26. Under-hoodEmissionsControlLabel(19!16,1997modell
EmissionGroupldentification
Example:
tsFCOOUNI, USE'o'EO SOLUTION
VACUUMHOSEROUTINGDIAGRAM
VEHICLEEMISSIONCONTROLINFORMATION
ENGlrlEFAM|LYvHNl6vJcrcrD.SB-ACEME{Tls90.F}q?O0 CIVIC
EvApoMtrvtFAMrryvHNroTTByMAc p:9
CATALYST rwcHo2s{2)sFl
Hrr.n u stcv'ctMAuArro' aDoflror{A,'N.oRMAro. ff-Tl
TUN!LPCODNOIIS:ENGIN!ATNOFMAIOPFMTINGTTM'EqA-U8!. I I|rf '
ALtACCESSoRTESTUq{EooFf,CooUNGFANoFf,
TiANSMISSIONINNEUIML
N0ollrEFaDJUSTT,TENTSNE!DEo. oBD CERTtftED
IOLESPEED
TMNSMISSION
12"l I3TDC
T!
e+l rr_9.,.'
THISVTHICLECONFORMSIO U.S.EPAANOSIAIE
OFCALIFO8NIAREGULAIIO1TSAPPLICAELETO1997
MOOELYEANNEI1MOTONVEHICIES. ililulIl
CEBT]FICANON NtR1
IN.USE NEA1FUTL
112 nE-N2 H0N0AMOTO8C0.,tTD.
50ST{50States}:
THISVEHICLECONFORMSTO U.S.EPAAND STATEOF
C A L I F O R N I AR E G U L A T I O N SA P P L I C A B L ET O 1 9 9 7
MODELYEARNEWMOTORVEHICLES.
49ST(49States/Fodoral):
THISVEHICLECONFORMSTO U.S.EPAREGULATIONS
APPLICABLETO 1997MODELYEARNEWMOTORVEHI-
CAL(Californis):
THISVEHICLECONFORMSTO U.S.EPAAND STATEOF
C A L I F O R N I AR E G U L A T I O N SA P P L I C A B L ET O 1 9 9 7
M O D E LY E A RN E WP A S S E N G E RC A R SP R O V I D E D
THATTHISVEHICLEIS ONLYINTRODUCEDINTOCOM.
MERCEFORSALEINTHESTATEOFCALIFORNIA.
EngineandEvaporativeFamilies
EngineFamily: V H N1 . 6 V J G K G K
Model Ysar
T: 1996
V; 1997
Manufacturer
HN:Honda
Di3placomont
Clsss
V: Light DutyVehicle/PassengerCar
FuolSystsm and Numbsr of Valvo3
J: ElectronicSequentialMultiponInjection
(threeor morevalvespercylinder)
FuolTyp€
G:Gasoline
Standard
F;49or 50StatesTier1
K: 49 or 50StatesTier 1
1:CaliforniaTier 1
2: CaliforniaTLEV
3: CaliforniaLEV
4:CaliforniaULEV
ModetYsar T T
T: 1996 |
V : 1 9 9 7
]Manutaqturer
Catalyst
E,F,G, H:ThreeWay Catalyst
OBD
K- T:OBDEquipped
Evaporative Family:
HN:Honda
Storage System
1:Canister
Canirtor Wolking Caprcity lgrEmsl
CanisterContigurstion
A: PlasticHousing(ClosedBottom)
B:PlasticHousing{OpenEottom)
Fu€lSystem
Y: FuelInjection
Fuel Tank
M: Metal
Standard
A: CurrentEvap
E:EnhancedEvap
Wild Card
V H N 1 0 7 7B Y M A C
(cont'd)
1-25
27. Under-hoodEmissionsControlLabel(1998modell
(cont'd)
EmissionGroupldentification
Example:
50ST{50States):
THISVEHICLECONFORMSTO U.S.EPAANDSTATEOF
C A L I F O R N I AR E G U L A T I O N SA P P T I C A B L ET O I 9 9 8
MODELYEARNEWMOTORVEHICLES.
49ST(49States/Fed€ral):
THISVEHICLECONFORMSTO U.S.EPAREGULATIONS
APPLICABLETO 1998MODELYEARNEWMOTORVEHI.
LLEJ.
CAL(Calilornial:
THISVEHICLECONFORMSTO U.S.EPAANDSTATEOF
C A L I F O R N I AR E G U L A T I O N SA P P L I C A B L ET O 1 9 9 8
M O D E LY E A RN E W P A S S E N G E RC A R SP R O V I D E D
THATTHISVEHICLEISONLYINTRODUCEDINTOCOM-
MERCEFORSALEINTHESTATEOFCALIFORNIA,
VEHICTEEMISSIONCONTROLINFORIVIATION
STAT€OFCALTORNLARECULATIONSAPPLICABLE
TO1933MOOELYEARNEWTLFVPASSENGEfr
INTBOOUCEOINTOCOMMERCEFORSALEN TNE
CATALYSTtwo1r02s1?tEcR/sFt/0B0| cEBTtFE0
VAIV€LASH
NONDAMOTORCOLTD
1-26
EngineandEvaporativeFamilies
L
EngineFamily: W HNXV 01.6JL2
Model Y6ar
W: 1998
Manutacturer
HNX:Honda
Type
V: LightDutyVehicle/PassengerCar
Displac€ment
SequenceCharaqters
EvaporativeFamily:
Mod€lYear
0065AAD
W: 1998
Manufacturar
HNX:Honda
Type
E:EVAP
CaniaterWork Capacitylgrams)
S€quoncaChrract6ls
W H N X E
28. Lift andSupportPoints
Lift andSafetyStands
@ When heavy rear compon€nts such as suspension,fu€l tank, spar6 tir€, hatch, and trunk lid ara to bo
romovod,placaldditional woight in the luggagerrea beforehoisting. Whon substantialwoight b ramovodfrom the r6a1
ot thc vohlcle,tha centerof gravlty mty changaand cancaussthe vehicloto tip forwsld on tho hoist.
NOTE:
. Sinceeachtire/whe€lassemblyweighsapproximately30 lbs {14kg).placingthe frontwheelsin the luggageareacan
assistwith theweightdistribution.
. Usethe samesupportpointsto supportthe vehicleon safetystands.
1. Placethe lift blocksasshown.
2. Raisethehoistafewinches(centimeters)androckthevehicletobesureitisfirmlysupported.
3. Raisethe hoisttolull height,andinspectlift pointstorsolidsupport.
REARSUPPORTPOINT
(cont'd)
1-27
29. Lift andSupportPoints
l .
(cont'dl
FloorJack
Setthe parkingbrakeand blockthe wheelsthat are
not beinglifted.
Whenliftingthe rearof thevehicle,putthe gearshift
lever in reverse(Automatictransmission/CW in E
position).
Raisethe vehiclehigh enoughto insertthe safety
stands.
Adjust and placethe safetystandsso the vehicle
will be approximatelylevel.then lowerthe vehicle
ontothem.
Alway3 u3asafoty stand3whcn working on 01undol
anv vchiclothat b 3upportodby only a iack.
Nover attompt to uso a bumper iack for lifting or
supportingtho vohicl€.
Center the jacking
bracket in the middle
of the jack lift platform.
LIFTPLA
REAR:
Centerthe jack
b.acketin the middle
of the jack lifr plattorm.
k-
l l
1-28
30. Towing
It thevehicleneedsto betowed,calla professionaltow-
ing service.Nevertow the vehiclebehindanothervehi-
clewith justa ropeor chain,lt isverydangerous,
Em6rgencyTowing
Therearethreepopularmethodsof towinga vehicle:
Flat-bedEquipment- The operatorloadsthe vehicleon
the backof a truck.This isthe bestway oftransponingthe
vehicle.
Wh6d Lift Equipmont- The tow truck usestwo pivoting
a.msthatgo underthetires(frontor rear)and liftsthem
off the ground.The othertwo wheelsremainon the
ground,
Sling-typ6Equipm€nt- Thetow truck usesmetalcables
with hookson the ends.Thesehooksgo aroundpartsof
the frameoJsuspension,and the cableslift that end of
the vehicleoff the ground.Thevehicle'ssuspensionand
bodycanbe seriouslydamagedit this methodof towing
is attemDted.
lf the vehiclecannotbetransportedby flat-bed,it should
be towedwith the front wheelsoff the ground.lf dueto
damage,the vehiclemust be towed with the front
wheelson the ground,do thefollowing:
ManuslTransmissionandCVT
. Releasethe parkingbrake.
. Shiftthetransmissionto neutral(CVTto E position).
AutomaticTransmission
. Releasethe parkingbrake.
. Startthe engine.
. Shiftto lpl position,thenE position.
. Turnoff the engine.
CAUTION:
. lmproper towing propantion will damsgo the trans-
mi3sion,Follow tho above procodur€€x6ctly. It you
cannot 3hift the lransmission 01 start th€ engine
(automltic trsnsmissionl.your v€hicl9mu3t be trang
portod on a ffot-b€d.
It is best to tow tho vshicls no farthol th.n 5{t mibs
(80km),lnd kosptho sp€edbdow 35 mph (55km/h).
Trying to lift or tow your vehicle by ths bumpeB will
causasorious damage.The bumpers are not d*ignod
to support tho vohicl6'3weight.
1-29
Front:
Roar:
TIEOOWNHOOKS
TOWING
47. Unit of length mm lin)
ITEM METRIC ENGLISH NOTES
STEEBING
SYSTEM
Type
OverallRatio
Turns,Lock-to-Lock
SteeringWheelDia.
P/S
M/S
Powsrassisted,rackand pinion
Sackand pinion
P/S:17.7,lt4/Sr20.3
P/S:3.6,M/S:4.1
380rnm i 15in
SUSPENSION Type Front and Rear
ShockAbsorber Frontand Rear
Independentdoublewishbone,coilsprins
Telescopic,hydraulicnitrogengasfilled
WHEEL
ALIGNMENT
Camber Front
Rear
Caster Front
TotalToe Front
Bear
0.00'
1'40'
I n 1 . 0m m l / 1 6i n
I n2 . 0m m I n 1 / 1 6i n
BRAKESYSTEM
Rear
ParkingBrake Type
Rear
Power-assistedsel{-adiusting
ventilated disc
Powe.assisted self-adjustingsolid disc
37.5cm,2 5.8sq-inx 2
44.1cm,x2 6.94sq-inx 2
6 7 . 2c m ,x 2 1 0 . 4 s q - i n x 2
50.2cm, x2 7.8sq-inx 2
l,lechanicalactuating,rearNvowheel brakes
Unit:mm (in)
5,110Stamped on ths
2056Stampedon the
caliper body
Oruml.D.:200(7.9)
Drum l.D.:180(7.'!)
TIRE Size Front and Rear 2-door Coupe
2-door Hatchback
4-doorSedan
SpareTire
P175D0R1382S:DX
P185/65R'1485S:EX,HX (USA),Si (Canada)
P175t0R1382S:CX,DX (USA),CX G {Canada)
P175t0Rr382S:DX (USA),LX (Canada)
Pl85/65R1485S: LX/EX(USA),
EX (canada)
T105/80D13CarswithoutABS Except
2-doorCoupeEX (uSA),Si
(Canada)
T105t0D142'doorCoupeEX (USA),S;
(Canada)CarswithoutABS
T115/70D14DX (USA),4'doorSedanLX lUSA),
2-doorCoupeDX (Canada)Cars
with ABS
T125r0O14Carswith ABS 2 door Coupe,
4 door SodanLX,EX (USA),
4'doorSedanEX (Canada),
2-doorCoupeSi (Canada)Cars
with ABS
WASHER
RESERVOIR
Capacity| (uS qt,lmpqt) 2-doot coupe 2.5 l.2.6,2.21
4'door Sedan 4.5 {4.8,4.0}
2-doorhatchback2.5(2.6,
4.5(4.8,
2.2)
4.0)
USAmodel
Canadamodel
DX
ExceptOX
ELECTRICAL Batt€ry
Staner
In UnderdashFuse/RelayBox
In Under-hood Fuse/RelayBox
In Under-hood ABS Fuse/RelayBox
Headlights HighAow
FrontTurn Signal/ParkingLights
ReErTurn SignalLights
Brek€/Taillights
InnerTaillights*'
HighMount Brak€Light
Backup Lights
LicensePlateLights
CeilingLight
TrunkLights
GaugeLights
Indicator Lights
llluminationand PilotLights
HeaterControl PanelLights
12V - 38AH/5HR
12V - 1.0kW, 1.2kW
1 2 V - 1 5 4
7.5A, 10A, 15A, 20A
7.5A, 10A, 15A, 20 A,30 A, 40 A, 80 A
7.54,20 A, 40A
1 2 V - 6 0 A s W
12V 21tsW
't2v - 21W
12V-21/5W
1 2 V 5 W
12V_ 18W*" 21Wrl.+3
1 2 V - 2 1 W
1 2 V 5 W
12V- 8 W (Withmoonroof)
12V-5 W (Witholtmoonroof)
1 2 v - 1 . 4 W , 3 W
1 2 V - 1 . 1 2 W ,1 . 4W
1 2 V - 0 . 8 4 W ,1 . 4W
1 2 V - 1 . 4 W
t
P/S:Powersteering,M/S:Manualsteering
*l: 2-doorCoupe *2:2-doorHatchback *3: 4-doorSedan
*4: USA(HAM),Canada(HCM)produced
*5:JAPANoroduced
3-17
52. LubricationPoints
No. LUBRICANONPOINIS LUBRICANT
'I Engine APIServiceGrade:UseSJ 'EnergyConserving"
gradeoil.
Theoil containerm8y alsodisplsytheAPICenificationmark
shownbelow.Makesureit says"ForGasolineEngines,"
SAEViscosity:Se6chartbelow.
2 Transmission Manual GenuineHondaMTF*1
Automatic GenuineHondaPremiumFormula
AutomaticTransmissionFluid(ATF)*,
CW GenuineHondaCVTFluid'3
3 BrEkaLing GenuineHond8DOT3BrakeFluid*.
1 clutch Lin€ GenuineHondaDOT3BrskeFluid'a
c Pow€rste€ringgesrbox StesringgreaseP/N08733- 8070E
6 Shiftleverpivots{manualtransmission) Gressewith molvbdenumdisulfide
7 Releasetork(manualtransmission) SuperHighTemp UreaGrease{P/N08798- 9002)
I
o
1 0
1 1
1 2
1 3
Steeringboots
Tailgatehingesand latches(2-doorHatchbackl
Steeringballjoints
Shift lever (sutomatictransmission)
P6dallinkage
Braksmast6rcylind6r pushrod
Multi-purposegrease
l'[
1 5
1 6
17
Trunkhingesand lstch(,|-doorSedanand2-door
Couoe)
Door hingesupperand lower
Door opening dstents
Hood hings and hood latch
HondaWhite Lithim Grease
18
19
20
21
22
Fuelfillorlid
Clutchm8st6rcylinderpushrod
Throttlecabl€ondandthronl6linksge
Rearbrakgshoe linkages
Steeringwheel(backside)
Multi-purposegrease
23
21
Caliper piston seal,dust seal,
caliperpin,piston
Throttle cableend (dsshboardlower Danel)
Siliconsgrease
25 Pow6rst66ringsystem(for carswith P/Sl GenuineHondaPowerSteeringFluid-Vor S'5
26 Air conditioningcomprsssor Comoressoroil:
SANDEN:SP-10P/N38At - P13-A01AH or3@9- P13-A01
(ForR6frigsrant:HFC-1348(R-f34a))
-
I
For th6 details of lubrication points and types of lubricantsto b€ applied, rsfsr to the lllustrated Index and various work
proc€durss(suchasAsssmbly/Reassembly,Replacement,Overhaul,Installation,etc.)containedin eachsection.
APISEFVICELABCL RecornmendodEngineOil
L q
APICERTIFICAIIOIISEAL
ffiNOTE:Th€ following information as marked*1, *2, 13,*4 and 15on abovechart detailsfor 1997model.
Il: Alwsys use GenuineHondaMaoualTransmissionFluid(MTF).Usingmotor oil can causestiffershiftingbecauseit
dogs not containthe proporadditiv€s,
*2:AlwaysuseGenuineHondaPremiumFormulaAutomaticTransmissionFluid(ATF).Usinga non-HondaATFcanaffect
shiftquality.
*3: Us6Genuin6HondaCVTfluid only. Usingotherfluid csn aftecttransmissionoperationand may reducetransmissionlif6.
r,l: Always uss GenuineHondaDOT3BrakeFluid.Usinga non-Hondabrakefluid cancausecorrosionand decressethe life
ot the system.
:5: Alwsys use Gonuine Honda Pow6r Stooring Fluid-Vor S. Using 8ny other type of pow6r stssring fluid or sutomstic
transmissionfluidcancauseincr€assw€ar8ndpoorsteoringin coldweathsr.
r ,--;--i------ t
Engineoil viscosityfor
ambrenttempe€tureranges
(
4-2
53. @ (4{oo. s.d.n) @
NOTE:Lubricateall hinges,latchesand locksoncea year.
In corrosiveareas.morefrequentlubricationis necessary.
We recommendHondaWhiteLithiumGrease.
4-3
54. I
MaintenanceSchedulefor 1996Model
NormalConditions
c + t
_ N i . j
6 X
+ r ;
E E
3 . . ;
) t a =
5 : ! {
! : a : I
e = > : *
E E* ='
x ; ; - 3
E E E E E
+ . i ( * - ;
E 6 6 E 6
i ;
F 9
9 ;
: 6
! :
5 :
BE
, 9 Q
; ;
} E
s 9l 9
E
.!
;
3
.2
E =
f ;
q a = l
l i ? : i J
=E i S d
; 9 9 | ;
; E : : E
E N ; : :
i *;eE;
F ; E : : *
: : ; e 3 E
; i f . ; ! 3
* E1 ! t $
E E , E ' 9 g g
; EI q : 8
;;,u*B?. - i E
E E
. : = b ;
Etzl ctz]
= F . . i 5
E S3 i Se
: 6 6 - 9 6 6€ 6 6 . ! 6 6
= + r+ ; N + r
3EF5FF
: ) l l l
q q r ' ? c ? :
:at ct ci ci
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g>E3i
3
l - o
; E
; : * Ft r . < q
> E c i ;
i " . 6 d c i 6
5P4 s-;€
s E E= q 3
E ;E 3 : ;; - : r - =
I aEci33
€:i€EEE
.E
,. q.r
6 E q
= N <
: 6 e
9 f a
; q c )
: ; ;
€ @ :
i r i d
3 5 5
^ . E
R E
6 o
I P
E d
* 1 5
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o * E
E,i;
: = ?
,i ,ig
. - 6 " ? |
E x . . - 9
e9fr9E
* 2 * 2 9
: 3 : 3 E
9 . :
F l
ni r-' ;
t i ;
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=
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i
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z
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4-4
t . .
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c E *
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: a I :
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r r !* : ' =
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' : 5
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; d -
6 o : I
r E t
o r : I
3 P v
- d F
( ' ) i E
9 E ,' ; E
; !
= - r P
; Y X =
- E ; +
o i 6 [
3 b : ;o o d
F o r q i D
g - o I F
E m E PE ; . : -
c b F >
n o
EE i rg :
; :
9 E E : E
' F : . !
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9 2 F 6
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6 1 2 i u
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6 ' E . Eb
g b 6 !
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o r E : : E
. h > : = o
! 3 i 6 . 9
o€ o E tr
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E g E ; i
i F i r ;
z
9 o l l
gFx
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z
i
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_x;5
6 6 - -
! q '
r E 9
t I t = ^
I E 9 ;
6 3 6 g
F i
! t a
€8f,
E i -
9 t E . 9
** Ee ; 6
! E g
1 5 6
: e 3a q :
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$ ; E
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L
56. I
MaintenanceSchedulefor 1996Model
SevereGonditions
E
az
.2
I
.9
6
g
.E
t
9
6
r €
: c '
E - . < F
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r sEgi33
t : i 5 r 6 ;
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t ( : !
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n ; : i
E 9 : E
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E t t 2 t
* * ; E ;
: .
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n 3
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? o
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o n
r -!p
.9
;
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' Z a
: =
6 9
3 t6 O
!
5 rir3
F.q"i
; * >
€ , o :
'6 r. a
(.)oo
+ ? ;
+ 5 $ 5
* s * e 3
r 2 * Z e
2 6 2 0 >
F l
6 0 ( ,
i a = h
i i ? : i J: . Y - f i |
B E . ? c i 9
: 9 9 r ;
E ! F : E
E N ; ; . :
i 6 = E ;
q 6 0 a { u ?
Ee = ( D T i
- sb z + ; ;
e g ; E Xs
H E P b s i
6 _ 9 6 6 E !
6 ! 3 - Ed E
: ; o s Q Q
3 8 9 < . <
c z t . t z
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r:'q =
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ts ii n.9
; n i : o
n 6.9p
= E 5 t
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57. *
6
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(!)
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t i t
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r F - . . r !
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q = ; : o
h - E i J - a
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F F - 0 ; Es c : = > i
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4-15
68. EngineRemovaUlnstallation
Removal
@. Mako surs iacks and 3atety stands ar6 placed properly
and hoist bracketsaro attached to ihe corroct posi-
tions on th€ engine.
. Mako surc the brehiclowill not roll olf rtands and fall
whilo you are working und.r it.
CAUTION:
. Uso tandar covors to ayoid damaging painted sur-
face.
. Unplugthe wiri||g connoctorscarefullywhilo holding
the conn6ctorpoiion to ayoid damago.
. Mrrk all wiring and hosssto lvoid misconnoction.
Abo, be sur6that thoy do not contactother wiring or
hos€sor interf?ro with othor parts,
1, Securethe hoodasoDenas possible.
2.. Disconnectthe batterynegativeterminalfirst,then
the positiveterminal.
3. Disconnectthe batterycablesfrom the under-hood
fuse/relaybox and batterypositiveterminal.
BATTERYCABLES
TERMINAL
5-2
{
4. Remove the battery and battery base.
I x 1.25mm
21N.m l2.1kgl.m, 17lbf-ftl
I (
Disconnecttheconnectorsfrom the ECM/PCM.
Disconnectthe mainwire harnessconnsctor.
MAINWIREHARNESS
CONNECTOR
{
ECM/PCM
69. }
L
7. Removethe intakeairductandair cleanerhousing.
D16Y7enqine:
a. Removethe resonatorandintakeair duct.
INTAKEAIR
DUCT
RESONATOR
Disconnectthe intakeairtemperature(lAT)sen-
sorconnector,thenremovetheaircleanerhous-
ing.
o.
AIRCLEANER
6 x 1 . 0 m m
9.8N.m11.0kgf.m,t.2lbtft)
6 x 1 . 0 m m
D16Y5,Dl5Y8 engines:
a. Disconnectthe IAT sensorconnector,then
removethe intakeair ductandair cleanerhous-
Ing.
6 x 1 . 0 m m
9.8N.m{1.0kgt.m,7.2lbt.ft)
INTAKEAIR
OUCT
IATSENSOR
CONNECTOR
8. Disconnectthe enginewire harnessconnector
the leftsideof the enginecompartment.
(cont'd)
5-3
70. EngineRemoval/lnstallation
Removal(cont'dl
9. Relievefuelpressure(seesection11),
!@ uo not smot(ewhdeworking on th€ tuol
system. Kogp open flams or spark away from tho
work arga.Drainfuelonlyinto an approvedcoDtainer.
10. Removethe evaporativeemission(EVAp)control
canisterhoseandfuelfeedhose
D16Y7engin€:
FUELFEEDHOSE
Dl6Y5.D16Y8engines:
BANJOEOLT
33N.m(3.4kg{.m,
2stbf.ftl
5-4
11. Removethe brakeboostervacuumhose,fuelreturn
hoseandvacuumhose.
D16Y7engine:
Dl6Y5,D16Y8engines:
VACUUMHOSE
71. I
12. Removethe throttlecableby looseningthe locknut,
then slip the cableend out of the acceleratorlink
age.
NOTE:
a Takecarenot to bendthe cablewhen removing
it. Always replaceany kinkedcablewith a new
one.
. Adjustthe throttlecablewheninstalling(seesec-
tion11).
D16Y7engine:
Dl6Y5,D16Y8engines:
LOCKNUT
NUT
LOCKNUT
13. Removethe grommetand wire harnessclamps,
thenpulloutthe ECM/PCMconnectors.
6 x 1 . 0 m m
14.
[ocK aoLT
8x 1.25mm
24N.m(2.4kgf.m,17lbt.ftl
MOUNTINGBOLT
8 x 1.25mm
24 N.m (2.4kgf.m,17lbf.ftl
Removethemountingboltandlockbolt,thenremove
thepowersteering(P/S)pumpbeltandpump.
NOTE:Do not disconnectthe P/Shoses.
(cont'd)
5-5
72. EngineRemoval/lnstallation
Removal(cont'dl
15. Loosenthe idler pulleycenternut and adjusting
bolt, then removethe air conditioning(A/C)com-
pressorbelt.
Remove the transmission
clamp.
HOSECLAMP
groundcableand hose1 6 .
IOLERPULLEYCENTER
NUT
10x 1.25mm
4,rN'm 14.5ksf.m.33 lbl.ftl
6 x 1 . 0 m m
GROUNDCABLE
, 5-6
17. Removethe clutchslavecylinderand line/hose
assembly(M/T).
NOTE:
. Do notdisconnectthe pipe/hoseassembly.
. Do not operatethe clutchpedaloncethe slave
cylinderhasbeenremoved.
. Takecarenotto bendthe line.
6 x f . 0 m m 8 x 1 . 2 5 f i f i
,t N.m (t.1 kg ,m, 21N.m l2.1kgr.m,
6 tbr.ft) 17lbnftl
18. Removethe shiftcable(CVT).
WASHER
LOCKNUT
29 N.m{3.0kgt m, 22lbtft)
PLASTIC
SHIFTCABLE
73. 19. Disconnectthe power
switchconnector,and
clamp.
steeringpressure(PSP)
removethe wire harness
20. Remove the radiator cap.
2 1 .
22.
E@@ use care when removing the radiator
capto avoid scaldingby hot coolant or steam.
Raisethe hoistto full height.
Removethefronttires/wheelsandsplashshield.
9.8N.m(1.0kd m,
7.2rbl.ft)
6 x 1 . 0 m m SHIELD
23. Drainthe enginecoolant(seepage 10-6),Loosen
the drainplugin the radiator.
24. Drainthetransmissionfluid.Reinstallthe drainplug
usinga newwasher(seesection13.14).
25. Drainthe engineoil. Reinstallthe drainbolt usinga
newwasher(seepage8-5).
26. Removethe shiftrodandextensionrod (M,/T).
SHIFTROO
8x 1.25mm
22N.m(2-2kgf.m,16lbf,ft)
27. RemovetheA,/Ccompressor.
NOTE:Do notdisconnecttheA,/Choses.
8 x 1.25mm
2,rN.m {2.{ kgf.m, 17lbf.ft}
(cont'd)
5-7
A/C COMPRESSOR
74. EngineRemoval/lnstallation
l
Removal(cont'd)
28. Removethe shiftcable(A,/T).
NOTE:
. Takecarenot to bendthe cablewhen removing
it. Always replaceany kinkedcablewith a new
one,
. Adjustthe shift cablewhen installing(seesec-
tion14).
I x 1.25mm
22N.m12.2kgd.m.16lbtft)
6 x 1 . 0 m m
14N.m {1.4kgf.m.10lbf.ft)
L
29. RemoveexhaustpipeA.
D16Y5,D16Y7engines:
8 x 1.25mm
22 N.m (2.2kgt m, 16lbl.ftl
Replace.
SELF-LOCKING
8 x 1.25mm
16N.m11.6kgt.m,
12tbf'ft|
Replace.
Dl6Y8 engine:
8 x'1.25mm
22 N.m12,2kgf.m,16lbtftl
GASKET
Feplace.
SELF.LOCKINGNUT
8 x'1.25mm
16N.m(1.6kg'i.m,'12lbf'ftI
Replace.
SELF.LOCKINGNUT
PIPEA 10x 1.25m.n
33N.m(3.4kgtm,
25 tbt.ftt
Replace.
{
EXHAUST
PIPEA
SELF,LOCKINGNUT
10x 1.25mm
5{ N.m {5.5kgt.m,,10lbf.tt}
Replace.
5-8
75. 30.
J t ,
Removethe damperlorks(seesection'18).
Disconnectthe suspensionlowerarm balljoints
(seesection18).
Removethe driveshafts.
CAUTION:
o Do not pull on the driveshaft,the CV ioini may
com€ apart.
. Usecarewhen prying out the assembly.
Pull il straight to avoid damagingthe difterential
oil sealor intermediatsshaft dust seal.
NOTE;Coatall orecision-finishedsurfaceswith
cleanengineoil.Tie plasticbagsoverthe driveshaft
enos.
34.
Lowerthe hoist.
Removethe upperand lowerradiatorhosesand
heaterhoses.
Removethe ATFcoolerhoses,then plugthe
coolerhosesandDipes(Ay'T).
ATF35.
RADIATORHOSE
HOSES
(cont'd)
5-9
77. 37. Removethe leftandriqhtfront mountandbracket.
FROI{T
MOUNT/BRACKET
Replace.
38. Removethe rear mount bracket.
39. Removethe uooerbracket.
40. Removethe transmissionmount bracket,then
removethetransmissionmount.
TRANSMISSIOt{
MOUNT
T
TRANSMISSION
MOUNT
BRACKET
42.
41. Checkthat the engine/transmissionis completely
free of vacuumhoses,fuel and coolanthosesand
electricalwirino.
Slowly raisethe engine approximately 150mm (6 in).
Checkonce again that all hosesand wires are discon-
nectedf rom the engine/transmission
Raisethe engineallthe way, and removeit from the
car,
UPPER
43.
5 - 1 1
78. t'
EngineRemovaUlnstallation
Installation
BracketBoltsTorqueSpecifications:
D16Y5.O16Y8enginGs(M/Tl:
I
REARSTIFFENER
8 x 1.25mm
24 N.m 12.4kgf.m, 17lbtft)
EXCEPTD16Y5,D16Y8engines {M/T):
STIFFENER
Tightentheboltsonthestiffener
inthe numberedsequenceasshown
10x 1,25mm
44 N.m{4.5kgl.m,
33tbtft)
10x 1.25mm
,14N.m {4.5kgt m,
33rbtftl
ALTERNATOF
BRACKET
10x 1.25mm
44N.m {4.5kgf.m,
33rbtft)
10x 1.25mm
54N.m (5.5kgf.m,
a0 lbf.ftl
10x 1.25mm
/t4N.m {4.5kgf.m,
33 rbtft)
(O-O). e ) 8 x 1 . 2 5 m m
24N.m(2.4kg[.m.
17rbt.ftl
{
O 10x 1.25mm
44 N.m{4.5kgf.m.
33 rbf.ft) 8 x 1.25mm
24 N.m {2.4kgf.m,
17rbf.ft)
A/C COMPRESSOR
BRACKET
D16Y5.O16Y8
engine3lM/Tl:
FRONT
STIFFENER
10x 1.25mm
44 N.m{i1.5kgf.m,
33 tbtft)
{
8 x 1.25mm
24 N.m {2.4kgf.m,
17tbf.ftl
10x 1.25mm
44N.m (4.5kg,tm.
33 rbf.ft,
E 4 6
c - t z
79. t
EngineInstallation:
Installtheenginein the reverseorderof removal.
Reinstallthe mountbolts/nutsin thefollowingsequence.
Failureto follow theseproceduresmay causeexcessive
noiseandvibration,andreducebushinglife.
1. Installthe transmissionmountand bracket,then
tightenthe boltson theframeside.
NOTE:Do not tightenthe bolts/nutson the trans-
missionside.
CW:
TNANSMISSION
MOUNTBRACKET
38 N.m 13.9kgf.m,28 lbf.ftl
ExceptCw:
TRANSMISSION
MOUNT
(412x1.25mm
?4N.m{7.5kgtm,
54tbf.ftl
(il 12x 1.25mm
74N.m17.5kg{.m,
54 rbf.ftl
12x l 25 mm
64N.m {6.5kgf.m,
17tbt.ftl
UPPER
BRACKET
2. lnstallthe upper bracket,then tighten the nuts in
the numberedsequenceshown(O - @).
(cont'd)
5 - 1 3
80. EngineRemovaUlnstallation
Installation(cont'd)
Installthe rearmountbracket,thentightenthe bolts
inthe numberedsequenceshown(O - @).
cvT:
O 12x 1.25mm
59N.m (6.0kgJm,
(} rbtfrl
Replace.
12x 1.25mm
59 N.m 16.0kgt'm,
a:l lbt ft)
Replace.
O 12x 1.25mm
59N.m 16.0kgJm,
€ tbf.fr)
Replace.
Except CVT:
O
't2x 1.25mm
59N.m 16.0kg{.m.
$ tbt.ft)
Replace.
O 1 4 x t . 5 m m
tB N.m 18.5kgf.m,
61 tbf.ftl
Replace.
5-14
I
-
4. Tightenthe bolt/nutson the transmissionmount
bracketin the numberedsequenceshown(Ot- @).
O 12x t.25mm
74N.m{7.5kg{.m,5illbtft)
Tightenthe boltson the rightfront mounvbracketin
the numberedsequenceshown(O - O).
CW:
O to x t.zsmm
54N.m15.5kgt.m,
/r0lbf.ftl
5.
12x 1.25mm
64 N.m(6.5kgt.m,
47 tbtftl
81. ExceptCVT:
Tightenthe bolts/nuton the leftfront mount in the
numberedsequenceshown(O - O)
O 12x 1.25mm
83 N.m (8.5 kgl.m, 61
44 N'm 14.5kgt.m,
33 rbf.ftl
@ 12 x 1.25 mm
59 N.m 16.0kgt.m,
43 lbf'frl
Replace.
10x L25 mm
a4N.m 14.5kgf.m,
33tbtf0
7. Performthefollowing:
Cleanthe areaswherethe driveshaft(s)and the
intermediateshaftcontactthe transmission(dif-
ferential)thoroughlywith solventor carburetor
cleaner.anddrv with compressedair.
Checkthatthe setringson the endsof the drive-
shaftandintermediateshaftclickintoDlace.
CAUTION:Usenew set rings.
Adjustthe shiftcable(seesection'14,.
Adjustthethrottlecable(seesection11).
Adjustthe cruisecontrolcable(seesection23).
Refillthe enginewith engineoil (seepage8-5).
Refillthe transmissionwith fluid (seesection13,
1 4 ) .
Refillthe radiatorwith enginecoolant(seepage
10-6).
Bleedairfrom thecoolingsystemwith the heater
valveopen(seepage10-6).
Cleanthe batterypostsand cableterminalswith
sandpaper.assemblethem,thenapplygreaseto
prevenrcorroston.
Inspectfor fuelIeakage(seesection11).
Afterassemblingthetuelline,turn on {ll)the igni-
tionswitch(donotoperatethestarter)sothatthe
fuel pump runsfor approximatelytwo seconds
and the fuel line pressurizes.Repeatthis opera-
tion two or threetimes,then checkfor fuel leak-
ageat anypointin thefuelline.
a
a
a
a
a
(cont'd)
5 - 1 5
82. EngineRemoval/lnstallation
Installation(cont'd)
Mount and EracketBolts/Nuts TorqueValueSpecifications:
A: 10x '1.25mm
64 N.m(6.5kgf.m,47lbnft)
Br10x 1.25mm
44N.m(4.5kgnm,33lbift)
C:12x 1.25mm
83N.m(8.5kgf.m,61lbl.ft)
D:12x 1.25mm
59 N.m(6.0kgt m, 43lbl.ft)
Replace.
SIDEENGINE
MOUNT
RIGHTFRONT
MOUNT
5 - 1 6
83.
84. SpecialTools
g
- J
a
6-2 .;*'
Rel. No. ToolNumber Description oty PageRetsrsnce
o
@
@
@
@
@
o
o r O - 1
a n d O - 2
@
o
OTHAH- PJTOlOB
07JAA- 001010A
07JAB- 0010204
OTLAJ. PR3O2OB
07NAB- 0010404
07NAJ- P07010A
07406- 0020201
OTMAJ- PY4O11A
OTMAJ PY4O120
07406- 0070300
07742- 0010100
ValveGuideReamer,5.5mm
Socket,17mm
HolderHandle
Air Stopper
HolderAttachment,50 mm
PressureGaugeAdapter
A/'I PressureHose
A"/TPressureHose,2.210mm
A/T PressureAdapter
A/f LowPressureGaugeW/Panel
ValveGuideDriver,5.5mm
6,43
6-8,10
6-4
6-4
6-4
6-4
6-4
6-41,42
e='T------_ts
o
@ @ @
@
@
I
85. VTECControlSystem
Troubleshooting Flowchart
tFl2Egl Il"-:1"".
toolindicatesDiasnosticTroubleCode(DTC)Pl259:A problemintheVTECPressureSwitchcircuitor
- - - -
V I t C S o l e n o r dV a l v ec r r c u i t .
Referto page 11 38 through 11'55 before troubleshooting.
* RoadTest:
Acceleratein lst gearto an enginespeedover3,000rpm
(D16Y5engine)or 6,000rpm (D16Y8engine).
Holdthatenginespeedfor at leasttwo seconds.
lf the DTCP1259is not repeatedduring the first road test,
repeatthistesttwo moretimes.
VTECPRESSURESWITCH
CONNECTOR
TERMINALSIDEOFMALE
TERMINALS
vTM
/Ta
{sr-ulelrt
fll
3-l I
I
{9)
Y
I-L
WIFESIOEOFFEMALE
TERMINALS
(cont'd)
6-3
TheMILhasbeenreportedon.
DTCP1259is stored.
Checkthe VTECControl System:
1. Do the enginecontrolmodule
(ECM)/powertraincontrolmod
ule(PCM)ResetProcedLrre(see
section11).
2. Starttheengine.
3. Warmuptheengineto normal
operalingtemperature(cool-
ingfancomeson).
4. DotheRoadTest.*
Intermittentfailure.system is OK
at this time.
Checktor poor conneqlionsor
loose wires at VTEC oressure
switch. VTECsolenoidvalve and
ECM/PCM.
ls DTC P1259indicated?
Testthe VTECPresslre Switch:
'1. TurntheignitionswitchOFF.
2. Disconnectthe VTECPressure
swrtchconnector.
3. Checkfor continuitybetween
VTECpressureswitchconnec-
torterminalNo.1 andNo.2.
ls there continuity? fleplace the VTEC pressrre switch.
T6st the VTEC Pressur€Switch
Wi16:
1. TurntheignitionswitchON(ll).
2. Measurethe voltag€between
VTECpressureswitchconnec'
tor No.1 andbodyground.
Inspect for an open oa short to
ground in the wir€ betweon tho
VTECpressureswitch and ECM/
PCMtCls).
It the wire is OK. sub3titute a
known-good ECM/PCM rnd
rech6ck.
lsthereapprox.12V?
YES
(Topage6-4)
86. VTECControlSystem
TroubleshootingFlowchart(cont'dl
(Frompage6-3) VTECPRESSURESWITCH
CONNECTOR
WIRESIDEOFFEMALE
TERMINAL
A/T LOWPRESSURE
W/PAiIEL
07406-0070300
L-
NOTE:Keepmeasuringtime as short as
possiblebecauseengineis runningwith no
load(lessthanoneminute).
A/T PRESSUREHOSE
07406- 0020201
A/T PRESSUREHOSE,
2,210nn
A/I PRESSUREHOSE
07i106- 0020201
A/T PRESSUREHOSE,
2-210mm
07MAJ- PY4O11Aand
A/T PRESSUREADAPTER
OTMAJ- PY|{}l20
PRESSUREGAUGE
ADAPTER
07NAJ- P07010A
IOW PRESSUREGAUGEWPANEL
07406-O070300
07MAJ- PYlOltA .nd
A/T PRESSUREADAPTER
OTMAJ- PYO12O
PRESSURE
GAUGEADAPTER
07NAJ- P07010A
.-,,-t
Tost the VTECPt.ssure Switch
Wire:
MeasurevoltageacrosstheVTEC
pressureswitchconnector.
Ropair open in the wire batwe'€n
VTECDr€66ureswitch and A10 or
A23ot tho ECM/FCM.
ll the wire ia OK, 3ubstilut€ a
known-good ECM/PCM .nd
rochock.
lsthereapprox.12V?
Testthe VTECSolonoidValve:
1. TurntheignitionswitchOFF.
2. Removethe VTECpressure
switchand installthe special
tool as shown,then reinstall
theVTECpressureswitch.
3. Connecta tachometer(seesec-
tion11).
4. Starttheengine.
5- Warm up engineto normal
operatingtemperature(cooling
fancomeson).
6. Checkoii pressureat the fol-
lowingenginespeeds:D16Y5
engine:1000and 3000rpm,
Dl6Y8engine:1000,3000and
5000rpm.
ls pressurebelow 49kPa
{0.5kgflcm' ,7psi)? Insoectihe VTECsolenoidvalv6.
Testthe VTECSolenoidValvel
1. TurntheignitionswitchOFF.
2. DisconnecttheVTECsolenoid
valveconnector.
3. Attachthe bafterypositiveter
minalto the GFNIYELtermi'
nal.
4. Starttheengineandcheckthe
oil pressureat the following
enginespeed:D16Y5engine
3000rpm,D16YBengine5000
rpm.
lsthe pressureabove:D16Y5
engine:250kPa(2.5kgvcm?,
36psi),D16Y8enginer390kPa
(4.0kgf/cm' ,57psi)?
In3oocttha VTECsolonoidvalve.
(Topage6 5)
6-4
87. lFrompage6-4)
T6t lhe VTECPr6.sureSwitch:
1. Turnthe ignitionswitchOFF.
2. Reconnectthe VTECpressure
swrtchconnector,
3. Stafttheengine.
4. With the batterypositiveter-
minalconnectedto the VTEC
solenoidvalve,measurevolt-
age betweenC15and A'10or
A.23
lsthsre approx.'12V above
5,000rpm? R€plac€the VTECpressureswitch.
Testth. VTECSolenoidValve:
1. TurntheignitionswitchOFF.
2. Disconnectthe batterypositive
terminalfrom the VTECsole-
noidvalve,
3. Checkfor continuitybetween
the VTECsol€noidvalvecon-
neclorterminalNo.1andbody
grouno.
lsthere14- 30O? ReDlacethe VTECsolonoidvalve.
Tosi tho VTECSolenoid Valv€
Wi.e:
Checkfor continuitybetweenthe
VTECsolenoidvalve connector
terminalNo. I andA8.
R€pair open in the wiro botweon
the ECM/PCM{48} and VTECaote-
noidvalvoconnoclor.
lstherecontinuhy?
Tost tho VTECSolenoid Valvo
Whe:
Checkfor continuitybetweenthe
VTECsolenoidvalveconnectorter-
min6lNo.1andbodyground.
RoDair3hort in the wire betwoon
rho€cM/PcM (A8landVIECsot€-
noid valv6connoctor,
lstherecontinuity?
Sub3tituto a known-good ECM/
PCMand roch6ck.lf symptom/
indic.tion goo3 away, .oplace
th. originelECM/PCM.
ECMCONNECTORS
A (32P1 c (3rP)
VTECSOLENOID
VALVE
CONNECTOR
ECMCONNECTOR
A (32P1
ws
{GRN/YELI
6-5
WIRESIDEOFFEMALE
TERMINALS
VTECSOLENOIDVALVE
CONNECTON
tT------ I
l[-]f-rI
I
I-L
TERMINALSIDEOFMALE
TERMINAL
WIRESIOEOFFEMALE
TERMINALS
VTECSOLENOIDVALVE
CONNECTOR
r=
I t--lI
I
r5'Y
I
WIRESIDEOFFEMALE
TERMINAL
88. VTECSolenoidValve
2. Measureresistancebetweenthe terminaland body
grouno.
Resistance:14- 30 O
lf the resistanceis within specifications,removethe
VTECsolenoidvalveassemblyfrom the cylinder
head.and checkthe VTECsolenoidvalvefilter for
cloggrng.
. lf thereis clogging,replacethe engineoil filter
andtheengineoil.
VTECSOLENOIDVALVEASSEMBLY
Inspection
'1. Disconnectthe
'lP
connectorfrom the VTECsole-
noidvalve.
VTECSOLENOID
VALVEFILTER
Replace.
6 x 1 . 0 m m
12N.m{1.2ksf.m,8.7lbf.tr}
o-o
4. If the filter is not clogged,pushthe VTECsolenoid
valvewith yourfingerandcheckits movement.
. lf the VTECsolenoidvalve is normal,checkthe
engineoil pressure.
6 x 1 . 0 m m
12N.m(1.2kgtm,8.7lbtftl
{
89. VTECRockerArms
ManualInspection(D16Y5engine)
2.
1 . Setthe No. 1 pistonat TDC.
Removethecylinderheadcover.
NOTE:Referto page6-46when installingthe cylin-
der headcover.
lvlovethe intakesecondaryrockerarm on the No. 1
cylindermanually.
Checkthat the intakesecondaryrockerarm moves
independentlyof the primaryintakerockerarm.
SECONDARY PBIMARYROCKERARM
ROCKERARM
. Pushandpull.
Checkthe intakesecondaryrockerarm of each
cylinderatTDC.
. lf the intakesecondaryrockerarm doesnotmove,
removethe primaryand secondaryintakerocker
armsasanassemblyandcheckthatthe pistonsin
the secondaryand primaryrockerarms move
smoothly.
. lf anyrockerarm needsreplacing.replacethe pri-
maryandsecondaryrockerarmsasan assembly.
PBIMARYROCKERARM
2.
3.
ManualInspection(D16Y8engine)
'1.
Setthe No. I pistonat TDC.
Removethecylinderheadcover.
NOTE:Referto page6-46when installingthe cylin-
der headcover.
Pushthe intakemid rockerarm on the No, I cylin-
dermanually.
Checkthatthe intakemid rockerarm movesindepen-
dentlyof the primaryand secondaryintakerocker
arms.
MID ROCKER
ARM
SECONOARY
ROCKERARM
Checkthe intakemid rockerarm of eachcylinderat
TDC.
. lf the intakemid rockerarm does not move,
removethe mid, primaryand secondaryintake
rockerarmsasanassemblyandcheckthatthepis-
tons in the mid and primaryrockerarms move
smoothly.
. lf any rockerarm needsreplacing,replacethe
primary,mid, and secondaryrockerarms as an
assemoly.
6-7
