
then write down the frequencies for the radio's preset crimped side of the ring terminal (A) is facing out.
buttons.
2. Disconnect the battery negative cable, then
disconnect the positive cable, and wait at least 3
minutes.
3. Remove the resonator.
4. Disconnect the starter cable (A) from the B terminal
on the solenoid, then disconnect the BLK/WHT wire
(B) from the S terminal.
2. 7. Connect the battery positive cable and negative
cable to the battery.
3. 8. Enter the anti-theft code for the radio, then enter the
customer's radio station presets.

2. 5. Remove the two bolts holding the starter, then


remove the starter.

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Engine Electrical - Starting System

4-10
Starting System
Starter Overhaul

Disassembly/Reassembly - D15Y2, D16W7 (KG model), D16W8, D17Z1 (Except Malaysia model), D17Z2,
D17Z3, D17A1, D17A2 (Except Malaysia model), D17A5 (Except Indonesia model) engines
1. STARTER SOLENOID
2. MOLYBDENUM DISULPHIDE
3. SOLENOID LEVER
4. GEAR HOUSING
5. OVERRUNNING CLUTCH
ASSEMBLY
6. ARMATURE
7. ARMATURE HOUSING
8. MOLYBDENUM DISULPHIDE
9. MOLYBDENUM DISULPHIDE
10. BRUSH HOLDER
11. END COVER

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Engine Electrical - Starting System

4-11
Starting System
Starter Overhaul (cont'd)

Disassembly/Reassembly - D15Y3 (Philippine model), D16W9 (Philippine model), D17Z1 (Malaysia model),
D17Z5, D17A2 (Malaysia model), D17A5 (Indonesia model) engines
1. STARTER SOLENOID
2. MOLYBDENUM DISULPHIDE
3. STARTER LEVER
4. GEAR HOUSING
5. FRONT BEARING
6. MOLYBDENUM DISULPHIDE
7. OVERRUNNING CLUTCH
ASSEMBLY
8. ARMATURE
9. END COVER
10. BRUSH
11. BRUSH HOLDER
12. BRUSH SPRING
13. ARMATURE HOUSING

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Engine Electrical - Starting System

4-12
Starting System
Starter Overhaul (cont'd)

Disassembly/Reassembly - Except D15Y2, D15Y3 (Philippine model), D16W7 (KG model), D16W8, D16W9,
D17Z1, D17Z2, D17Z3, D17A1, D17A2, D17A5 engines
1. STARTER SOLENOID
2. MOLYBDENUM
DISULPHIDE
3. SOLENOID LEVER
4. GEAR HOUSING
5. FRONT BEARING
6. MOLYBDENUM
DISULPHIDE
7. OVERRUNNING
CLUTCH ASSEMBLY
8. ARMATURE
9. END COVER
10. REAR BEARING
11. MOLYBDENUM
DISULPHIDE
12. BRUSH HOLDER
INSULATOR
13. ARMATURE HOUSING
14. BRUSH
15. BRUSH HOLDER
16. BRUSH SPRING

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Engine Electrical - Starting System

4-13
Starting System
Starter Overhaul (cont'd)

Armature Inspection and Test 1. 5. Check the commutator diameter. If the diameter is
below the service limit, replace the armature.
1. 1. Remove the starter (see page 4-9).
Commutator Diameter
2. Disassemble the starter as shown at the beginning of
this procedure. Standard (New): 27.9 - 28.0 mm (1.09 - 1.10 in.)
3. Inspect the armature for wear or damage from
Service Limit: 27.0 mm (1.06 in.)
contact with the permanent magnet. If there is wear
or damage, replace the armature.

2. 4. Check the commutator (A) surface. If the surface is


dirty or burnt, resurface with emery cloth or a lathe 2. 6. Measure the commutator (A) runout.
within the following specifications, or recondition with If the commutator runout is within the service
#500 or #600 sandpaper (B). limit, check the commutator for carbon dust or
brass chips between the segments.
If the commutator runout is not within the service
limit, replace the armature.
Commutator Runout
D15Y2, D16W7 (KG model), D16W8, D17Z1 (Except
Malaysia model), D17A2, D17Z3, D17A1, D17A2
(Except Malaysia model), D17A5 (Except Indonesia
model) engines:
Standard (New): 0.02 mm (0.001 in.) max.
Service Limit: 0.05 mm (0.002 in.)

Except D15Y2, D16W7 (KG model), D16W8, D17Z1


(Except Malaysia model), D17Z2, D17Z3, D17A1,
D17A2 (Except Malaysia model), D17A5 (Except
Indonesia model) engines:
Standard (New): 0.05 mm (0.002 in.) max.
Service Limit: 0.4 mm (0.002 in.)

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Engine Electrical - Starting System

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Engine Electrical - Starting System

4-14
Starting System
Starter Overhaul (cont'd)

1. 7. Check the mica depth (A). If the mica is too high (B), 1. 9. Place the armature (A) on an armature tester (B).
undercut the mica with a hacksaw blade to the Hold a hacksaw blade (C) on the armature core. If
proper depth. Cut away all the mica (C) between the the blade is attracted to the core or vibrates while
commutator segments. The undercut should not be the core is turned, the armature is shorted. Replace
too shallow, too narrow, or V-shaped (D). the armature.
Commutator Mica Depth
Standard (New): 0.50 - 0.75 mm (0.020 - 0.030 in.)
Service Limit: 0.2 mm (0.008 in.)

2. 10. Check with an ohmmeter that no continuity exists


between the commutator (A) and armature coil core
2. 8. Check for continuity between the segments of the (B), and between the commutator and armature shaft
commutator. If an open circuit exists between any (C). If continuity exists, replace the armature.
segments, replace the armature.

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Engine Electrical - Starting System

4-15
Starting System
Starter Overhaul (cont'd)

Starter Brush Inspection Starter Field Winding Test


1. 11. Measure the brush length. If it is not within the 1. 12. Check for continuity between the brushes (A). If
service limit, replace the armature housing assembly. there is no continuity, replace the armature housing
Brush Length (B).
D15Y2, D16W7 (KG model), D16W8, D17Z1 (Except D15Y2, D15Y3 (Philippine model), D16W7 (KG
Malaysia model), D17Z2, D17Z3, D17A1, D17A2 model), D16W8, D16W9, D17Z1, D17Z2, D17Z3,
(Except Malaysia model), D17A5 (Except Indonesia D17A1, D17A2, D17A5 engines:
model) engines:
Standard (New): 14.0 - 14.5 mm
(0.55 - 0.57 in.)
Service Limit: 9.0 mm (0.35 in.)

Except D15Y2, D16W7 (KG model), D16W8, D17Z1


(Except Malaysia model), D17Z2, D17Z3, D17A1,
D17A2 (Except Malaysia model), D17A5 (Except
Indonesia model) engines:
Standard (New): 9.7 - 10.3 mm (0.38 - 0.41 in.) Except D15Y2, D15Y3 (Philippine model), D16W7
Service Limit: 6.0 mm (0.24 in.) (KG model), D16W8, D16W9, D17Z1, D17Z2,
D17Z3, D17A1, D17A2, D17A5 engines:

2. 13. Check for continuity between each brush (A) and the
armature housing (B). If there is continuity, replace
the armature housing.

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Engine Electrical - Starting System

4-16
Starting System
Starter Overhaul (cont'd)

Starter Brush Holder Test: Brush Spring Inspection (D15Y2, D16W7 (KG
1. 14. Check that there is no continuity between the (+) model), D16W8, D17Z1 (Except Malaysia model),
brush holder (A) and (-) brush holder (B). If there is D17Z2, D17Z3, D17A1, D17A2 (Except Malaysia
continuity, replace the brush holder assembly. model), D17A5 (Except Indonesia model) engines)
D15Y2, D16W7 (KG model), D16W8, D17Z1 1. 15. Insert the brush (A) into the brush holder, and bring
(Except Malaysia model), D17Z2, D17Z3, D17A1, the brush into contact with the commutator, then
D17A2 (Except Malaysia model), D17A5 (Except attach a spring scale (B) to the spring (C). Measure
Indonesia model) engines: the spring tension at the moment the spring lifts off
the brush.
Spring 13.7 - 17.7 N (1.40 - 1.80 kgf, 3.09 -
Tension: 4.00 lbf)

D15Y3 (Philippine model), D16W9 (Philippine


model), D17Z1 (Malaysia model), D17Z5, D17A2
(Malaysia model), D17A5 (Indonesia model)
engines:

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Engine Electrical - Starting System

4-17
Starting System
Starter Overhaul (cont'd)

Overrunning Clutch Inspection Starter Reassembly (D15Y3 (Philippine model),


1. 16. Slide the overrunning clutch along the shaft. D16W9 (Philippine model), D17Z1 (Malaysia model),
Replace it, if it does not slide smoothly. D17Z5, D17A2 (Malaysia model), D17A5 (Indonesia
17. Rotate the overrunning clutch (A) both ways. model) engines)
Does it lock in one direction and rotate smoothly in 1. 19. Pry back each brush spring with a screwdriver, then
reverse ? If it does not lock in either direction or it position the brush about halfway out of its holder,
locks in both directions, replace it. and release the spring to hold it there.
D15Y2, D16W7 (KG model), D16W8, D17Z1
(Except Malaysia model), D17Z2, D17Z3, D17A1,
D17A2 (Except Malaysia model), D17A5 (Except
Indonesia model) engines:

Except D15Y2, D16W7 (KG model), D16W8, D17Z1


(Except Malaysia model), D17Z2, D17Z3, D17A1, 2. 20. Install the armature in the housing and install the
D17A2 (Except Malaysia model), D17A5 (Except brush holder. Next, pry back each brush spring
Indonesia model) engines: again, and push the brush down until it seats against
the commutator, then release the spring against the
end of the brush.
NOTE: To seat new brushes, slip a strip of #500 or #600
sandpaper, with the grit side up, between the commutator
and each brush, and smoothly rotate will be sanded to the
same contour as the commutator.

2. 18. If the starter drive gear (B) is worn or damaged,


replace the overrunning clutch assembly; the gear is
not available separately.
Check the condition of the flywheel or torque converter ring
gear if the starter drive gear teeth are damaged.

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Engine Electrical - Starting System

4-18
Starting System
Starter Overhaul (cont'd)

1. 21. Install the washer (A) starter end cover (B) to retain Starter Reassembly (D15Y2, D16W7 (KG model),
the brush holder (C). D16W8, D17Z1 (Except Malaysia model), D17Z2,
D17Z3, D17A1, D17A2 (Except Malaysia model),
D17A5 (Except Indonesia model) engines)
1. 22. 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.

2. 23. Install the armature in the housing and install the


brush holder. 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.
NOTE: To seat new brushes, slip a strip of #500 or #600
sandpaper, with the grit side up, between the commutator
and each brush, and smoothly rotate will be sanded to the
same contour as the commutator.

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Engine Electrical - Starting System

4-19
Starting System
Starter Overhaul (cont'd)

1. 24. Install the starter end cover (A) to retain the brush Starter Reassembly (Except D15Y2, D15Y3
holder (B). (Philippine model), D16W7 (KG model), D16W8,
D16W9, D17Z1, D17Z2, D17Z3, D17A1, D17A2,
D17A5 engines)
1. 25. Install the armature in the housing, and install the
brush holder, then install the tach brush in the
holder.
NOTE: To seat new brushes, slip a strip of #500 or #600
sandpaper, with the grit side up, between the commutator
and each brush, and smoothly rotate will be sanded to the
same contour as the commutator.
2. 26. Compress the spring, and install it in the brush
holder.

3. 27. Install the brush holder insulator (A) and end cover
(B).

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Engine Electrical - Ignition System

4-20
Ignition System
Component Location Index

1. SPARK PLUG
Inspection, page 4-25
2. IGNITION COIL
Troubleshooting, page 4-23
Removal/Installation, page 4-24

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Engine Electrical - Ignition System

4-21
Ignition System
Circuit Diagram

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Engine Electrical - Ignition System

4-22
Ignition System
Ignition Timing Inspection

1. 1. Start the engine. Hold the engine at 3,000 rpm (min - 1. 5. Point the light toward the pointers (A) on the timing
1 ) with no load Shift lever in Park or Neutral, until the belt cover. Check the ignition timing under a no load
radiator fan comes on, then let it idle. conditions: headlights, blower fan, rear window
2. Check the idle speed, and adjust it if necessary: defogger, and air conditioner are not operating. If the
4-door(KB, KE, KG, TR models) (see page 11- ignition timing differs from the specification below,
125). replace the ECM/PCM, 4-door (see page 11-3) or 5-
4-door(except KB, KE, KG, TR models) (see page door (see page 11-311).
11-285). Ignition Timing:
5-door(KE model) (see page 11-425). M/T:
5-door(except KE models) (see page 11-560). 8o + 2o BTDC (RED mark (B))
2. 3. Short the SCS terminal to ground: during idling in neutral
Using the SCS short connector (KB, KE, KG, TR A/T, HONDA 8o + 2o BTDC (RED mark (B))
models) (see page 19-55). MULTI MATIC: during idling in P or N
Using the DLC terminal box (except KB, KE, KG,
TR models) (see step 1 on page 19-57).
Using the Honda PGM Tester (except KB, KE,
KG, TR models) (see step 1 on page 19-57).
3. 4. Connect the timing light to the No. 1 ignition coil
wire.

2. 6. Disconnect the SCS short connector.

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Engine Electrical - Ignition System

4-23
Ignition System
Ignition Coil Troubleshooting

NOTE: Perform an ignition coil test after finishing the 1. 6. Disconnect ECM/PCM connector A (31P).
fundamental tests for the ignition system and the fuel and 7. Check for continuity between the body ground and
emissions system. ECM/PCM connector terminals A27, A28, A29 and/or
A30 individually.
1. 1. Remove the ignition coil cover.
ECM/PCM CONNECTOR A (31P)
2. Disconnect the four ignition coil 3P connectors.
3. Measure the voltage at the No. 3 terminal of each
ignition coil 3P connector with the ignition switch ON
(ll).
IGNITION COIL 3P CONNECTOR

Wire side of female terminals


Is there continuity?
YES - Repair short in the wire between ignition coil and
ECM/PCM.
NO - Go to step 8.
Wire side of female terminals 2. 8. Connect the ECM/PCM connector A (31P).
Is there battery voltage? 9. Measure the voltage at the No. 1 terminal of each
YES - Go to step 4. ignition coil 3P connector with the ignition switch to
start (lll).
NO - Repair open in the wire between ignition coil and No.
IGNITION COIL 3P CONNECTOR
1 (15A) fuse in the under-dash fuse/relay box.
2. 4. Turn the ignition switch OFF.
5. Check for continuity between the No. 2 terminal of
each ignition coil 3P connector and body ground.
IGNITION COIL 3P CONNECTOR

Wire side of female terminals


Is there approx. 0.5 V?
YES - Replace the ignition coil.
NO - Repair open in the wire between ignition coil and
Wire side of female terminals
ECM/PCM.
Is there continuity?
YES - Go to step 6.
NO - Repair open in the wire between ignition coil and
body ground (G101).

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Engine Electrical - Ignition System

4-24
Ignition System
Ignition Coil Removal/Installation

1. 1. Remove the ignition coil cover (A), then remove the


ignition coils (B).

2. 2. Install the ignition coils in the reverse order of


removal.

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Engine Electrical - Ignition System

4-25
Ignition System
Spark Plug Inspection

1. 1. Inspect the electrodes and ceramic insulator. 1. 3. Replace the plug at the specified interval, or if the
Burned or worn electrodes may be caused by: centre electrode is rounded (A). Use only the spark
Advanced ignition timing plugs listed below.
Loose spark plug Spark Plugs:
Plug heat range too hot Engine Type Spark Plug Type
Insufficient cooling D14Z5, D15Y6, ZFR5J-11 (NGK)
Fouled plug may be caused by: D15Y4, D16W7 KJ16CR-L11 (DENSO)
Retarded ignition timing
D15Y5, D17A1, ZFR6J-11 (NGK)
Oil in combustion chamber
D17A2, D17Z1, KJ20CR-L11 (DENSO)
Incorrect spark plug gap
Plug heat range too cold D17Z4
Excessive idling/low speed running D17A5 BKR6E-N11 (NGK)
Clogged air cleaner element K20PR-L11 (DENSO)
Deteriorated ignition coils
D15Y2, D15Y3, BKR5E-11 (NGK)
D16V2, D16W8 K16CR-L11 (DENSO)
D17Z2, D17Z3 ZFR6J-11 (NGK)
ZFR7J-11 (NGK)
KJ20CR-L11 (DENSO)
KJ22CR-L11 (DENSO)

2. 1. Cracked insulator
2. Damaged gasket 2. 4. Apply a small quantity of anti-seize compound to the
3. Worn or deformed electrodes plug threads, and screw the plugs into the cylinder
4. Improper gap head finger-tight. Then torque them to 18 Nm (1.8
Oil-fouling kgf/m, 13 lbf/ft).
Carbon deposits
Cracked centre electrode insulator

3. 2. Do not adjust the gap of platinum tip plugs (A);


replace the spark plug if the gap is out of
specification.
Electrode Gap:
Standard (New): 1.0 - 1.1 mm (0.039 - 0.043 in.)
Service Limit: 1.3 mm (0.05 in.)

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Engine Electrical - Charging System

4-26
Charging System
Component Location Index

1. UNDER-HOOD FUSE/RELAY
BOX
(Has built-in ELECTRICAL LOAD
DETECTOR (ELD) UNIT*)
2. CHARGING SYSTEM
INDICATOR
(In the gauge assembly)
3. Test, page 22-84ALTERNATOR-
COMPRESSOR BELT
Inspection and Adjustment, page
4-37
4. ALTERNATOR
Troubleshooting, page 4-28
5. Replacement, page 4-31Overhaul,
page 4-32BATTERY
Test, page 22-79

*: KU, KT, KX, KK models

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Engine Electrical - Charging System

4-27
Charging System
Circuit Diagram

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Engine Electrical - Charging System

4-28
Charging System
Charging Circuit Troubleshooting

If the charging system indicator does not come on or does not Is there battery voltage?
go off, or the battery is dead or low, test the following items in YES - Go to step 7.
the order listed below:
NO - Check for a blown No. 4 (10A) fuse. If the fuse is OK,
Battery (see page 22-79) repair open in the wire between the alternator and the
Charging system indicator under-dash fuse/relay box.
Alternator and regulator circuit 1. 7. Turn the ignition switch OFF
Alternator control system (KU, KT, KX, KK models) 8. Disconnect ECM/PCM connector B (24P)
9. Check continuity between the ECM/PCM connector
Charging System Indicator Test
terminal B10 and alternator 4P connector terminal
1. 1. Turn the ignition switch ON (II). No. 3.
Does the charging system indicator come on? ECM/PCM CONNECTOR B (24P)
YES - Go to step 2.
NO - Go to step 3.
2. 2. Start the engine.
Does the charging system indicator go off?
YES - Charging system indicator circuit is OK.
NO - Go to step 3.
3. 3. Turn the ignition switch OFF.
4. Troubleshoot the multiplex control system (see page ALTERNATOR 4P CONNECTOR
22-273). Wire side of female terminals
Is the multiplex control system OK?
Is there continuity?
YES - Go to step 5.
YES - Go to step 10.
NO - Check the multiplex control system as indicated by
NO - Repair open in the wire between the alternator and
the DTC (see page 22-273).
the ECM/PCM.
4. 5. Disconnect the alternator 4P connector from the
2. 10. Check continuity between the ECM/PCM connector
alternator.
terminal B10 and body ground.
6. Measure the voltage at the No. 1 terminal of the
ECM/PCM CONNECTOR B (24P)
alternator 4P connector with the ignition switch ON
(II).
ALTERNATOR 4P CONNECTOR

Wire side of female terminals


Is there continuity?
Wire side of female terminals YES - Repair short in the wire between the alternator and
the ECM/PCM.
NO - Go to alternator and regulator test.

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Engine Electrical - Charging System

4-29
Charging System
Charging Circuit Troubleshooting (cont'd)

Alternator and Regulator Circuit Test 1. 6. Read the voltage at 13.5 V.


NOTE: Adjust the voltage by turn the blower motor, rear
1. 1. Be sure the battery is sufficiently charged (see page
window defogger, brake lights and etc. on.
22-79).
2. Hook up the following equipment: Is the amperage 60A or more?
Ammeter, 0-400A YES - Alternator/regulator operation is OK.
Voltmeter, 0-20V (accurate within 0.1 V) NO - Repair the alternator components (see page 4-32).

2. 3. Start the engine. Hold the engine at 3,000 rpm (min -


1 ) with no load shift lever in Park or Neutral, until the
radiator fan comes on then let it idle.
3. 4. Raise the engine speed to 2,000 rpm (min -1 ) and
hold it there.
5. Turn the headlights (high beam) on, and measure
voltage at the alternator terminal.
Is the voltage between 13.9 and 15.1V?
YES - Go to step 6.
NO - Repair the alternator components (see page 4-32).

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Engine Electrical - Charging System

4-30
Charging System
Charging Circuit Troubleshooting (cont'd)

Alternator Control System Test (KU, KT, KX, KK 1. 7. Check for continuity between ECM/PCM connector
models) terminal B18 and body ground.
ECM/PCM CONNECTOR B (24P)
1. 1. Check for proper operation of the ELD by checking
the MIL 4-door (see page 11-3) or 5-door (see page
11-309).
2. Disconnect the alternator 4P connector from the
alternator.
3. Start the engine, and turn the headlights (high beam)
ON.
4. Measure voltage between the alternator 4P connector
terminal No. 2 and the positive terminal of the Wire side of female terminals
battery. Is there continuity?
BATTERY YES - Repair short in the wire between the alternator and
ECM/PCM.
NO - Substitute a known-good ECM/PCM, and recheck
(see page 11-3) or 5-door (see page 11-309). If prescribed
voltage is now available, replace the original ECM/PCM.
2. 8. Turn the headlight and ignition switch OFF.
9. Disconnect ECM/PCM connector B (24P).
10. Check for continuity between ECM/PCM connector
terminal B18 and alternator 4P connector terminal
ALTERNATOR 4P CONNECTOR No. 2.
Wire side of female terminals ECM/PCM CONNECTOR B (24P)
Is there 1 V or less?
YES - Go to step 8.
NO - Go to step 5.
2. 5. Turn the headlight and ignition switch OFF.
6. Disconnect ECM/PCM connector B (24P).

ALTERNATOR 4P
CONNECTOR
Wire side of female terminals
Is there continuity?
YES - Repair the alternator (see page 4-32).
NO - Repair open in the wire between the alternator and
ECM/PCM.

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Engine Electrical - Charging System

4-31
Charging System
Alternator Replacement

1. 1. Make sure you have the anti-theft code for the radio, 1. 5. Loosen the adjusting bolt (A), and remove the lock
then write down the frequencies for the radio's preset bolt (B) and mounting bolt (C), then remove the
buttons. alternator belt and alternator.
2. Disconnect the battery negative terminal.
3. Remove the adjust plate mounting bolt (A), locknut
(B), and mounting bolt (C), then remove the power
steering (P/S) pump belt (D) and pump without
disconnecting the P/S hoses (P/S).

2. 6. Install in the reverse order of removal.


7. Adjust the alternator belt tension (see page 4-38) or
the alternator-compressor belt tension (see page 4-
37).
8. Enter the anti-theft code for the radio, then enter the
customer's radio station presets.

2. 4. Disconnect the 4P connector (A) and alternator cable


(B) from the alternator.

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Engine Electrical - Charging System

4-32
Charging System
Alternator Overhaul

Exploded View
1. BEARING RETAINER
2. FRONT BEARING
3. DRIVE-END HOUSING
4. PULLEY LOCKNUT
5. PULLEY
6. ROTOR
7. REAR BEARING
8. REAR HOUSING ASSEMBLY
9. TERMINAL INSULATOR

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Engine Electrical - Charging System

4-33
Charging System
Alternator Overhaul (cont'd)

Special Tools Required 1. 5. Separate the rear housing from the drive-end
housing by inserting a flat tip screwdriver into the
Handle driver, 07749-0010000
openings and prying them apart.
Driver attachment, 52 x 55 mm, 07746-0010400
NOTE: Be careful not to damage the stator with the tip of
NOTE: Refer to the Exploded View as needed during this
the screwdriver.
procedure.
1. 1. Test the alternator and regulator before you remove
them (see page 4-28).
2. Remove the alternator (see page 4-31).
3. Remove the four through bolts.

2. 6. Separate the rear housing (A) and drive-end housing


(B) with the stator (C) attached to the rear housing.

2. 4. Heat the rear bearing seat with a 1,000 W hair drier


for about 5 minutes (50 - 60 o C, 129 - 140o F).

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Engine Electrical - Charging System

4-34
Charging System
Alternator Overhaul (cont'd)

1. 7. If you are not replacing the front bearing and/or rear 1. 10. Remove the rear bearing using the puller as shown.
bearing, go to step 15. Clamp the rotor in a soft-
jawed vice, then remove the pulley locknut.

2. 11. Use a hand press to install the new rear bearing.


Apply pressure only on the inner race to avoid
damaging the bearing.

2. 8. Remove the rotor using a puller as shown.

3. 9. Inspect the rotor shaft for galling, and inspect the


bearing journal surface in the drive-end housing for
seizure marks.
If either the rotor or drive-end housing is
damaged, replace the alternator.
If both the rotor and the drive-end housing are
OK, go to step 10.

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Engine Electrical - Charging System

4-35
Charging System
Alternator Overhaul (cont'd)

1. 12. Remove the front bearing retainer plate. 1. 14. With a hammer and the special tools, install a new
front bearing in the drive-end housing.

2. 13. Support the drive-end housing in a vice, and drive


out the front bearing with a brass drift (A) and Alternator Brush Inspection
hammer. 2. 15. Measure the length of both brushes with a vernier
calliper.
If either brush is shorter than the service limit,
replace the rear housing assembly.
If brush length is OK, go to step 16.
Alternator Brush Length:
Standard (New): 19.0 mm (0.75 in.)
Service Limit: 5 mm (0.2 in.)

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Engine Electrical - Charging System

4-36
Charging System
Alternator Overhaul (cont'd)

Rotor Slip Ring Test 1. 21. Heat the rear bearing seat with a 1,000 W hair drier
1. 16. Check that there is continuity between the slip rings for about 5 minutes (50 - 60 o C, 129 - 140o F).
(A). 22. Put the rear housing assembly (A) and drive-end
If there is continuity, go to step 17. housing/rotor assembly (B) together, tighten the four
If there is no continuity, replace the rotor through bolts (C) and pull put the pin (D).
assembly.

2. 17. Check that there is no continuity between each slip


ring (A) and the rotor (B) and the rotor shaft (C).
If there is no continuity, replace the rear housing
assembly, go to step 18.
If there is continuity, replace the rotor assembly.
Alternator Reassembly
3. 18. If you removed the pulley, put the rotor in the drive- 2. 23. After assembling the alternator, turn the pulley by
end housing, then tighten its locknut to 111 Nm (11.3 hand to make sure the rotor rotates smoothly and
kgf/m, 81.7 lbf/t). without noise.
19. Remove any grease or any oil from the slip rings. 24. Reinstall the alternator, and adjust its belt tension
20. Push the brushes (A) in, then insert a pin or drill bit (see page 4-37).
(B) (about 1.8 mm (0.77 in.) diameter) to hold them
there.

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Engine Electrical - Charging System

4-37
Charging System
Alternator-A/C Compressor Belt Inspection and
Adjustment

Special Tools Required Deflection Method


Belt Tension Gauge, 07JGG-0010100 Inspection
Belt Tension Gauge Method 1. 1. Apply a force of 98 Nm (10 kgf, 22 lbf), and measure
Inspection the deflection at the mid point (A) between the
alternator and crankshaft pulley. If the belt is worn or
1. 1. Attach the belt tension gauge to the belt and
damaged, replace it. If the belt needs adjustment, go
measure the tension. Follow the gauge
to step 2.
manufacturer's instructions. If the belt is worn or
Deflection:
damaged, replace it. If the belt needs adjustment, go
to step 2. Used Belt: 8.5 - 11.0 mm (0.33 - 0.43 in.)
Tension: New Belt: 5.6 - 6.5 mm (0.20 - 0.26 in.)
Used Belt: 390 - 540 N (40 - 55 kgf, 88 - 120 lbf)
New Belt: 830 - 980 N (85 - 100 kgf, 190 - 220 lbf)

Adjustment
2. 2. Loosen the mounting bolt (B),lock bolt (C) and lower
bracket mounting bolt mounting bolt (D).
3. Torque the mounting bolt to 20 N.m (2.0kgf.m,14
lbf.ft).
4. Turn the adjusting bolt (E) to obtain the proper belt
Adjustment tension, then retighten the lock bolt, mounting bolt
2. 2. Loosen the mounting bolt (A),lock bolt (B) and lower and lower bracket mounting bolt.
bracket mounting bolt mounting bolt (C). 5. Recheck the belt tension.
3. Torque the mounting bolt to 20 N.m (2.0kgf.m,14 6. If you installed a new belt, run the engine for 5
lbf.ft). minutes, then readjust the belt to the used belt
4. Turn the adjusting bolt (D) to obtain the proper belt specification.
tension, then retighten the lock bolt, mounting bolt 7. Check the power steering pump belt adjustment (see
and lower bracket mounting bolt. page 17-12).
5. Recheck the belt tension.
6. If you installed a new belt, run the engine for 5
minutes, then readjust the belt to the used belt
specification.
7. Check the power steering pump belt adjustment (see
page 17-12).

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Engine Electrical - Charging System

4-38
Charging System
Alternator Belt Inspection and Adjustment

Special Tools Required Deflection Method


Belt Tension Gauge, 07JGG-0010100 Inspection
Belt Tension Gauge Method 1. 1. Apply a force of 98 Nm (10 kgf, 22 lbf), and measure
Inspection the deflection at the mid point (A) between the
alternator and crankshaft pulley. If the belt is worn or
1. 1. Attach the belt tension gauge to the belt and measure the
damaged, replace it. If the belt needs adjustment, go
tension. Follow the gauge manufacturer's instructions. If
to step 2.
the belt is worn or damaged, replace it. If the belt needs
Deflection:
adjustment, go to step 2.
Tension: Used Belt: 8.5 - 11.0 mm (0.33 - 0.43 in.)
Used Belt: 340 - 490 N (35 - 50 kgf, 77 - 110 New Belt: 6.5 - 8.5 mm (0.26 - 0.33 in.)
lbf)
New Belt: 540 - 740 N (55 - 75 kgf, 120 - 170
lbf)

Adjustment
2. 2. Loosen the mounting bolt (B),lock bolt (C) and lower
bracket mounting bolt mounting bolt (D).
3. Torque the mounting bolt to 20 N.m (2.0kgf.m,14
lbf.ft).
Adjustment 4. Turn the adjusting bolt (E) to obtain the proper belt
tension, then retighten the lock bolt, mounting bolt and
2. 2. Loosen the mounting bolt (A),lock bolt (B) and lower
lower bracket mounting bolt.
bracket mounting bolt mounting bolt (C).
5. Recheck the belt tension.
3. Torque the mounting bolt to 20 N.m (2.0kgf.m,14 lbf.ft).
6. If you installed a new belt, run the engine for 5
4. Turn the adjusting bolt (D) to obtain the proper belt tension,
minutes, then readjust the belt to the used belt
then retighten the lock bolt, mounting bolt and lower
specification.
bracket mounting bolt.
7. Check the power steering pump belt adjustment (see
5. Recheck the belt tension.
page 17-12).
6. If you installed a new belt, run the engine for 5 minutes,
then readjust the belt to the used belt specification.
7. Check the power steering pump belt adjustment (see page
17-12).

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Engine Electrical - Cruise Control

4-39
Cruise Control
Component Location Index

1. CLUTCH PEDAL POSITION


SWITCH (M/T)
Test, page 4-49
Clutch Pedal Adjustment, page 12-
4
2. CRUISE CONTROL INDICATOR
(Built into gauge assembly)
Bulb Locations, page 22-87
3. SET/RESUME/CANCEL SWITCH
Test/Replacement, page 4-46
4. CRUISE CONTROL UNIT
Input Test, page 4-44
5. BRAKE PEDAL POSITION
SWITCH
Test, page 22-122Pedal Height
Adjustment, page 19-5
6. MAIN SWITCH
Test/Replacement, page 4-46
7. ACTUATOR CABLE
Adjustment, page 4-44
8. TRANSMISSION RANGE SWITCH
(A/T)
Test 4-door, page 14-159 or
5-door, page 14-160
9. ACTUATOR
Test, page 4-47Replacement, page
4-48

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Engine Electrical - Cruise Control

4-40
Cruise Control
Circuit Diagram

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Engine Electrical - Cruise Control

4-41
Cruise Control
Symptom Troubleshooting Index

NOTE:
The numbers in the table show the troubleshooting sequence.
Before troubleshooting.
check the No. 10 (7.5 A) and No. 4 (10 A) fuses in the under-dash fuse/relay box, and the No. 7 (15 A) fuse in the
under-hood fuse/relay box.
check that the horn sounds.
check the tachometer to see if it works properly.
Symptom Diagnostic procedure Also check for
Cruise control cannot be 1. 1. Check main switch (see page 4-46) Poor ground:
set 2. Check SET/RESUME/CANCEL switch (see page 4-46) G101(A/T),
3. Check brake pedal position switch and mounting (see G401(M/T), G501
page 19-5) Open circuit,
4. Check clutch pedal position switch and mounting (M/T) loose or
(see page 4-49) disconnected
5. Check transmission range switch (A/T) (see page 14- terminals: LT
160) GRN, BLK/ORN,
6. Check control unit (see page 4-44) GRY/RED, BLU,
LT BLU,
BLU/WHT
Cruise control can be set 1. 1. Check dimming circuit in gauge (see page 22-88) Poor ground:
but indicator light does not 2. Check control unit (see page 4-44) G501
go on Open circuit,
loose or
disconnected
terminals: YEL,
BLK/YEL
Cruise speed is noticeably 1. 1. Check vehicle speed sensor (VSS) (see page 22-96)
higher or lower than what 2. Check actuator (see page 4-47)
was set 3. Check control unit (see page 4-44)
Excessive overshooting or 1. 1. Check actuator (see page 4-47)
undershooting when trying 2. Check vehicle speed sensor (VSS) (see page 22-96)
to set speed 3. Check control unit (see page 4-44)
Speed fluctuation on a flat 1. 1. Check vehicle speed sensor (VSS) (see page 22-96)
road with cruise control 2. Check actuator (see page 4-47)
set 3. Check control unit (see page 4-44)
Vehicle does not 1. 1. Check SET/RESUME/CANCEL switch (see page 4-46) Open circuit, loose or
decelerate or accelerate 2. Check control unit (see page 4-44) disconnected terminals:
accordingly when GRY/RED, LT GRN/BLK
SET/RESUME/CANCEL
button is pushed
Set speed not cancelled 1. 1. Check clutch pedal position switch and mounting (see Short to ground in the LT BLU
(engine rpm stays high) page 4-49) wire
when clutch pedal is 2. Check control unit (see page 4-44)
pushed (M/T)
Set speed not cancelled 1. 1. Check transmission range switch (see page 14-160) Short to ground in the LT BLU
when shift lever is moved 2. Check control unit (see page 4-44) wire
to Neutral position (A/T)
Set speed not cancelled 1. 1. Check brake pedal position switch and mounting (see Open circuit, loose or
when brake pedal is page 19-6) disconnected terminals:
pushed 2. Check control unit (see page 4-44) WHT/BLK

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Engine Electrical - Cruise Control

4-42
Cruise Control
Symptom Troubleshooting Index (cont'd)

Symptom Diagnostic procedure Also check for


Set speed, does not 1. 1. Check main switch (see page 4-46) Short to power in the LT
cancel when main switch is 2. Check control unit (see page 4-44) GRN wire.
pushed OFF
Set speed, does not 1. 1. Check SET/RESUME/CANCEL switch (see page Open circuit, loose or
cancel when CANCEL 4-46) disconnected terminals:
button is pushed 2. Check control unit (see page 4-44) GRY/RED, LT GRN/BLK
Set speed will not resume 1. 1. Check SET/RESUME/CANCEL switch (see page Open circuit, loose or
when RESUME button is 4-46) disconnected terminals: LT
pushed (with main switch 2. Check control unit (see page 4-44) GRN/BLK
on, when set speed is
temporarily cancelled)
The transmission shifts 1. 1. Troubleshoot the cruise control communication
down slower than normal circuit (see page 4-43)
when going up a hill with
the cruise control on (A/T)

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Engine Electrical - Cruise Control

4-43
Cruise Control
Cruise Control Communication Circuit
Troubleshooting (A/T)

1. 1. Start the engine. 1. 7. Connect a voltmeter between the No. 8 terminal of


2. Turn on the cruise control main switch, then drive the the cruise control unit 14 P connector and body
vehicle to speeds over 25 mph (40 km/h) with the ground. Test-drive the vehicle at speeds over 25
cruise control. mph (40 km/h) with the cruise control set, and watch
Does the cruise control operate? the voltmeter.
YES - Go to step 3. CRUISE CONTROL UNIT 14P CONNECTOR
NO - Check the cruise control unit (see page 4-44) or
cruise control actuator.
2. 3. Turn the ignition switch OFF.
4. Disconnect ECM/PCM connector E (31P) and cruise
control unit 14P connector.
5. Check for continuity between ECM/PCM connector
terminal E12 and body ground.
ECM/PCM CONNECTOR E (31P) Wire side of female terminals
Is there about 1 V?
YES - Go to step 8.
NO - Replace the cruise control unit.
2. 8. Connect a voltmeter between ECM/PCM connector
terminal E12 and body ground. Drive the vehicle at
speeds over 25 mph (40 km/h) with the cruise
control set, and watch the voltmeter.
ECM/PCM CONNECTOR E (31P)
Wire side of female terminals
Is there continuity?
YES - Repair short to ground in the wire between PCM
connector terminal E12 and the cruise control unit 14P
connector terminal No. 8.
NO - Go to step 6.
3. 6. Reconnect ECM/PCM connector E (31P) and the
cruise control unit 14P connector.
Wire side of female terminals
Is there about 1 V?
YES - Check for loose connectors. If necessary replace the
ECM/PCM and recheck (see page 11-3) or 5-door (see
page 11-309).
NO - Repair open in the wire between ECM/PCM
connector terminal E12 and the control unit 14P connector
terminal No. 8.

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Engine Electrical - Cruise Control

4-44
Cruise Control
Control Unit Input Test

SRS components are located in this area. Review the SRS component locations (see page 23-25), precautions and procedures
(see page 23-25) in the SRS before performing repairs or service.
1. 1. Remove the driver's dashboard lower cover.
2. Disconnect the 14P connector from the control unit.
3. Inspect the connector and socket terminals to be sure they are all making good contact.
If the terminals are bent, loose, or corroded, repair them as necessary and recheck the system.
If the terminals look OK, go to step 4.
1. 14P CONNECTOR
2. CRUISE CONTROL UNIT
3. Wire side of female terminals

2. 4. With the 14P connector disconnected, make these input tests.


Cavity Wire Test condition Test: Desired result Possible cause if result is
not obtained
1 BRN/WHT Connect battery power Check the operation of the magnetic Faulty actuator
clutch: Clutch should click and output Poor ground (G301)
link should be locked. An open in the wire
2 BLU Ignition switch ON (II), main Check for voltage to ground: Faulty brake pedal
switch ON and brake pedal There should be 0 V with the pedal position switch
pressed, then released pressed and battery voltage with the An open in the wire
pedal released.
3 BLK Under all conditions Check for continuity to ground: Poor ground (G501)
There should be continuity. An open in the wire

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Engine Electrical - Cruise Control

4-45
Cruise Control
Control Unit Input Test (cont'd)

Cavity Wire Test condition Test: Desired result Possible cause if result is
not obtained
4 BLK/ORN Ignition switch ON (II) Check for voltage to ground: Blown No. 4 (10 A)
There should be battery voltage. fuse in the under-
dash driver's
fuse/relay box
An open in the wire
5 WHT/BLK Brake pedal pressed, then Check for voltage to ground: Blown No. 7 (15 A)
released There should be battery voltage with the fuse in the under-
pedal pressed, and 0 V with the pedal hood fuse/relay box
released. Faulty brake pedal
position switch
An open in the wire
6 GRY/RED Set button pushed Check for voltage to ground: Blown No. 7 (15 A)
7 LT GRN/BLK Resume button pushed There should be battery voltage. fuse in the under-
hood fuse/relay box
Faulty horn relay
Faulty
set/resume/cancel
switch
Faulty cable reel
An open in the wire
8 BLU/ORN Reconnect the cruise Check for voltage to ground: There Faulty cruise control
control unit 14P should be about 1V unit
connector, start the Short to ground
engine, turn the main
switch ON and drive the
vehicle to speeds over 25
mph (40 km/h) with the
cruise control set.
9 BRN Connect battery power to Check the operation of the actuator Faulty actuator
11 BRN/YEL
the BRN terminal and motor: You should be able to hear the An open in the wire
ground to the BRN/YEL motor
terminal
10 BLU/YEL Ignition switch ON (II) Attach to ground: Blown bulb
Cruise indicator light in the gauge Blown No. 10 (7.5
assembly should comes on. A) fuse in the
under-dash
fuse/relay box
Faulty dimming
circuit in the gauge
assembly
An open in the wire
12 BLU/WHT Ignition switch ON (II) and Check for voltage between the Faulty ECM/PCM
main switch ON; raise the BLU/WHT (+) and BLK (-) terminals: An open in the wire
front of the vehicle, and There should be 0 5 V or more
rotate one wheel slowly repeatedly.
while holding the other
wheel
13 LT GRN Ignition switch ON (II) and Check for voltage to ground: Blown No. 4 (10 A)
main switch ON There should be battery voltage. fuse in the under-
dash fuse/relay box

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Engine Electrical - Cruise Control

Faulty main switch


An open in the wire
14 LT BLU A/T: Shift lever in or
Check for continuity to ground: Faulty transmission
There should be continuity. range switch
NOTE: There should be no continuity Faulty clutch pedal
M /T: Clutch pedal position switch
released when the clutch pedal is pressed or
when the shift lever is in other positions. Poor ground (M/T:
G401, A/T: G101)
An open in the wire

1. 5. If any test indicates a problem, find and correct the cause, then recheck the system. If all the input tests prove OK, the
control unit must be faulty; replace it.

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Engine Electrical - Cruise Control

4-46Set/Resume/Cancel Switch Test/Replacement


Cruise Control
Main Switch Test/Replacement

1. 1. Carefully pry the switch panel -assembly out of the 1. 1. Remove the two screws, then remove the switch.
instrument panel.
Terminal side of male terminals

2. 2. Disconnect the 5P connector from the main switch,


then remove the switch.
3. Check for continuity between the terminals in each Terminal side of male terminal.
switch position according to the table. If there is no
continuity, replace the switch. 2. 2. Check for continuity between the terminals in switch
position according to the table.
If there is continuity, and it matches the table, but
switch failure is occurred on the cruise control
unit input test, check and repair the wire harness
on the switch circuit.
If there is no continuity in one or both positions,
replace the switch.

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Engine Electrical - Cruise Control

4-47
Cruise Control
Actuator Test

1. 1. Disconnect the 4P connector (A) from the actuator 1. 6. Check the operation of the actuator motor in each
(B). output linkage position according to the table. You
should be able to hear the motor.
Battery power Output linkage position
polarities
(+) (-) FULL MIDDLE FULL
CLOSE POSITION OPEN
No. 4 No. 3 The The motor The
Terminal Terminal motor runs. motor
runs. stops.
No. 3 No. 4 The The motor The
Terminal Terminal motor runs. motor
stops. runs.

Terminal side of male terminals


2. 2. Remove the cover (A), and check the output linkage
(B) for smooth movement.

2. 1. FULL OPEN
2. OUTPUT LINKAGE
3. FULL CLOSE
4. MIDDLE POSITION

3. 3. Connect the battery power to the No. 2 terminal and


ground to the No. 1 terminal.
4. 4. Check for a clicking sound from the magnetic clutch.
The output linkage should be locked.
5. If the output linkage is not locked, replace the
actuator assembly.

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Engine Electrical - Cruise Control

4-48
Cruise Control
Actuator/Cable Replacement

1. 1. Loosen the locknut (A), then disconnect the actuator 1. 4. Remove the actuator cover.
cable (B) from the throttle linkage.

2. 2. Disconnect the 4P connector (A) from the actuator. 2. 5. Remove the actuator cable from the actuator.

3. 6. Install the reverse order of removal, and adjust the


free play at the throttle linkage after connecting the
actuator cable.

3. 3. Remove the two mounting bolts, and remove the


actuator assembly (B).

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Engine Electrical - Cruise Control

4-49 Clutch Pedal Position Switch Test


Cruise Control
Actuator Cable Adjustment

1. 1. Check that the actuator cable (A) moves smoothly 1. 1. Disconnect the 2P connector from the clutch pedal
with no binding or sticking. position switch (A).
CLUTCH PEDAL POSITION SWITCH 2P CONNECTOR

2. 2. Measure the amount of movement of the output


linkage (B) until the engine speed starts to increase.
At first, the output linkage should be located at the
fully closed position (C). The free play (D) should be
3.75 + 0.5 mm (0.15 +0.02 in.). 2. 2. Remove the clutch pedal position switch.
3. If the free play is not within specs, loosen the 3. Check for continuity between the terminals according
locknut, and turn the adjusting nut until the free play to the table.
is as specified, then retighten the locknut.

3. 4. If necessary, replace the clutch pedal position switch


or adjust the pedal height (see page 12-4).

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General Information - Engine Assembly

Engine Assembly

Special Tools 5-2


Engine Removal 5-3
Engine Installation 5-13
Cylinder Head 6-1
Engine Block 7-1
Engine Lubrication 8-1
Intake Manifold/Exhaust System 9-1
Engine Cooling 10-1

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General Information - Engine Assembly

5-2
Engine Assembly
Special Tools

Ref. No. Tool Number Description Qty


1 07KAK-SJ40101 Engine Tilt Hanger Set 1

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General Information - Engine Assembly

5-3
Engine Assembly
Engine Removal

NOTE: 1. 5. Remove the battery and battery base.


Use fender covers to avoid damaging painted 6. Remove the battery cables (A) from the fuse box and
surfaces. remove the harness clamps (B).
To avoid damage, unplug the wiring connectors
carefully while holding the connector portion.
Mark all wiring and hoses to avoid misconnection.
Also, be sure that they do not contact other wiring or
hoses, or interfere with other parts.
1. 1. Secure the hood in the wide open position (support
rod in the lower hole).
2. Make sure you have the anti-theft code for the radio,
then write down the frequencies for the radio's preset
buttons.
3. Disconnect the battery negative terminal first, then
the positive terminal.
4. Remove the intake resonator.

2. 7. Remove the intake air duct (A) and ground cable (B).

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General Information - Engine Assembly

5-4
Engine Assembly
Engine Removal (cont'd)

1. 8. Remove the clutch slave cylinder (A) and clutch line 1. 10. Remove the shift cable (Honda multi matic).
bracket mounting bolt (B) (M/T).

2. 9. Remove the shift cable (A) and select cable (B)


(M/T).
2. 11. Relieve fuel pressure, 4-door (see page 11-130), or
5-door (see page 11-430).
12. Remove the evaporative emission (EVAP) canister
hose.

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General Information - Engine Assembly

5-5
Engine Assembly
Engine Removal (cont'd)

1. 13. Remove the brake booster vacuum hose. 1. 14. Remove the glove box stops, then open the glove
RHD models: (4-door) box.
15. Disconnect the engine control module
(ECM)/powertrain control module (PCM) connectors.
RHD models:

LHD models:
RHD models: (5-door)

LHD models:

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General Information - Engine Assembly

5-6
Engine Assembly
Engine Removal (cont'd)

1. 16. Remove the harness clamps (A) and grommet (B), 1. 17. Remove the throttle cable (A) and cruise control
then pull the engine wire harness through the cable (B) by loosening the locknuts (C), then slipping
bulkhead. the cable ends out of the accelerator linkage. Take
RHD models: care not to bend the cables when removing them.
Always replace any kinked cable with a new one.

2. 18. Remove the adjust plate mounting bolt (A), lock nut
(B) and mounting bolt (C), then remove the power
steering (P/S) pump belt (D) and pump without
disconnecting the P/S hoses (P/S).
LHD models:

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General Information - Engine Assembly

5-7
Engine Assembly
Engine Removal (cont'd)

1. 19. Remove the alternator (see page 4-31). 1. 22. Remove the radiator cap.
2. 20. Remove the air conditioning (A/C) hose bracket (A) 23. Raise the hoist to full height.
and P/S hose bracket (B). 24. Remove the front tyres/wheels.
25. Remove the splash shield.

2. 26. Loosen the drain plug in the radiator, drain the


3. 21. Remove the alternator lower bracket (A), then engine coolant (see page 10-8).
remove the A/C compressor (B) without 27. Drain the transmission fluid. Reinstall the drain plug
disconnecting the A/C hoses. using a new washer:
Manual transmission (see page 13-3).
Automatic transmission (see page 14-122).
Honda multi matic (see page 14-312).
3. 28. Drain the engine oil. Reinstall the drain bolt using a
new washer (see page 8-5).

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General Information - Engine Assembly

5-8
Engine Assembly
Engine Removal (cont'd)

1. 29. Disconnect the primary heated oxygen sensor 1. 33. Remove the shift cable covers (A), then remove the
(primary HO2S) connector (A) (D14Z5, D15Y2, shift control cable (B) (A/T).
D15Y4, D16W7, D16W8, D17A2, D17Z3 engines).

2. 34. Disconnect the suspension lower arm ball joints and


stabiliser links (see page 18-18).
35. Remove the driveshafts (see page 16-3). Coat all
precision finished surfaces with clean engine oil. Tie
2. 30. Disconnect the secondary heated oxygen sensor plastic bags over the driveshaft ends.
(secondary HO2S) connector (B) (D14Z5, D15Y4,
D16W7, D17A2 engines).
31. Remove exhaust pipe A (C) (D14Z5, D15Y2, D15Y3,
D15Y4, D16V2, D16W7, D16W8, D17A2, D17A5,
D17Z3 engines).
32. Remove the exhaust pipe/muffler assembly (D15Y5,
D15Y6, D17A1, D17Z1, D17Z2 engines).

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General Information - Engine Assembly

5-9
Engine Assembly
Engine Removal (cont'd)

1. 36. Lower the hoist. 1. 38. Remove the heater hose.


2. 37. Remove the ground cable (A), upper radiator hose RHD models:
(B), lower radiator hose (C) and heater hose (D).

LHD models:

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General Information - Engine Assembly

5-10
Engine Assembly
Engine Removal (cont'd)

1. 39. Remove the ATF cooler hoses, then plug the ATF 1. 41. Remove the front mount mounting bolt.
cooler hoses and lines (A/T. Honda multi matic).

2. 40. Attach the engine tilt hanger set (commercially


available tool for EU models) to the engine as
shown.

2. 42. Remove the side engine mount bracket mounting


nuts.

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General Information - Engine Assembly

5-11
Engine Assembly
Engine Removal (cont'd)

1. 43. Remove the transmission mount bracket mounting 1. 44. Make sure the hoist brackets are positioned properly.
bolt/nuts. Raise the hoist to full height.
M/T: 45. Remove the rear mount mounting bolts.

A/T:

HONDA MULTI MATIC:

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General Information - Engine Assembly

5-12
Engine Assembly
Engine Removal (cont'd)

1. 46. Use a marker to make alignment marks on the 1. 48. Check that the engine/transmission is completely free
reference lines (A) that align with the centres of the of vacuum hoses, fuel and coolant hoses and
rear sub-frame mounting bolts (B). electrical wiring.
49. Slowly lower the engine approximately 150 mm (6
in.). Check once again that all hoses and wires are
disconnected from the engine/transmission.
50. Lower the engine all the way. Remove the chain
hoist from the engine.
51. Remove the engine from under the vehicle.

2. 47. Remove the front sub-frame.

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General Information - Engine Assembly

5-13
Engine Assembly
Engine Installation

1. 1. Install the accessory brackets and tighten their bolts and nuts to the specified torques.
1. REAR STIFFENER
(D15Y4,D17A2 engines
M/T, HONDA
MULTIMATIC)
2. REAR STIFFENER
(D17A2 engine A/T)
3. P/S PUMP BRACKET
(P/S)
4. ENGINE MOUNT
BRACKET
5. A/C COMPRESSOR
BRACKET
6. STIFFENER
(Except D15Y4, D17A1
engines)
7. FRONT STIFFENER
(D15Y4, D17A2
engines)

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General Information - Engine Assembly

5-14
Engine Assembly
Engine Installation (cont'd)

1. 2. Position the engine under the vehicle. Attach the 1. 4. Tighten the rear mount mounting bolts.
chain hoist to the engine, then lift the engine into
position in the vehicle.

Reinstall the mounting bolts/support nuts in the sequence


given. Failure to follow this sequence may cause excessive
noise and vibration and reduce bushing life.
2. 3. Install the sub-frame (A). Align the reference lines (B)
on the sub-frame with the bolt head centre, then
tighten the bolts.

2. 5. Lower the hoist.


3. 6. Tighten the side engine mount bracket mounting
nuts.

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General Information - Engine Assembly

5-15
Engine Assembly
Engine Installation (cont'd)

1. 7. Tighten the transmission mount bracket mounting 1. 8. Tighten the front mount mounting bolt.
bolt/nuts.
M/T:

2. 1. 12x1.25mm
64 Nm (6.5 kgf/m, 47 lbf/ft)
Replace.

3. 9. Remove the chain hoist from the engine.


A/T: 10. Raise the hoist to full height.
11. Install a new spring clip on the end of each
driveshaft, then install the driveshafts. Make sure
each clip ''clicks'' into place in the differential and
intermediate shaft.
12. Connect the suspension lower arm ball joints and
stabiliser links (see page 18-18).
13. Install the shift control cable (A), then install the shift
cable covers (B) (A/T).

HONDA MULTI MATIC:

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General Information - Engine Assembly

5-16
Engine Assembly
Engine Installation (cont'd)

1. 14. Install exhaust pipe A (A): use new gaskets (B) and 1. 18. Install the splash shield.
new self-locking nuts (C) (D14Z5, D15Y2, D15Y3,
D15Y4, D16V2, D16W7, D16W8, D17A2, D17A5,
D17Z3 engines).

2. 19. Install the front tyres/wheels.


20. Lower the hoist.
21. Install the ATF cooler hoses (A/T, Honda multi
matic).

2. 1. C
10x 1.25 mm
33 Nm (3.4 kgf/m, 25 lbf/ft)
Replace.

3. 15. Connect the primary HO2S connector (D) D14Z5,


D15Y2, D15Y4, D16W7, D16W8, D17A2, D17Z3
engines).
16. Connect the secondary HO2S connector (E) (D14Z5,
D15Y4, D16W7, D17A2 engines).
17. Install the exhaust pipe/muffler assembly (A); use a
new gasket (B) (D15Y5, D15Y6, D17A1, D17Z1,
D17Z2 engines).

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General Information - Engine Assembly

5-17
Engine Assembly
Engine Installation (cont'd)

1. 22. Install the heater hose. 1. 23. Install the upper radiator hose (A), lower radiator
RHD models: hose (B), heater hose (C) and ground cable (D).

LHD models:

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General Information - Engine Assembly

5-18
Engine Assembly
Engine Installation (cont'd)

1. 24. Install the A/C compressor (A), then install the 1. 26. Loosely install the alternator.
alternator lower bracket (B). 27. Adjust the alternator belt tension (see page 4-38) or
the alternator-compressor belt tension (see page 4-
37).
28. Loosely install the P/S pump belt and pump.
29. Adjust the P/S pump belt (see page 17-23).
30. Push the ECM/PCM connectors through the
bulkhead, then install the grommet (A).
RHD models:

2. 25. Install the A/C hose bracket (A) and P/S hose
bracket (B).
LHD models:

2. 31. Install the harness clamps (B).

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General Information - Engine Assembly

5-19
Engine Assembly
Engine Installation (cont'd)

1. 32. Connect the PCM connectors. 1. 34. Install the cruise control cable, then adjust the cable
RHD models: (see page 4-48).
35. Install the throttle cable, then adjust the cable (see
page 11-148).
36. Install the brake booster vacuum hose.
RHD models (4-door):

LHD models:

RHD models (5-door):

2. 33. Install the glove box stops.

LHD models:

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General Information - Engine Assembly

5-20
Engine Assembly
Engine Installation (cont'd)

1. 37. Install the EVAP canister hose. 1. 39. Install the select cable (A) and shift cable (B) using
the plastic washers (C), washers (D) and new cotter
pins (E) (M/T).

2. 38. Install the shift cable (A) using the plastic washer (B),
washer (C) and spring pin (D) (Honda multi matic).

2. 40. Install the clutch slave cylinder (A) and clutch line
bracket mounting bolt (B) (M/T).

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General Information - Engine Assembly

5-21
Engine Assembly
Engine Installation (cont'd)

1. 41. Install the battery base. 1. 44. Install the intake resonator.
2. 42. Install the intake air duct (A) and ground cable (B).

2. 45. Clean the battery posts and cable terminals with


sandpaper, then assemble them and apply grease to
prevent corrosion.
3. 43. Install the battery cable (A) on the under-hood 46. Move the shift lever to each gear and verify that the
fuse/relay box, then install the harness clamps (B). A/T gear position indicator, follows the transmission
range switch (A/T, Honda multi matic).
47. Check that the transmission shifts into gear smoothly
(M/T).
48. Inspect for fuel leaks. Turn ON (II) the ignition switch
(do not operate the starter) so that the fuel pump
runs for approximately 2 seconds and pressurises
the fuel line. Repeat this operation 2 or 3 times, then
check for fuel leakage at any point in the fuel line.
49. Refill the engine with engine oil (see page 8-5).
50. Refill the transmission with fluid:
Manual transmission (see page 13-3).
Automatic transmission (see page 14-122).
Honda multi matic (see page 14-312).
3. 51. Refill the radiator with engine coolant, and bleed air
from the cooling system with the heater valve open
(see page 10-8).
52. Check the wheel alignment (see page 18-4).
53. Enter the anti-theft code for the radio, then enter the
customer's radio station presets.

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Engine Mechanical - Cylinder Head

6-2
Cylinder Head
Special Tools

Ref. No Tool Number Description Qty


1 07HAH-PJ70100 Valve Guide Reamer, 5.525 mm 1
2 07JAA-0010200 Socket Wrench, 19 mm 1
3 07JAB-0010200 Handle 1
4 07JAB-0010400 Pulley Holder Attachment, HEX 50 mm 1
5 07LAJ-PR30101 Valve Inspection Set 1
6 07LAJ-PR30201 Air Stopper 1
7 07MAB-PY30100 Pulley Holder Attachment, HEX 50 mm 1
8 07NAJ-P070100 Oil Pressure Gauge Attachment 1
9 07PAD-0010000 Stem Seal Driver 1
10 07ZAJ-S5A0200 Hose, Oil Pressure 1
11 07406-0070001 Low Pressure Gauge 1
12 07742-0010100 Valve Guide Driver, 5.5 mm 1
13 07757-0010000 Valve Spring Compressor 1

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Engine Mechanical - Cylinder Head

6-3
Cylinder Head
Component Location Index

1. CYLINDER HEAD COVER


2. HEAD COVER GASKET
3. UPPER COVER
4. RUBBER SEAL
5. LOWER COVER
6. CRANKSHAFT PULLEY
Replacement, page 6-16
7. TDC SENSOR
8. CAMSHAFT PULLEY
9. CRANKSHAFT PULLEY BOLT
Replacement, 6-16
10. TIMING BELT
Removal, page 6-18
Inspection, page 6-18Installation, page 6-
22
11. AUTO-TENSIONER
12. TIMING BELT DRIVE PULLEY
13. Install with concave surface facing in.
14. CKP SENSOR
15. SIDE ENGINE MOUNT BRACKET

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Engine Mechanical - Cylinder Head

6-4
Cylinder Head
Component Location Index (cont'd)

1. WATER PASSAGE
2. CYLINDER HEAD BOLT
3. DOWEL PIN
4. O-RING
5. CYLINDER HEAD GASKET
6. GASKET

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Engine Mechanical - Cylinder Head

6-5
Cylinder Head
Component Location Index (cont'd)

D15Y4, D16V2, D16W7, D17A2, D17A5, D17Z3 engines:


1. CYLINDER HEAD PLUG
2. O-RING
3. ROCKER ARM ASSEMBLY
Overhaul, page 6-35
Inspection, 6-38
4. DOWEL PIN
5. CAMSHAFT
Inspection, page 6-40
6. INTAKE VALVE SPRING
7. SEAL
8. CAMSHAFT PULLEY
9. INTAKE VALVE SEAL
Replacement, page 6-42
10. VALVE GUIDE
Replacement, page 6-44
11. BACK COVER
12. RUBBER SEAL
13. EXHAUST VALVE
Removal, page 6-42
Installation, page 6-48
14. INTAKE VALVE
15. CYLINDER HEAD
Removal, page 6-28
Inspection, page 6-34
Installation, page 6-50
16. VALVE GUIDE
17. VALVE SPRING SEAT
18. EXHAUST VALVE SEAL
19. EXHAUST VALVE SPRING
20. SPRING RETAINER
21. VALVE KEEPERS
22. VTEC SOLENOID VALVE FILTER
23. VTEC SOLENOID VALVE
24. OIL CONTROL ORIFICE
25. O-RING

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Engine Mechanical - Cylinder Head

6-6
Cylinder Head
Component Location Index (cont'd)

D16W8 engine:
1. LOST MOTION ASSEMBLY
2. LOST MOTION HOLDER
3. ROCKER ARM ASSEMBLY
Overhaul, page 6-36
Inspection, page 6-38
4. DOWEL PIN
5. CAMSHAFT
Inspection, page 6-40
6. INTAKE VALVE SPRING
7. SEAL
8. CAMSHAFT PULLEY
9. INTAKE VALVE SEAL
Replacement, page 6-42
10. VALVE GUIDE
Replacement, page 6-44
11. BACK COVER
12. RUBBER SEAL
13. EXHAUST VALVE
Removal, page 6-42
Installation, page 6-48
14. INTAKE VALVE
15. CYLINDER HEAD
Removal, page 6-
28Inspection, page 6-34
Installation, page 6-50
16. VALVE GUIDE
17. VALVE SPRING SEAT
18. EXHAUST VALVE GUIDE
19. EXHAUST VALVE SPRING
20. SPRING RETAINER
21. VALVE KEEPERS
22. VTEC SOLENOID VALVE
FILTER
23. VTEC SOLENOID VALVE
24. CYLINDER HEAD PLUG
25. O-RING
26. OIL CONTROL ORIFICE
27. O-RING

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Engine Mechanical - Cylinder Head

6-7
Cylinder Head
Component Location Index (cont'd)

D14Z5, D15Y2, D15Y3, D15Y5, D15Y6, D17A1, D17Z1, D17Z2 engines:


1. CYLINDER HEAD PLUG
2. O-RING
3. ROCKER ARM ASSEMBLY
Overhaul, page 6-37
Inspection, page 6-38
4. DOWEL PIN
5. CAMSHAFT
Inspection, page 6-40
6. VALVE SPRING
7. SEAL
8. CAMSHAFT PULLEY
9. INTAKE VALVE SEAL
Replacement, page 6-42
10. VALVE GUIDE
Replacement, page 6-44
11. BACK COVER
12. RUBBER SEAL
13. EXHAUST VALVE
Removal, page 6-42
Installation, page 6-48
14. INTAKE VALVE
15. CYLINDER HEAD
Removal, page 6-28
Inspection, page 6-34
Installation, page 6-50
16. VALVE GUIDE
17. VALVE SPRING SEAT
18. EXHAUST VALVE SEAL
19. VALVE SPRING
20. SPRING RETAINER
21. VALVE KEEPERS
22. OIL CONTROL ORIFICE

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Engine Mechanical - Cylinder Head

6-8
Cylinder Head
Engine Compression Inspection

1. 1. Warm up the engine to normal operating temperature 1. 9. Connect a tachometer.


(cooling fan comes on). 10. Open the throttle fully, then crank the engine with the
2. 2. Turn the ignition switch OFF. starter motor and measure the compression.
3. Remove the air cleaner housing (see step 6 on page Compression Pressure:
6-29). Above 930 kpa (9.5 kgf/cm2, 135 psi)-250
4. Disconnect all four injector connectors. rpm (min-1)
5. Start the engine and let it run until it stalls. 11. Measure the compression on the remaining
6. Remove the all four ignition coils (see page 4-24). cylinders.
7. Remove the all four spark plugs. Maximum variation:
8. Attach the compression gauge to the spark plug hole.
Within 200 kPa (2.0 kgf/cm2, 28 psi)
12. If the compression is not within specifications, check
the following items, then remeasure the
compression.
Damaged or worn valves and seats
Damaged cylinder head gasket
Damaged or worn piston rings
Damaged or worn piston and cylinder bore

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Engine Mechanical - Cylinder Head

6-9 VTEC Rocker Arm Test


Cylinder Head
VTEC Oil Pressure Switch Replacement

1. 1. Remove the resonator (see step 5 on page 6-29). Special Tools Required
2. 2. Remove the bolt (A) and loosen the bolt (B) securing
Air Stopper, 07LAJ-PR30201
the VTEC solenoid valve, then remove the harness
Valve Inspection Set, 07LAJ-PR30101
bracket (C) from the VTEC solenoid valve.
D15Y4, D16V2, D16W7, D17A2, D17A5, D17Z3
engines:
1. 1. Remove the resonator (see step 5 on page 6-29).
2. Remove the ignition coil cover, then remove the four
ignition coils (see page 4-24).
3. Remove the throttle cable clamps and harness
holder from the cylinder head cover (see step 9 on
page 6-19).
4. Remove the cylinder head cover (see step 10 on
page 6-19).
5. Set the No. 1 piston at TDC (see step 3 on page 6-
18).
6. Verify that the intake secondary rocker arm (A)
moves independently of the intake primary rocker
arm (B).
If the intake secondary rocker arm does not
move, remove the primary and secondary rocker
arms as an assembly and check that the pistons
in the secondary and primary rocker arms move
smoothly. If any rocker arm needs replacing,
3. 3. Remove the harness clamp (D) from the connecting
replace the primary and secondary rocker arms
pipe.
as an assembly and retest.
4. Disconnect the VTEC oil pressure switch connector,
If the intake secondary rocker arm moves freely,
then remove the VTEC oil pressure switch (A).
go to step 7.

4. 5. Install the VTEC oil pressure switch using a new O-


ring (B).
2. 7. Repeat step 6 on the remaining intake secondary
rocker arms with each piston at TDC. When all the
secondary rocker arms pass the test, go to step 8.

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Engine Mechanical - Cylinder Head

6-10
Cylinder Head
VTEC Rocker Arm Test (cont'd)

1. 8. Check that the air pressure on the shop air 1. 13. Loosen the valve on the regulator and apply the
compressor gauge indicates over 400 kPa (4 specified air pressure:
kgf/cm2, 57 psi). Specified Air Pressure:
2. 9. Inspect the valve clearance (see page 6-14). 250 kPa (2.5 kgf/cm2, 36 psi)
10. Cover the timing belt with a shop towel to protect the NOTE: If the synchronising piston does not move after
belt. applying air pressure, move the primary or secondary
11. Plug the relief hole with the air stopper. rocker arm up and down manually by rotating the
crankshaft counter-clockwise.
2. 14. Move the intake secondary rocker arm (A) for the
No. 1 cylinder. The primary rocker arm (B) and
secondary rocker arm should move together.
If the intake primary rocker arm does not move,
remove the primary and secondary rocker arms
as an assembly and check that the piston in the
secondary and primary rocker arms move
smoothly. If any rocker arm needs replacing,
replace the primary and secondary rocker arms
3. 12. Remove the sealing bolt (A) from the inspection hole as an assembly and retest.
(B) and connect the valve inspection set.

3. 15. Remove the special tools.


16. After inspection, check that the MIL does not come
on.

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Engine Mechanical - Cylinder Head

6-11
Cylinder Head
VTEC Rocker Arm Test (cont'd)

D16W8 engine: 1. 8. Check that the air pressure on the shop air
1. 1. Remove the resonator (see step 5 on page 6-29). compressor gauge indicates over 400 kPa (4 kgf/cm,
2. Remove the ignition coil cover, then remove the 4 57 psi).
ignition coils (see page 4-24). 9. Inspect the valve clearance (see page 6-14).
3. Remove the throttle cable clamps and harness 10. Cover the timing belt with a shop towel to protect the
holder from the cylinder head cover (see step 9 on belt.
page 6-19). 11. Plug the relief hole with the air stopper.
4. Remove the cylinder head cover (see step 10 on
page 6-19).
5. Set the No. 1 piston at TDC (see step 3 on page 6-
18).
6. Move the intake secondary rocker arm (A) moves
independently of the intake mid rocker arm (B) and
intake primary rocker arm (C).
If the intake secondary rocker arm does not
move, remove the mid, primary and secondary
rocker arms as assembly and check that the
pistons in the mid and primary rocker arms move
smoothly. If any rocker arm needs replacing, 2. 12. Remove the sealing bolt (A) from the inspection hole
replace the mid, primary and secondary rocker A (B) and connect the valve inspection set.
arms as an assembly and retest.
If the intake secondary rocker arm moves freely,
go to step 7.

2. 7. Repeat step 6 on the remaining intake secondary


rocker arms with each piston at TDC. when all the
secondary rocker arms pass the test, go to step 8.

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Engine Mechanical - Cylinder Head

6-12
Cylinder Head
VTEC Rocker Arm Test (cont'd)

1. 13. Loosen the valve on the regulator and apply the 1. 15. Stop applying air pressure and push up the timing
specified air pressure. plate (A); the synchronising piston (B) will return to
Specified Air Pressure: its original position with a click.
Visually check the disengagement of the synchronising
250 kPa (2.5 kgf/cm2, 36 psi)
piston. Replace the intake rocker arms as an assembly if
2. 14. With the specified air pressure applied, push up the there is any abnormality.
timing plate (A); the synchronising piston will pop out
and engage the intake primary rocker arm (B) and NOTE: When the timing plate is pushed up, it releases the
intake secondary rocker arm (C). timing piston (C), letting the return spring (D) move the
NOTE: synchronising piston to its original positions.
The synchronising piston (D) can be seen in the
gap between the secondary and primary rocker
arms.
When the timing plate is engaged in the groove A
(E) on the timing piston (F), the piston will be
locked in the pushed out piston.

2. 16. Remove the valve inspection set from the inspection


hole A, then tighten the sealing bolt.
17. Remove the sealing bolt (A) from the inspection hole
B (B) and connect the valve inspection set.

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Engine Mechanical - Cylinder Head

6-13
Cylinder Head
VTEC Rocker Arm Test (cont'd)

1. 18. Loosen the valve on the regulator and apply the 1. 20. Remove the special tools, then tighten the sealing
specified air pressure. bolt.
Specified Air Pressure: 21. Use a 10 mm (0.39 in.) diameter rod (A) to depress
each lost motion assembly through its full movement,
250 kPa (2.5 kgf/cm2, 36 psi)
replace any lost motion assembly that does move
2. 19. Make sure that the intake primary rocker arm (A) and smoothly.
secondary rocker arm (B) are mechanically
connected by piston and that the intake mid rocker
arm (C) does not move when pushed manually. If
any intake mid rocker arm moves independently of
the intake primary and intake secondary rocker arms,
replace the rocker arms as a set.

2. 22. After inspection, check that the MIL does not come
on.

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Engine Mechanical - Cylinder Head

6-14
Cylinder Head
Valve Clearance Adjustment

NOTE: Adjust the valves only when the cylinder head 1. 6. Select the correct thickness feeler gauge for the valves you
temperature is less than 38 o C (100 o F). are going to check.
1. 1. Remove the ignition coil cover, then remove Intake: 0.18 - 0.22 mm (0.007 - 0.009 in.)
the four ignition coils (see page 4-25). Exhaust: 0.23 - 0.27 mm (0.009 - 0.011 in.)
2. Remove the throttle cable clamps and
harness holder from the cylinder head cover Adjusting screw location:
(see step 9 on page 6-19).
INTAKE
3. Remove the cylinder head cover (see step 10
on page 6-19).
4. Remove the grommet from the upper cover
and disconnect the TDC sensor connector.
Remove the upper cover (see step 1 on page
6-57).
5. Set the No. 1 piston at TDC. The ''UP'' mark
(A) on the camshaft pulley should be at the
top and the TDC marks (B) on the pulley
should line up with the top edge of the head.

EXHAUST
2. 7. Insert the feeler gauge (A) between the adjusting screw (B)
and the end of the valve stem and slide it back and forth;
you should feel a slight amount of drag.

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Engine Mechanical - Cylinder Head

6-15
Cylinder Head
Valve Clearance Adjustment (cont'd)

1. 8. If you feel too much or too little drag, loosen the 1. 10. Rotate the crankshaft 180o counter-clockwise
locknut (A) and turn the adjusting screw (B) until the
(camshaft pulley turns 90 o ). The ''UP'' mark (A) on
drag on the feeler gauge is correct.
the camshaft pulley should be toward the exhaust
D15Y4, D16V2, D16W7, D17A2, D17A5, D17Z3 side of the head.
engines:

2. 11. Check and if necessary, adjust the valve clearance


on No. 3 cylinder.
D14Z5, D15Y2, D15Y3, D15Y5, D15Y6, D17A1, 12. Rotate the crankshaft 180o counter-clockwise to
D17Z1, D17Z2 engines: bring No. 4 piston to TDC. TDC marks (A) are visible
again.

2. 9. Tighten the locknut and recheck the clearance.


Repeat the adjustment if necessary. 3. 13. Check and if necessary, adjust the valve clearance
on No. 4 cylinder.

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Engine Mechanical - Cylinder Head

6-16 Crankshaft Pulley Removal and Installation


Cylinder Head
Valve Clearance Adjustment (cont'd)

1. 14. Rotate the crankshaft 180o counter-clockwise to Special Tools Required


bring No. 2 piston to TDC. The ''UP'' mark (A) should Socket, 19 mm, 07JAA-001020A
be on the intake side of the head. Handle, 07JAB-0010200
Pulley holder attachment, HEX 50 mm, 07JAB-
0010400
Pulley holder attachment, HEX 50 mm, 07MAB-
PY30100
Removal
1. 1. Hold the pulley with holder handle (A) and holder
attachment (B).
With P/S:

2. 15. Check and if necessary, adjust the valve clearance


on No. 2 cylinder.
16. Install the cylinder head cover (see page 6-55).

With EPS:

2. 2. Remove the bolt with a 19 mm socket (C) and


breaker bar.

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Engine Mechanical - Cylinder Head

6-17
Cylinder Head
Crankshaft Pulley Removal and Installation
(cont'd)

Installation 1. 2. Install the crankshaft pulley and hold the pulley with
1. 1. Remove any oil from the pulleys (A), guide plate (B), holder handle (A) and holder attachment (B).
crankshaft (C), bolt (D) and washer (E). Clean and With P/S:
lubricate as shown below.
O: Clean
X: Remove any oil
: Lubricate

With EPS:

2. 3. Tighten the bolt to 20 Nm (2.0 kgf/m, 14 lbf/ft) with a


torque wrench and 19 mm socket (C). Do not use an
impact wrench.
4. Tighten the pulley bolt an additional 90 o .

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Engine Mechanical - Cylinder Head

6-18 Timing Belt Removal


Cylinder Head
Timing Belt Inspection

1. 1. Remove the ignition coil cover, then remove the four Special Tools Required
ignition coils.
Socket, 19 mm, 07JAA-001020A
2. 2. Remove the throttle cable clamps and harness
Handle, 07JAB-0010200
holder mounting bolts.
Pulley holder attachment, HEX 50 mm, 07JAB-
3. Remove the cylinder head cover.
0010400
4. Inspect the timing belt for cracks and oil or coolant
Pulley holder attachment, HEX 50 mm, 07MAB-
soaking. Replace the belt if it is oil or coolant soaked.
PY30100
Remove any oil or solvent that gets on the belt.
1. 1. Make sure you have the anti-theft code for the radio,
then write down the frequencies for the radio's
preset buttons.
2. Disconnect the battery negative terminal.
3. Turn the crankshaft pulley so its TDC mark (A) lines
up with the pointers (B).

3. 5. After inspecting, retorque the crankshaft pulley bolt


(see page 6-17).
2. 4. Remove the front tyres/wheels.
5. Remove the splash shield.

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Engine Mechanical - Cylinder Head

6-19
Cylinder Head
Timing Belt Removal (cont'd)

1. 6. Remove the adjust plate mounting bolt (A), locknut 1. 10. Remove the cylinder head cover.
(B) and mounting bolt (C), then remove the power
steering (P/S) pump belt (D) and pump without
disconnecting the P/S hoses.

2. 7. Remove the alternator (see page 4-32).


8. Remove the four ignition coils (see page 4-24).
9. Remove the throttle cable clamps (A) and harness
holder (B) from the cylinder head cover.

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Engine Mechanical - Cylinder Head

6-20
Cylinder Head
Timing Belt Removal (cont'd)

1. 11. Hold the pulley with holder handle (A) and holder 1. 13. Support the engine with a jack and wood block
attachment (B). under the oil pan.
With P/S 14. Remove the upper bracket.

With EPS

2. 15. Remove the grommet (A) from the upper cover and
disconnect the TDC sensor connector (B).

2. 12. Remove the bolt with a 19 mm socket (C) and


breaker bar.

3. 16. Remove the upper cover (C) and lower cover (D).

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Engine Mechanical - Cylinder Head

6-21
Cylinder Head
Timing Belt Removal (cont'd)

1. 17. Remove the side engine mount bracket. 1. 19. Move the auto-tensioner to remove tension from the
timing belt, then remove the timing belt.

2. 18. Remove the CKP sensor from the oil pump without
disconnecting the connector.

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Engine Mechanical - Cylinder Head

6-22
Cylinder Head
Timing Belt Installation

Special Tools Required 1. 3. Clean the camshaft pulley and set it to TDC.
Socket, 19 mm, 07JAA-001020A 1. The ''UP'' mark (A) on the camshaft pulley should
Handle, 07JAB-0010200 be at the top.
Pulley holder attachment, HEX 50 mm, 07JAB- 2. Align the TDC marks (B) on the camshaft pulley
0010400 with the top edge of the head.
Pulley holder attachment, HEX 50 mm, 07MAB-
PY30100
NOTE: If you are removing the auto-tensioner, refer to the
auto-tensioner installation procedure.
1. 1. Clean the timing belt pulleys and the upper and lower
covers.
2. Set the crankshaft to TDC. Align the TDC mark (A)
on the timing belt drive pulley with the pointer (B) on
the oil pump.

2. 4. Install the timing belt in a counter-clockwise


sequence, starting with the drive pulley.
1. Drive pulley (A).
2. Tensioner pulley (B).
3. Water pump pulley (C).
4. Camshaft pulley (D).

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Engine Mechanical - Cylinder Head

6-23
Cylinder Head
Timing Belt Installation (cont'd)

1. 5. Install the CKP sensor. 1. 7. Install the lower cover.

2. 6. Install the all bolts loosely, then tighten the mounting


bolts as the numbered sequence shown.

2. 8. Clean the pulley bolt and washer.


9. Clean all oil off the inside face (A) of the crankshaft
pulley and apply lubricant to the pulley bolt (B) and
washer (C).
O: Clean
X: Remove any oil
: Lubricate

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Engine Mechanical - Cylinder Head

6-24
Cylinder Head
Timing Belt Installation (cont'd)

1. 10. Install the crankshaft pulley and hold the pulley with 1. 13. Rotate the crankshaft pulley about 5 or 6 turns
holder handle (A) and holder attachment (B). counter-clockwise so that the timing belt positions on
With P/S: the pulleys.
14. Turn the crankshaft pulley so its TDC mark (A) lines
up with the pointers (B).

With EPS:

2. 15. Check the camshaft pulley marks (A)


If the camshaft pulley marks are also at TDC, go
to step 16.
If the camshaft pulley marks are not at TDC,
remove the timing belt and repeat steps 2 through
12.

2. 11. Tighten the bolt to 20 Nm (2.0 kgf/m, 14 lbf/ft) with a


torque wrench and 19 mm socket (C). Do not use an
impact wrench.
12. Tighten the pulley bolt an additional 90 o .

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Engine Mechanical - Cylinder Head

6-25
Cylinder Head
Timing Belt Installation (cont'd)

1. 16. Install the upper cover (A), then connect the TDC 1. 18. Install the cylinder head cover (see page 6-55).
sensor connector (B) and install the grommet (C). 19. Install the harness holder (A) and throttle cable
clamps (B).

2. 17. Install the upper bracket (A), then tighten the nuts in
the numbered sequence shown.
2. 20. Loosely install the alternator.
21. Adjust the alternator belt tension (see page 4-38) or
the alternator-compressor belt tension (see page 4-
37).
22. Loosely install the P/S pump belt and pump.
23. Adjust the P/S pump belt (see page 17-23).
24. Install the splash shield.
25. Install the front tyres/wheels.
26. Clean the battery posts and cable terminals with
sandpaper, then assemble them and apply grease to
prevent corrosion.
27. Enter the anti-theft code for the radio, then enter the
customer's radio station presets.

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Engine Mechanical - Cylinder Head

6-26
Cylinder Head
Auto-Tensioner Removal/Installation

Removal: Installation:
1. 1. Remove the timing belt (see page 6-18).
1. 1. Clean the timing belt pulleys and the upper and
2. Remove the auto-tensioner.
lower covers.
2. Set the crankshaft to TDC. Align the TDC mark (A)
on the timing belt drive pulley with the pointer (B) on
the oil pump.

2. 3. Clean the camshaft pulley and set it to TDC.


1. The ''UP'' mark (A) on the camshaft pulley should
be at the top.
2. Align the TDC marks (B) on the camshaft pulley
with the top edge of the head.

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Engine Mechanical - Cylinder Head

6-27
Cylinder Head
Auto-Tensioner Removal/Installation (cont'd)

1. 4. Align the holes on the tensioner pulley (A) and 1. 6. Install the auto-tensioner, then tighten the auto-
tensioner base (B), then insert 3.0 mm (0.12 in.) tensioner mounting bolt (A) to 9.8 Nm (1.0 kgf/m, 7.2
diameter pin (C) into the holes. lbf/ft).

2. 7. Loosen the auto-tensioner mounting bolt 180o .


8. Install the timing belt in a counter-clockwise
sequence, starting with the drive pulley.
1. Drive pulley (A).
2. 5. Install the tensioner spring (A) on the auto-tensioner
2. Tensioner pulley (B).
(B).
3. Water pump pulley (C).
4. Camshaft pulley (D).

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Engine Mechanical - Cylinder Head

6-28 Cylinder Head Removal


Cylinder Head
Auto-Tensioner Removal/Installation (cont'd)

1. 9. Install the tensioner spring on the tensioner bolt. NOTE:


Use fender covers to avoid damaging painted
surfaces.
To avoid damage, unplug the wiring connectors
carefully while holding the connector portion.
To avoid damaging the cylinder head, wait until the
engine coolant temperature drops below 38 o C
(100 o F) before loosening the cylinder head bolts.
Mark all wiring and hoses to avoid misconnection.
Also, be sure that they do not contact other wiring or
hoses, or interfere with other parts.
1. 1. Make sure you have the anti-theft code for the radio,
then write down the frequencies for the radio's
2. 10. Rotate the crankshaft pulley 2 turns counter- preset buttons.
clockwise so that the timing belt positions on the 2. Disconnect the battery negative terminal.
pulleys. 3. Drain the engine coolant (see page 10-8).
11. Set the No. 1 piston at TDC. 4. Remove the throttle cable (A) and cruise control
12. Tighten the auto-tensioner mounting bolt (A) to 44 cable (B) by loosening the locknuts (C), then slipping
Nm (4.5 kgf/m, 33 lbf/ft), then remove the pin (B) the cable ends out of the accelerator linkage. Take
from the auto-tensioner. care not to bend the cables when removing them.
Always replace any kinked cable with a new one.

3. 13. Install the remaining parts.

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Engine Mechanical - Cylinder Head

6-29
Cylinder Head
Cylinder Head Removal (cont'd)

1. 5. Remove the intake resonator. 1. 7. Remove the brake booster vacuum hose (A) and
positive crankcase ventilation (PCV) hose (B).

2. 6. Disconnect the intake air temperature (IAT) sensor 2. 8. Relieve fuel pressure, 4-door (see page 11-129), or
connector (A) and remove the breather hose, then 5-door (see page 11-427).
remove the air cleaner housing (B). 9. Remove the EVAP canister hose.

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Engine Mechanical - Cylinder Head

6-30
Cylinder Head
Cylinder Head Removal (cont'd)

1. 10. Remove the ground cable (A), upper radiator hose 1. 12. Remove the adjusting plate mounting bolt (A),
(B), lower radiator hose (C), heater hose (D) and locknut (B) and mounting bolt (C), then remove the
water bypass hose (E). power steering (P/S) pump belt (D) and pump
without disconnecting the P/S hoses.

2. 11. Remove the two bolts securing the connecting pipe, 2. 13. Remove the alternator (see page 4-31).
then remove the connecting pipe from the water 14. Remove the air conditioning (A/C) hose bracket (A)
passage. and P/S hose bracket (B).

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Engine Mechanical - Cylinder Head

6-31
Cylinder Head
Cylinder Head Removal (cont'd)

1. 15. Remove the engine wire harness connectors and 1. 18. Remove the cover (A), then remove the exhaust
wire harness clamps from the intake manifold. manifold (B).
Idle air control (IAC) valve connector D15Y5, D15Y6, D17A1, D17Z1, D17Z2 engines:
Throttle position sensor connector
Manifold absolute pressure (MAP) sensor
connector
Evaporative emission (EVAP) canister purge valve
connector (Except KT, KW models)
Engine coolant temperature (ECT) sensor
connector
Radiator fan switch connector
CKP sensor connector
TDC sensor connector
Exhaust gas recirculation (EGR) connector
(D14Z5, D15Y4, D16W7, D17A2 engines)
VTEC solenoid valve connector (D15Y4, D16V2,
D16W7, D17A2, D17A5, D17Z3 engines)
VTEC oil pressure switch connector (D16W7
engine)
Oil pressure sensor connector Except D15Y5, D15Y6, D17A1, D17Z1, D17Z2
2. 16. Support the engine with a jack and wood block engines:
under the oil pan.
17. Remove the upper bracket.

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Engine Mechanical - Cylinder Head

6-32
Cylinder Head
Cylinder Head Removal (cont'd)

1. 19. Remove the intake manifold. 1. 22. Remove the cylinder head cover.

2. 20. Remove the four ignition coils (see page 4-24).


21. Remove the throttle cable clamps (A) and harness
holder (B) from the cylinder head cover. 2. 23. Remove the timing belt (see page 6-18).

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Engine Mechanical - Cylinder Head

6-33
Cylinder Head
Cylinder Head Removal (cont'd)

1. 24. Remove the camshaft pulley (A) and back cover (B). 1. 25. Remove the cylinder head bolts. To prevent
warpage, unscrew the bolts in sequence 1/3 turn at
a time; repeat the sequence until all bolts are
loosened.
CYLINDER HEAD BOLTS LOOSENING
SEQUENCE:

2. 26. Remove the cylinder head.

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Engine Mechanical - Cylinder Head

6-34 Rocker Arm Assembly Removal


Cylinder Head
Cylinder Head Inspection for Warpage

NOTE: If camshaft-to-holder oil clearances (see page 6-40) are 1. 1. Loosen the adjusting screws (A).
not within specifications, the cylinder head cannot be resurfaced.
If camshaft-to-holder oil clearances are within specifications,
check the cylinder head for warpage.
Measure along the edges and three ways across the centre.
If warpage is less than 0.05 mm (0.002 in.) cylinder
head resurfacing is not required.
If warpage is between 0.05 mm (0.002 in.) and 0.2 mm
(0.008 in.), resurface cylinder head.
Maximum resurface limit is 0.2 mm (0.008 in.) based on
a height of 93 mm (3.7 in.).
Cylinder Head Height:
Standard (New): 92.95 - 93.05 mm (3.659 - 3.663
in.)
2. 2. Remove the bolts and the rocker arm assembly.
1. Unscrew the camshaft holder bolts 2 turns at a
time, in a criss-cross pattern, to prevent
damaging the valves or rocker arm assembly.
2. When removing the rocker arm assembly, do
not remove the camshaft holder bolts. The bolts
will keep the camshaft holders, the springs and
the rocker arms on the shafts.
CAMSHAFT HOLDER BOLT LOOSENING
SEQUENCE:

1. 1. PRECISION STRAIGHT EDGE

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Engine Mechanical - Cylinder Head

6-35
Cylinder Head
Rocker Arms and Shafts
Disassembly/Reassembly

NOTE:
Identify parts as they are removed to ensure reinstallation in original location.
Inspect the rocker shafts and rocker arms (see page 6-38).
The rocker arms must be installed in the same positions if reused.
When removing or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the
holders, springs and rocker arms on the shaft.
Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact points.
D15Y4, D16V2, D16W7, D17A2, D17A5, D17Z3 engines:
1. RUBBER BAND
2. INTAKE ROCKER SHAFT
3. COLLAR B
4. INTAKE ROCKER ARM
ASSEMBLY
5. COLLAR A
6. No. 1 CAMSHAFT HOLDER
7. EXHAUST ROCKER ARM A
8. Letter "A" is stamped on the rocker
arm.
9. EXHAUST ROCKER SHAFT
10. Letter "B" is stamped on the rocker
arm.
11. SPRING
12. EXHAUST ROCKER ARM B
13. No. 5 CAMSHAFT HOLDER
14. No. 4 CAMSHAFT HOLDER
15. No. 3 CAMSHAFT HOLDER
16. No. 2 CAMSHAFT HOLDER

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Engine Mechanical - Cylinder Head

6-36
Cylinder Head
Rocker Arms and Shafts
Disassembly/Reassembly (cont'd)

NOTE:
Identify parts as they are removed to ensure reinstallation in original location.
Inspect the rocker shafts and rocker arms (see page 6-38).
The rocker arms must be installed in the same positions if reused.
When removing or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the
holders, springs and rocker arms on the shaft.
Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact points.
Bundle the rocker arms with rubber bands to keep them together as a set.
D16W8 engine:
1. RUBBER BAND
2. INTAKE ROCKER ARM
ASSEMBLY
3. INTAKE ROCKER SHAFT
4. COLLAR B
5. SPRING
6. TIMING PLATE
7. RETURN SPRING
8. COLLAR A
9. No. 1 CAMSHAFT HOLDER
10. EXHAUST ROCKER ARM A
11. Letter "A" is stamped on the
rocker arm.
12. EXHAUST ROCKER SHAFT
13. Letter "B" is stamped on the
rocker arm.
14. SPRING
15. EXHAUST ROCKER ARM B
16. No. 5 CAMSHAFT HOLDER
17. No. 4 CAMSHAFT HOLDER
18. No. 3 CAMSHAFT HOLDER
19. No. 2 CAMSHAFT HOLDER

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Engine Mechanical - Cylinder Head

6-37
Cylinder Head
Rocker Arms and Shafts
Disassembly/Reassembly (cont'd)

NOTE:
Identify parts as they are removed to ensure reinstallation in original location.
Inspect the rocker shafts and rocker arms (see page 6-38).
The rocker arms must be installed in the same positions if reused.
When removing or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the
holders, springs and rocker arms on the shaft.
Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact points.
D14Z5, D15Y2, D15Y3, D15Y5, D15Y6, D17A1, D17Z1, D17Z2 engines:
1. COLLAR
2. Letter "B" is stamped on the
rocker arm.
3. INTAKE ROCKER ARM B
4. INTAKE ROCKER SHAFT
5. INTAKE ROCKER ARM A
6. Letter "A" is stamped on the
rocker arm.
7. SPRING
8. No. 1 CAMSHAFT HOLDER
9. EXHAUST ROCKER ARM A
10. Letter "A" is stamped on the
rocker arm.
11. EXHAUST ROCKER SHAFT
12. Letter "B" is stamped on the
rocker arm.
13. SPRING
14. EXHAUST ROCKER ARM B
15. No. 5 CAMSHAFT HOLDER
16. No. 4 CAMSHAFT HOLDER
17. No. 3 CAMSHAFT HOLDER
18. No. 2 CAMSHAFT HOLDER

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Engine Mechanical - Cylinder Head

6-38
Cylinder Head
Rocker Arms and Shafts Inspection

1. 1. Measure the diameter of the shaft at the first rocker 1. 3. Measure the inside diameter of the rocker arm and
location. check it for an out-of-round condition.
Rocker Arm-to-Shaft Clearance:
Standard (New):
Intake: 0.017 - 0.050 mm
(0.0007 - 0.0020 in.)
Exhaust: 0.018 - 0.054 mm
(0.0007 - 0.0021 in.)
Service Limit: 0.08 mm (0.003 in.)

2. 2. Zero the gauge (A) to the shaft diameter.

2. 1. Inspect rocker arm face for wear.

3. 4. Repeat for all rockers and both shafts. If the


clearance is over the limit, replace the rocker shaft
and all overtolerance rocker arms. If any VTEC
intake rocker arm needs replacement, replace rocker
arms (primary and secondary as a set, or primary,
mid and secondary as a set).

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Engine Mechanical - Cylinder Head

6-39
Cylinder Head
Rocker Arms and Shafts Inspection (cont'd)

1. 5. Inspect the synchronising piston (s) (A) and timing 1. 6. Assemble each timing plate (A) and return spring (B)
piston (B). Push it manually. If it does not move on its camshaft holder as shown (D16W8 engine).
smoothly, replace the rocker arm assembly.
NOTE:
When reassembling the primary rocker arm (C),
carefully apply air pressure to its oil passage.
Apply oil to the pistons when reassembling.
D15Y4, D16V2, D16W7, D17A2, D17A5, D17Z3
engines:

D16W8 engine:

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Engine Mechanical - Cylinder Head

6-40
Cylinder Head
Camshaft Inspection

NOTE: 1. 4. Unscrew the camshaft holder bolts 2 turns at a time,


Do not rotate the camshaft during inspection. in a criss-cross pattern. Then remove the camshaft
Remove the rocker arms and rocker shafts. holders from the cylinder head.
1. 1. Put the camshaft and the camshaft holders on the 5. Lift the camshaft out of the cylinder head, wipe them
cylinder head, then tighten the bolts to the specified clean, then inspect the lift ramps. Replace the
torque. camshaft if any lobes are pitted, scored, or
Specified torque: excessively worn.
8 mm bolts: 20 Nm (2.0 kgf/m, 14 lbf/ft) 6. Clean the camshaft journal surfaces in the cylinder
head, then set the camshaft back in place. Place a
Apply engine oil to the bolt plastigage strip across each journal.
threads. 7. Install the camshaft holders, then tighten the bolts to
6 mm bolts: 12 Nm (1.2 kgf/m, 8.7 lbf/ft) the specified torque as shown in step 1.
Apply engine oil to the bolt 8. Remove the camshaft holders. Measure the widest
threads. portion of plastigage on each journal.
6 mm bolts: (11), (12), (13), (14) If the camshaft-to-holder clearance is within
limits, go to step 10.
If the camshaft-to-holder clearance is beyond the
service limit and the camshaft has been replaced,
replace the cylinder head.
If the camshaft-to-holder clearance is beyond the
service limit and the camshaft has not been
replaced, go to step 9.
Camshaft-to-Holder Oil Clearance:
Standard (New): 0.050 - 0.089 mm
(0.0020 - 0.0035 in.)
Service Limit: 0.15 mm (0.006 in.)
2. 2. Seat the camshaft by pushing it away from the
camshaft pulley end of the cylinder head.
3. Zero the dial indicator against the end of the
camshaft, then push the camshaft back and forth and
read the end play.
Camshaft End Play:
Standard (New): 0.05 - 0.15 mm
(0.002 - 0.006 in.)
Service Limit: 0.5 mm (0.02 in.)

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Engine Mechanical - Cylinder Head

6-41
Cylinder Head
Camshaft Inspection (cont'd)

1. 9. Check the total runout with the camshaft supported 1. 10. Measure cam lobe height.
on V-blocks. Cam Lobe Height Standard (New):
If the total runout of the camshaft is within the INTAKE EXHAUST
service limit, replace the cylinder head.
D15Y4 engine PRI 38.427 mm 38.784 mm
If the total runout is beyond the service limit,
replace the camshaft and recheck the camshaft- (1.5129 in.) (1.5269 in.)
to-holder oil clearance. If the oil clearance is still SEC 32.292 mm
out of tolerance, replace the cylinder head.
(1.2713 in.)
Camshaft Total Runout:
D16V2, D16W7 engines PRI 38.427 mm
Standard (New): 0.03 mm (0.001 in.) max. 38.784 mm
(1.5129 in.) (1.5269 in.)
Service Limit: 0.04 mm (0.002 in.)
SEC 32.848 mm
(1.2932 in.)
D17A2, D17A5, D17Z3 PRI 38.604 mm 38.784 mm
engines (1.5198 in.) 1.5269 in.)
SEC 32.848 mm
1.2932 in.)

D16W8 engine PRI 36.662 mm 38.008 mm


(1.4434 in.) (1.4964 in.)
MID 38.274 mm
2. 1. Rotate camshaft while measuring.
(1.5068 in.)
SEC 32.848 mm
1.2932 in.)
D14Z5 engine 34.158 mm 36.488 mm
(1.3448 in.) (1.4365 in.)
D15Y2, D15Y3, D15Y5, D15Y6, 35.299 mm 37.281 mm
D17A1, D17Z1, D17Z2 engines (1.3897 in.) (1.4678 in.)

PRI: Primary SEC: Secondary


IN: Intake EX: Exhaust T/B: Timing Belt

D15Y4, D16W7, D17A2, D17A5 engines:

D16W8 engine:

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Engine Mechanical - Cylinder Head

6-42 Valve Inspection


Cylinder Head
Valves, Springs and Valve Seals Removal

Special Tools Required Measure the valve in these areas.


Valve Spring Compressor, 07757-0010000 Except D15Y2, D15Y3, D16V2, D16W8, D17A5
Identify the valves and valve springs as they are removed so engines:
that each item can be reinstalled in its original position. Intake Valve Dimensions
1. 1. Using an appropriate-sized socket (A) and plastic
A Standard (New): 29.85 - 30.15 mm
mallet (B), lightly tap the valve retainer to loosen the
(1.175 - 1.187 in.)
valve keepers.
B Standard (New): 118.27 - 118.87 mm
(4.656 - 4.680 in.)
C Standard (New): 5.480 - 5.490 mm
(0.2157 - 0.2161 in.)
C Service Limit: 5.45 mm (0.215 in.)

Exhaust Valve Dimensions


A Standard (New): 25.85 - 26.15 mm
(1.018 - 1.030 in.)

2. 2. Install the valve spring compressor. Compress the B Standard (New): 115.65 - 116.25 mm
spring and remove the valve keepers. (4.553 - 4.577 in.)
C Standard (New): 5.450 - 5.460 mm
(0.2146 - 0.2150 in.)
C Service Limit: 5.42 mm (0.213 in.)

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Engine Mechanical - Cylinder Head

6-43 Valve Stem-to-Guide Clearance Inspection


Cylinder Head
Valve Inspection (cont'd)

D15Y2, D15Y3, D16V2, D16W8, D17A5 engines: 1. 1. Slide the valve out of its guide about 10 mm, then
Intake Valve Dimensions measure the guide-to-stem clearance with a dial
indicator while rocking the stem in the direction of
A Standard (New): 29.85 - 30.10 mm normal thrust (wobble method).
(1.175 - 1.185 in.) If the measurement exceeds the service limit,
B Standard (New): 118.27 - 118.87 mm recheck it using a new valve.
(4.656 - 4.680 in.) If the measurement is now within the service limit,
reassemble using a new valve.
C Standard (New): 5.480 - 5.490 mm If the measurement with a new valve still exceeds
(0.2157 - 0.2161 in.) the service limit, go to step 2.
C Service Limit: 5.45 mm (0.215 in.) Intake Valve Stem-to-Guide Clearance:
Standard (New): 0.04 - 0.10 mm
Exhaust Valve Dimensions (0.002 - 0.004 in.)
A Standard (New): 25.90 - 26.10 mm Service Limit: 0.16 mm (0.006 in.)
(1.020 - 1.028 in.)
B Standard (New): 115.65 - 116.25 mm Exhaust Valve Stem-to-Guide Clearance:
(4.553 - 4.577 in.) Standard (New): 0.10 - 0.16 mm
C Standard (New): 5.450 - 5.460 mm (0.004 - 0.006 in.)
(0.2146 - 0.2150 in.) Service Limit: 0.22 mm (0.009 in.)
C Service Limit: 5.42 mm (0.213 in.)

2. 2. Subtract the O.D. of the valve stem, measured with a


micrometer, from the I.D. of the valve guide,
measured with an inside micrometer or ball gauge.
Take the measurements in 3 places along the valve stem
and three places inside the valve guide.
The difference between the largest guide measurement and
the smallest stem measurement should not exceed the
service limit.
Intake Valve Stem-to-Guide Clearance:
Standard (New): 0.02 - 0.05 mm
(0.0008 - 0.0020 in.)
Service Limit: 0.08 mm (0.003 in.)

Exhaust Valve Stem-to-Guide Clearance:


Standard (New): 0.05 - 0.08 mm
(0.0020 - 0.0031 in.)
Service Limit: 0.11 mm (0.004 in.)

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Engine Mechanical - Cylinder Head

6-44
Cylinder Head
Valve Guide Replacement

Special Tools Required 1. 4. Working from the camshaft side, use the driver and
Valve guide driver, 5.5 mm, 07742-0010100 an air hammer to drive the guide about 2 mm (0.1
Valve guide reamer, 5.525 mm, 07HAH-PJ70100 in.) towards the combustion chamber. This will knock
1. 1. As illustrated below, use a commercially available air- off some of the carbon and make removal easier.
impact valve guide driver (A) modified to fit the Hold the air hammer directly in line with the valve
diameter of the valve guides. In most cases, the guide to prevent damaging the driver.
same procedure can be done using the special tool 5. Turn the head over and drive the guide out toward
and a conventional hammer. the camshaft side of the head.

2. 2. Select the proper replacement guides and chill them


in the freezer section of a refrigerator for about an
hour.
3. Use a hot plate or oven to evenly heat the cylinder
head to 150o C (300 o F). Monitor the temperature with
a cooking thermometer. Do not get the head hotter
than 150o C (300 o F); excessive heat may loosen the
valve seats.

2. 6. If a valve guide will not move, drill it out with an 8


mm (5/16 inch) bit, then try again. Drill guides only in
extreme cases; you could damage the cylinder head
if the guide breaks.
7. Remove the new guide(s) from the freezer, one at a
time, as you need them.

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Engine Mechanical - Cylinder Head

6-45
Cylinder Head
Valve Guide Replacement (cont'd)

1. 8. Apply a thin coat of clean engine oil to the outside of 1. 9. Coat both reamer and valve guide with cutting oil.
the new valve guide. Install the guide from the 10. Rotate the reamer clockwise the full length of the
camshaft side of the head; use the special tool to valve guide bore.
drive the guide in to the specified installed height (A)
of the guide (B). If you have all 16 guides to do, you
may have to reheat the head.
Valve Guide Installed Height:
Intake: 17.85 - 18.35 mm (0.703 - 0.722
in.)
Exhaust: 18.65 - 19.15 mm (0.734 - 0.754
in.)

2. 11. Continue to rotate the reamer clockwise while


removing it from the bore.
12. Thoroughly wash the guide in detergent and water to
remove any cutting residue.
13. Check the clearance with a valve (see page 6-43).
Verify that the valve slides in the intake and exhaust
valve guides without exerting pressure.

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Engine Mechanical - Cylinder Head

6-46
Cylinder Head
Valve Seat Reconditioning

If the valve guides are worn (see page 6-43), replace them 1. 2. After resurfacing the seat, inspect it for even valve
(see page 6-44) before cutting the valve seats. seating: Apply Prussian Blue compound (A) to the
1. 1. Renew the valve seats in the cylinder head using a valve face. Insert the valve in its original location in
valve seat cutter. the head, then lift it and snap it closed against the
seat several times.
1. Carefully cut a 45 o seat, removing only enough
material to ensure a smooth and concentric seat.
2. Bevel the upper edge of the seat with the 30 o
cutter and the lower edge of the seat with the
67.5 o cutter (Intake) or 60 o cutter (exhaust).
Check the width of the seat and adjust
accordingly.
3. Make one more very light pass with the 45 o cutter
to remove any possible burrs caused by the other
cutters.
2. 3. The actual valve seating surface (B), as shown by
Valve Seat Width: the blue compound, should be centred on the seat.
Intake: If it is too high (closer to the valve stem), you
Standard (New): 0.85 - 1.15 mm must make a second cut with the 67.5 o cutter
(0.033 - 0.045 in.) (Intake) or 60 o cutter (exhaust) to move it down,
Service Limit: 1.60 mm (0.063 in.) then one more cut with the 45 o cutter to restore
seat width.
Exhaust: If it is too low (closer to the valve edge), you
Standard (New): 1.25 - 1.55 mm must make a second cut with the 30 o cutter to
(0.049 - 0.061 in.) move it up, then one more cut with the 45 o cutter
to restore seat width.
Service Limit: 2.00 mm (0.079 in.)
NOTE: The final cut should always be made with the 45 o
cutter.

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Engine Mechanical - Cylinder Head

6-47
Cylinder Head
Valve Seat Reconditioning (cont'd)

1. 4. Insert the intake and exhaust valves in the head and


measure the valve stem installed height (A).
Valve Stem Installed Height:
Standard (New): 53.17 - 53.64 mm
(2.093 - 2.112 in.)
Service Limit: 53.89 mm (2.122 in.)

2. 5. If the valve stem installed height is over the service


limit, replace the valve and recheck. If it is still over
the service limit, replace the cylinder head; the valve
seat in the head is too deep.

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Engine Mechanical - Cylinder Head

6-48
Cylinder Head
Valves, Springs and Valve Seals Installation

Special Tools Required 1. 5. Install the valve spring and valve retainer. Place the
Stem seal driver, 07PAD-0010000 end of the valve spring with closely wound coils
Valve spring compressor, 07757-0010000 toward the cylinder head.
1. 1. Coat the valve stems with engine oil. Install the 6. Install the valve spring compressor. Compress the
valves in the valve guides. spring and install the valve keepers.
2. Check that the valves move up and down smoothly.
3. Install the spring seats on the cylinder head.
4. Install the new valve seals (A) using the stem seal
driver (B).
NOTE: Exhaust valve seal (C) has a black spring (D) and
intake valve seal (E) has a white spring (F). They are not
interchangeable.

2. 7. Lightly tap the end of each valve stem 2 or 3 times


with a plastic mallet (A) to ensure proper seating of
the valve and valve keepers. Tap the valve stem
only along its axis so you do not bend the stem.

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Engine Mechanical - Cylinder Head

6-49
Cylinder Head
Camshaft/Rocker Arms, Camshaft Seal and
Pulley Installation

NOTE: To prevent the rocker arm assembly from coming apart, 1. 6. Set the rocker arm assembly in place and loosely
leave the camshaft holder bolts in the holes. install the bolts. Make sure that the rocker arms are
1. 1. After wiping down the camshaft and the journals in properly positioned on the valve stems.
the cylinder head, lubricate both surfaces and install 7. Tighten each bolt 2 turns at a time, in the sequence
the camshaft. shown below to ensure that the rockers do not bind
2. Clean and install the oil control orifice (A) with a new on the valves.
O-ring (B). Specified torque:
8 mm bolts: 20 Nm (2.0 kgf/m, 14 lbf/ft)
Apply engine oil to the bolt
threads.
6 mm bolts: 12 Nm (1.2 kgf/m, 8.7 lbf/ft)
Apply engine oil to the bolt
threads.
6 mm bolts: (11), (12), (13), (14)

2. 3. Turn the camshaft until its keyway (C) is facing up


(No. 1 piston TDC).
4. Loosen all the valve adjusting screws.
5. Apply liquid gasket to the head mating surface
(shaded areas) of the No. 1 and No. 5 camshaft
holders.

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Engine Mechanical - Cylinder Head

6-50 Cylinder Head Installation


Cylinder Head
Camshaft/Rocker Arms, Camshaft Seal and Pulley Installation (cont'd)

1. 8. Align the marks (A) on the new cylinder head plug Install the cylinder head in the reverse order of removal:
(B) with the top edge of the head, then install the
1. 1. Clean the cylinder head and block surface.
cylinder head plug in the cylinder head.
2. Install the cylinder head gasket (A) and dowel pins
(B) on the cylinder block. Always use a new cylinder
head gasket.

2. 9. Install the back cover (A), then install the camshaft


pulley (B).

2. 3. Set the crankshaft to TDC. Align the TDC mark (A)


on the timing belt drive pulley with the pointer (B) on
the oil pump.

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Engine Mechanical - Cylinder Head

6-51
Cylinder Head
Cylinder Head Installation (cont'd)

1. 4. Clean the camshaft pulley and set it to TDC. 1. 6. Apply engine oil to the bolt threads and under the
bolt heads of all the cylinder head bolts.
1. The ''UP'' mark (A) on the camshaft pulley should be at 7. Tighten the cylinder head bolts sequentially in 3
the top. steps.
2. Align the TDC marks (B) on the camshaft pulley with the 1st step torque: 20 Nm (2.0 kgf/m, 14 lbf/ft)
top edge of the head.
2nd step torque: 49 Nm (5.0 kgf/m, 36 lbf/ft)
3rd step torque: 67 Nm (6.8 kgf/m, 49 lbf/ft)

Use a beam-type torque wrench. When using a preset-type


torque wrench, be sure to tighten slowly and do not
overtighten. If a bolt makes any noise while you are torquing
it, loosen the bolt and retighten it from the 1st step.
CYLINDER HEAD BOLTS TORQUE SEQUENCE:

2. 5. Install the cylinder head on the block.

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Engine Mechanical - Cylinder Head

6-52
Cylinder Head
Cylinder Head Installation (cont'd)

1. 8. Install the timing belt (see page 6-22). 1. 13. Install the new exhaust manifold gasket (A) and
2. 9. Adjust the valve clearance (see page 6-14). exhaust manifold (B). Loosely install the new nuts,
10. Install the cylinder head cover (see page 6-55). then install the cover (C) and loosely install the new
11. Install the intake manifold (A) and tighten the bolts.
bolts/nuts in a criss-cross pattern in 2 or 3 steps, D15Y5, D15Y6, D17A1 D17Z1, D17Z2 engines:
beginning with the inner nut. Always use a new
intake manifold gasket (B).

Except D15Y5, D15Y6, D17A1, D17Z1, D17Z2


engines:

3. 12. Tighten the three nuts securing the intake manifold


and brackets.

2. 14. Tighten the bolts/nuts in a criss-cross pattern in 2 or


3 steps.
15. Install the exhaust pipe with a new gasket (D).
16. Install the exhaust manifold bracket (E) (D15Y5,
D15Y6, D17A1, D17Z1, D17Z2 engines).

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Engine Mechanical - Cylinder Head

6-53
Cylinder Head
Cylinder Head Installation (cont'd)

1. 17. Install the A/C hose bracket (A) and P/S hose 1. 23. Install the ground cable (A), upper radiator hose (B),
bracket (B). lower radiator hose (C), heater hose (D) and water
bypass hose (E).

2. 18. Loosely install the alternator. 2. 24. Install the EVAP canister hose.
19. Adjust the alternator belt tension (see page 4-38) or
the alternator-compressor belt tension (see page 4-
37).
20. Loosely install the P/S pump belt and pump.
21. Adjust the P/S pump belt (see page 17-23).
22. Install the connecting pipe (A) with a new O-ring (B).

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Engine Mechanical - Cylinder Head

6-54
Cylinder Head
Cylinder Head Installation (cont'd)

1. 25. Install the brake booster vacuum hose (A) and PCV 1. 27. Install the intake resonator.
hose (B).

2. 26. Install the air cleaner housing (A), then connect the
IAT sensor connector (B) and breather hose. 2. 28. Install the cruise control cable, then adjust the cable
(see page 4-49).
29. Install the throttle cable, then adjust the cable (see
page 11-148).
30. After installation, check that all tubes, hoses and
connectors are installed correctly.
31. Clean the battery posts and cable terminals with
sandpaper, then assemble them and apply grease to
prevent corrosion.
32. Inspect for fuel leaks. Turn ON (II) the ignition switch
(do not operate the starter) so that the fuel pump
runs for approximately 2 seconds and pressurises
the fuel line. Repeat this operation 2 or 3 times, then
check for fuel leakage at any point in the fuel line.
33. Refill the radiator with engine coolant and bleed air
from the cooling system with the heater valve open
(see page 10-8).
34. Enter the anti-theft code for the radio, then enter the
customer's radio station presets.

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Engine Mechanical - Cylinder Head

6-55
Cylinder Head
Cylinder Head Cover Installation

1. 1. Thoroughly clean the head cover gasket and the 1. 5. Hold the head cover gasket in the groove by placing
groove. your fingers on the camshaft holder contacting
2. 2. Install the head cover gasket (A) in the groove of the surfaces (top of the semicircles). Set the spark plug
cylinder head cover (B). Seat the head cover gasket seals (A) on the spark plug tubes. Once the cylinder
in the recesses for the camshaft first, then work it head cover (B) is on the cylinder head, slide the
into the groove around the outside edges. Make sure cover slightly back and forth to seat the head cover
the head cover gasket is seated securely in the gasket.
corners of the recesses (C) with no gap.

3. 3. Check that the mating surfaces are clean and dry.


4. Apply liquid gasket, part No. 08C70-K0234M, 08C70-
K0334M or, 08C70-X0331S to the head cover gasket
2. 6. Inspect the cover washers (C). Replace any washer
at the four corners of the recesses (A).
that is damaged or deteriorated.
NOTE: Do not install the parts if 5 minutes or more
have elapsed since applying liquid gasket. Instead,
reapply liquid gasket after removing old residue.

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Engine Mechanical - Cylinder Head

6-56
Cylinder Head
Cylinder Head Cover Installation (cont'd)

1. 7. Tighten the bolts in 2 or 3 steps. In the final step, 1. 9. Install the ignition coils (see page 4-24).
tighten all bolts, in sequence, to 9.8 Nm (1.0 kgf/m, 10. Check that all tubes, hoses and connectors are
7.2 lbf/ft). installed correctly.
11. After assembly, wait at least 30 minutes before filling
the engine with oil.

2. 8. Install the harness holder (A) and throttle cable


clamps (B).

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Engine Mechanical - Cylinder Head

6-57
Cylinder Head

TDC Sensor Replacement CKP Sensor Replacement


1. 1. Remove the grommet (A) from the upper cover and 1. 1. Remove the grommet (A) from the upper cover and
disconnect the TDC sensor connector (B). disconnect the TDC sensor connector (B).

2. 2. Remove the upper cover (C).


3. Remove the TDC sensor from the cylinder head.

2. 2. Remove the upper cover (C) and lower cover (D).


3. Disconnect the CKP sensor connector, then remove
the CKP sensor from the oil pump.

3. 4. Install the TDC sensor in reverse order of removal.

3. 4. Install the CKP sensor in reverse order of removal.

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Engine Mechanical - Engine Block

Engine Block
Special Tools 7-2
Component Location Index 7-3
Flywheel Removal and Installation 7-5
Drive Plate Removal and Installation 7-5
Connecting Rod and Crankshaft End Play Inspection 7-6
Crankshaft Main Bearing Replacement 7-7
Connecting Rod Bearing Replacement 7-9
Crankshaft and Piston Removal 7-11
Crankshaft Inspection 7-13
Block and Piston Inspection 7-14
Cylinder Honing 7-16
Piston, Pin and Connecting Rod Replacement 7-17
Piston Ring Replacement 7-19
Piston Installation 7-21
Crankshaft Installation 7-22
Oil Pan Installation 7-25
Knock Sensor Replacement 7-26

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Engine Mechanical - Engine Block

7-2
Engine Block
Special Tools

Ref. No. Tool Number Description Qty


1 07LBA-PV00100 Ring Gear Holder 1
2 07PAF-0010000 Piston Pin Assembly Tool Set 1
3 07PAF-0010650 Pilot Collar, O.D. 19 mm 1
4 07749-0010000 Handle Driver 1
5 07948-SB00101 Driver Attachment, 96 mm 1

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Engine Mechanical - Engine Block

7-3
Engine Block
Component Location Index
1. DRAIN BOLT
2. WASHER
3. OIL PAN
Installation for Aluminium Oil Pan Type,
page 7-24
4. FLYWHEEL (M/T)
5. CRANKSHAFT
End play, page 7-6
Runout, page 7-13
Out-of-Round, page 7-13
Removal, page 7-11
Installation, page 7-22
6. CRANKSHAFT OIL SEAL,
TRANSMISSION END
Installation, page 7-22
7. ENGINE BLOCK END COVER
8. DOWEL PIN
9. THRUST WASHERS
10. DOWEL PIN
11. O-RING
12. OIL PUMP
Overhaul, page 8-9
13. CRANKSHAFT OIL SEAL, PULLEY END
Installation, page 8-9
14. KNOCK SENSOR
Replacement, page 7-26
15. MAIN BEARINGS
Oil clearance, page 7-7
Selection, page 7-7
16. GASKET
17. OIL SCREEN
18. MAIN BEARING CAP BRIDGE
19. OIL PAN
Installation for Steel Oil Pan Type, page
7-25

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Engine Mechanical - Engine Block

7-4
Engine Block
Component Location Index (cont'd)
1. PISTON RINGS
Replacement, page 7-19
2. PISTON
Removal, page 7-11
Measurement, page 7-14
3. PISTON PIN
Removal, page 7-17
Inspection, page 7-17
Installation, page 7-17
4. ENGINE BLOCK
Cylinder bore inspection, page 7-14
Warpage inspection, page 7-14
Cylinder bore honing, page 7-16
Ridge removal, page 7-11
5. CONNECTING ROD BEARING CAP
6. CONNECTING ROD BEARINGS
Oil Clearance, page 7-9
Selection, page 7-9
7. CONNECTING ROD
End play, page 7-6
Small end measurement, page 7-17

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Engine Mechanical - Engine Block

7-5 Drive Plate Removal and Installation


Engine Block
Flywheel Removal and Installation
Special Tools Required Remove the six drive plate bolts, then separate the drive plate
from the crankshaft flange. After installation, tighten the bolts
Ring Gear Holder, 07LAB-PV00100
in a criss-cross pattern.
Remove the six flywheel bolts, then separate the flywheel from
the crankshaft flange. After installation, tighten the bolts in a
criss-cross pattern.

1. 1. Inspect ring gear teeth for wear or damage.

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Engine Mechanical - Engine Block

7-6
Engine Block
Connecting Rod and Crankshaft End Play
Inspection

1. 1. Measure the connecting rod end play with a feeler 1. 4. Push the crankshaft firmly away from the dial
gauge between the connecting rod and crankshaft. indicator, and zero the dial against the end of the
Connecting Rod End Play: crankshaft. Then pull the crankshaft firmly back
toward the indicator; the dial reading should not
Standard (New): 0.15 - 0.30 mm
exceed the service limit.
(0.006 - 0.012 in.)
Crankshaft End Play:
Service Limit: 0.40 mm (0.016 in.)
Standard (New): 0.10 - 0.35 mm
(0.004 - 0.014 in.)
Service Limit: 0.45 mm (0.018 in.)

2. 2. If the connecting rod end play is out-of-tolerance,


install a new connecting rod and recheck. If it is still
out-of-tolerance; replace the crankshaft (see page 7-
11).
3. Mount a dial indicator on the block so that it's tip 2. 5. If the end play is excessive, inspect the thrust
contacts the end of the crankshaft. washers and thrust surface on the crankshaft.
Replace parts as necessary. Thrust washer thickness
is fixed and must not be changed either by grinding
or shimming.

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Engine Mechanical - Engine Block

7-7
Engine Block
Crankshaft Main Bearing Replacement

Main Bearing Clearance Inspection 1. 5. Remove the cap and bearing half, and measure the
widest part of the plastigage.
1. 1. To check main bearing-to-journal oil clearance,
remove the main caps and bearing halves. Main Bearing-to-Journal Oil Clearance:
2. Clean each main journal and bearing half with a D14Z5, D15Y2, D15Y3, D15Y4, D15Y5, D15Y6
clean shop towel. Standard (New):
3. Place one strip of plastigage across each main
journal. No. 1, 5: 0.018 - 0.036 mm
NOTE: If the engine is still in the car when you bolt (0.0007 - 0.0014 in.)
the main cap down to check the clearance, the
No. 2, 3, 4: 0.020 - 0.038 mm
weight of the crankshaft and drive plate will flatten
the plastigage further than just the torque on the cap (0.0009 - 0.0017 in.)
bolt and give you an incorrect reading. For an Service Limit: 0.05 mm
accurate reading, support the crank with a jack under
(0.002 in.)
the counterweights, and check only one bearing at a
time.
4. Reinstall the bearings and caps, then torque the D16V2, D16W7, D16W8, D17Z1, D17Z2, D17Z3,
bolts. Do not rotate the crankshaft. D17A1, D17A2, D17A5
Tightening torque: Standard (New):
D14Z5, D15Y2, D15Y3, D15Y4, D15Y5, D15Y6 No. 1, 5: 0.018 - 0.036 mm
Engines: 44 Nm (4.5 kgf/m, 33 lbf/ft) (0.0007 - 0.0014 in.)
No. 2, 3, 4: 0.024 - 0.042 mm
D16V2, D16W7, D16W8, D17Z1, D17Z2, D17Z3,
(0.0009 - 0.0017 in.)
D17A1, D17A2, D17A5
Service Limit: 0.05 mm
Engines: 51 Nm (5.2 kgf/m, 38 lbf/ft)
(0.002 in.)

2. 6. If the plastigage measures too wide or too narrow,


(remove the engine if it's still in the car), remove the
crankshaft, and remove the upper half of the bearing.
Install a new, complete bearing with the same colour
code and recheck the clearance. Do not file, shim, or
scrape the bearings or the caps to adjust clearance.
7. If the plastigage shows the clearance is still
incorrect, try the next larger or smaller bearing (the
colour listed above or below that one) and check
again. If the proper clearance cannot be obtained by
using the appropriate larger or smaller bearings,
replace the crankshaft and start over.

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Engine Mechanical - Engine Block

7-8
Engine Block
Crankshaft Main Bearing Replacement (cont'd)

Main Bearing Selection


Crankshaft Bore Code Location
Letters have been stamped on the end of the block as a code
for the size of each of the five main journal bores.
Use them, and the numbers stamped on the crankshaft (codes
for main journal size), to choose the correct bearings. If the
codes are indecipherable because of an accumulation of dirt
and dust, do not scrub them with a wire brush or scraper.
Clean them only with solvent or detergent.

1. 1. No. 1 BORE (PULLEY END)


2. No. 4 BORE (DRIVE PLATE END)

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Engine Mechanical - Engine Block

7-9
Engine Block
Connecting Rod Bearing Replacement

1. 1. Remove the connecting rod cap and bearing half. 1. 6. If the plastigage measures too wide or too narrow,
2. Clean the crankshaft rod journal and bearing half with remove the upper half of the bearing, install a new,
a clean shop towel. complete bearing with the same colour code and
3. Place a strip of plastigage across the rod journal. recheck the clearance. Do not file, shim, or scrape
4. Reinstall the bearing half and cap and torque the the bearings or the caps to adjust clearance.
bolts to 32 Nm (3.3 kgf/m, 24 lbf/ft). Do not rotate the 2. 7. If the plastigage shows the clearance is still
crankshaft. incorrect, try the next larger or smaller bearing (the
5. Remove the rod cap and bearing half and measure colour listed above or below that one) and check
the widest part of the plastigage. clearance again. If the proper clearance cannot be
Connecting Rod Bearing-to-Journal Oil Clearance: obtained by using the appropriate larger or smaller
Standard (New): 0.024 - 0.042 mm bearings, replace the crankshaft and start over.
(0.0009 - 0.0017 in.)
Service Limit: 0.05 mm (0.002 in.)

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Engine Mechanical - Engine Block

7-10
Engine Block
Connecting Rod Bearing Replacement (cont'd)

Rod Bearing Selection


Each rod falls into one of four tolerance ranges (from 0 to
0.024 mm (0.0009 in.), in 0.006 mm (0.0002 in.) increments)
depending on the size of its big end bore.
It's then stamped with a number (1,2,3, or 4), indicating the
range.
You may find any combination of 1, 2, 3, or 4 in any engine.
Normal Bore Size:
D14Z5 engines: 43.0 mm (1.69 in.)
D15Y2, D15Y3, D15Y4, D15Y5, D15Y6 engines: 45.0
mm (1.77 in.)
D16V1, D16W7, D16W8, D17Z1, D17Z2, D17Z3,
D17A1, D17A2, D17A5 engines: 48.0 mm (1.89 in.)
Inspect the connecting rod for cracks and heat damage.
Connecting Rod Journal Code Locations
Numbers have been stamped on the side of each connecting
rod as a code for the size of the big end. Use them, and the
letters stamped on the crank (codes for rod journal size), to
choose the correct bearings. If the codes are indecipherable
because of an accumulation of dirt and dust, do not scrub them
with a wire brush or scraper. Clean them only with solvent or
detergent.

1. 1. Half of number is stamped on bearing cap and the other half


is stamped on rod.

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Engine Mechanical - Engine Block

7-11
Engine Block
Crankshaft and Piston Removal

1. 1. Remove the oil pan. 1. 4. Remove the bearing cap bolts. To prevent warpage,
2. Remove the engine block end cover. unscrew the bolts in sequence 1/3 turn at a time;
repeat the sequence until all bolts are loosened.
BEARING CAP BOLTS LOOSENING SEQUENCE:

2. 3. Remove the oil screen (A), then remove the oil pump
(B).
2. 5. Remove the bearing cap bridge/bearings. Keep all
bearings in order.
6. Turn the crankshaft so No. 2 and No. 3 crankpins
are at the top.
7. Remove the rod caps/bearings. Keep all
caps/bearings in order.
8. Lift the crankshaft out of the engine, being careful
not to damage the journals.

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Engine Mechanical - Engine Block

7-12
Engine Block
Crankshaft and Piston Removal (cont'd)

1. 9. Remove the upper bearing halves from the 1. 14. To avoid mix-up on reassembly, mark each
connecting rods, and set them aside with their piston/connecting rod assembly with its cylinder
respective caps. number.
10. Reinstall the bearing cap bridge and bearings on the NOTE: The existing number on the connecting rod does not
engine in the proper order. indicate its position in the engine, it indicates the rod size.
11. If you can feel a ridge of metal or hard carbon around
the top of each cylinder, remove it with a ridge
reamer (A). Follow the reamer manufacturer's
instructions. If the ridge is not removed, it may
damage the pistons as they are pushed out.

2. 12. Use the wooden handle of a hammer (A) to drive out


the pistons (B).

3. 13. Reinstall the connecting rod bearing and caps after


removing each piston/connecting rod assembly.

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Engine Mechanical - Engine Block

7-13
Engine Block
Crankshaft Inspection

Straightness Out-of-Round and Taper


1. 1. Measure out-of-round at the middle of each rod and
NOTE:
main journal in two places. The difference between
Clean the crankshaft oil passages with pipe cleaners measurements on each journal must not be more
or a suitable brush. than the service limit.
Check the keyway and threads. Journal Out-of-Round:
1. 1. Support the crankshaft with a lathe-type tool or V-
blocks. Standard (New): 0.0025 mm (0.0001 in.) max.
2. Measure runout on all main journals to make sure Service Limit: 0.005 mm (0.0002 in.)
the crank is not bent. Rotate the crankshaft two
complete revolutions. The difference between
measurements on each journal must not be more
than the service limit.
Crankshaft Total Indicator Runout:
Standard (New): 0.03 mm (0.001 in.) max.
Service Limit: 0.04 mm (0.002 in.)

2. 2. Measure taper at the edge of each rod and main


journal. The difference between measurements on
each journal must not be more than the service limit.
Journal Taper:
Standard (New): 0.0025 mm (0.0001 in.) max.
Service Limit: 0.005 mm (0.0002 in.)

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Engine Mechanical - Engine Block

7-14
Engine Block
Block and Piston Inspection

1. 1. Check the piston for distortion or cracks. 1. 3. Measure wear and taper in direction X and Y at 3
2. Measure the piston diameter at a point 13 mm (0.5 levels in each cylinder as shown. If measurements in
in.) from the bottom of the skirt. any cylinder are beyond the Oversize Bore Service
Piston Diameter: Limit, replace the block. If the block is to be rebored,
refer to step 6 after reboring.
Standard (New): 74.98 - 74.99 mm
(2.9520 - 2.9524 in.) Cylinder Bore Size:

Service Limit: 74.97 mm Standard (New): 75.00 - 75.02 mm


(2.9516 in.) (2.9528 - 2.9535 in.)
Service Limit: 75.07 mm (2.9555 in.)

Oversize:
0.25: 75.25 - 75.27 mm (2.9626 - 2.9634 in.)
0.50: 75.50 - 75.52 mm (2.9724 - 2.9732 in.)
Reboring limit: 0.5 mm (0.02 in.) max.

Bore Taper:
Limit: (Difference between first and third
measurement) 0.05 mm (0.002 in.)

2. 1. SKIRT DIAMETER

Oversize Piston Diameter:


0.25: 75.23 - 75.24 mm (2.9618 - 2.9622 in.)
0.50: 75.48 - 75.49 mm (2.9716 - 2.9720 in.)

2. 1. First Measurement
2. Second Measurement
3. Third Measurement

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Engine Mechanical - Engine Block

7-15
Engine Block
Block and Piston Inspection (cont'd)

1. 4. Scored or scratched cylinder bores must be honed. 1. 6. Calculate the difference between the cylinder bore
5. Check the top of the block for warpage. Measure diameter and the piston diameter. If the clearance is
along the edges and across the centre as shown. near or exceeds the service limit, inspect the piston
Engine Block Warpage: and cylinder block for excessive wear.
Standard (New): 0.07 mm (0.003 in.) max. Piston-to-Cylinder Clearance:
Service Limit: 0.10 mm (0.004 in.) Standard (New): 0.010 - 0.040 mm
(0.0004 - 0.0016 in.)
Service Limit: 0.05 mm (0.002 in.)

2. 1. PISTON-TO-CYLINDER CLEARANCE

2. 1. PRECISION STRAIGHT EDGE

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Engine Mechanical - Engine Block

7-16
Engine Block
Cylinder Honing

Only a scored or scratched cylinder bore must be honed.


1. 1. Measure the cylinder bores (see page 7-14).
If the block is to be reused, hone the cylinders and
remeasure the bores.
2. Hone the cylinder bores with honing oil and a fine
(400 grit) stone in a 60 degree cross-hatch pattern
(A). Use only a rigid hone with 400 grit or finer stone
such as Sunnen, Ammco, or equivalent. Do not use
stones that are worn or broken.

2. 3. When honing is complete, thoroughly clean the


engine block of all metal particles. Wash the cylinder
bores with hot soapy water, then dry and oil them
immediately to prevent rusting. Never use solvent, it
will only redistribute the grit on the cylinder walls.
4. If scoring or scratches are still present in the cylinder
bores after honing to the service limit, rebore the
cylinder block. Some light vertical scoring and
scratching is acceptable if it is not deep enough to
catch your fingernail and does not run the full length
of the bore.

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Engine Mechanical - Engine Block

7-17
Engine Block
Piston, Pin and Connecting Rod Replacement
Special Tools Required Inspection
1. 1. Measure the diameter of the piston pin.
Piston pin assembly tool set, 07PAF-0010000
Piston Pin Diameter:
Pilot collar, O.D. 19 mm, 07PAF-0010650
Disassembly Standard (New): 18.996 - 19.000 mm
1. 1. Set the pilot collar (A) the piston pin assembly tool (0.7479 - 0.7480 in.)
set (B), then adjust the piston pin assembly tool set
as shown.

2. 2. Zero the dial indicator to the piston pin diameter.


2. 2. With the embossed mark facing up, place the piston
assembly (A) on the special tool (B). Be sure you
position the recessed flat on the piston against the
lugs on the special tool.

3. 3. Press the pin (C) out with the driver (D), pilot collar
(E) and a hydraulic press.

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Engine Mechanical - Engine Block

7-18
Engine Block
Piston, Pin and Connecting Rod Replacement
(cont'd)
1. 3. Measure the piston pin-to-piston clearance. Reassembly
Piston Pin-to-Piston Clearance: 1. 1. Assemble the piston and connecting rod with the
connecting rod oil hole (A) facing the ''IN'' mark (B)
Standard (New): 0.010 - 0.020 mm
side.
(0.0004 - 0.0008 in.)

2. 4. Check the difference between the piston pin diameter


and connecting rod small end diameter. 2. 2. Insert the pilot collar (A) into the piston and
Piston Pin-to-Connecting Rod Interference: connecting rod.

Standard (New): 0.016 - 0.036 mm


(0.0006 - 0.0014 in.)

3. 3. With the embossed mark facing up, place the piston


assembly (B) on the special tool (C). Be sure you
position the recessed flat on the piston against the
lugs on the base attachment.
4. Press the pin (D) in with the pin driver (E) and a
hydraulic press.

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Engine Mechanical - Engine Block

7-19
Engine Block
Piston Ring Replacement
1. 1. Using a ring expander (A), remove the old piston 1. 3. Using a piston, push a new ring (A) into the cylinder
rings (B). bore 15 - 20 mm (0.6 - 0.8 in.) from the bottom.

2. 2. Clean all ring grooves thoroughly with a squared-off 2. 4. Measure the piston ring end-gap (B) with a feeler
broken ring or ring groove cleaner with a blade to fit gauge:
the piston grooves. If the gap is too small, check to see if you have the
The top ring groove is 1.0 mm (0.04 in.) wide. The second proper rings for your engine.
ring groove is 1.2 mm (0.05 in.) wide. The oil ring groove is If the gap is too large, recheck the cylinder bore
2.8 mm (0.11 in.) wide (D15Y2, D15Y3, D16V2, D16W8, diameter against the wear limits (see page 7-14).
D17A5 engines) 2.0 mm (0.08 in.) wide (Except D15Y2, If the bore is over the service limit, the cylinder block must
D15Y3, D16V2, D16W8, D17A5 engines). be rebored.
File down a blade if necessary. Piston Ring End-Gap:
Do not use a wire brush to clean the ring grooves, or cut Top Ring
the ring grooves deeper with cleaning tools. Standard (New): 0.15 - 0.30 mm
NOTE: If the piston is to be separated from the connecting (0.006 - 0.012 in.)
rod, do not install new rings yet.
Service Limit: 0.60 mm (0.024 in.)

Second Ring
Standard (New): 0.30 - 0.45 mm
(0.012 - 0.018 in.)
Service Limit: 0.60 mm (0.024 in.)

Oil Ring
D15Y2, D15Y3, D16V2, D16W8, D17A5 engines:
Standard (New): 0.20 - 0.80 mm
(0.008 - 0.031 in.)
Service Limit: 0.90 mm (0.035 in.)

Except D15Y2, D15Y3, D16V2, D16W8, D17A5


engines:
Standard (New): 0.20 - 0.70 mm
(0.008 - 0.028 in.)
Service Limit: 0.80 mm (0.031 in.)

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Engine Mechanical - Engine Block

7-20
Engine Block
Piston Ring Replacement (cont'd)
1. 5. Install the top ring (A) and second ring (B) as shown. 1. 6. Rotate the rings in their grooves to make sure they
The manufacturing marks (C) must be facing upward. do not bind.
2. 7. Position the ring end gaps as shown:

3. 8. After installing a new set of rings, measure the ring-


to-groove clearances:
Top Ring Clearance
D15Y2, D15Y3, D16V2, D16W8, D17A5 engines:
Standard (New): 0.35 - 0.55 mm
(0.014 - 0.022 in.)
Service Limit: 0.13 mm (0.005 in.)

Except D15Y2, D15Y3, D16V2, D16W8, D17A5


engines:
Standard (New): 0.35 - 0.60 mm
(0.014 - 0.024 in.)
Service Limit: 0.13 mm (0.005 in.)

Second Ring Clearance


Standard (New): 0.30 - 0.55 mm
(0.012 - 0.022 in.)
Service Limit: 0.13 mm (0.005 in.)

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Engine Mechanical - Engine Block

7-21
Engine Block
Piston Installation
If the crankshaft is already installed If the crankshaft is not installed
1. 1. Remove the connecting rod caps, then install the
1. 1. Set the crankshaft to BDC for each cylinder.
ring compressor, and check that the bearing is
2. Remove the connecting rod caps and slip short
securely in place.
sections of rubber hose (A) over the connecting rod
2. Position the arrow (A) facing the timing belt side of
bolts. Then install the ring compressor, and check
the engine.
that the bearing is securely in place.

2. 3. Position the arrow (B) facing the timing belt side of


the engine.
4. Position the piston in the cylinder and tap it in using 2. 3. Position the piston in the cylinder and tap it in using
the wooden handle of a hammer (A). the wooden handle of a hammer (A).
Maintain downward force on the ring compressor (B) Maintain downward force on the ring compressor (B)
to prevent the rings from expanding before entering to prevent the rings from expanding before entering
the cylinder bore. the cylinder bore.

3. 5. Stop after the ring compressor pops free, and check 3. 4. Position all pistons at top dead centre.
the connecting rod-to-crank journal alignment before
pushing the piston into place.
6. Check the connecting rod bearing clearance with
plastigage (see page 7-9).
7. Apply engine oil to the bolt threads, then install the
rod caps with bearings. Torque the nuts to 32 Nm
(3.3 kgf/m, 24 lbf/ft).

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Engine Mechanical - Engine Block

7-22
Engine Block
Crankshaft Installation
Special Tools Required 1. 10. Check the main bearing clearance with plastigage
(see page 7-7).
Handle Driver, 07749-0010000
2. 11. Install the bearing cap bridge. Coat the bolt threads
Driver Attachment, 96 mm, 07948-SB00101
with engine oil.
1. 1. Apply engine oil to the main bearings and rod
12. Torque the cylinder head bolts sequentially in 2
bearings.
steps.
2. Install the bearing halves in the cylinder block and
1st step torque: 25 Nm (2.5 kgf/m, 18 lbf/ft)
connecting rods.
3. Hold the crankshaft so rod journal No. 2 and rod 2nd step torque:
journal No. 3 are straight up and lower the crankshaft D14Z5, D15Y2, D15Y3, D15Y4, D15Y5, D15Y6
into the block.
Engines: 44 Nm (4.5 kgf/m, 33 lbf/ft)
4. Install the thrust washers (A) on both edges of the
No. 4 main bearing recess.
D16V2, D16W7, D16W8, D17Z1, D17Z2, D17Z3,
D17A1, D17A2, D17A5 engines:
51 Nm (5.2 kgf/m, 38 lbf/ft)

NOTE: Whenever any crankshaft or connecting rod bearing


is replaced, it is necessary after reassembly to run the
engine at idling speed until it reaches normal operating
temperature, then continue to run it for approximately 15
minutes.
BEARING CAP BOLTS TIGHTENING SEQUENCE:

2. 5. Apply engine oil to the threads of the connecting rod


bolts.
6. Seat the rod journals into connecting rod No. 1 and
connecting rod No. 4. Install the caps and nuts finger
tight. Install the cap so the bearing recess is on the
same side as the recess in the rod.
7. Rotate the crankshaft clockwise and seat the journals
into connecting rod No. 2 and connecting rod No. 3.
Install the connecting rod cap and bolts finger tight.
8. Check the connecting rod bearing clearance with
plastigage (see page 7-9).
9. Tighten the connecting rod bolts to 32 Nm (3.3 kgf/m,
24 lbf/ft).

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Engine Mechanical - Engine Block

7-23
Engine Block
Crankshaft Installation (cont'd)
1. 13. The seal mating surface on the engine block end 1. 16. Clean and dry the engine block end cover mating
cover should be dry. Apply a light coat of grease to surfaces.
the crankshaft and to the lip of the seal. 2. 17. Apply liquid gasket, part No. 08C70-K0234M,
14. Drive the crankshaft oil seal squarely into the engine 08C70-K0334M or 08C70-X0331S, evenly to the
block end cover. block mating surface of the engine block end cover
and to the inner threads of the bolt holes. Install the
dowel pins (A), and the engine block end cover (B)
on the cylinder block.
NOTE: Do not install the parts if 5 minutes or more have
elapsed since applying the liquid gasket. Instead, reapply
liquid gasket after removing the old residue.

2. 15. Confirm that the clearance is equal all the way


around with a feeler gauge.
Clearance: 0.5 - 0.8 mm (0.02 - 0.03 in.)

3. 18. After assembly, wait at least 30 minutes before filling


the engine with oil.

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Engine Mechanical - Engine Block

7-24 Oil Pan Installation


Engine Block
Crankshaft Installation (cont'd)
1. 19. Clean and dry the oil pump mating surfaces. Aluminium Oil Pan Type:
20. Install the oil pump (A). 1. 1. Clean and dry the oil pan mating surfaces and bolt
1. Install a new crankshaft oil seal in the oil pump holes.
(see step 12 on page 8-11). 2. Apply liquid gasket, part No. 08C70-K0334M or
2. Apply liquid gasket, part No. 08C70-K0234M, 08C70-X0331S, evenly to the oil pan mating surface
08C70-K0334M or 08C70-X0331S, evenly to the of the block and to the inner threads of the bolt
block mating surface of the oil pump and to the holes.
inner threads of the bolt holes. NOTE:
3. Grease the lip of the oil seal and apply oil to the Apply liquid gasket 4 mm wide.
new O-ring (B). Apply liquid gasket doubly to the jointing point of
4. Install the dowel pins (C), then align the inner the liquid gasket.
rotor with the crankshaft and install the oil pump.
5. Clean the excess grease off the crankshaft and
check the seal for distortion.

2. 1. Apply liquid gasket along the broken line.

3. 3. Install the oil pan.


4. Tighten the bolts in 2 or 3 steps. In the final step,
tighten all bolts, in sequence to 12 Nm (1.2 kgf/m,
8.7 lbf/ft).

2. 21. Install the oil screen (D) with a new gasket (E).
22. Install the oil pan (see page 7-24).

4. 5. After assembly, wait at least 30 minutes before filling


the engine with oil.

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Engine Mechanical - Engine Block

7-25
Engine Block
Oil Pan Installation (cont'd)
Steel Oil Pan Type: 1. 4. Tighten bolts and nuts finger tight at six points as
shown below.
1. 1. Clean and dry the oil pan mating surfaces and bolt
holes.
2. Apply liquid gasket, part No. 08C70-K0334M or
08C70-X0331S, on the oil pump and engine block
end cover mating areas.

2. 5. Tighten all bolts and nuts, stating from nut (1),


clockwise in 3 steps. In the final step, tighten all
bolts, in sequence to 12 Nm (1.2 kgf/m, 8.7 lbf/ft).
6. After assembly, wait at least 30 minutes before filling
the engine with oil.

2. 1. Apply liquid gasket to these points.

3. 3. Apply liquid gasket, part No. 08C70-K0334M or


08C70-X0331S, to the new oil pan gasket (A) at the
four corners of the recesses (B), then install the oil
pan (C).

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Engine Mechanical - Engine Block

7-26
Engine Block
Knock Sensor Replacement

1. 1. Disconnect the knock sensor connector, then remove


the knock sensor.

2. 2. Install the knock sensor.

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Engine Machanical - Engine Lubrication

Engine Lubrication

Special Tools 8-2


Component Location Index 8-3
Oil Pressure Switch Test 8-4
Oil Pressure Test 8-4
Engine Oil Replacement 8-5
Engine Oil Filter Replacement 8-6
Oil Pump Overhaul 8-9
Oil/Air Separator Installation 8-12
Oil Pressure Switch Replacement 8-12

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Engine Machanical - Engine Lubrication

8-2
Engine Lubrication
Special Tools

Ref. No. Tool Number Description Qty


1 07HAA-PJ70100 Oil Filter Wrench 1
2 07406-0030000 Oil Pressure Gauge Attachment 1
3 07506-3000000 Oil Pressure Gauge 1
4 07746-0010400 Driver Attachment, 52 x 55 mm 1
5 07749-0010000 Handle Driver 1
6 07912-6110001 Oil Filter Wrench 1

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Engine Machanical - Engine Lubrication

8-3
Engine Lubrication
Component Location Index

1. DOWEL PIN
2. O-RING
3. OIL PRESSURE SWITCH
Circuit Diagram, page 22-88
Switch Test, page 8-4
Oil Pressure Test, page 8-4
Replacement, page 8-12
4. OIL FILTER
Replacement, page 8-6
5. OIL/AIR SEPARATOR
Installation, page 8-12
6. BREATHING PORT COVER
7. WASHER
8. DRAIN BOLT
9. OIL PAN
Installation, page 7-24
10. BAFFLE PLATE
11. OIL SCREEN
12. GASKET
13. OIL PUMP
Overhaul, page 8-9

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Engine Machanical - Engine Lubrication

8-4 Oil Pressure Test


Engine Lubrication
Oil Pressure Switch Test

1. 1. Remove the YEL/RED wire (A) from the engine oil Special Tools Required
pressure switch (B). Oil pressure gauge attachment, 07406-0030000
Oil pressure Gauge, 07506-3000000
If the oil pressure warning light stays on with the engine
running, check the engine oil level. If the oil level is correct.
1. 1. Connect a tachometer.
2. Remove the engine oil pressure switch and install
the special tools.

2. 2. Check for continuity between the positive terminal


(C) and the engine (ground). There should be
continuity with the engine stopped. There should be
no continuity with the engine running.
3. If the switch fails to operate, check the engine oil
level. If the engine oil level is OK, check the engine 2. 3. Start the engine. Shut it off immediately if the gauge
oil pressure. If the oil pressure is OK, replace the oil registers no oil pressure. Repair the problem before
pressure switch. continuing.
4. Allow the engine to reach operating temperature (fan
comes on at least twice). The pressure should be:
Engine Oil Temperature: 80° C (176° F)
Engine Oil Pressure:
At Idle: 70 kPa (0.7 kgf/cm2 , 10 psi
minimum)
At 3,000 rpm 340 kPa (3.5 kgf/cm2 , 50 psi
(min -1 ): minimum)
3. 4. If oil pressure is NOT within specifications, inspect
the oil pump (see step 7 on page 8-10).

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Engine Machanical - Engine Lubrication

8-5
Engine Lubrication
Engine Oil Replacement

1. 1. Warm up the engine. 1. 4. Refill with the recommended oil (see page 3-2).
2. 2. Remove the drain bolt (A) and drain the engine oil. Capacity
D15Y4, D17A2 (KU, KQ models), D17A5 (KN
D15Y4, D17A2 (KU, KQ models), D17A5 (KN
model) engines:
model) engines:
3.3 l (3.5 US qt, 2.9 Imp qt) at oil change
3.5 l (3.7 US qt, 3.1 Imp qt) at oil change
including filter
4.2 l (4.4 US qt, 3.7 Imp qt) after engine
overhaul
Except D15Y4, D17A2 (KU, KQ models), D17A5
(KN model) engines:
3.0 l (3.2 US qt, 2.6 Imp qt) at oil change
3.2 l (3.4 US qt, 2.8 Imp qt) at oil change
including filter
4.2 l (4.4 US qt, 3.7 Imp qt) after engine
overhaul
Except D15Y4, D17A2 (KU, KQ models), D17A5 2. 5. Run the engine for more than 3 minutes then check
(KN model) engines: for oil leakage.

3. 3. Reinstall the drain bolt with a new washer (B).

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Engine Machanical - Engine Lubrication

8-6
Engine Lubrication
Engine Oil Filter Replacement

Special Tools Required 1. 5. If 4 numbers or marks (1 to 4 or to


Oil filter wrench, 07HAA-PJ70100 )are printed around the outside of
Oil filter wrench, 07912-6110001 the filter, use the following procedure to
Engine Oil Filter Replacement (oil filter type A) tighten the filter.
1. 1. Remove the oil filter with the special oil filter wrench. Spin the filter until its seal lightly seats
2. Inspect the threads (A) and rubber seal (B) on the new filter. against the block and note which number
Wipe off the seat on the engine block, then apply a light coat or mark is at the bottom.
of oil to the filter rubber seal. Use only filters with a built-in Tighten the filter by turning it clockwise 3
bypass system. numbers or marks from the one you
noted. For example, if number 2 is at the
bottom when the seal is seated, tighten
the filter until the number 1 comes around
the bottom.

2. 3. Install the oil filter by hand.


4. After the rubber seal seats, tighten the oil filter clockwise with
the special tool.
Tighten: 3/4 turn clockwise
Tightening torque: 22 Nm (2.2 kgf/m, 16 lbf/ft)

2. 6. After installation, fill the engine with oil up to


the specified level, run the engine for more
than 3 minutes, then check for oil leakage.

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Engine Machanical - Engine Lubrication

8-7
Engine Lubrication
Engine Oil Filter Replacement (cont'd)

Engine Oil Filter Replacement (oil filter type B) 1. 5. If 8 numbers or marks (1 to 8) are printed
1. 1. Remove the oil filter with the special oil filter wrench. around the outside of the filter, use the following
2. Inspect the threads (A) and rubber seal (B) on the new procedure to tighten the filter.
filter. Wipe off the seat on the engine block, then apply a Spin the filter until its seal lightly seats
light coat of oil to the filter rubber seal. Use only filters with against the block and note which number is
a built-in bypass system. at the bottom.
Tighten the filter by turning it clockwise 7
numbers from the one you noted. For
example, if number 2 is at the bottom when
the seal is seated, tighten the filter until the
number 1 comes around the bottom.

2. 3. Install the oil filter by hand.


4. After the rubber seal seats, tighten the oil filter clockwise
with the special tool.
Tighten: 7/8 turn clockwise
Tightening torque: 22 Nm (2.2 kgf/m, 16
lbf/ft)

2. 6. After installation, fill the engine with oil up to


the specified level, run the engine for more than
3 minutes, then check for oil leakage.

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Engine Machanical - Engine Lubrication

8-8
Engine Lubrication
Engine Oil Filter Replacement (cont'd)

Engine Oil Filter Replacement (oil filter type C) 1. 5. If 4 numbers or marks (1 to 4) are printed
1. 1. Remove the oil filter with the commercially available oil filter around the outside of the filter, use the
wrench (LABINAL-Purflux 76). following procedure to tighten the filter.
2. Inspect the threads (A) and rubber seal (B) on the new filter. Spin the filter until its seal lightly seats
Wipe off the seat on the engine block, then apply a light coat of against the block and note which
oil to the filter rubber seal. Use only filters with a built-in bypass number is at the bottom.
system. Tighten the filter by turning it clockwise
3 numbers from the one you noted. For
example, if number 2 is at the bottom
when the seal is seated, tighten the filter
until the number 4 comes around the
bottom.

2. 3. Install the oil filter by hand.


4. After the rubber seal seats, tighten the oil filter clockwise with
the commercially available oil filter wrench (LABINAL-Purflux 76)
Tighten: 3/4 turn clockwise
Tightening torque: 22 Nm (2.2 kgf/m, 16 lbf/ft)

2. 6. After installation, fill the engine with oil up


to the specified level, run the engine for
more than 3 minutes, then check for oil
leakage.

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Engine Machanical - Engine Lubrication

8-9
Engine Lubrication
Oil Pump Overhaul

Exploded View
1. DOWEL PIN
2. INNER ROTOR
3. PUMP COVER
4. OUTER ROTOR
5. O-RING
Replace
6. PUMP HOUSING
Apply liquid gasket to mating
surface of the cylinder block
when installing
7. RELIEF VALVE
Valve must slide freely in
housing bore.
Replace if scored.
8. SEALING BOLT
39 Nm (4.0 kgf/m, 29 lbf/ft)
9. SPRING
10. OIL SEAL
Replace

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Engine Machanical - Engine Lubrication

8-10
Engine Lubrication
Oil Pump Overhaul (cont'd)

Special Tools Required Inspection


Driver, 07749-0010000 1. 7. Check the inner-to-outer rotor radial clearance between the
Driver Attachment, 52 x 55 mm, 07746- inner rotor (A) and outer rotor (B). If the inner-to-outer rotor
0010400 radial clearance exceeds the service limit, replace the oil
NOTE: Refer to the exploded view as needed during this pump assembly.
procedure. Inner Rotor-to-Outer Rotor Radial Clearance
Removal Standard (New): 0.02 - 0.07 mm (0.001 -
1. 1. Drain the engine oil. 0.003 in.)
2. Remove the timing belt (see page 6-18). Service Limit 0.15 mm (0.006 in.)
3. Remove the oil pan.
4. Remove the oil screen (A).

2. 8. Check the housing-to-rotor axial clearance between the


rotor (A) and pump housing (B). If the housing-to-rotor
axial clearance exceeds the service limit, replace the oil
pump assembly.
Housing-to-Rotor Axial Clearance
Standard (New): 0.02 - 0.07 mm (0.001 -
0.003 in.)
2. 5. Remove the mounting bolts and the oil pump
assembly (B). Service Limit 0.15 mm (0.006 in.)
6. Remove the screws from the pump housing,
then separate the housing and cover.

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Engine Machanical - Engine Lubrication

8-11
Engine Lubrication
Oil Pump Overhaul (cont'd)

1. 9. Check the housing-to-outer rotor radial clearance Installation


between the outer rotor (A) and pump housing (B). If 1. 14. Reassemble the oil pump.
the housing-to-outer rotor radial clearance exceeds 15. Check that the oil pump turns freely.
the service limit, replace the oil pump assembly. 16. Clean and dry the oil pump mating surface.
Housing-to-Outer Rotor Radial Clearance 17. Install the oil pump (A).
Standard 0.10 - 0.18 mm (0.004 - 0.007 a. Apply liquid gasket, Part No. 08C70-K0234M, 08C70-
(New): in.) K0334M or 08C70-X0331S, evenly to the block mating
Service Limit 0.20 mm (0.008 in.) surface of the oil pump and to the inner threads of the
bolt holes.
b. Grease the lips of the oil seal and apply oil to the new
O-ring (B).
c. Install dowel pins (C), then align the inner rotor with the
crankshaft and install the oil pump.
d. Clean the excess grease off the crankshaft and balancer
shaft and check the seal for distortion.

2. 10. Inspect both rotors and the pump housing for scoring
or other damage. Replace parts if necessary.
11. Remove the old oil seal from the pump.
12. Gently tap in the new oil seal until the special tool
bottoms on the pump.

2. 18. Install the oil screen (D) with a new gasket (E).
19. Install the oil pan (see page 7-24).
3. 13. Apply liquid thread lock to the pump housing screws.

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Engine Machanical - Engine Lubrication

8-12 Oil Pressure Switch Replacement


Engine Lubrication
Oil/Air Separator Installation

1. 1. Clean and dry the oil/air separator mating surfaces. 1. 1. Disconnect the oil pressure switch connector, then
2. 2. Apply liquid gasket, Part No 08C70-K0234M, 08C70- remove the oil pressure switch.
K0334M or 08C70-X0331S, evenly to the block
mating surface of the oil/air separator and to the
inner threads of the bolt holes.

3. 3. Install the oil/air separator.


2. 2. Apply liquid gasket to the oil pressure switch threads,
then install the oil pressure switch.

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Engine Mechanical - Intake Manifold and Exhaust System

Intake Manifold and Exhaust System

Intake Manifold Removal and Installation 9-2


Exhaust Manifold Removal and Installation 9-3
Exhaust Pipe and Muffler Replacement 9-5

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Engine Mechanical - Intake Manifold and Exhaust System

9-2
Intake Manifold and Exhaust System
Intake Manifold Removal and Installation

NOTE: Use a new O-rings and gasket when reassembling.


1. O-RING
Replace.
2. MANIFOLD ABSOLUTE
PRESSURE (MAP) SENSOR
3. THROTTLE BODY
4. O-RING
Replace.
5. INJECTOR BASE STIFFENER
6. GASKET
Replace.
7. INJECTOR BASE
8. INTAKE MANIFOLD BRACKET
9. O-RINGS
Replace.
10. INTAKE MANIFOLD
Replace if cracked or if mating
surfaces are damaged.

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Engine Mechanical - Intake Manifold and Exhaust System

9-3
Intake Manifold and Exhaust System
Exhaust Manifold Removal and Installation

NOTE: Use a new gaskets and self-locking nuts when reassembling.


D15Y5, D15Y6, D17A1, D17Z1, D17Z2 engines:
1. 8 x 1.25 mm
31 Nm (3.2 kgf/m, 23 lbf/ft)
Replace.
2. COVER
3. EXHAUST MANIFOLD
4. GASKET
Replace.
5. 8 x 1.25 mm
31 Nm (3.2 kgf/m, 23 lbf/ft)
Replace.
6. SECONDARY HEATED
OXYGEN SENSOR
(SECONDARY HO2S)
(D15Y6, D17Z2 engines)
44 Nm (4.5 kgf/m, 33 lbf/ft)
7. EXHAUST MANIFOLD
BRACKET
8. THREE WAY CATALYTIC
CONVERTER
9. 8 x 1.25 mm
31 Nm (3.2 kgf/m, 23 lbf/ft)
Replace.
10. PRIMARY HEATED OXYGEN
SENSOR (PRIMARY HO2S)
44 Nm (4.5 kgf/m, 33 lbf/ft)
11. COVER

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Engine Mechanical - Intake Manifold and Exhaust System

9-4
Intake Manifold and Exhaust System
Exhaust Manifold Removal and Installation
(cont'd)

NOTE: Use a new gasket when reassembling.


Except D15Y5, D15Y6, D17A1, D17Z1, D17Z2 engines:
1. COVER
2. GASKET
Replace.
3. EXHAUST MANIFOLD
4. 8 x 1.25 mm
31 Nm (3.2 kgf/m, 23 lbf/ft)
Replace.
5. 8 x 1.25 mm
31 Nm (3.2 kgf/m, 23 lbf/ft)
Replace.

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Engine Mechanical - Intake Manifold and Exhaust System

9-5
Intake Manifold and Exhaust System
Exhaust Pipe and Muffler Replacement

NOTE: Use a new gaskets when reassembling.


D15Y5, D15Y6, D17A1, D17Z1, D17Z2 engines:
1. GASKET
Replace.
2. MUFFLER
3. 8 x 1.25 mm
22 Nm (2.2 kgf/m, 16 lbf/ft)
Replace.
Tighten the bolts in steps,
alternating side-to-side
4. HEATSHIELD
5. EXHAUST PIPE B
6. 8 x 1.25 mm
22 Nm (2.2 kgf/m, 16 lbf/ft)
Replace.
Tighten the bolts in steps,
alternating side-to-side
7. GASKET
Replace.

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Engine Mechanical - Intake Manifold and Exhaust System

9-6
Intake Manifold and Exhaust System
Exhaust Pipe and Muffler Replacement(cont'd)

NOTE: Use new gaskets and self-locking nuts when reassembling.


D14Z5, D15Y2, D15Y4, D16W7, D16W8, D17Z1, D17Z3, D17A2 engines:
1. GASKET
Replace.
2. MUFFLER
3. 8 x 1.25 mm
22 Nm (2.2 kgf/m, 16 lbf/ft)
Replace.
Tighten the bolts in steps, alternating
side-to-side
4. HEATSHIELD
5. 6 x 1.0 mm
98 Nm (1.0 kgf/m, 7.2 ibf/ft)
6. EXHAUST PIPE B
7. GASKET
Replace.
8. THREE WAY CATALYTIC
CONVERTER
9. PRIMARY HEATED OXYGEN
SENSOR (PRIMARY HO2S)
(D14Z5, D15Y2, D15Y4, D16W7,
D16W8, D17Z3, D17A2 engines)
44 Nm (4.5 kgf/m, 33 lbf/ft)
10. 8 x 1.25 mm
22 Nm (2.2 kgf/m, 16 lbf/ft)
Replace.
Tighten the bolts in steps, alternating
side-to-side
11. EXHAUST PIPE A
12. GASKET
Replace.
13. SECONDARY HEATED OXYGEN
SENSOR (SECONDARY HO2S)
(D14Z5, D15Y4, D16W7, D17Z3,
D17A2 engines)
44 Nm (4.5 kgf/m, 33 lbf/ft)
14. SELF-LOCKING NUT
10 x 1.25 mm
33 N (3.4 kgf/m, 25 lbf/ft)
Replace.

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Engine Mechanical - Intake Manifold and Exhaust System

9-7
Intake Manifold and Exhaust System
Exhaust Pipe and Muffler Replacement(cont'd)

NOTE: Use new gaskets and self-locking nuts when reassembling.


D15Y3, D16V2, D17A5 engines:
1. GASKET
Replace.
2. MUFFLER
3. 8 x 1.25 mm
22 Nm (2.2 kgf/m, 16 lbf/ft)
Replace.
Tighten the bolts in steps,
alternating side-to-side
4. HEATSHIELD
5. EXHAUST PIPE B
6. GASKET
Replace.
7. EXHAUST PIPE A
8. 8 x 1.25 mm
22 Nm (2.2 kgf/m, 16 lbf/ft)
Replace.
Tighten the bolts in steps,
alternating side-to-side
9. GASKET
Replace.
10. SELF-LOCKING NUT
10 x 1.25 mm
33 N (3.4 kgf/m, 25 lbf/ft)
Replace.

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Engine Cooling - Engine Cooling

   
Engine Cooling
Cooling System
Component Location Index 10-2
Radiator Cap Test 10-5
Radiator Test 10-5
Fan Motor Test 10-6
Thermostat Test 10-6
Water Pump Inspection 10-7
Water Pump Replacement 10-7
Coolant Check 10-8
Coolant Replacement 10-8
Thermostat Replacement 10-10
Radiator and Fan Replacement 10-11
ECT Sensor Replacement 10-12

Fan Controls
Component Location Index 10-13
Symptom Troubleshooting Index 10-14
Circuit Diagram 10-15
Radiator Fan Circuit Troubleshooting 10-16
Radiator Fan Switch Circuit Troubleshooting (Open) 10-18
Radiator Fan Switch Circuit Troubleshooting (Short) 10-18
Radiator Fan Switch Test 10-19
Radiator Fan Switch Replacement 10-19

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Engine Cooling - Cooling System

10-2
Cooling System
Component Location Index

DENSO:
1. A/C CONDENSER FAN
ASSEMBLY
Replacement, page 10-11
Fan Motor Test, page 10-6
2. O-RING
3. UPPER RADIATOR HOSE
4. RADIATOR CAP
5. RADIATOR
Replacement, page 10-11
6. COOLANT RESERVOIR
7. LOWER RADIATOR HOSE
8. ATF COOLER HOSES
9. DRAIN PLUG
10. RADIATOR FAN
Replacement, page 10-11
11. RADIATOR FAN SHROUD
Replacement, page 10-11
12. RADIATOR FAN MOTOR
Test, page 10-6
Replacement, page 10-11

TOYO RADIATOR:
1. A/C CONDENSER FAN
ASSEMBLY
Replacement, page 10-11
Fan Motor Test, page 10-6
2. O-RING
3. UPPER RADIATOR HOSE
4. RADIATOR CAP
5. RADIATOR
Replacement, page 10-11
6. COOLANT RESERVOIR
7. LOWER RADIATOR HOSE
8. ATF COOLER HOSES
9. DRAIN PLUG
10. RADIATOR FAN
Replacement, page 10-11
11. RADIATOR FAN MOTOR
Test, page 10-6
Replacement, page 10-11
12. RADIATOR FAN SHROUD
Replacement, page 10-11

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Engine Cooling - Cooling System

10-3
Cooling System
Component Location Index (cont'd)

RHD models:
1. WATER BYPASS HOSE
2. WATER PASSAGE
3. CONNECTING PIPE
4. HEATER HOSES
5. HEATER VALVE

LHD models:
1. WATER BYPASS HOSE
2. WATER PASSAGE
3. CONNECTING PIPE
4. HEATER VALVE
5. HEATER HOSES

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Engine Cooling - Cooling System

10-4
Cooling System
Component Location Index (cont'd)

1. O-RING
2. GASKET
3. EXHAUST GAS RECIRCULATION (EGR)
VALVE
(D14Z5, D15Y4, D16W7, S17A2 (KQ, KU
models) engines)
4. ENGINE COOLANT TEMPERATURE
(ECT) SENSOR
5. O-RING
6. RADIATOR FAN SWITCH
7. O-RING
8. WATER PASSAGE
9. O-RING
10. CONNECTING PIPE
11. CONNECTING PIPE
12. O-RING
13. WATER PUMP
Inspection, page 10-7
Replacement, page 10-7

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Engine Cooling - Cooling System

10-5 Radiator Test


Cooling System
Radiator Cap Test

1. 1. Remove the radiator cap (A), wet its seal with engine 1. 1. Wait until the engine is cool, then carefully remove
coolant, then install it on the pressure tester (B) the radiator cap and fill the radiator with engine
(commercially available). Use a small adapter H- coolant to the top of the filler neck.
901122-09 (C) (commercially available) to install the 2. 2. Attach the pressure tester (A) (commercially
radiator cap. available) to the radiator. Use a small adapter H-
901122-09 (B) (commercially available) to attach the
pressure tester.

2. 2. Apply a pressure of 93 - 123 kPa (0.95 - 1.25


kgf/cm 2 , 14 - 18 psi).
3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.

3. 3. Apply a pressure of 93 - 123 kPa (0.95 - 1.25


kgf/cm 2 , 14 - 18 psi).
4. Inspect for engine coolant leaks and a drop in
pressure.
5. Remove the tester and reinstall the radiator cap.
6. Check for engine oil in the coolant and/or coolant in
the engine oil.

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Engine Cooling - Cooling System

10-6 Thermostat Test


Cooling System
Fan Motor Test

1. 1. Disconnect the 2P connectors from the radiator fan Replace the thermostat if it is open at room temperature.
motor and condenser fan motor. To test a closed thermostat:
Terminal side of male terminals 1. 1. Suspend the thermostat (A) in a container of water.
Do not let the thermometer (B) touch the bottom of the
hot container.

2. 2. Test the motor by connecting battery power to the B


terminal and ground to the A terminal.
3. If the motor fails to run or does not run smoothly,
replace it.
2. 2. Heat the water and check the temperature with a
thermometer. Check the temperature at which the
thermostat first opens and at which it is fully open.
3. Measure the lift height of the thermostat when it is
fully open.
STANDARD THERMOSTAT
Lift height: above 8.0 mm (0.31
in.)
Starts opening: 76 - 80 o C (169 –
176 o F)
Fully open: 90 o C (194 o F)

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Engine Cooling - Cooling System

10-7 Water Pump Replacement


Cooling System
Water Pump Inspection

1. 1. Remove the timing belt (see page 6-18). 1. 1. Remove the timing belt (see page 6-18).
2. 2. Turn the water pump pulley counter-clockwise. Check 2. 2. Remove the water pump (A) by removing four bolts.
that it turns freely.
3. Check for signs of seal leakage. A small amount of
''weeping'' from the bleed hole (A) is normal.

3. 3. Inspect and clean the O-ring groove and mating


surface with the cylinder block.
4. Install the water pump with a new O-ring (B) in the
reverse order of removal.
5. Clean up any spilled engine coolant.

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Engine Cooling - Cooling System

10-8 Coolant Replacement


Cooling System
Coolant Check

1. 1. Look at the coolant level in the coolant reservoir. 1. 1. Start the engine. Set the heater temperature control
Make sure it is between the MAX (A) and MIN mark dial to maximum heat, then turn off the ignition
(B). switch. Make sure the engine and radiator are cool to
the touch.
2. 2. Make sure you have the anti-theft code for the radio,
then write down the frequencies for the radio's
preset buttons.
3. Remove the battery.
4. Remove the radiator cap.
5. Loosen the drain plug (A) and drain the coolant.

2. 2. If the coolant level in the coolant reservoir is at or


below the MIN mark, add coolant to bring it up to the
MAX mark and inspect the cooling system for leaks.

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Engine Cooling - Cooling System

10-9
Cooling System
Coolant Replacement (cont'd)

1. 6. Remove the drain bolt (A) from the rear of the 1. 10. Pour genuine Honda All Season Antifreeze/Coolant
cylinder block. Type 2 into the radiator up to the base of the filler
neck.
NOTE:
Always use genuine Honda All Season
Antifreeze/Coolant Type 2. Using a non-Honda
coolant can result in corrosion, causing the
cooling system to malfunction or fail.
Genuine Honda All Season Antifreeze/Coolant
Type 2 is a mixture of 50% antifreeze and 50%
water. Pre-mixing is not required.
Engine Coolant Refill Capacity [including the
reservoir capacity of 0.4 l (0.4 US qt, 0.4 lmp qt)]:
M/T: 4.0 l (4.2 US qt, 3.5 lmp
qt)
2. 7. After the coolant has drained, apply liquid gasket to
the drain bolt threads, then reinstall the bolt with a A/T, HONDA MULTI 3.9 l (4.1 US qt, 3.4 lmp
new washer and tighten it securely. MATIC: qt)
8. Tighten the radiator drain plug securely.
9. Remove, drain and reinstall the reservoir. Fill the
tank to the MAX mark (A) with genuine Honda All
Season Antifreeze/Coolant Type 2.

2. 11. Install the radiator cap loosely.


12. Install the battery.
13. Start the engine and let it run until it warms up (the
radiator fan comes on at least twice).
14. Turn off the engine. Check the level in the radiator
and add genuine Honda All Season
Antifreeze/Coolant Type 2 if needed.
15. Put the radiator cap on tightly, then run the engine
again and check for leaks.
16. Enter the anti-theft code for the radio, then enter the
customer's radio station presets.

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Engine Cooling - Cooling System

  10-10
Cooling System
Thermostat Replacement

1. WATER PASSAGE
2. PIN
3. RUBBER SEAL
Replace.
4. THERMOSTAT COVER
5. THERMOSTAT
Install with pin up.

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Engine Cooling - Cooling System

  10-11
Cooling System
Radiator and Fan Replacement

1. 1. Drain engine coolant.


2. Remove the front bumper (see page 20-104).
3. Remove the hood latch (see page 20-106).
4. Remove the upper and lower radiator hoses and ATF cooler hoses.
1. A/C CONDENSER FAN
ASSEMBLY
2. O-RING
Replace.
3. UPPER RADIATOR HOSE
4. RADIATOR CAP
5. UPPER BRACKET AND
CUSHION
6. RADIATOR
7. COOLANT RESERVOIR
8. LOWER RADIATOR HOSE
9. CONDENSER BRACKET
10. LOWER CUSHION
11. FAN MOTOR
CONNECTORS
12. ATF COOLER HOSES
13. DRAIN PLUG
14. RADIATOR FAN
ASSEMBLY

5. Disconnect the fan motor connectors and compressor clutch connector.


6. Remove the radiator upper brackets, then pull up the radiator.
7. Remove the fan shroud assemblies and other parts from the radiator.
8. Install the radiator in the reverse order of removal. Make sure the upper and lower cushions are set securely.
9. Fill the radiator with engine coolant and bleed the air.

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Engine Cooling - Cooling System

10-12
Cooling System
ECT Sensor Replacement

1. 1. Remove the resonator.


2. 2. Disconnect the ECT sensor connector, then remove
the ECT sensor (A).

3. 3. Install the ECT sensor using a new O-ring (B).


4. Install the resonator.

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Engine Cooling - Fan Controls

  10-13
Fan Controls
Component Location Index

1. RADIATOR FAN RELAY


Test, page 22-80
2. UNDER-HOOD FUSE/RELAY BOX
3. CONDENSER FAN RELAY
Test, page 22-80
4. RADIATOR FAN SWITCH
Test, page 10-9Replacement, page 10-19
5. CONDENSER FAN ASSEMBLY
Motor Test, page 10-6
6. RADIATOR FAN ASSEMBLY
Motor Test, page 10-6

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Engine Cooling - Fan Controls

  10-14
Fan Controls
Symptom Troubleshooting Index

Before performing any troubleshooting procedures check:


Fuses
Grounds
Cleanliness and tightness of all connectors
SYMPTOM PROCEDURE
Radiator fan does not run at all Radiator Fan Circuit Troubleshooting (see page 10-16).
Radiator fan does not runs for engine cooling, but it runs Radiator Fan Switch Circuit Troubleshooting (Open) (see page 10-
with A/C on 18).
Radiator fan runs with ignition switch ON (II), A/C off and Radiator Fan Switch Circuit Troubleshooting (Short) (see page 10-
engine temperature below 93 o C (199 o F) 18).

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Engine Cooling - Fan Controls

  10-15
Fan Controls
Circuit Diagram

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Engine Cooling - Fan Controls

  10-16
Fan Controls
Radiator Fan Circuit Troubleshooting

1. 1. Check the No. 4 (20A) fuse in the under-hood 1. 4. Connect the No. 1 and No. 2 terminals of the
fuse/relay box and the No. 14 (10A) fuse in the radiator fan relay 4P socket with a jumper wire.
driver's under-dash fuse/relay box. RADIATOR FAN RELAY 4P SOCKET
Is the fuse (s) OK?
YES - Go to step 2.
NO - Replace the fuse (s) and recheck.
2. 2. Remove the radiator fan relay from the under-hood
fuse/relay box and test it (see page 22-80).
Is the relay OK?
Terminal side of female terminals
YES - Go to step 3.
Does the radiator fan run?
NO - Replace the radiator fan relay.
YES - Go to step 5.
3. 3. Measure the voltage between the No. 1 terminal of
NO - Go to step 6.
the radiator fan relay 4P socket and body ground.
RADIATOR FAN RELAY 4P SOCKET 2. 5. Disconnect the jumper, and turn the ignition switch
ON (II). Check for voltage between the No. 3
terminal of the radiator fan relay 4P socket and body
ground.
RADIATOR FAN RELAY 4P SOCKET

Terminal side of female terminals


Is there battery voltage?
YES - Go to step 4.
NO - Replace the under-hood fuse/relay box.

Terminal side of female terminals


Is there battery voltage?
YES - Go to step 9.
NO - Check for an open in the wire between the under-
hood fuse/relay box and under-dash fuse/relay box.

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Engine Cooling - Fan Controls

  10-17
Fan Controls
Radiator Fan Circuit Troubleshooting (cont'd)

1. 6. Disconnect the radiator fan motor 2P connector. 1. 9. Reinstall the radiator fan relay.
2. 7. Check for continuity between the No. 2 terminal of 2. 10. Disconnect the radiator fan switch 2P connector.
the radiator fan relay 4P socket and the No. 2 jumper terminals No. 1 and No. 2 to see if fan runs.
terminal of the radiator fan motor 2P connector. Does the radiator fan run?
RADIATOR FAN RELAY 4P SOCKET YES - Replace the radiator fan switch.
Terminal side of female terminals NO - Go to step 11.
3. 11. Remove the jumper wire, and measure the voltage
between the No. 2 terminal of the radiator fan switch
connector and body ground.
RADIATOR FAN SWITCH 2P CONNECTOR

Wire side of female terminals


RADIATOR FAN MOTOR 2P CONNECTOR
Is there continuity?
YES - Go to step 8.
NO - Repair open in the wire between the under-hood
fuse/relay box and the radiator fan motor 2P connector
terminal No. 2. Wire side of female terminals

3. 8. Check for continuity between the No. 1 terminal of Is there battery voltage?
the radiator fan motor 2P connector and body YES - Check for an open in the wire between radiator fan
ground. switch 2P connector terminal No. 1 and body ground. If the
RADIATOR FAN MOTOR 2P CONNECTOR wire is OK, check for a poor ground at G101.
NO - Repair open in the wire between the radiator fan
switch terminal No. 2 and the under-hood fuse/relay box.

Wire side of female terminals


Is there continuity?
YES - Replace the radiator fan motor.
NO - Check for an open in the wire between radiator fan
motor 2P connector terminal No. 1 and body ground. If the
wire is OK, check for a poor ground at G201.

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Engine Cooling - Fan Controls

10-18 Radiator Fan Switch Circuit Troubleshooting (Short)


Fan Controls
Radiator Fan Switch Circuit Troubleshooting (Open)

1. 1. Disconnect the radiator fan switch 2P connector. 1. 1. Remove the radiator fan relay from the under-hood
2. 2. Turn the ignition switch ON (II). fuse/relay box and test it (see page 22-80).
3. Measure voltage between the No. 2 terminal of the Is the relay OK?
radiator fan switch 2P connector and body ground.
YES - Go to step 2.
RADIATOR FAN SWITCH 2P CONNECTOR
NO - Replace the radiator fan relay.
2. 2. Remove the radiator fan switch and test it (see page
10-19).
Is the radiator fan switch OK?
YES - Go to step 3.
NO - Replace the radiator fan switch.
3. 3. Disconnect ECM/PCM connector B (24P) and under-
hood fuse relay box 14P connector.
4. Check for continuity between the No. 2 terminal of
the radiator fan switch 2P connector and body
Wire side of female terminals ground.
RADIATOR FAN SWITCH 2P CONNECTOR
Is there battery voltage?
YES - Go to step 4.
NO - Repair open in the wire between the radiator fan
switch 2P connector terminal No. 2 and under-hood
fuse/relay box.
3. 4. Turn the ignition switch OFF and check for continuity
between the No. 1 terminal of the radiator fan switch
2P connector and body ground.
RADIATOR FAN SWITCH 2P CONNECTOR

Wire side of female terminals


Is there continuity?
YES - Repair short in the wire between the radiator fan
switch 2P connector terminal No. 2 and under-hood
fuse/relay box.
NO - Replace the under-hood fuse/relay box.

Wire side of female terminals


Is there continuity?
YES - Replace the radiator fan switch.
NO - Check for an open in the wire between the radiator
fan switch 2P connector terminal No. 1 and body ground. If
the wire is OK, check for a poor ground at G101.

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Engine Cooling - Fan Controls

10-19 Radiator Fan Switch Replacement


Fan Controls
Radiator Fan Switch Test

NOTE: Bleed air from the cooling system after installing the 1. 1. Disconnect the radiator fan switch connector, then
radiator fan switch (see page 10-8). remove the radiator fan switch (A).
1. 1. Remove the radiator fan switch from the thermostat
cover (see page 10-19).
2. Suspend the radiator fan switch (A) in a container of
water as shown.

2. 2. Install the radiator fan switch using a new O-ring (B).

2. 3. Heat the water and check the temperature with a


thermometer. Do not let the thermometer (B) touch
the bottom of the hot container.
4. Measure the continuity between the A terminal (C)
and B terminal (D) according to the table.

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Fuel and Emissions - Fuel and Emissions

Fuel and Emissions

4-door (KB, KE, KG, TR models) 11-1


4-door (except KB, KE, KG, TR models) 11-165
5-door (KE model) 11-309
5-door (except KE model) 11-465

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4-door

4-door
(KB, KE, KG, TR models)

Fuel and Emissions Systems


Special Tools 11-2
General Troubleshooting Information 11-3
DTC Troubleshooting Index 11-7
Symptom Troubleshooting Index 11-10
System Descriptions 11-11

PGM-FI System
Component Location Index 11-56
DTC Troubleshooting 11-59
MIL Circuit Troubleshooting 11-100
VTEC Solenoid Valve Test 11-112
Injector Replacement 11-113
Primary HO2S Replacement 11-115
Secondary HO2S Replacement 11-115

Idle Control System


Component Location Index 11-116
DTC Troubleshooting 11-117
A/C Signal Circuit Troubleshooting 11-119
Alternator FR Signal Circuit Troubleshooting 11-120
EPS Signal Circuit Troubleshooting 11-122
Brake Pedal Position Switch Signal Circuit Troubleshooting 11-123
Idle Speed Inspection 11-125

Fuel Supply System


Component Location Index 11-126
Fuel Pump Circuit Troubleshooting 11-127
Fuel Pressure Relieving 11-130
Fuel Pressure Test 11-131
Fuel Lines Inspection 11-132
Fuel Tube/Quick-Connect Fittings Precautions 11-134
Fuel Tube/Quick-Connect Fittings Removal 11-135
Fuel Tube/Quick-Connect Fittings Installation 11-136
Fuel Pressure Regulator Replacement 11-138
Fuel Filter Replacement 11-138
Fuel Pump/Fuel Gauge Sending Unit Replacement 11-139
Fuel Tank Replacement 11-140
Fuel Gauge Sending Unit Test 11-141
Low Fuel Indicator Light Test 11-143

Intake Air System


Component Location Index 11-144
Throttle Body Test 11-145
Air Cleaner Replacement 11-146

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4-door

Air Cleaner Element Replacement 11-147


Resonator Replacement 11-148
Throttle Cable Adjustment 11-149
Throttle Cable Removal/Installation 11-150
Throttle Body Removal/Installation 11-151
Throttle Body Disassembly/Reassembly 11-152

Catalytic Converter System


DTC Troubleshooting 11-153
Tailpipe Emission Test 11-153

EGR System
DTC Troubleshooting 11-154

PCV System
PCV Valve Inspection and Test 11-159

EVAP System
Component Location Index 11-160
DTC Troubleshooting 11-161
EVAP Control System Troubleshooting 11-163
EVAP Two Way Valve Test 11-164

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Fuel and Emissions - Fuel and Emissions Systems

11-2
Fuel and Emissions Systems
Special Tools

Ref. No. Tool Number Description Qty

(1) 07LAA-PT50101 O2 Sensor Socket Wrench 1


(2) 07NAJ-P070100 Oil Pressure Gauge Attachment 1
(3) 07WAA-0010100 Adjustable Ring Wrench 1
(4) 07ZAJ-S5A0100 Fuel Pressure Gauge Set 1
(5) 07ZAJ-S5A0200 Hose, Oil Pressure 1
(6) 07406-0070001 Low Pressure Gauge 1
(7) 07406-0040002 Fuel Pressure Gauge 1

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Fuel and Emissions - Fuel and Emissions Systems

11-3
Fuel and Emissions Systems
General Troubleshooting Information

Intermittent Failures 1. 2. If the MIL stays on, connect the Honda PGM Tester
The term ''intermittent failure'' means a system may have had (A) or a scan tool to the Data Link Connector (DLC)
a failure, but it checks OK now. If the Malfunction Indicator (B) located under the driver's side of the dashboard.
Lamp (MIL) on the dash does not come on, check for poor
connections or loose wires at all connectors related to the
circuit that you are troubleshooting.
Opens and Shorts
''Open'' and ''Short'' are common electrical terms. An open is a
break in a wire or at a connection. A short is an accidental
connection of a wire to ground or to another wire. In simple
electronics, this usually means something will not work at all. In
complex electronics (like ECM's/PCM's) this can sometimes
mean something works, but not the way it is supposed to.
How to Use the PGM Tester or a Scan Tool
*: The illustration shows LHD model.
If the MIL (Malfunction Indicator Lamp) has come
on 2. 3. Turn the ignition switch ON (II).
4. Check the Diagnostic Trouble Code (DTC) and note
1. 1. Start the engine and check the MIL.
it. Also check the freeze frame data. Refer to the
DTC Troubleshooting Index and begin the
appropriate troubleshooting procedure.
NOTE:
Freeze frame data indicates the engine conditions
when the first malfunction, misfire or fuel trim
malfunction was detected.
The scan tool and the Honda PGM Tester can read
the DTC, freeze frame data, current data, and other
Engine Control Module (ECM)/Powertrain Control
Module (PCM) data.
For specific operations, refer to the user's manual
that came with the scan tool or Honda PGM Tester.
If the MIL did not come on
If the MIL did not come on but there is a driveability problem,
refer to the Symptom Troubleshooting Index in this section.
If you cannot duplicate the DTC
Some of the troubleshooting in this section requires you to
reset the ECM/PCM and try to duplicate the DTC. If the
problem is intermittent and you cannot duplicate the code, do
not continue through the procedure. To do so will only result in
confusion and, possibly, a needlessly replaced ECM/PCM.

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Fuel and Emissions - Fuel and Emissions Systems

11-4
Fuel and Emissions Systems
General Troubleshooting Information (cont'd)

How to Reset the ECM/PCM How to Remove the ECM/PCM for Testing
You can reset the ECM/PCM in either of 2 ways: If the inspection for a trouble code requires voltage or
Use the scan tool or Honda PGM Tester to clear the resistance checks at the ECM/PCM connectors, remove the
ECM's/PCM's memory. ECM/PCM and test it:
See the scan tool or Honda PGM Tester user's 1. 1. Remove the passenger's dashboard lower cover (see
manuals for specific instructions. page 20-78), the passenger's kick panel (see page
Turn the ignition switch OFF, and remove the No. 6 20-64), and the glove box (see page 20-79).
ECU (ECM/PCM) (15A) fuse (A) from the under-hood 2. Remove the bolt. Cut the plastic cross brace in the
fuse/relay box (B) for 10 seconds. glove box opening with diagonal cutters in the area
shown, and discard it.

2. 3. Remove the relays (A), then remove the bolts and


How to End a Troubleshooting Session (required the glove box frame (B).
after any troubleshooting)
1. 1. Reset the ECM/PCM as described above.
2. Turn the ignition switch OFF.
3. Disconnect the scan tool or Honda PGM Tester from
the DLC.
NOTE: The ECM/PCM is part of the immobiliser system. If
you replace the ECM/PCM, it will have a different
immobiliser code. In order for the engine to start, you must
rewrite the immobiliser code with the Honda PGM Tester.

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Fuel and Emissions - Fuel and Emissions Systems

11-5
Fuel and Emissions Systems
General Troubleshooting Information (cont'd)

1. 4. Remove the grey 20P ECM/PCM wire harness How to Troubleshoot Circuits at the ECM/PCM
connector from the ECM/PCM mounting bracket. 1. 1. Gently slide the sharp tester probe (A) into the
Remove the ECM/PCM mounting bolt (A) and the connector from wire side until it touches the end of
bracket. the wire terminal.

*: The illustration shows LHD model. *: The illustration shows LHD model.
2. 5. Remove the nuts, then remove the ECM/PCM (B). 2. 2. If you cannot get to the wire side of the connector or
the wire side is sealed (A), disconnect the connector
and probe the terminals (B) from the terminal side.
Do not force the probe into the connector.

Do not puncture the insulation on a wire. Punctures can


cause poor or intermittent electrical connections.

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Fuel and Emissions - Fuel and Emissions Systems

11-6
Fuel and Emissions Systems
General Troubleshooting Information (cont'd)

How to Substitute the ECM/PCM


1. 1. Remove the ECM/PCM from the vehicle.
2. Install a known-good ECM/PCM in the vehicle.
3. Rewrite the immobiliser code with the ECM/PCM
replacement procedure on the Honda PGM Tester. It
allows you to start the engine.
4. After completing your tests, reinstall the original
ECM/PCM and rewrite the immobiliser code with the
ECM/PCM replacement procedure on the Honda
PGM Tester again.

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Fuel and Emissions - Fuel and Emissions Systems

11-7
Fuel and Emissions Systems
DTC Troubleshooting Index

Scan tool DTC Honda DTC Detection Item Page

DTC Temporary DTC (MIL Temporary


DTC Indication*) DTC
P0107 - 3-1 (3) - Manifold Absolute Pressure (MAP) Sensor Circuit (see
Low Voltage page 11-
59)

P0108 - 3-2 (3) - Manifold Absolute Pressure (MAP) Sensor Circuit (see
High Voltage page 11-
60)

P0112 - 10-1 (10) - Intake Air Temperature (IAT) Sensor Circuit Low (see
Voltage page 11-
61)

P0113 - 10-2 (10) - Intake Air Temperature (IAT) Sensor Circuit High (see
Voltage page 11-
62)

P0117 - 6-1 (6) - Engine Coolant Temperature (ECT) Sensor Circuit (see
Low Voltage page 11-
63)

P0118 - 6-2 (6) - Engine Coolant Temperature (ECT) Sensor Circuit (see
High Voltage page 11-
64)

P0122 - 7-1 (7) - Throttle Position (TP) Sensor Circuit Low Voltage (see
page 11-
65)

P0123 - 7-2 (7) - Throttle Position (TP) Sensor Circuit High Voltage (see
page 11-
67)

P0131 - 1-1 (1) - Primary Heated Oxygen Sensor (Primary HO2S) (see
(Sensor 1) Circuit Low Voltage page 11-
68)

P0132 - 1-2 (1) - Primary Heated Oxygen Sensor (Primary HO2S) (see
(Sensor 1) Circuit High Voltage page 11-
69)

P0133 P0133 61-1 (61) T61-1 Primary Heated Oxygen Sensor (Primary HO2S) (see
(Sensor 1) Slow Response page 11-
70)

P0135 - 41-2 (41) - Primary Heated Oxygen Sensor (Primary HO2S) (see
(Sensor 1) Heater Circuit Malfunction page 11-
71)

P0137 P0137 63-1 (63) T61-1 Secondary Heated Oxygen Sensor (Secondary (see
HO2S) (Sensor 2) Circuit Low Voltage page 11-
73)

P0138 P0138 63-2 (63) T63-2 Secondary Heated Oxygen Sensor (Secondary (see
HO2S) (Sensor 2) Circuit High Voltage page 11-
74)

P0139 P0139 63-3 (63) T63-3 Secondary Heated Oxygen Sensor (Secondary (see

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Fuel and Emissions - Fuel and Emissions Systems

11-8
Fuel and Emissions Systems
DTC Troubleshooting Index (cont'd)
Scan tool DTC Honda DTC Detection Item Page

DTC Temporary DTC (MIL Temporary


DTC Indication*) DTC
P0301 P0301 71-1(71) T71-1 No. 1 Cylinder Misfire (see page 11-80)

P0302 P0302 72-1(72) T72-1 No. 2 Cylinder Misfire (see page 11-80)

P0303 P0303 73-1(73) T73-1 No. 3 Cylinder Misfire (see page 11-80)

P0304 P0304 74-1(74) T74-1 No. 4 Cylinder Misfire (see page 11-80)

P0325 - 23-1 (23) - Knock Sensor Circuit Malfunction (see page 11-85)

P0335 - 4-1 (4) - Crankshaft Position (CKP) Sensor No Signal (see page 11-88)

P0336 - 4-2 (4) - Crankshaft Position (CKP) Sensor Intermittent (see page 11-88)
Interruption

P0401 P0401 80-1 (80) T80-1 Exhaust Gas Recirculation (EGR) Insufficient (see page 11-154)
Flow

P0420 P0420 67-1 (67) T67-1 Catalyst System Efficiency Below Threshold (see page 11-153)

P0443 - 92-4 (92) - Evaporative Emission (EVAP) Canister Purge (see page 11-161)
Valve Circuit Malfunction

P0500*3 - 17-1 (17) - Vehicle Speed Sensor (VSS) Circuit Malfunction (see page 11-90)

P0501*2 - 17-2*2 - Vehicle Speed Sensor (VSS) (see page 11-90)


Range/Performance

P0563 - 34-2 (34) - Engine Control Module (ECM)/Powertrain (see page 11-91)
Control Module (PCM) Power Source Circuit
Unexpected Voltage

P0600 - 39-1 (39) - Serial Communication Link Malfunction Refer to the Multiplex Control
System Troubleshooting (see
page 22-273).

P07xx** 70-2 (70)*2 - Automatic Transaxle System Malfunction*2 Refer to the Automatic
*2 Transmission DTC
Troubleshooting Index

P1107 - 13-1 (13) - Barometric Pressure (BARO) Sensor Circuit (see page 11-93)
Low Voltage

P1108 - 13-2 (13) - Barometric Pressure (BARO) Sensor Circuit (see page 11-93)
High Voltage

P1259*1 - 22-4 (22)*1 - VTEC System Malfunction*1 (see page 11-94)

P1324 - 23-2 (23) - Knock Sensor Power Source Circuit Low (see page 11-87)
Voltage

*: These DTCs will be indicated by the blinking of the MIL when SCS short connector is connected.
**: The D indicator light and the MIL may come on simultaneously.
*1: D16W7, D16V1 engines
*2: A/T

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Fuel and Emissions - Fuel and Emissions Systems

11-9
Fuel and Emissions Systems
DTC Troubleshooting Index (cont'd)
Scan tool DTC Honda DTC Detection Item Page

DTC Temporary DTC (MIL Temporary


DTC Indication*) DTC
P1361 - 8-2 (8) - Top Dead Centre (TDC) Sensor Intermittent (see page 11-98)
Interruption

P1362 - 8-1 (8) - Top Dead Centre (TDC) Sensor No Signal (see page 11-98)

P1491 P1491 12-3 (12) T12-3 Exhaust Gas Recirculation (EGR) Valve (see page 11-154)
Insufficient Lift

P1498 - 12-2 (12) - Exhaust Gas Recirculation (EGR) Valve Position (see page 11-158)
Sensor Circuit High Voltage

P1519 - 14-3 (14) - Idle Air Control (IAC) Valve Circuit Malfunction (see page 11-117)

P1607 - 0-2 - Engine Control Module (ECM)/Powertrain (see page 11-99)


Control Module (PCM) Internal Circuit
Malfunction

P17xx** - 70-3 (70)*2 - Automatic Transaxle System Malfunction*2 Refer to the Automatic
*2 Transmission DTC
Troubleshooting Index

*: These DTCs will be indicated by the blinking of the MIL when SCS short connector is
connected.
**: The D indicator light and the MIL may come on simultaneously.
*1: D16W7, D16V1 engines
*2: A/T
*3: M/T

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Fuel and Emissions - Fuel and Emissions Systems

11-10
Fuel and Emissions Systems
Symptom Troubleshooting Index

When the vehicle has one of these symptoms, check the Diagnostic Trouble Code (DTC) with the scan tool. If there is no DTC, do
the diagnostic procedure for the symptom, in the sequence listed, until you find the cause.
Symptom Diagnostic procedure Also check for

Engine will not start (MIL works OK, no 1. Test the battery (see page 22- Low compression
DTCs set) 79). Intake air leaks
2. Test the starter (see page 4-8). Locked up engine
3. Troubleshoot the fuel pump Slipped/ broken timing belt
circuit (see page 11-127). Contaminated fuel

Engine will not start (MIL comes on and Troubleshoot the MIL circuit (see page 11-
stays on, or never comes on at all, no 100).
DTCs set)

Engine will not start (immobiliser Troubleshoot the immobiliser system (see
indicator light comes on) page 22-245).

Hard starting (MIL works OK, no DTCs 1. Test the battery (see page 22- Low compression
set) 79). Intake air leaks
2. Check the fuel pressure (see Contaminated fuel
page 11-131).

Cold fast idle too low (MIL works OK, no Check the idle speed (see page 11-125).
DTCs set)

Cold fast idle too high (MIL works OK, 1. Check the idle speed (see page
no DTCs set) 11-125).
2. Inspect/adjust the throttle cable
(see page 11-149).
3. Inspect and test the throttle body
(see page 11-145).

Idle speed fluctuates (MIL works OK, no 1. Check the idle speed (see page Intake air leaks
DTCs set) 11-125).
2. Inspect/adjust the throttle cable
(see page 11-149).
3. Inspect and test the throttle body
(see page 11-145).

After warming up idle speed is below 1. Troubleshoot the ALT FR signal Vacuum hose clogged/cracked/poor
specifications with no load (MIL works circuit (see page 11-120). connection
OK, no DTCs set) 2. Inspect and test the throttle body
(see page 11-145).

After warming up idle speed is above Troubleshoot the ALT FR signal circuit (see
specifications with no load (MIL works page 11-120).
OK, no DTCs set)

Low power (MIL works OK, no DTCs 1. Check the fuel pressure (see Low compression
set) page 11-131).
2. Inspect and test the throttle body
(see page 11-145).
3. Inspect/adjust the throttle cable
(see page 11-149).

Engine stalls (MIL works OK, no DTCs 1. Check the fuel pressure (see Intake air leaks
set) page 11-131). Faulty harness and sensor
2. Check the idle speed (see page connections

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Fuel and Emissions - Fuel and Emissions Systems

11-11
Fuel and Emissions Systems
System Descriptions

Electronic Control System


The functions of the fuel and emission control systems are managed by the Engine Control Module (ECM) on vehicles with manual
transmissions or the Powertrain Control Module (PCM) on vehicles with automatic transmissions.
Fail-safe Function
When an abnormality occurs in a signal from a sensor, the ECM/PCM ignores that signal and assumes a pre-programmed value
for that sensor that allows the engine to continue to run.
Back-up Function
When an abnormality occurs in the ECM/PCM, the injectors are controlled by a back-up circuit independent of the system to permit
minimal driving.
Self-diagnosis
When an abnormality occurs in the signal from a sensor, the ECM/PCM supplies ground for the Malfunction Indicator Lamp (MIL)
and stores the Diagnostic Trouble Code (DTC) in erasable memory. When the ignition is first turned on, the ECM/PCM supplies
ground for the MIL for 2 seconds to check the MIL bulb condition.
Two Driving Cycle Detection Method
To prevent false indications, the ''two driving cycle detection method'' is used for some self-diagnostic functions. When an
abnormality occurs, the ECM/PCM stores it in its memory. When the same abnormality recurs after the ignition switch is turned
OFF and ON (II) again, the ECM/PCM informs the driver by turning on the MIL.

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Fuel and Emissions - Fuel and Emissions Systems

11-12
Fuel and Emissions Systems
System Descriptions (cont'd)

ECM/PCM Data
You can retrieve data from the ECM/PCM by connecting the scan tool or the Honda PGM Tester to the Data Link Connector (DLC).
The items listed in the table below conform to SAE recommended practice. The Honda PGM Tester also reads data beyond that
recommended by SAE so that this data may help you find the causes of intermittent problems.
NOTE:
The ''operating values'' listed are approximate and may vary depending on the environment and the individual vehicle.
Unless noted otherwise, ''at idle speed'' means idling with the engine completely warmed up, A/T in Park or neutral, M/T
in neutral position, and the A/C and all accessories turned off.
Data Description Operating Freeze
Value Data
Diagnostic Trouble If the ECM/PCM detects a problem, it will store it as a code consisting of one If no problem YES
Code (DTC) letter and four numbers. Depending on the problem, an SAE-defined code is detected,
(P0xxx) or a Honda-defined code (P1xxx) will be output to the tester. there is no
output.

Engine Speed The ECM/PCM computes engine speed from the signals sent from the Nearly the YES
Crankshaft Position (CKP) sensor. This data is used for determining the time same as
and amount of injected fuel. tachometer
indication
At idle
speed:
650+50 rpm
(min-1)

Vehicle Speed The ECM/PCM converts pulse signals from Vehicle Speed Sensor (VSS). Nearly the YES
same as
speedometer
indication

Manifold Absolute The absolute pressure caused in the intake manifold by engine load and With engine YES
Pressure (MAP) speed. stopped:
Nearly the
same as
atmospheric
pressure
At idle
speed: about
20-34 kPa
(150-260
mmHg, 6-10
in.Hg), 0.7-
1.1 V

Engine Coolant The ECT sensor converts coolant temperature into voltage and signals the With cold YES
Temperature (ECT) ECM/PCM. The sensor is a thermistor whose internal resistance changes with engine:
coolant temperature. The ECM/PCM uses the voltage signals from the ECT Same as
sensor to determine the amount of injected fuel. ambient
temperature
and IAT
With engine
warmed up:
about 80-
100°C (176-
212°F), 0.5-
0.8 V

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Fuel and Emissions - Fuel and Emissions Systems

11-13
Fuel and Emissions Systems
System Descriptions (cont'd)

ECM/PCM Data (cont'd)


Data Description Operating Freeze
Value Data

Fuel System Fuel system status is indicated as ''open'' or ''closed''. At idle YES
Status Closed: Based on the HO2S output, the ECM/PCM determines the air/fuel ratio and speed:
controls the amount of injected fuel. closed
Open: ignoring HO2S output, the ECM/PCM refers to signals from the Throttle Position
(TP), Manifold Absolute Pressure (MAP), Intake Air Temperature (IAT), Barometric
Pressure (BARO) and Engine Coolant Temperature (ECT)) sensors to control the amount
of injected fuel.

Short Term The air/fuel ratio correction coefficient for correcting the amount of injected fuel when the 0.6-1.5 YES
Fuel Trim Fuel System Status is ''closed. ''When the ratio is leaner than the stoichiometric ratio, the
ECM/PCM increases short term fuel trim gradually, and the amount of injected fuel
increases. The air/fuel ratio gradually gets richer, causing a lower oxygen content in the
exhaust gas. Consequently, the short term fuel trim is lowered, and the ECM/PCM reduces
the amount of injected fuel.
This cycle keeps the air/fuel ratio close to the stoichiometric ratio when in closed loop
status.

Long Term Long term fuel trim is computed from short term fuel trim and indicates changes occurring 0.8-1.2 YES
Fuel Trim in the fuel supply system over a long period.
If long term fuel trim is higher than 1.00, the amount of injected fuel must be increased. If it
is lower than 1.00, the amount of injected fuel must be reduced.

Intake Air The IAT sensor converts intake air temperature into voltage and signals the ECM/PCM. With cold YES
Temperature When intake air temperature is low, the internal resistance of the sensor increases, and engine:
(IAT) the voltage signal is higher. Same as
ambient
temperature
and ECT

Throttle Based on the accelerator pedal position, the opening angle of the throttle valve is At idle YES
Position indicated. speed:
about 10 %

Ignition Ignition timing is the ignition advance angle set by the ECM/PCM. The ECM/PCM matches At idle NO
Timing ignition timing to the driving conditions. speed:
8°+2°
BTDC when
the SCS
short
connector is
connected

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Fuel and Emissions - Fuel and Emissions Systems

11-14
Fuel and Emissions Systems
System Descriptions (cont'd)

ECM/PCM Inputs and Outputs at Connector A (31P)

Wire side of female terminals


NOTE: Standard battery voltage is 12 V.
Terminal Wire Terminal name Description Signal
number colour
1 BLK/WHT PO2SHTC (PRIMARY HEATED Drives primary With ignition switch ON (II): battery
OXYGEN SENSOR (PRIMARY HO2S) HO2S heater voltage
HEATER CONTROL) With fully warmed up engine running:
duty controlled
2 YEL/BLK IGP2 (POWER SOURCE) Power source for With the ignition switch ON (II): battery
the ECM/PCM voltage
circuit With the ignition switch OFF: about 0 V
3 YEL/BLK IGP1 (POWER SOURCE) Power source for With the ignition switch ON (II): battery
the ECM/PCM voltage
circuit With the ignition switch OFF: about 0 V
4 BLK PG2 (POWER GROUND) Ground for the Less than 1.0 V at all times
ECM/PCM circuit
5 BLK PG1 (POWER GROUND) Ground for the Less than 1.0 V at all times
ECM/PCM circuit
6 WHT PHO2S (PRIMARY HEATED OXYGEN Detects primary With throttle fully opened from idle with
SENSOR (PRIMARY HO2S), SENSOR HO2S sensor fully warmed up engine: about 0.6 V
1) (sensor 1) signal With throttle quickly closed: below 0.4 V
7 BLU CKP (CRANKSHAFT POSITION (CKP) Detects CKP sensor With engine running: pulses
SENSOR) signal
8 YEL VCCR (SENSOR VOLTAGE RETURN) Detects sensor With ignition switch ON (II): about 5 V
voltage With the ignition switch OFF: about 0 V
9 RED/BLU KS (KNOCK SENSOR) Detects knock With engine knocking: pulses
sensor signal With ignition switch ON (II): about 5 V
10 GRN/YEL SG2 (SENSOR GROUND) Sensor ground Less than 1.0 V at all times
11 GRN/WHT SG1 (SENSOR GROUND) Sensor ground Less than 1.0 V at all times
12 BLK/RED IACV (IDLE AIR CONTROL (IAC) Drives IAC valve With engine running: duty controlled
VALVE) With ignition switch ON (II): about 5 V
13 WHT/BLK EGRP (EXHAUST GAS Detects EGR valve With engine running: 1.2 V-2.0 V
RECIRCULATION (EGR) VALVE position sensor (depending on EGR valve lift)
POSITION SENSOR) signal
15 RED/BLK

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Fuel and Emissions - Fuel and Emissions Systems

11-15
Fuel and Emissions Systems
System Descriptions (cont'd)

ECM/PCM Inputs and Outputs at Connector A (31P)

Wire side of female terminals


NOTE: Standard battery voltage is 12 V.

Terminal number Wire colour Terminal name Description Signal

MAP (MANIFOLD With ignition switch ON (II): about 3 V


19 GRN/RED ABSOLUTE Detects MAP sensor
At idle: about 1.0 V (depending on
PRESSURE (MAP) signal
engine speed)
SENSOR)

VCC2 (SENSOR Provides sensor With ignition switch ON (II): about 5 V


20 YEL/BLU
VOLTAGE) voltage With ignition switch OFF: about 0 V

VCC1 (SENSOR Provides sensor With ignition switch ON (II): about 5 V


21 YEL/RED
VOLTAGE) voltage With ignition switch OFF: about 0 V

Ground for the


23 BRN/YEL LG2 (LOGIC GROUND) Less than 1.0 V at all times
ECM/PCM circuit

Ground for the


24 BRN/YEL LG1 (LOGIC GROUND) Less than 1.0 V at all times
ECM/PCM circuit

TDC (TOP DEAD


26 GRN CENTRE (TDC) Detects TDC sensor With engine running: pulses
SENSOR)

IGPLS4 (No. 4
Drives No. 4 ignition
27 BRN IGNITION COIL
coil
PULSE)

IGPLS3 (No. 3
Drives No. 3 ignition
28 WHT/BLU IGNITION COIL
coil
PULSE) With ignition switch ON (II): about 0 V
With engine running: pulses
IGPLS2 (No. 2
Drives No. 2 ignition
29 BLU/RED IGNITION COIL
coil
PULSE)

IGPLS1 (No. 1
Drives No. 1 ignition
30 YEL/GRN IGNITION COIL
coil
PULSE)

*1: D16W7, D16V1 engines


*2: A/T

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Fuel and Emissions - Fuel and Emissions Systems

11-16
Fuel and Emissions Systems
System Descriptions (cont'd)

ECM/PCM Inputs and Outputs at Connector B (24P)

Wire side of female terminals


NOTE: Standard battery voltage is 12 V.
Terminal Wire Terminal name Description Signal
number colour
2 YEL INJ4 (No. 4 INJECTOR) Drives No. 4 injector With ignition switch ON (II): battery
voltage
3 BLU INJ3 (No. 3 INJECTOR) Drives No. 3 injector
At idle: duty controlled
4 RED INJ2 (No. 2 INJECTOR) Drives No. 2 injector
5 BRN INJ1 (No. 1 INJECTOR) Drives No. 1 injector
6 GRN FANC (RADIATOR FAN CONTROL) Drives radiator fan With radiator fan running: about 0 V
relay With radiator fan stopped: battery
voltage
7*2 RED/BLK LSA + (A/T PRESSURE CONTROL Drives A/T pressure With the ignition switch ON (II): duty
SOLENOID VALVE A + SIDE control solenoid valve controlled
A
8 RED/WHT ECT (ENGINE COOLANT Detects ECT sensor With the ignition switch ON (II): about
TEMPERATURE (ECT) SENSOR) signal 0.1-4.8 V
(depending on engine coolant
temperature)
9*1 BLU/BLK VTPSW (VTEC OIL PRESSURE Detects VTEC oil At idle: about 0 V
SWITCH) pressure switch signal
10 WHT/BLU ALTL (ALTERNATOR L SIGNAL) Detects alternator L With ignition switch ON (II): about 0 V
signal With engine running: battery voltage
13 WHT/RED ALTF (ALTERNATOR FR SIGNAL) Detects alternator FR With engine running: 0 V-5 V
signal (depending on electrical load)
14 BLU/RED EGR (EXHAUST GAS Drives EGR valve With EGR operating: duty controlled
RECIRCULATION (EGR) VALVE) With EGR not operating: about 0 V
15*1 GRN/YEL VTS (VTEC SOLENOID VALVE) Drives VTEC solenoid At idle: about 0 V
valve
16*2 BLK/RED LSB + (A/T PRESSURE CONTROL Drives A/T pressure With the ignition switch ON (II): duty
SOLENOID VALVE B + SIDE control solenoid valve controlled
B
17 RED/YEL IAT (INTAKE AIR TEMPERATURE Detects IAT sensor With ignition switch ON (II): about 0.1
(IAT) SENSOR) signal V-4.8 V

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Fuel and Emissions - Fuel and Emissions Systems

11-17
Fuel and Emissions Systems
System Descriptions (cont'd)

PCM Inputs and Outputs at Connector C (22P)

Wire side of female terminals


NOTE: Standard battery voltage is 12 V.
Terminal Wire Terminal name Description Signal
number colour
1*2 WHT/BLK LSA- (A/T PRESSURE CONTROL Ground for A/T pressure
SOLENOID VALVE A-SIDE control solenoid valve A
2*2 YEL/BLU LC (TORQUE CONVERTER Drives torque converter clutch With lock-up ON: battery voltage
CLUTCH SOLENOID VALVE) solenoid valve With lock-up OFF: about 0 V
4*2 GRN/WHT SHB (SHIFT SOLENOID VALVE B) Drives shift solenoid valve B With engine running in 1st, 2nd
gears: battery voltage
With engine running in 3rd, 4th
gears: about 0 V
6*2 BLU/BLK SHA (SHIFT SOLENOID VALVE A) Drives shift solenoid valve A With engine running in 2nd, 3rd
gears: battery voltage
With engine running in 1st, 4th
gears: about 0 V
7*2 WHT/RED NM (MAINSHAFT SPEED Detects mainshaft speed With engine running: pulses
SENSOR) sensor signals
8*2 BRN/WHT LSB- (A/T PRESSURE CONTROL Ground for A/T pressure
SOLENOID VALVE B-SIDE control solenoid valve B
9*2 RED ATPD3 (TRANSMISSION RANGE Detects transmission range In D3 position: about 0 V
SWITCH D3 POSITION) switch D3 position signal In any other position: about 5 V or
battery voltage
10*2 WHT ATPR (TRANSMISSION RANGE Detects transmission range In R position: about 0 V
SWITCH R POSITION) switch R position signal In any other position: about 5 V or
battery voltage
11*2 BLU ATP2 (TRANSMISSION RANGE Detects transmission range In 2nd position: about 0 V
SWITCH 2 POSITION) switch 2 position signal In any other position: about 5 V or
battery voltage
12*2 BLU/WHT ATPNP (TRANSMISSION RANGE Detects transmission range In Park or neutral: about 0 V
SWITCH NEUTRAL/PARK switch Neutral/Park position In any other position: about 5 V or
POSITION) signal battery voltage
14*2 GRN NCSG (COUNTERSHAFT SPEED Ground for countershaft
SENSOR GROUND) speed sensor

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Fuel and Emissions - Fuel and Emissions Systems

11-18
Fuel and Emissions Systems
System Descriptions (cont'd)

ECM/PCM Inputs and Outputs at Connector E (31P)

Wire side of female terminals


NOTE: Standard battery voltage is 12 V.
Terminal Wire Terminal name Description Signal
number colour
1 GRN/YEL IMO FPR (IMMOBILIZER FUEL PUMP Drives PGM-FI main relay 0 V for 2 seconds after turning
RELAY) 2 ignition switch ON (II), then
battery voltage
2 WHT/RED SHO2S (SECONDARY HEATED Detects secondary HO2S With throttle fully opened from
OXYGEN SENSOR (SECONDARY (sensor 2) signal idle with fully warmed up
HO2S), SENSOR 2) engine: above 0.6 V
With throttle quickly closed:
below 0.4 V
3 BRN/YEL LG3 (LOGIC GROUND) Ground for the ECM/PCM Less than 1.0 V at all times
control circuit
4 PNK SG3 (SENSOR GROUND) Sensor ground Less than 1.0 V at all times
6 BLK/WHT SO2SHTC (SECONDARY HEATED Drives secondary HO2S With ignition switch ON (II):
OXYGEN SENSOR (SECONDARY HO2S) heater battery voltage
HEATER CONTROL) With fully warmed up engine
running: duty controlled
7 RED/YEL MRLY (PGM-FI MAIN RELAY) Drives PGM-FI main relay With ignition switch ON (II):
1 Power source for the about 0 V
DTC memory With ignition switch OFF:
battery voltage
9 YEL/BLK IG1 (IGNITION SIGNAL) Detects ignition signal With ignition switch ON (II):
battery voltage
With ignition switch OFF: about
0V
16 LT EPSLD (ELECTRICAL POWER Detects power steering At idle with steering wheel in
GRN/BLK STEERING LOAD DETECT) load signal straight ahead position: about 0
V
At idle with steering wheel at
full lock: battery voltage
momentarily
18 RED ACC (A/C CLUTCH RELAY) Drives A/C clutch relay With compressor ON: about 0 V
With compressor OFF: battery
voltage
22 WHT/BLK BKSW (BRAKE PEDAL POSITION Detects brake pedal With brake pedal released:

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Fuel and Emissions - Fuel and Emissions Systems

11-19
Fuel and Emissions Systems
System Descriptions (cont'd)

Vacuum Hose Routing


1. To EVAPORATIVE EMISSION
(EVAP) CANISTER
2. EVAPORATIVE EMISSION (EVAP)
CANISTER PURGE VALVE
3. FRONT OF VEHICLE

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Fuel and Emissions - Fuel and Emissions Systems

11-20
Fuel and Emissions Systems
System Descriptions (cont'd)

Vacuum Distribution

(1) PRIMARY HEATED OXYGEN SENSOR (PRIMARY HO2S) (13) FUEL PRESSURE REGULATOR
(SENSOR 1)

(14) FUEL PUMP

(2) SECONDARY HEATED OXYGEN SENSOR (SECONDARY (15) FUEL TANK


HO2S) (SENSOR 2)

(16) AIR CLEANER

(3) MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR (17) RESONATOR

(4) ENGINE COOLANT TEMPERATURE (ECT) SENSOR (18) EXHAUST GAS RECIRCULATION (EGR) VALVE and
POSITION SENSOR

(5) INTAKE AIR TEMPERATURE (IAT) SENSOR

(6) CRANKSHAFT POSITION (CKP) SENSOR (19) POSITIVE CRANKCASE VENTILATION (PCV) VALVE

(7) KNOCK SENSOR (20) THREE WAY CATALYTIC CONVERTER

(8) IDLE AIR CONTROL (IAC) VALVE (21) EVAPORATIVE EMISSION (EVAP) CANISTER

(9) THROTTLE BODY (22) EVAPORATIVE EMISSION (EVAP) CANISTER PURGE


VALVE

(10) INJECTOR

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Fuel and Emissions - Fuel and Emissions Systems

11-21
Fuel and Emissions Systems
System Descriptions (cont'd)

PGM-FI System Engine Coolant Temperature (ECT) Sensor


The Programmed Fuel Injection (PGM-FI) system is a The ECT sensor is a temperature dependent resistor
sequential multiport fuel injection system. (thermistor). The resistor of the thermistor decreases as the
Air Conditioning (A/C) Compressor Clutch Relay engine coolant temperature increases.
When the ECM/PCM receives a demand for cooling from the
A/C system, it delays the compressor from being energised,
and enriches the mixture to assure smooth transition to the A/C
mode.
Alternator Control
The alternator signals the Engine Control Module
(ECM)/Powertrain Control Module (PCM) during charging.
Barometric Pressure (BARO) Sensor 1. 1. THERMISTOR

The BARO sensor is inside the ECM/PCM. It converts Ignition Timing Control
atmospheric pressure into a voltage signal that modifies the The ECM/PCM contains the memory for basic ignition timing at
basic duration of the fuel injection discharge. various engine speeds and manifold absolute pressure. It also
Crankshaft Position (CKP) Sensor adjusts the timing according to engine coolant temperature.
The CKP sensor detects engine speed and determines ignition Injector Timing and Duration
timing and timing for fuel injection of each cylinder. The ECM/PCM contains the memory for basic discharge
duration at various engine speeds and manifold pressures. The
basic discharge duration, after being read out from the
memory, is further modified by signals sent from various
sensors to obtain the final discharge duration.
By monitoring long term fuel trim, the ECM/PCM detects long
term malfunctions in the fuel system, and will set a Diagnostic
Trouble Code (DTC).
Intake Air Temperature (IAT) Sensor
The IAT sensor is a temperature dependent resistor
(thermistor). The resistance of the thermistor decreases as the
intake air temperature increases.
1. 1. MAGNET

2. 1. THERMISTOR

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Fuel and Emissions - Fuel and Emissions Systems

11-22
Fuel and Emissions Systems
System Descriptions (cont'd)

Knock Sensor Primary Heated Oxygen Sensor (Primary HO2S)


The knock control system adjusts the ignition timing to The primary HO2S detects the oxygen content in the exhaust
minimise knock. gas and sends signals to the ECM/PCM which varies the
duration of fuel injection accordingly. To stabilise its output, the
sensor has an internal heater. The primary HO2S is installed in
the exhaust manifold. By controlling the air fuel ratio with
primary HO2S and secondary HO2S, the deterioration of the
primary HO2S can be evaluated by its feedback period. When
the feedback period exceeds a certain value during stable
driving conditions, the sensor is considered deteriorated and
1. 1. WEIGHT the ECM/PCM sets a DTC.
2. PIEZO ELEMENT

Manifold Absolute Pressure (MAP) Sensor


The MAP sensor converts manifold absolute pressure into
electrical signals to the ECM/PCM.

1. 1. ZIRCONIA ELEMENT
2. SENSOR TERMINALS
3. HEATER TERMINALS
4. HEATER

Secondary Heated Oxygen Sensor (Secondary


HO2S)
The secondary HO2S detects the oxygen content in the
2. 1. SENSOR UNIT exhaust gas downstream of the Three Way Catalytic Converter
(TWC) and sends signals to the ECM/PCM which varies the
duration of fuel injection accordingly. To stabilise its output, the
sensor has an internal heater. The secondary HO2S is
installed in the TWC.

2. 1. ZIRCONIA ELEMENT
2. SENSOR TERMINALS
3. HEATER TERMINALS
4. HEATER

Starting Control
When the engine is started, the ECM/PCM provides a rich
mixture by increasing injector duration.

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Fuel and Emissions - Fuel and Emissions Systems

11-23
Fuel and Emissions Systems
System Descriptions (cont'd)

Throttle Position (TP) Sensor Idle Control System


The TP sensor is a potentiometer connected to the throttle When the engine is cold, the A/C compressor is on, the
valve shaft. As the throttle position changes, the sensor varies transmission is in gear, the brake pedal is pressed, the power
the signal voltage to the ECM/PCM. The TP sensor is not steering load is high, or the alternator is charging, the
replaceable apart from the throttle body. ECM/PCM controls current to the Idle Air Control (IAC) valve to
maintain the correct idle speed. Refer to the System Diagram
to see the functional layout of the system.
Brake Pedal Position Switch
The brake pedal position switch signals the ECM/PCM when
the brake pedal is pressed.
Electrical Power Steering (EPS) Signal
The EPS signals the ECM/PCM when the power steering load
is high.
Idle Air Control (IAC) Valve
1. 1. ELEMENT
2. BRUSH HOLDER To maintain the proper idle speed, the IAC valve changes the
3. BRUSH amount of air bypassing the throttle body in response to an
electrical signal from the ECM/PCM.
Top Dead Centre (TDC) Sensor
The TDC sensor detects the position of the No. 1 cylinder as a
reference for sequential fuel injection to each cylinder.

1. 1. VALVE
2. From AIR CLEANER
3. To INTAKE MANIFOLD

2. 1. MAGNET

Vehicle Speed Sensor (VSS)


The VSS is driven by the differential. It generates a pulsed
signal from an input of 5 volts. The number of pulses per
minute increases/decreases with the speed of the vehicle.

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Fuel and Emissions - Fuel and Emissions Systems

11-24
Fuel and Emissions Systems
System Descriptions (cont'd)

Fuel Supply System Intake Air System


Fuel Cut-off Control Refer to the System Diagram to see the functional layout of the
During deceleration with the throttle valve closed, current to the system.
injectors is cut off to improve fuel economy at speeds over 850 Throttle Body
rpm (min-1). Fuel cut-off action also occurs when engine The throttle body is a single-barrel down draft type. The side
speed exceeds 6,400 rpm (min-1) (D14Z5, D14Z6 engines), portion of the IAC valve is heated by engine coolant from the
6,500 rpm (min-1) (D16W7, D16V1 engines), regardless of the cylinder head.
position of the throttle valve, to protect the engine from over-
revving. With A/T model, when the vehicle is stopped, the PCM
cuts the fuel at engine speeds over 5,000 rpm (min-1).
Fuel Pump Control
When the ignition is turned on, the ECM/PCM grounds the
PGM-FI main relay which feeds current to the fuel pump for 2
seconds to pressurise the fuel system. With the engine running,
the ECM/PCM grounds the PGM-FI main relay and feeds
current to the fuel pump. When the engine is not running and
the ignition is on, the ECM/PCM cuts ground to the PGM-FI
main relay which cuts current to the fuel pump.
PGM-FI Main Relay 1 and 2
The PGM-FI relay consists of two separate relays. The PGM-
FI main relay 1 is energised whenever the ignition switch is
ON (II) which supplies battery voltage to the ECM/PCM, power
to the injectors, and power for the PGM-FI main relay 2. The
PGM-FI main relay 2 is energised to supply power to the fuel 1. 1. TP SENSOR
pump for 2 seconds when the ignition switch is turned ON (II), 2. IAC VALVE
and when the engine is running.

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Fuel and Emissions - Fuel and Emissions Systems

11-25
Fuel and Emissions Systems
System Descriptions (cont'd)

Catalytic Converter System Exhaust Gas Recirculation (EGR) System


Three Way Catalytic Converter (TWC) Refer to the System Diagram to see the functional layout of the
The TWC converts hydrocarbons (HC), carbon monoxide (CO), system.
and oxides of nitrogen (NOx) in the exhaust gas to carbon EGR Valve
dioxide (CO2), dinitrogen (N2), and water vapour. The EGR valve is designed to lower peak combustion
temperatures and reduce oxides of nitrogen emissions (NOx)
by recirculating exhaust gas through the intake manifold and
into the combustion chambers.
Positive Crankcase Ventilation (PCV) System
The PCV valve prevents blow-by gasses from escaping into
the atmosphere by venting them into the intake manifold.

1. 1. HOUSING
2. FRONT OF VEHICLE
3. THREE WAY CATALYSTS

1. 1. PCV HOSE
2. BREATHER PIPE
3. INTAKE MANIFOLD
4. PCV VALVE
5. BLOW BY VAPOUR
6. FRESH AIR

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Fuel and Emissions - Fuel and Emissions Systems

11-26
Fuel and Emissions Systems
System Descriptions (cont'd)

Evaporative Emission (EVAP) Control System


Refer to the System Diagram to see the functional layout of the
system.
EVAP Canister
The EVAP canister temporarily stores fuel vapour from the fuel
tank until it can be purged back into the engine and burned
(refer to the System Diagram to see the functional layout of the
system).
EVAP Canister Purge Valve
When the engine coolant temperature is below 70°C (158°F),
the ECM/PCM turns off the EVAP canister purge valve which
cuts vacuum to the EVAP canister.

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Fuel and Emissions - Fuel and Emissions Systems

11-27
Fuel and Emissions Systems
System Descriptions (cont'd)

Idle Control System Diagram


The idle speed of the engine is controlled by the Idle Air Control (IAC) valve:
After the engine starts, the IAC valve opens for a certain amount of time. The amount of air is increased to raise the idle
speed.
When the engine coolant temperature is low, the IAC valve is opened to obtain the proper fast idle speed. The amount of
bypassed air is thus controlled in relation to engine coolant temperature.

Intake Air System Diagram


This system supplies air for engine needs. A resonator in the intake air pipe provides additional silencing as air is drawn into the
system.

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Fuel and Emissions - Fuel and Emissions Systems

11-28
Fuel and Emissions Systems
System Descriptions (cont'd)

Exhaust Gas Recirculation (EGR) System Diagram


The EGR system reduces oxides of nitrogen (NOx) emissions by recirculating exhaust gas through the EGR valve and the intake
manifold into the combustion chambers. The ECM/PCM memory includes the ideal EGR valve position for varying operating
conditions.
The EGR valve position sensor detects the amount of EGR valve lift and sends it to the ECM/PCM. The ECM/PCM then compares
it with the ideal lift in its memory (based on signals sent from other sensors). If there is any difference between the two, the
ECM/PCM cuts current to the EGR valve.

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Fuel and Emissions - Fuel and Emissions Systems

11-29
Fuel and Emissions Systems
System Descriptions (cont'd)

Evaporative Emission (EVAP) Control Diagram


The EVAP controls minimise the amount of fuel vapour escaping to the atmosphere. Vapour from the fuel tank is temporarily stored
in the EVAP canister until it can be purged from the EVAP canister into the engine and burned.
The EVAP canister is purged by drawing fresh air through it and into a port on the intake manifold.
The purging vacuum is controlled by the EVAP canister purge valve, which is open whenever engine coolant temperature is
above 70°C (158°F).
When vapour pressure in the fuel tank is higher than the set value of the EVAP two way valve, the valve opens and
regulates the flow of fuel vapour to the EVAP canister.

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Fuel and Emissions - Fuel and Emissions Systems

11-30
Fuel and Emissions Systems
System Descriptions (cont'd)

ECM/PCM Circuit Diagram

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Fuel and Emissions - Fuel and Emissions Systems

11-31
Fuel and Emissions Systems
System Descriptions (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

11-32
Fuel and Emissions Systems
System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

11-33
Fuel and Emissions Systems
System Descriptions (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

11-34
Fuel and Emissions Systems
System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

11-35
Fuel and Emissions Systems
System Descriptions (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

11-36
Fuel and Emissions Systems
System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

11-37
Fuel and Emissions Systems
System Descriptions (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

11-38
Fuel and Emissions Systems
System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

11-39
Fuel and Emissions Systems
System Descriptions (cont'd)

1. FLOOR WIRE HARNESS

NOTE Connector with male terminals (double outline): View from terminal
side
Connector with female terminals (single outline): View from wire side
O: Related to ECM/PCM control.

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Fuel and Emissions - Fuel and Emissions Systems

11-40
Fuel and Emissions Systems
System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)


LHD model:
1. ENGINE COMPARTMENT
WIRE HARNESS
2. ENGINE WIRE HARNESS

*1: D16W7, D16V1 engines


*2: A/T

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Fuel and Emissions - Fuel and Emissions Systems

11-41
Fuel and Emissions Systems
System Descriptions (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

11-42
Fuel and Emissions Systems
System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)


LHD model:
1. ENGINE WIRE HARNESS

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Fuel and Emissions - Fuel and Emissions Systems

11-43
Fuel and Emissions Systems
System Descriptions (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

11-44
Fuel and Emissions Systems
System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)


LHD model:
1. DASHBOARD WIRE HARNESS
A
2. DASHBOARD WIRE HARNESS
B
3. ENGINE COMPARTMENT WIRE
HARNESS
4. ECM/PCM WIRE HARNESS

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Fuel and Emissions - Fuel and Emissions Systems

11-45
Fuel and Emissions Systems
System Descriptions (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

11-46
Fuel and Emissions Systems
System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)


LHD model:
1. DASHBOARD WIRE
HARNESS
2. ENGINE WIRE HARNESS
3. ECM/PCM WIRE
HARNESS
4. FLOOR WIRE HARNESS
5. ENGINE COMPARTMENT
WIRE HARNESS A

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Fuel and Emissions - Fuel and Emissions Systems

11-47
Fuel and Emissions Systems
System Descriptions (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

11-48
Fuel and Emissions Systems
System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)


RHD model:
1. ENGINE COMPARTMENT
WIRE HARNESS
2. ENGINE WIRE HARNESS

*1: D16W7 engine


*2: A/T

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Fuel and Emissions - Fuel and Emissions Systems

11-49
Fuel and Emissions Systems
System Descriptions (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

11-50
Fuel and Emissions Systems
System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)


RHD model:
1. ENGINE WIRE HARNESS

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Fuel and Emissions - Fuel and Emissions Systems

11-51
Fuel and Emissions Systems
System Descriptions (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

11-52
Fuel and Emissions Systems
System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)


RHD model:
1. DASHBOARD WIRE
HARNESS A
2. ECM/PCM WIRE HARNESS
3. ENGINE COMPARTMENT
WIRE HARNESS
4. DASHBOARD WIRE
HARNESS B

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11-53
Fuel and Emissions Systems
System Descriptions (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

11-54
Fuel and Emissions Systems
System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)


RHD model:
1. ENGINE WIRE
HARNESS
2. DASHBOARD WIRE
HARNESS A
3. FLOOR WIRE
HARNESS
4. ECM/PCM WIRE
HARNESS

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11-55
Fuel and Emissions Systems
System Descriptions (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

11-125).
3. Troubleshoot the brake pedal
position switch signal circuit (see
page 11-123).

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Fuel and Emissions - PGM-FI System

11-56
PGM-FI System
Component Location Index

1. THROTTLE POSITION (TP) SENSOR


Troubleshooting, page 11-65
2. INTAKE AIR TEMPERATURE (IAT)
SENSOR
Troubleshooting, page 11-61
3. MANIFOLD ABSOLUTE PRESSURE
(MAP) SENSOR
Troubleshooting, page 11-59
4. TOP DEAD CENTRE (TDC) SENSOR
Troubleshooting, page 11-98
5. CRANKSHAFT POSITION (CKP)
SENSOR
Troubleshooting, page 11-88
6. KNOCK SENSOR
Troubleshooting, page 11-85
7. ENGINE COOLANT TEMPERATURE
(ECT) SENSOR
Troubleshooting, page 11-63
8. PRIMARY HEATED OXYGEN SENSOR
(PRIMARY HO2S) (SENSOR 1)
Troubleshooting, page 11-68
Replacement, page 11-115
9. SECONDARY HEATED OXYGEN
SENSOR (SECONDARY HO2S)
(SENSOR 2)
Troubleshooting, page 11-73
Replacement, page 11-115

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11-57
PGM-FI System
Component Location Index (cont'd)

1. INJECTORS
Replacement, page 11-113

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Fuel and Emissions - PGM-FI System

11-58
PGM-FI System
Component Location Index (cont'd)

1. DATA LINK CONNECTOR (DLC)


General Troubleshooting Information,
page 11-3

*: The illustration shows LHD model.


1. ENGINE CONTROL
MODULE/POWERTRAIN CONTROL
MODULE (ECM/PCM)
General Troubleshooting Information, page
11-3
Troubleshooting, page 11-99
2. PGM-FI MAIN RELAY 1
Troubleshooting, page 11-100
3. INERTIA SWITCH
Troubleshooting, page 11-100

*: The illustration shows LHD model.

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Fuel and Emissions - PGM-FI System

11-59
PGM-FI System
DTC Troubleshooting

DTC P0107: MAP Sensor Circuit Low Voltage Is there about 5 V?


1. 1. Turn the ignition switch ON (II). YES - Repair open in the wire between ECM/PCM (A21)
2. Check the MAP with the scan tool. and the MAP sensor.
Is about 101 kPa (760 mmHg, 30 in.Hg) or 2.9 V indicated?
NO - Substitute a known-good ECM/PCM and recheck
YES - Intermittent failure, system is OK at this time.
(see page 11-6). If symptom/indication goes away,
Check for poor connections or loose wires at the replace the original ECM/PCM.
MAP sensor and at the ECM/PCM.
NO - Go to step 3. 1. 8. Check the MAP with the scan tool.
Is 2 kPa (15 mmHg, 0.6 in.Hg) or less or 0 V indicated?
2. 3. Turn the ignition switch OFF. YES - Go to step 9.
4. Disconnect the MAP sensor 3P connector.
5. Turn the ignition switch ON (II). NO - Replace the MAP sensor.
6. Measure voltage between the MAP sensor 3P
connector terminals No. 1 and No. 3. 2. 9. Turn the ignition switch OFF.
MAP SENSOR 3P CONNECTOR 10. Disconnect ECM/PCM connector A (31P).
11. Check for continuity between the MAP sensor
connector terminal No. 2 and body ground.
MAP SENSOR 3P CONNECTOR

Wire side of female terminals


Is there about 5 V?
YES - Go to step 8.
Wire side of female terminals
NO - Go to step 7. Is there continuity?
YES - Repair short in the wire between the ECM/PCM
3. 7. Measure voltage between ECM/PCM connector
(A19) and the MAP sensor.
terminals A11 and A21.
ECM/PCM CONNECTOR A (31P) NO - Substitute a known-good ECM/PCM and recheck
(see page 11-6). If symptom/indication goes away,
replace the original ECM/PCM.

Wire side of female terminals

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Fuel and Emissions - PGM-FI System

11-60
PGM-FI System
DTC Troubleshooting (cont'd)

DTC P0108: MAP Sensor Circuit High Voltage 1. 9. Measure voltage between the MAP sensor 3P
1. 1. Start the engine. Hold the engine at 3,000 rpm with connector terminals No. 1 and No. 3.
no load (in Park or neutral) until the radiator fan MAP SENSOR 3P CONNECTOR
comes on, then let it idle.
2. Check the MAP with the scan tool.
Is about 101 kPa (760 mmHg, 30 in.Hg) or higher, or about
2.9 V or higher indicated?
YES - Go to step 3.
NO - Intermittent failure, system is OK at this time.
Check for poor connections or loose wires at the Wire side of female terminals
MAP sensor and at the ECM/PCM. Is there about 5 V?
YES - Go to step 10.
2. 3. Turn the ignition switch OFF.
4. Disconnect the MAP sensor 3P connector. NO - Repair open in the wire between the ECM/PCM
5. Connect the MAP sensor 3P connector terminals No. (A11) and the MAP sensor.
2 and No. 3 with a jumper wire.
MAP SENSOR 3P CONNECTOR 2. 10. Turn the ignition switch OFF.
11. Connect ECM/PCM connector terminals A11 and
A19 with a jumper wire.
ECM/PCM CONNECTOR A (31P)

JUMPER WIRE
Wire side of female terminals
3. 6. Turn the ignition switch ON (II). JUMPER WIRE
7. Check the MAP with the scan tool. Wire side of female terminals
Is about 101 kPa (760 mmHg, 30 in.Hg) or higher, or about 3. 12. Turn the ignition switch ON (II).
2.9 V or higher indicated? 13. Check the MAP with the scan tool.
Is about 101 kPa (760 mmHg, 30 in.Hg) or higher, or about
YES - Go to step 8. 2.9 V or higher indicated?
NO - Replace the MAP sensor. YES - Substitute a known-good ECM/PCM and recheck
(see page 11-6). If symptom/indication goes away,
4. 8. Remove the jumper wire. replace the original ECM/PCM.
NO - Repair open in the wire between the ECM/PCM
(A19) and the MAP sensor.

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Fuel and Emissions - PGM-FI System

11-61
PGM-FI System
DTC Troubleshooting (cont'd)

DTC P0112: IAT Sensor Circuit Low Voltage 1. 8. Check the temperature reading on the scan tool.
1. 1. Turn the ignition switch ON (II). Be aware that if the engine is warm, the reading will be
2. Check the IAT with the scan tool. higher than ambient temperature. If the engine is cold, the
Is 150°C (302°F) or higher (or H-Limit in Honda mode of IAT and ECT will have the same value.
PGM Tester) or 0 V indicated? Is the correct ambient temperature indicated?
YES - Go to step 3. YES - Intermittent failure, system is OK at this time.
NO - Go to step 8.
Check for poor connections or loose wires at the
IAT sensor and at the ECM/PCM.

2. 3. Disconnect the IAT sensor 2P connector. NO - Replace the IAT sensor.


4. Check the IAT with the scan tool.
Is 150°C (302°F) or higher (or H-Limit in Honda mode of
PGM Tester) or 0 V indicated?
YES - Go to step 5.
NO - Replace the IAT sensor.

3. 5. Turn the ignition switch OFF.


6. Disconnect ECM/PCM connector B (24P).
7. Check for continuity between the IAT sensor 2P
connector terminal No. 2 and body ground.
IAT SENSOR 2P CONNECTOR

Wire side of female terminals


Is there continuity?
YES - Repair short in the wire between the ECM/PCM
(B17) and the IAT sensor.
NO - Substitute a known-good ECM/PCM and recheck
(see page 11-6). If symptom/indication goes away,
replace the original ECM/PCM.

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Fuel and Emissions - PGM-FI System

11-62
PGM-FI System
DTC Troubleshooting (cont'd)

DTC P0113: IAT Sensor Circuit High Voltage 1. 7. Check the IAT with the scan tool.
1. 1. Turn the ignition switch ON (II). Is -20°C (-4°F) or less (or L-Limit in Honda mode of PGM
2. Check the IAT with the scan tool. Tester) or 5 V indicated?
Is -20°C (-4°F) or less (or L-Limit in Honda mode of PGM
YES - Go to step 8.
Tester) or 5 V indicated?
YES - Go to step 3. NO - Replace the IAT sensor.

NO - Intermittent failure, system is OK at this time.


2. 8. Turn the ignition switch OFF.
Check for poor connections or loose wires at the
9. Remove the jumper wire.
IAT sensor and at the ECM/PCM.
10. Connect ECM/PCM connector terminals A10 and
B17 with a jumper wire.
2. 3. Turn the ignition switch OFF. ECM/PCM CONNECTORS
4. Disconnect the IAT sensor 2P connector.
5. Connect the IAT sensor 2P connector terminals No.
1 and No. 2 with a jumper wire.
IAT SENSOR 2P CONNECTOR

JUMPER WIRE
Wire side of female terminals
3. 11. Turn the ignition switch ON (II).
JUMPER WIRE 12. Check the IAT with the scan tool.
Wire side of female terminals Is -20°C (-4°F) or less (or L-Limit in Honda mode of PGM
3. 6. Turn the ignition switch ON (II). Tester) or 5 V indicated?
YES - Substitute a known-good ECM/PCM and recheck
(see page 11-6). If symptom/indication goes away,
replace the original ECM/PCM.
NO - Repair open in the wire between the ECM/PCM
(A10, B17) and the IAT sensor.

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Fuel and Emissions - PGM-FI System

11-63
PGM-FI System
DTC Troubleshooting (cont'd)

DTC P0117: ECT Sensor Circuit Low Voltage 1. 7. Check for continuity between the ECT sensor 2P
1. 1. Turn the ignition switch ON (II). connector terminal No. 2 and body ground.
2. Check the ECT with the scan tool. ECT SENSOR 2P CONNECTOR
Is 150°C (302°F) or higher (or H-Limit in Honda mode of
PGM Tester) or 0 V indicated?
YES - Go to step 3.
NO - Intermittent failure, system is OK at this time.
Check for poor connections or loose wires at the
ECT sensor and at the ECM/PCM.
Wire side of female terminals
Is there continuity?
2. 3. Disconnect the ECT sensor 2P connector.
4. Check the ECT with the scan tool. YES - Repair short in the wire between the ECM/PCM
Is 150°C (302°F) or higher (or H-Limit in Honda mode of (B8) and the ECT sensor.
PGM Tester) or 0 V indicated? NO - Substitute a known-good ECM/PCM and recheck
YES - Go to step 5. (see page 11-6). If symptom/indication goes away,
replace the original ECM/PCM.
NO - Replace the ECT sensor.

3. 5. Turn the ignition switch OFF.


6. Disconnect ECM/PCM connector B (24P).

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Fuel and Emissions - PGM-FI System

11-64
PGM-FI System
DTC Troubleshooting (cont'd)

DTC P0118: ECT Sensor Circuit High Voltage 1. 7. Check the ECT with the scan tool.
1. 1. Turn the ignition switch ON (II). Is -20°C (-4°F) or less (or L-Limit in Honda mode of PGM
2. Check the ECT with the scan tool. Tester) or 5 V indicated?
Is -20°C (-4°F) or less (or L-Limit in Honda mode of PGM
YES - Go to step 8.
Tester) or 5 V indicated?
YES - Go to step 3. NO - Replace the ECT sensor.

NO - Intermittent failure, system is OK at this time.


2. 8. Turn the ignition switch OFF.
Check for poor connections or loose wires at the
9. Remove the jumper wire.
ECT sensor and at the ECM/PCM.
10. Connect ECM/PCM connector terminals A10 and B8
with a jumper wire.
2. 3. Turn the ignition switch OFF. ECM/PCM CONNECTORS
4. Disconnect the ECT sensor 2P connector.
5. Connect the ECT sensor 2P connector terminals No.
1 and No. 2 with a jumper wire.
ECT SENSOR 2P CONNECTOR

JUMPER WIRE
Wire side of female terminals
3. 11. Turn the ignition switch ON (II).
JUMPER WIRE 12. Check the ECT with the scan tool.
Wire side of female terminals Is -20°C (-4°F) or less (or L-Limit in Honda mode of PGM
Tester) or 5 V indicated?
3. 6. Turn the ignition switch ON (II).
YES - Substitute a known-good ECM/PCM and recheck
(see page 11-6). If symptom/indication goes away,
replace the original ECM/PCM.
NO - Repair open in the wire between the ECM/PCM
(A10, B8) and the ECT sensor.

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Fuel and Emissions - PGM-FI System

11-65
PGM-FI System
DTC Troubleshooting (cont'd)

DTC P0122: TP Sensor Circuit Low Voltage 1. 8. At the sensor side, measure resistance between the
1. 1. Turn the ignition switch ON (II). TP sensor 3P connector terminals No. 1 and No. 3
2. Check the throttle position with the scan tool. with the throttle fully closed.
Is there about 10% or 0.5 V when the throttle is fully closed TP SENSOR 3P CONNECTOR
and about 90% or 4.5 V when the throttle is fully opened?
YES - Intermittent failure, system is OK at this time.
Check for poor connections or loose wires at the TP
sensor and at the ECM/PCM.
NO - Go to step 3.

Terminal side of male terminals


2. 8. Turn the ignition switch OFF. Is there about 0.5-0.9 k ohms?
9. Disconnect the TP sensor 3P connector.
10. Turn the ignition switch ON (II). YES - Go to step 9.
11. Measure voltage between the TP sensor 3P NO - Replace the throttle body.
connector terminals No. 1 and No. 3.
TP SENSOR 3P CONNECTOR
2. 9. Measure resistance between the TP sensor 3P
connector terminals No. 1 and No. 2 with the throttle
fully closed.
TP SENSOR 3P CONNECTOR

Wire side of female terminals


Is there about 5 V?
YES - Go to step 7.
Terminal side of male terminals
NO - Go to step 14.
Is there about 4.5k ohms?

3. 7. Turn the ignition switch OFF. YES - Go to step 10.


NO - Replace the throttle body.

10. Disconnect ECM/PCM connector A (31P).

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Fuel and Emissions - PGM-FI System

11-66
PGM-FI System
DTC Troubleshooting (cont'd)

1. 11. At the wire harness side, check for continuity 1. 13. At the wire harness side, check for continuity
between TP sensor 3P connector terminal No. 2 and between TP sensor 3P connector terminals No. 2
body ground. and body ground.
TP SENSOR 3P CONNECTOR TP SENSOR 3P CONNECTOR

Wire side of female terminals Wire side of female terminals


Is there continuity? Is there continuity?
YES - Repair short in the wire between the ECM/PCM YES - Substitute a known-good ECM/PCM and recheck
(A15) and the TP sensor. (see page 11-6). If symptom/indication goes away,
replace the original ECM/PCM.
NO - Go to step 12.
NO - Repair open in the wire between the ECM/PCM
(A15) and the TP sensor.
12. Connect ECM/PCM connector terminal A15 and body
ground with a jumper wire.
14. Measure voltage between ECM/PCM connector
ECM/PCM CONNECTOR A (31P) terminals A10 and A20.

ECM/PCM CONNECTOR A (31P)

Wire side of female terminals

Wire side of female terminals


Is there about 5 V?
YES - Repair open in the wire between the ECM/PCM
(A20) and the TP sensor.
NO - Substitute a known-good ECM/PCM and recheck
(see page 11-6). If symptom/indication goes away,
replace the original ECM/PCM.

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Fuel and Emissions - PGM-FI System

11-67
PGM-FI System
DTC Troubleshooting (cont'd)

DTC P0123: TP Sensor Circuit High Voltage 1. 7. Measure voltage between ECM/PCM connector
terminals A10 and A20.
ECM/PCM CONNECTOR A (31P)
1. 1. Turn the ignition switch ON (II).
2. Check the throttle position with the scan tool.
Is there about 10% or 0.5 V when the throttle is fully closed
and about 90% or 4.5 V when the throttle is fully opened?
YES - Intermittent failure, system is OK at this time.
Check for poor connections or loose wires at the TP
sensor and at the ECM/PCM. Wire side of female terminals
Is there about 5 V?
NO - Go to step 3.
YES - Repair open in the wire between the ECM/PCM
(A10) and the TP sensor.
2. 3. Turn the ignition switch OFF.
4. Disconnect the TP sensor 3P connector. NO - Substitute a known-good ECM/PCM and recheck
5. Turn the ignition switch ON (II). (see page 11-6). If symptom/indication goes away,
6. At the wire harness side, measure voltage between replace the original ECM/PCM.
the TP sensor 3P connector terminals No. 1 and No.
3.
TP SENSOR 3P CONNECTOR

Wire side of female terminals


Is there about 5 V?
YES - Replace the throttle body.
NO - Go to step 7.

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Fuel and Emissions - PGM-FI System

11-68
PGM-FI System
DTC Troubleshooting (cont'd)

DTC P0131: Primary HO2S (Sensor 1) Circuit Low 1. 9. Turn the ignition switch OFF.
Voltage
10. Disconnect ECM/PCM connector A (31P).
1. 1. Reset the ECM/PCM (see page 11-4).
11. Check for continuity between the primary HO2S (Sensor
2. Start the engine. Hold the engine at 3,000 rpm (min-
1) 4P connector terminal No. 2 and body ground.
1) with no load (in Park or neutral) until the radiator
fan comes on. PRIMARY HO2S (SENSOR 1) 4P CONNECTOR
3. Check the primary HO2S (Sensor 1) output voltage
with the scan tool during acceleration using wide
open throttle.
Does the voltage stay at 0.5 V or less?
YES - Go to step 4.
NO - Intermittent failure, system is OK at this time.
Check for poor connections or loose wires at the Terminal side of male terminals
primary HO2S (Sensor 1) and at the ECM/PCM. Is there continuity?
YES - Repair short in the wire between the ECM/PCM
2. 4. Check the fuel pressure (see page 11-131). (A6) and the primary HO2S (Sensor 1).
Is it normal?
NO - Substitute a known-good ECM/PCM and recheck
YES - Go to step 5. (see page 11-6). If symptom/indication goes away,
NO - Repair the fuel supply system.
replace the original ECM/PCM.

3. 5. Turn the ignition switch OFF.


6. Disconnect the primary HO2S (Sensor 1) 4P
connector.
7. Turn the ignition switch ON (II).
8. Check the primary HO2S (Sensor 1) output voltage
with the scan tool.
Does it stay at 0.5 V or less?
YES -