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SERVICE

MANUAL
CIVIC
CIVIC COUPE
MAINTENANCE, REPAIR &
CONSTRUCTION 01

How to Use This Manual

How to Use This Manual

This supplement contains information for the 2001 HONDA CIVIC


COUPE. Refer to following shop manual for service procedures
and data on this CD.
HONDA CIVIC MAINTENANCE, REPAIR
and CONSTRUCTION 2001

General Info
Specifications
Maintenance
Engine Electrical
Engine
Cooling
Fuel and Emissions

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

*Transaxle
* Body
* Body Electrical
*Restraints

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.
As you read this manual, you will find information that is
symbol. The purpose of this
preceded by a
message is to help prevent damage to your vehicle, other
property, or the environment.
First Edition 9/2000 341 pages
All Rights Reserved
HONDA MOTOR CO., LTD.
Service Publication Office
As sections with *include SRS components;
special precautions are required when servicing.

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A Few Words about Safety

A Few Words about Safety

IMPORTANT SAFETY PRECAUTIONS

Service Information

The service and repair information contained in this manual is


intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training, tools
and equipment could cause injury to you or others. It could
also damage the vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for
performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated
equipment. Any person who intends to use a replacement part,
service procedure or a tool that is not recommended by Honda,
must determine the risks to their personal safety and the safe
operation of the vehicle.
If you need to replace a part, use genuine Honda parts with
the correct part number or an equivalent part. We strongly
recommend that you do not use replacement parts of inferior
quality.
FOR YOUR CUSTOMER'S SAFETY
Proper service and maintenance are essential to the
customer's safety and the reliability of the vehicle. Any error or
oversight while servicing a vehicle can result in faulty
operation, damage to the vehicle, or injury to others.

WARNING

Improper service or repairs can create an unsafe


condition that can cause your customer or others
to be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
FOR YOUR SAFETY
Because this manual is intended for the professional service
technician, we do not provide warnings about many basic shop
safety practices (e.g., Hot parts - wear gloves). If you have not
received shop safety training or do not feel confident about
your knowledge of safe servicing practices, we recommend that
you do not attempt to perform the procedures described in this
manual.

WARNING

Failure to properly follow instructions and


precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.

Make sure you have a clear understanding of all


basic shop safety practices and that you are wearing
appropriate clothing and using safety equipment.
When performing any service task, be especially
careful of the following:
Read all of the instructions before you begin and
make sure you have the tools, the replacement or
repair parts and the skills required to perform the
tasks safely and completely.
Protect your eyes by using proper safety glasses,
goggles or face shields any time you hammer, drill,
grind or work around pressurised air or liquids and
springs or other stored-energy components. If there
is any doubt, put on eye protection.
Use other protective wear when necessary, for
example gloves or safety shoes. Handling hot or
sharp parts can cause severe burns or cuts. Before
you grab something that looks like it can hurt you,
stop and put on gloves.
Protect yourself and others whenever you have the
vehicle up in the air. Any time you lift the vehicle,
either with a hoist or a jack, make sure that it is
always securely supported. Use jack stands.
Make sure the engine is off before you begin any
servicing procedures, unless the instruction tells you
to do otherwise. This will help eliminate several
potential hazards:
Carbon monoxide poisoning from engine exhaust.
Be sure there is adequate ventilation whenever you
run the engine.
Burns from hot parts or coolant. Let the engine and
exhaust system cool before working in those areas.
Injury from moving parts. If the instruction tells you
to run the engine, be sure your hands, fingers and
clothing are out of the way.
Gasoline vapours and hydrogen gases from batteries
are explosive. To reduce the possibility of a fire or
explosion, be careful when working around gasoline
or batteries.
Use only a non-flammable solvent, not gasoline to
clean parts.
Never drain or store gasoline in an open container.
Keep all cigarettes, sparks and flames away from
the battery and all fuel-related parts.

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.

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Introduction - Introduction

Introduction

Supplemental Restraint System (SRS)

This model has an SRS which 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, seat belt buckle tenioners in the front seat belt
buckles and side airbags in the front seat-backs. Information necessary to safely service the SRS is included in the '01 Civic Shop
Manual, P/N 62S5A00. 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.
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 and/or side airbags.
Do not bump the SRS unit. Otherwise, the system may fail in a collision, or airbags may deploy when the ignition switch
is ON (II).
SRS electrical wiring harnesses are identified by yellow colour coding. Related components are located in the steering
column, front console, dashboard, dashboard lower panel, in the dashboard above the glove box, in the front seats and
around the floor. Do not use electrical test equipment on these circuits

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Introduction - Introduction

Introduction

Outline of Model Change


ITEM

General

DESCRIPTION

Coupe model added


D17A8, D17A9 engines added

2001 MODEL

REFERENCE
SECTION

Engine Electrical

D17A8, D17A9 engine added

Engine

D17A8, D17A9 engines added

Fuel and Emissions

Coupe model added

11

Automatic Transmission

Shift schedule added

14

Body

Coupe model added

20

Body Electrical

Coupe model added

22

Restraints

Coupe model added

23

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General Information - General Information

General Information

Chassis and Engine Numbers

1-2

Identification Number Locations

1-4

Abbreviations

1-5

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General Information - General Information

General Information

1-2

Chassis and Engine Numbers

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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
AREA CODE NAME
TYPE
CIVIC
COUPE

KB
KE

ENGINE
NUMBER

TRANSMISSION
NUMBER

LS

4AT

1HGEM22301L600001-

D17A8-1400001-

BMXA-5000001-

ES

4AT

1HGEM22901L600001-

D17A9-1400001-

BMXA-5000001-

SE
SE
Exective

KG

VEHICLE
IDENTIFICATION
NUMBER

LS
ES

5MT

1HGEM21301L600001-

D17A8-1400001-

SLW-1000001-

4AT

1HGEM22301L600001-

D17A8-1400001-

BMXA-5000001-

5MT

1HGEM21801L600001-

D17A9-140000-

SLW-1000001-

4AT

1HGEM22801L600001-

D17A9-1400001-

BMXA-5000001-

5MT

1HGEM21501L600001-

D17A8-1400001-

SLW-1000001-

4AT

1HGEM22501L600001-

D17A8-1400001-

BMXA-5000001-

5MT

1HGEM21901L600001-

D17A9-1400001-

SLW-1000001-

4AT

1HGEM22901L600001-

D17A9-1400001-

BMXA-5000001-

LS

5MT

1HGEM21301L600001-

D17A8-1400001-

SLW-1000001-

4AT

1HGEM22301L600001-

D17A8-1400001-

BMXA-5000001-

ES

5MT

1HGEM21901L600001-

D17A9-1400001-

SLW-1000001-

4AT

1HGEM22901L600001-

D17A9-1400001-

BMXA-5000001-

KK

EX

5MT

1HGEM21901L500001-

D17A2-1400001-

SLW-1000001-

4AT

1HGEM22901L500001-

D17A2-1400001-

BMXA-5000001-

KX

EX

5MT

1HGEM21901L900001-

D17A4-1400001-

SLW-1000001-

4AT

1HGEM22901L900001-

D17A4-1400001-

BMXA-5000001-

KR

KY

VTi

5MT

1HGEM219*1L700001-

D17A5-1400001-

SLW-1000001-

4AT

1HGEM229*1L700001-

D17A5-1400001-

BMXA-5000001-

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General Information - General Information

General Information

1-4

Identification Number Locations


1. Built Data and Vehicle Type
Except KK, KX, KY models
2. Vehicle Identification Number (VIN)
3. Engine Number
4. Certification Plate
(KK, KX models)
5. Certification Plate
(KY model)
6. Transmission Number
(Manual)
7. Transmission Number
(Automatic)

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General Information - General Information

1-5

General Information
Abbreviations

List of automotive abbreviations, which may be used in shop


manual.
ABS

Anti-lock Brake System

A/C

Air Conditioning, Air Conditioner

ACL

Air Cleaner

A/F

Air Fuel Ratio

ALR

Automatic Locking Retractor

ALT

Alternator

AMP

Ampere(s)

ANT

Antenna

API

American Petroleum Institute

APPROX.

Approximately

ASSY

Assembly

A/T

Automatic Transmission

ATDC

After Top Dead Centre

ATF

Automatic Transmission Fluid

ATT

Attachment

ATTS

Active Torque Transfer System

AUTO

Automatic

AUX

Auxiliary

BARO

Barometric

BAT

Battery

BDC

Bottom Dead Centre

BTDC

Before Top Dead Centre

CARB

Carburettor

CAT

Catalytic Converter

or CATA
CHG

Charge

CKF

Crankshaft Speed Fluctuation

CKP

Crankshaft Position

CO

Carbon Monoxide

COMP

Complete

CPB

Clutch Pressure Back up

CPC

Clutch Pressure Control

CPU

Central Processing Unit

CVT

Continuously Variable Transmission

CYL

Cylinder

CYP

Cylinder Position

DI

Distributor Ignition

DIFF

Differential

DLC

Data Link Connector

EPR

Evaporator Pressure Regulator

EPS

Electrical Power Steering

EVAP

Evaporative

EX

Exhaust

Front

FIA

Fuel Injection Air

FL

Front Left

FP

Fuel Pump

FR

Front Right

FSR

Fail Safe Relay

FWD

Front Wheel Drive

GAL

Gallon

GND

Ground

GPS

Global Positioning System

H/B

Hatchback

HC

Hydrocarbons

HID

High Intensity Discharge

HO2S

Heated Oxygen Sensor

IAB

Intake Air Bypass

IAC

Idle Air Control

IACV

Idle Air Control Valve

IAR

Intake Air Resonator

IAT

Intake Air Temperature

ICM

Ignition Control Module

ID

Identification

ID or I.D.

Inside Diameter

IG or IGN

Ignition

IMA

Idle Mixture Adjustment


Integrated Motor Assist

IMMOBI.

Immobiliser (Immobiliser)

IN

Intake

INJ

Injection

INT

Intermittent

KS

Knock Sensor

Left

L/C

Lock-up Clutch

LCD

Liquid Crystal Display

LED

Light Emitting Diode

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General Information - General Information

DOHC

Double Overhead Camshaft

DPI

Dual Point Injection

DTC

Diagnostic Trouble Code

EBD

Electronic Brake Distribution

ECM

Engine Control Module

ECT

Engine Coolant Temperature

EGR

Exhaust Gas Recirculation

ELD

Electrical Load Detector

LEV

Low Emission Vehicle

LF

Left Front

LH

Left Handle

LHD

Left Handle Drive

LR

Left Rear

LSD

Limited Slip Differential

L-4

In-line Four Cylinder (engine)

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General Information - General Information

1-6

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

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

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

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 & Valve Lift


Electronic Control

VVIS

Variable Volume Intake System

Proportioning Control Valve


PDU

Power Drive Unit

PGM-FI

Programmed-fuel Injection

PGM-IG

Programmed Ignition

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

Pressure Switch

5MT

5-speed Manual Transmission

6MT

6-speed Manual Transmission

PSW
Qty

Quantity

Park
Reverse

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

RON

Research Octane Number

Second

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General Information - General Information

RR

Rear Right

SAE

Society of Automotive Engineers

SCS

Service Check Signal

SEC

Second
Secondary

SOHC

Single Overhead Camshaft

SOL

Solenoid

Low
O/D

Over Drive

1ST

Low (gear)

2ND

Second (gear)

3RD

Third (gear)

4TH

Fourth (gear)

5TH

Fifth (gear)

6TH

Sixth (gear)

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Specifications - Specifications

Specifications
Standards and Service Limits
Engine Electrical

2-2

Engine Assembly

2-2

Cylinder Head

2-3

Engine Block

2-5

Engine Lubrication

2-5

Cooling

2-5

Fuel and Emissions

2-6

Clutch

2-6

Manual Transmission and Differential

2-7

Automatic Transmission and A/T Differential

2-9

Steering

2-15

Suspension

2-15

Brakes

2-16

Air Conditioning

2-16

Design Specifications
Dimensions

2-17

Weight

2-17

Engine

2-18

Starter

2-19

Clutch

2-19

Automatic Transmission

2-19

Steering

2-19

Suspension

2-19

Wheel Alignment

2-20

Brakes

2-20

Tyres

2-20

Air Conditioning

2-20

Electrical Ratings

2-21

Body Specifications
Illustration

2-22

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Specifications - Standards and Service Limits

2-2

Standards and Service Limits


Engine Electrical

Item

Measurement

Ignition coil

Rated voltage

12 V

Firing order

1-3-4-2

Type

D17A2, D17A8, D17A9 engines

Spark plug

Qualification

Standard or New

Service Limit

NGK:

ZFR6J-11,
ZFR7J-11

D17A5 engines

DENSO:

KJ22CR-L11

NGK:

BKR6E-N-11
BKR7E-N-11

DENSO:

K20PR-L11
K22PR-L11

Gap
Ignition timing

1.0-1.1 mm (0.039-0.043 in.)


At idle (check the red
mark)

M/T (in neutral): 8+2 BTDC at 700+50 rpm (min-1)


A/T (in

or

): 8+2 BTDC at 700+50 rpm (min-1)

Alternator belt
NOTE: Adjust a
new belt to the
new belt spec.,
run the engine for
5 minutes, then
readjust it to the
used belt spec.

Deflection with 98 N (10 kgf, 22 Without A/C (with A/C,


lbs) applied midway between
see "Compressor belt" in
pulleys
the A/C table)

Used belt: 8.5-11.0 mm (0.33-0.43 in.)

Tension (measured with belt


tension gauge)

Without A/C (with A/C,


see "Compressor belt" in
the A/C table)

Used belt: 340-490 N (35-55 kgf, 77-110 lbs)

Alternator

Output

At 13.5 V and normal


engine temperature

70 A

Coil (rotor) resistance

at 68F (20C)

1.84-2.10 ohms

Slip ring O.D.

Starter

Compression

New belt: 6.5-8.5 mm (0.26-0.33 in.)

New belt: 540-740 N (55-75 kgf, 120-170 lbs)

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)

Output

1.0 kW

Commutator mica depth

0.45-0.75 mm (0.018-0.030 in.)

Commutator runout

0.02 mm (0.001 in.) max.

0.05 mm (0.002 in)

Commutator O.D.

27.9-28.0 mm (1.098-1.102 in.)

27.0 mm (1.063 in.)

Brush length

14.0-14.5 mm (0.55-0.57 in.)

9.0 mm (0.35 in)

Brush spring tension

14.0-20.0 N (1.4 -2.0 kgf, 4.00-5.30 lbf)

Pressure check at 250 rpm


(min-1) with wide open throttle.
(See Design Specs for ratio.)

0.2 mm (0.008 in)

Minimum

930 kPa (9.5 kgf/cm2, 135 psi)

Maximum variation

200 kPa (2.0 kgf/cm2, 28 psi)

Qualification

Standard or New

Service Limit

930 kPa (9.5 kgf/cm2, 135 psi)

200 kPa (2.0 kgf/cm2, 28 psi)

Engine Assembly
Item

Measurement

Compression

Pressure check at 250 rpm (min- Minimum


1) with wide open throttle. (see
Maximum variation
Design Specs for ratio.)

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Specifications - Standards and Service Limits

Standards and Service Limits

2-3

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.)

End play

0.05-0.15 mm
(0.002-0.006 in.)

0.5 mm (0.02 in.)

Camshaft-to-holder oil
clearance

0.050-0.089 mm
(0.0020-0.0035 in.)

0.15 mm (0.006 in.)

Total runout

0.03 mm (0.001 in.) max.

0.04 mm (0.002 in.)

Cam lobe height D17A2,


D17A5, D17A9 engines

VTEC intake, Primary

38.604 mm (1.5198 in.)

VTEC intake, secondary

32.848 mm (1.2932 in.)

VTEC exhaust

38.299 mm (1.3897 in.)

35.299 mm (1.3897 in.)

Exhaust

37-281 mm (1.4678 in.)

Intake

0.18-0.22 mm (0.007-0.009 in.)

Exhaust

0.23-0.27 mm (0.009-0.01 in.)

Intake

5.48-5.49 mm
(0.2157-0.2161 in.)

5.45 mm (0.215 in.)

Exhaust

5-45-5.46 mm
(0.2146-0.2150 in.)

5.42 mm (0.213 in.)

Intake

0.02-0.05 mm
(0.0008-0.0020 in.)

0.08 mm (0.003 in.)

Exhaust

0.05-0.08 mm
(0.0020-0.0031 in.)

0.11 mm (0.004 in.)

Intake

0.85-1.15 mm
(0.033-0.045 in.)

1.60 mm (0.063 in.)

Exhaust

1.25-1.55 mm
(0.049-0.061 in.)

2.00 mm (0.079 in.)

Intake

53.17-53.64 mm
(2.093-2.112 in.)

53.89 mm (2.122 in.)

Exhaust

53-17-53.64 mm
(2.093-2.112 in.)

53.89 mm (2.112 in.)

Free length D17A2, D17A5,


D17A9 engines

VTEC intake

56-49 mm (2.224 in.)

VTEC exhaust

58-70 mm (2.31 in.)

Free length D17A8 engine

Intake

58.70 mm (2.311 in.)

Exhaust

58.70 mm (2.311 in.)

Intake

5.51-5.53 mm
(0.217-0.218 in.)

5.55 mm (0.219 in.)

Exhaust

5-51-5.53 mm
(0.217-0.218 in.)

5.55 mm (0.219 in.)

Intake

17.85-18.35 mm
(0.703-0.722 in.)

Exhaust

18-65-19.15 mm
(0.734-0.754 in.)

Intake

0.014-0.050 mm
(0.0007-0.0020 in.)

0.08 mm (0.003 in.)

Camshaft

Cam lobe height D17A8 engine Intake

Valves

Clearance (cold)

Stem O.D

Stem-to-guide clearance

Valve seats

Width

Stem installed height

Valve springs

Valve guides

I.D.

Installed height

Rocker arm

Arm-to-shaft clearance

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Specifications - Standards and Service Limits


Exhaust

0.018-0.054 mm
(0.0007-0.0021 in.)

0.08 mm (0.003 in.)

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Specifications - Standards and Service Limits

Standards and Service Limits

2-4

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
(2.9528-2.9535 in.)

75.07 mm (2.9555 in.)

Bore taper

0.05 mm (0.002 in.)

Reboring limit

0.5 mm (0.02 in.)

Skirt O.D. at 13 mm (0.5 in.)


from bottom of skirt

74.98-74.99 mm
(2.9520-2.9524 in.)

74.97 mm (2.9516 in.)

Clearance in cylinder

0.010-0.040 mm (0.0004-0.0016 in.)

0.05 mm (0.002 in.)

Ring groove width for D17A5


engines

Top

1.020-1.030 mm (0.0402-0.0406 in.)

1.05 mm (0.041 in.)

Second

1.220-1.230 mm (0.0481-0.0484 in.)

1.25 mm (0.049 in.)

Oil

2.805-2.820 mm (0.1104-0.1110 in.)

2.85 mm (0.112 in.)

1.020-1.030 mm (0.0402-0.0406 in.)

1.05 mm (0.041 in.)

1.220-1.230 mm (0.0481-0.0484 in.)

1.25 mm (0.049 in.)

Piston

Ring groove width for except


Top
D17A2, D17A8, D17A9 engines
Second

Piston rings

Oil

2.005-2.020 mm (0.0789-0.0795 in.)

2.05 mm (0.08 in.)

Ring-to-groove clearance for


except D17A8, D17A9 engines

Top

0.035-0.055 mm (0.0014-0.0022 in.)

0.13 mm (0.005 in.)

Second

0.030-0.055 mm (0.0012-0.0022 in.)

0.13 mm (0.005 in.)

Ring-to-groove clearance for


D17A5, engines

Top

0.035-0.060 mm (0.0014-0.0024 in.)

0.13 mm (0.005 in.)

Second

0.030-0.055 mm (0.0012-0.0022 in.)

0.13 mm (0.005 in.)

0.15-0.30 mm (0.006-0.012 in.)

0.60 mm (0.024 in.)

0.30-0.45 mm (0.012-0.018 in.)

0.60 mm (0.024 in.)

Oil

0.20-0.80 mm (0.008-0.031 in.)

0.90 mm (0.035 in.)

Top

0.15-0.30 mm (0.006-0.012 in.)

0.60 mm (0.024 in.)

Second

0.30-0.45 mm (0.012-0.018 in.)

0.60 mm (0.024 in.)

Oil

0.20-0.80 mm (0.008-0.031 in.)

0.90 mm (0.035 in.)

0.15-0.30 mm (0.006-0.012 in.)

0.60 mm (0.024 in.)

Second

0.30-0.45 mm (0.012-0.018 in.)

0.60 mm (0.024 in.)

Oil

0.20-0.70 mm (0.008-0.028 in.)

0.80 mm (0.031 in.)

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.)

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


(Nominal)

D17A2, D17A5, D17A8,


D17A9 engines

48.0 mm (1.89 in.)

0.15-0.30 mm (0.006-0.012 in.)

0.40 mm (0.016 in.)

Ring end gap for except


Top
D17A2, D17A8, D17A9 engines
Second

Ring end gap for D15Y3,


D17A5 engine

Ring end gap for D17A5 engine Top

Piston pin

Connecting rod

End play installed on crankshaft

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Specifications - Standards and Service Limits

Standards and Service Limits

2-5

Engine Block (cont'd)

Item

Measurement

Qualification

Standard or New

Service Limit

Crankshaft

Main journal diameter

D17A2, D17A5, D17A8,


D17A9 engines

54.976-55.000 mm (2.1644-2.1654 in.)

Rod journal diameter

D17A2, D17A5, D17A8,


D17A9 engines

44.976-45.000 mm (1.7707-1.7717 in.)

Rod/main journal taper

0.0025 mm (0.0001 in.)

0.005 mm (0.0002 in.)

Rod/main journal out-of-round

0.0025 mm (0.0001 in.)

0.005 mm (0.0002 in.)

End play

0.10-0.35 mm (0.004-0.014 in.)

0.45 mm (0.018 in.)

Runout

0.03 mm (0.001 in.) max.

0.04 mm (0.002 in.)

Main bearing-to-journal oil


clearance for D117A2, D17A5,
D17A8, D17A9 engines

No. 1 journal

0.018-0.036 mm (0.0007-0.0014 in.)

0.05 mm (0.002 in.)

0.024-0.042 mm (0.0009-0.0017 in.)

0.05 mm (0.002 in.)

0.024-0.042 mm (0.0009-0.0017 in.)

0.05 mm (0.002 in.)

Crankshaft
bearings

No. 5 journal
No. 2 journal
No. 3 journal
No. 4 journal

Rod bearing clearance

Engine Lubrication
Item

Measurement

Qualification

Standard or New

Engine oil

Capacity

D17A2, D17A5, D17A9


engines

4.2 l (4.4 US qt, 3.7 Imp qt) for engine overhaul

Service Limit

3.5 l (3.7 US qt, 3.1 Imp qt) for oil change, including filter
3.3 l (3.5 US qt, 2.9 Imp qt) for oil change, without filter

D17A8 engine

4.2 l (4.4 US qt, 3.7 Imp qt) for engine overhaul


3.2 l (3.4 US qt, 2.8 Imp qt) for oil change, including 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 in.)

0.20 mm (0.008 in.)

Pump housing-to-outer rotor


clearance

0.10-0.18 mm (0.004-0.007 in.)

0.20 mm (0.008 in.)

Pump housing-to-rotor axial


clearance

0.02-0.07 mm (0.001-0.003 in.)

0.15 mm (0.006 in.)

Oil pressure with oil temperature At idle


at 80C (176F)
at 3,000 rpm (min-1)

70 kPa (0.7kgf/cm2, 10 psi) min.

Item

Measurement

Qualification

Standard or New

Radiator

Coolant capacity (Includes


engine, heater, hoses and
reservoir)

M/T: engine overhaul

5.1 l (5.4 US qt, 4.5 lmp qt)

M/T: coolant change

4.0 l (4.2 US qt, 3.5 lmp qt)

A/T: engine overhaul

5.0 l (5.3 US qt, 4.4 lmp qt)

A/T: coolant change

3.9 l (4.1 US qt, 3.4 lmp qt)

340 kPa (3.5 kgf/cm2, 50 psi) min.

Cooling
Service Limit

Reservoir

Coolant capacity

0.4 l (0.4 US qt, 0.4 lmp qt)

Radiator cap

Opening pressure

93-123 kPa (0.95-1.25 kgf/cm2 , 14-18 psi)

Thermostat

Opening temperature

Begins to open

76-80C (169-176F)

Fully open

90C (194F)

8.0 mm (0.31 in.) min.

Valve lift at fully open


Radiator fan
switch

Thermoswitch "ON" temperature

91-95C (196-203F)

Thermoswitch "OFF" temperature

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

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Specifications - Standards and Service Limits

Standards and Service Limits

2-6

Fuel and Emissions

Item

Measurement

Qualification

Standard or New

Fuel pressure
regulator

Pressure with fuel pressure


gauge connected

270-320 kPa (2.8-3.3 kgf/cm2, 40-47 psi)

Fuel tank

Capacity

45 l (11.9 US gal, 9.9 Imp gal)

Engine idle

Idle speed with headlights and


radiator fan off

M/T in neutral

700+50 rpm

Fast idle

A/T in N.gif or P.gif

700+50 rpm

M/T in neutral

1,250+50 rpm

A/T in
Idle CO%

or

Service Limit

1,250+50 rpm

Except D17A5 engine

0.1 max.

D17A5 engine

1.0 max.

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 the floor

113 mm (4.4 in.) min.

Flywheel

Runout on clutch mating surface

0.06 mm (0.002 in.) max.

0.15 mm (0.006 in.)

Clutch disc

Rivet head depth

1.65-2.25 mm
(0.065-0.089 in.)

0.8 mm (0.03 in.)

Thickness

8.3-9.0 mm (0.33-0.35 in.)

5.7 mm (0.22 in.)

Warpage

0.03 mm (0.001 in.) max.

0.15 mm (0.006 in.)

Height of diaphragm spring


fingers

Measure with feeler gauge 0.6 mm (0.02 in.) max.


and special tool

Pressure plate

1.0 mm (0.04 in.)

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Specifications - Standards and Service Limits

Standards and Service Limits

2-7

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

Mainshaft 3rd and


4th gears

End play

0.11-0.18 mm
(0.004-0.007 in.)

Adjust

Diameter of ball bearing contact


area (clutch housing side)

25.977-25.990 mm
(1.0227-1.0232 in.)

25.92 mm
(1.021 in.)

Diameter of spacer collar


contact area

28.980-28.993 mm
(1.1409-1.1415 in.)

28.930 mm
(1.1390 in.)

Diameter of needle bearing


contact area

34.984-35.000 mm
(1.3773-1.3780 in.)

34.93 mm
(1.375 in.)

Diameter of ball bearing contact


area (transmission housing
side)

25.987-26.000 mm
(1.0231-1.0236 in.)

25.93 mm
(1.020 in.)

Run out

0.02 mm (0.001 in.) max.

0.05 mm (0.002 in.)

I.D.

39.009-39.025 mm
(1.5358-1.5364 in.)

39.070 mm
(1.5382 in.)

End play

3rd gear

0.06-0.21 mm
(0.002-0.008 in.)

0.33 mm
(0.013 in.)

4th gear

0.06-0.19 mm
(0.002-0.007 in.)

0.31 mm
(0.012 in.)

3rd gear

27.92-27.97 mm
(1.099-1.101 in.)

27.85 mm
(1.096 in.)

4th gear

27.02-27.07 mm
(1.064-1.066 in.)

26.95 mm
(1.061 in.)

39.009-39.025 mm
(1.5358-1.5364 in.)

39.070 mm
(1.5382 in.)

End play

0.06-0.19 mm
(0.002-0.007 in.)

0.31 mm
(0.012 in.)

Thickness

28.92-28.97 mm
(1.139-1.141 in.)

28.85 mm
(1.136 in.)

Diameter of needle bearing


contact area (clutch housing
side)

34.000-34.015 mm
(1.3386-1.3392 in.)

33.95 mm
(1.3366 in.)

Diameter of ball bearing contact


area (transmission housing
side)

24.980-24.993 mm
(0.9835-0.9840 in.)

24.93 mm
(0.981 in.)

Diameter of 1st gear contact


area

37.984-38.000 mm
(1.4954-1.4961 in.)

37.934 mm
(1.493 in.)

Run out

0.02 mm
(0.001 in.) max.

0.05 mm
(0.002 in.)

I.D.

43.009-43.025 mm
(1.6932-1.6939 in.)

43.070 mm
(1.6957 in.)

Endplay

0.03-0.10 mm
(0.001-0.039 in.)

0.22 mm
(0.009 in.)

Thickness

26.91-26.94 mm (1.059-1.061 in.)

26.86 mm (1.057 in.)

I.D.

45.009-45.025 mm
(1.7720-1.7726 in.)

45.070 mm
(1.7744 in.)

Thickness

Mainshaft 5th gear I.D.

Countershaft

Countershaft 1st
gear

Countershaft 2nd
gear

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Specifications - Standards and Service Limits

Countershaft 2nd
gear spacer collar

End play

0.04-0.12 mm (0.002-0.005 in.)

0.24 mm
(0.009 in.)

Thickness

27.41-27.46 mm (1.079-1.081 in.)

27.36 mm (1.077 in.)

I.D.

34.000-34.010 mm
(1.3386-1.3390 in.)

34.040 mm
(1.3402 in.)

O.D.

39.989-40.000 mm
(1.5744-1.5748 in.)

39.930 mm
(1.5720 in.)

Length

27.53-27.56 mm
(1.084-1.085 in.)

27.51 mm
(1.083 in.)

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Specifications - Standards and Service Limits

Standards and Service Limits

2-8

Manual Transmission and Differential (cont'd)

Item

Measurement

Qualification

Standard or New

Service Limit

Mainshaft 4th
and 5th gears
spacer collar

I.D.

29.002-29.012 mm
(1.1418-1.1422 in.)

29.060 mm
(1.1441 in.)

O.D.

34.989-35.000 mm
(1.3775-1.3780 in.)

34.930 mm
(1.3752 in.)

Length

51.97-52.03 mm
(2.046-2.048 in.)

24.03-24.06 mm
(0.946-0.947 in.)

I.D.

15.016-15.043 mm
(0.5912-0.5922 in.)

15.080 mm
(0.5937 in.)

Gear-to-reverse gear shaft clearance

0.032-0.077 mm
(0.0012-0.0030 in.)

0.140 mm
(0.0055 in.)

Synchro ring

Ring-to-gear clearance

Ring pushed against


gear

0.85-1.10 mm
(0.033-0.043 in.)

0.4 mm
(0.016 in.)

Dual cone
synchro

Outer synchro ring-to-synchro cone clearance

Ring pushed against


gear

0.5-1.0 mm
(0.02-0.04 in.)

0.3 mm
(0.01 in.)

Synchro cone-to-gear clearance

Ring pushed against


gear

0.5-1.0 mm
(0.02-0.04 in.)

0.3 mm
(0.01 in.)

Outer synchro ring-to-gear cone clearance

Ring pushed against


gear

0.95-1.68 mm
(0.037-0.066 in.)

0.6 mm
(0.02 in.)

Finger thickness

1st-2nd and 3rd-4th


forks

7.4-7.6 mm
(0.29-0.30 in.)

5th fork

6.7-6.9 mm
(0.26-0.27 in.)

Fork-to-synchro sleeve clearance

0.35-0.65 mm
(0.014-0.026 in.)

1.00 mm
(0.039 in.)

Pawl groove width

13.8-14.1 mm
(0.543-0.555 in.)

15.5 mm (0.610 in.)

Fork-to-reverse idler gear clearance

1.6-2.2 mm
(0.06-0.09 in.)

2.8 mm
(0.11 in.)

I.D.

13.973-14.000 mm (0.55010.5512 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
(0.008-0.020 in.)

0.62 mm
(0.024 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
(0.002-0.016 in.)

0.6 mm
(0.024 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
(0.0005-0.003 in.)

0.1 mm
(0.004 in.)

Pinion shaft contact area I.D.

18.010-18.028 mm

Reverse idler
gear

Shift fork

Reverse shift
fork

Shift arm

M/T differential

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Specifications - Standards and Service Limits


carrier

M/T differential
pinion gear

(0.7091-0.7098 in.)
Carrier-to-pinion shaft clearance

0.027-0.057 mm
(0.0011-0.0022 in.)

0.100 mm
(0.0039 in.)

Driveshaft contact area I.D.

26.025-26.045 mm
(1.0246-1.0254 in.)

Backlash

0.05-0.15 mm
(0.002-0.006 in.)

I.D.

18.042-18.066 mm
(0.7103-0.7113 in.)

Pinion gear-to-pinion shaft clearance

0.059-0.095 mm
(0.0023-0.0037 in.)

0.150 mm
(0.0059 in.)

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Specifications - Standards and Service Limits

Standards and Service Limits

2-9

Automatic Transmission and A/T Differential

Item

Measurement

Qualification

ATF (Automatic
Transmission
Fluid)

Capacity

Use genuine Honda ATF- For fluid change: 2.7 l (2.9 US qt, 2.4 Imp qt)
Z1
For overhaul: 6.0 l (6.3 US qt, 5.3 Imp qt)

ATF pressure

Line pressure

At 2,000 rpm (min-1) in

830 kPa
(8.5 kgf/cm2, 120 psi)

850-900 kPa
(8.7-9.2 kgf/cm2, 120-130 psi)

800 kPa
(8.2 kgf/cm2, 120 psi)

850-900 kPa
(8.7-9.2 kgf/cm2, 120-130 psi)

800 kPa
(8.2 kgf/cm2, 120 psi)

850-900 kPa
(8.7-9.2 kgf/cm2, 120-130 psi)

800 kPa
(8.2 kgf/cm2 120 psi)

880-930 kPa
(9.0-9.5 kgf/cm2, 120-130 psi)

830 kPa
(8.5 kgf/cm2, 120 psi)

880-930 kPa
(9.0-9.5 kgf/cm2, 120-130 psi)

830 kPa
(8.5 kgf/cm2, 120 psi)

D14Z5 engine

2,550 rpm (min-1)

2,400-2,700 rpm (min-1)

D15Y2, D15Y3, D15Y5,


D15Y6 engines

2,650 rpm (min-1)

2,500-2,800 rpm (min-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)

Torque converter side

27.000-27.021 mm (1.063-1.064 in.)

When worn or damaged

position

At 2,000 rpm (min-1) in


position

3rd clutch pressure

At 2,000 rpm (min-1) in

2nd clutch pressure

At 2,000 rpm (min-1) in

position

position
1st clutch pressure

At 2,000 rpm (min-1) in

1st-hold clutch pressure

At 2,000 rpm (min-1) in

position

position
Torque converter

Valve body

Stall speed
Check with vehicle on level
ground

Stator shaft needle bearing


contact I.D.

Service Limit

880-930 kPa
(9.0-9.5 kgf/cm2, 120-130 psi)

or
4th clutch pressure

Standard or New

ATF pump side

29.000-29.013 mm (1.1417-1.1422 in.)

When worn or damaged

ATF pump gear thrust


clearance

0.03-0.06 mm (0.001-0.002 in.)

0.07 mm (0.003 in.)

ATF pump gear-to-body


clearance

Drive gear

0.105-0.1325 mm (0.004-0.005 in.)

Driven gear

0.0350-0.0625 mm (0.001-0.002 in.)

ATF pump driven gear I.D.

14.016-14.034 mm (0.5518-0.5525 in.)

When worn or damaged

ATF pump driven gear shaft


O.D.

13.980-13.990 mm (0.5504-0.5508 in.)

When worn or damaged

Reverse shift fork

Fork finger thickness

5.90-6.00 mm (0.232-0.236 in.)

5.4 mm (0.213 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 I.D.

37.000-37.039 mm (1.4567-1.4582 in.)

37.045 mm (1.4585 in.)

Regulator valve
body

Sealing ring contact I.D.

35.000-35.025 mm (1.3780-1.3782 in.)

35.050 mm (1.3799 in.)

Stator shaft

Diameter of needle bearing


contact area

ATF pump side

29.000-29.013 mm (1.1417-1.1422 in.)

When worn or damaged

Torque converter side

27.000-27.021 mm (1.0630-1.0638 in.)

When worn or damaged

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Specifications - Standards and Service Limits

2-10

Standards and Service Limits

Automatic Transmission and Differential

Item

Measurement

Qualification

Clutch

Clutch end plate-to-top disc


clearance

1st and 2nd

0.65-0.85 mm
(0.026-0.033 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 length

1st, 2nd, 3rd and 4th clutches


end plate thickness

1st-hold clutch end plate


thickness

Service Limit

1st, 2nd, 3rd and 4th

30.5 mm (1.20 in.)

28.5 mm (1.12 in.)

1st-hold

34.6 mm (1.36 in.)

32.6 mm (1.28 in.)

1.94 mm (0.076 in.)

1st, 1st-hold

1.6 mm (0.06 in.)

When discoloured

2nd, 3rd and 4th

2.0 mm (0.079 in.)

Mark 1

2.1 mm (0.083 in.)

Mark 2

2.2 mm (0.087 in.)

Mark 3

2.3 mm (0.091 in.)

Mark 4

2.4 mm (0.094 in.)

Mark 5

2.5 mm (0.098 in.)

Mark 6

2.6 mm (0.102 in.)

Mark 7

2.7 mm (0.106 in.)

Mark 8

2.8 mm (0.110 in.)

Mark 9

2.9 mm (0.114 in.)

Mark 1

2.1 mm (0.083 in.)

Mark 2

2.2 mm (0.087 in.)

Mark 3

2.3 mm (0.091 in.)

Mark 4

2.4 mm (0.094 in.)

No Mark

2.5 mm (0.098 in.)

Mark 6

2.6 mm (0.102 in.)

Mark 7

2.7 mm (0.106 in.)

Clutch disc thickness


Clutch plate thickness

Standard or New

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Specifications - Standards and Service Limits

2-11

Standards and Service Limits

Automatic Transmission and Differential


(cont'd)

Item

Measurement

Qualification

Standard or New

Service Limit

Mainshaft

Diameter of needle bearing


contact area

at stator shaft

22.980-22.993 mm (0.9047-0.9052 in.)

When worn or damaged

at 2nd gear

35.975-35.991 mm (1.4163-1.4169 in.)

at 4th gear collar

31.975-31.991 mm (1.2589-1.2595 in.)

at 1st gear collar

30.975-30.991 mm (1.2195-1.2201 in.)

1st gear

35.000-35.016 mm (1.3780-1.3786 in.)

2nd gear

41.000-41.016 mm (1.6142-1.6148 in.)

4th gear

38.000-38.016 mm (1.4961-1.4967 in.)

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 thickness

4.435-4.525 mm (0.1746-0.1781 in.)

I.D. of gears

End play of gears

1st gear collar length

27.00-27.05 mm (1.063-1.065 in.)

No. 1

4.00 mm (0.157 in.)

When worn or damaged

No. 2

4.05 mm (0.159 in.)

No. 3

4.10 mm (0.161 in.)

No. 4

4.15 mm (0.163 in.)

No. 5

4.20 mm (0.165 in.)

No. 6

4.25 mm (0.167 in.)

No. 7

4.30 mm (0.169 in.)

No. 8

4.35 mm (0.171 in.)

No. 9

4.40 mm (0.173 in.)

No. 10

4.45 mm (0.175 in.)

Thrust washer thickness

26 x 45 x 3 mm

2.95-3.05 mm (0.116-0.120 in.)

1st gear, 26 mm

2.43-2.50 mm (0.096-0.098 in.)

Clutch feed pipe O.D.

1st clutch feed pipe at 15 8.97-8.98 mm (0.535-0.354 in.)


mm (0.6 in.) from end

8.95 mm (0.352 in.)

4th clutch feed pipe at 30 5.97-5.98 mm (0.2350-0.2354 in.)


mm (1.2 in.) from end

5.95 mm (0.234 in.)

35 mm sealing ring

1.87-1.97 mm (0.074-0.078 in.)

1.8 mm (0.071 in.)

29 mm sealing ring

1.87-1.97 mm (0.074-0.078 in.)

1.8 mm (0.071 in.)

1st clutch

9.000-9.015 mm (0.3543-0.3549 in.)

9.03 mm (0.356 in.)

4th clutch

6.018-6.030 mm (0.2369-0.2374 in.)

6.045 mm (0.2380 in.)

2.025-2.075 mm (0.0797-0.0811 in.)

2.095 mm (0.082 in.)

36.5 x 55 mm thrust washer


thickness

Sealing ring thickness

Clutch feed pipe bushing I.D.

Width of sealing ring groove

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Specifications - Standards and Service Limits

2-12

Standards and Service Limits

Automatic Transmission and Differential


(cont'd)

Item

Measurement

Qualification

Standard or New

Service Limit

Countershaft

Diameter of needle bearing


contact area

at left end

36.004-36.017 mm
(1.4175-1.4180 in.)

When worn or damaged

at 3rd gear

35.980-35.996 mm
(1.4165-1.4172 in.)

at 4th gear

27.980-27.993 mm
(1.1016-1.1021 in.)

at reverse gear collar

31.975-31.991 mm
(1.2589-1.2595 in.)

at 1st gear collar

31.975-31.991 mm
(1.2589-1.2595 in.)

1st gear

38.000-38.016 mm
(1.4961-1.4967 in.)

3rd gear

41.000-41.016 mm
(1.6142-1.6148 in.)

4th gear

33.000-33.016 mm
(1.2992-1.2998 in.)

Reverse gear

38.000-38.016 mm
(1.4961-1.4967 in.)

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.)

No. 1

39.00 mm (1.535 in.)

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.)

I.D. of gears

End play of gears

28 mm distance collar length

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


thickness

2.4-2.6 mm (0.094-0.102 in.)

When worn or damaged

1st gear collar length

14.5-14.6 mm (0.571-0.575 in.)

1st gear collar flange thickness

2.4-2.6 mm (0.094-0.102 in.)

When worn or damaged

3rd gear splined washer


thickness

4.95-5.00 mm (0.195-0.197 in.)

When worn or damaged

7.97-7.98 mm (0.3138-0.3142 in.)

7.95 mm (0.313 in.)

3rd clutch feed pipe bushing


I.D.

8.000-8.022 mm (0.3150-0.3158 in.)

8.03 mm (0.316 in.)

Reverse selector hub O.D.

51.87-51.90 mm (2.042-2.043 in.)

When worn or damaged

1st gear I.D. of one-way clutch


contact area

83.339-83.365 mm (3.2810-3.2821 in.)

When worn or damaged

3rd clutch feed pipe O.D.

At 15 mm (0.6 in.) from


end

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Specifications - Standards and Service Limits


Park gear diameter of one-way
clutch area

66.685-66.698 mm (2.6254-2.6259 in.)

When worn or damaged

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Specifications - Standards and Service Limits

2-13

Standards and Service Limits

Automatic Transmission and Differential


(cont'd)

Item

Measurement

Reverse idler gear

Sub-shaft

Standard or New

Service Limit

Reverse idler gear shaft


diameter at needle bearing
contact area

13.990-14.000 mm
(0.5508-0.5512 in.)

When worn or damaged

I.D.

18.007-18.020 mm
(0.7089-0.7094 in.)

When worn or damaged

End play

0.05-0.18 mm (0.002-0.007 in.)

I.D. of reverse idler gear shaft


holder

14.416-14.434 mm
(0.5676-0.5683 in.)

When worn or damaged

at transmission housing

25.991-26.000 mm
(1.023-1.024 in.)

When worn or damaged

at 4th gear collar

23.9935-23.0065 mm
(0.9446-0.9058 in.)

When worn or damaged

4th gear I.D.

32.000-32.016 mm
(1.2600-1.2605 in.)

When worn or 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 thickness

2.95-3.10 mm
(0.116-0.122 in.)

When worn or damaged

4th gear thrust washer


thickness

2.93-3.00 mm
(0.115-0.118 in.)

When worn or damaged

7.97-7.98 mm
(0.3138-0.3142 in.)

7.95 mm (0.313 in.)

Diameter of needle bearing


contact area

1st-clutch feed pipe O.D.

Item

Measurement

Qualification

at 15 mm (0.6 in.) from


end

Standard or New
Wire
O.D.
Diameter

Free Length No. of Coil

1.1 mm
(0.043 in.)

8.6 mm
(0.339 in.)

37.1 mm
(1.4161 in.)

13.4

1.4 mm
(0.055 in)

9.4 mm
(0.370 in.)

33.8 mm
(1.331 in.)

10.9

CPB valve spring

1.0 mm
(0.039 in.)

8.1 mm
(0.319 in.)

40.9 mm
(1.610 in.)

16.2

1-2 shift valve spring

0.9 mm
(0.035 in.)

7.6 mm
(0.299 in.)

41.3 mm
(1.626 in.)

16.3

2nd orifice control valve spring

0.7 mm
(0.028 in.)

6.6 mm
(0.260 in.)

34.8 mm
(1.370 in.)

22.0

Servo control valve spring

1.0 mm
(0.039 in.)

8.1 mm
(0.319 in.)

52.1 mm
(2.051 in.)

20.8

4.5 mm
(0.177 in.)

35.4 mm
(1.394 in.)

30.3 mm
(1.193 in.)

1.9

1.9 mm
(0.075 in.)

14.7 mm
(0.579 in.)

77.4 mm
(3.047 in.)

15.2

Regulator valve spring B

1.8 mm
(0.071 in.)

9.6 mm
(0.378 in.)

44.0 mm
(1.732 in.)

12.6

Cooler relief valve spring

1.0 mm
(0.039 in.)

8.4 mm
(0.331 in.)

33.8 mm
(1.331 in.)

8.2

Main valve body Relief valve spring


springs (see page
14-183)
Modulator valve spring

Regulator valve Stator reaction spring


body springs (see
page 14-186)
Regulator valve spring A

Qualification

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Specifications - Standards and Service Limits


Torque converter check valve
spring

1.0 mm
(0.039 in.)

8.4 mm
(0.331 in.)

33.8 mm
(1.331 in.)

8.2

Lock-up control valve spring

0.8 mm
(0.031 in.)

6.0 mm
(0.236 in.)

38.4 mm
(1.512 in.)

30.3

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Specifications - Standards and Service Limits

2-14

Standards and Service Limits

Automatic Transmission and Differential


(cont'd)

Item

Secondary valve
body springs (see
page 14-187)

Measurement

Qualification

Wire
Diameter

O.D.

Free
Length

No. of Coil

3-4 shift valve spring

0.9 mm
(0.035 in.)

7.6 mm
(0.299 in.)

57.0 mm
(2.244 in.)

26.8

2-3 shift valve spring

0.9 mm
(0.035 in.)

7.6 mm
(0.299 in.)

57.0 mm
(2.244 in.)

26.8

4th exhaust valve spring

0.9 mm
(0.035 in.)

6.1 mm
(0.240 in.)

36.4 mm
(1.433 in.)

19.5

3-4 orifice control valve spring

0.7 mm
(0.028 in.)

6.6 mm
(0.260 in.)

37.5 mm
(1.476 in.)

24.6

2.1 mm
(0.083 in.)

16.0 mm
(0.630 in.)

89.1 mm
(3.508 in.)

16.2

4th accumulator spring A

2.6 mm
(0.102 in.)

17.0 mm
(0.669 in.)

88.4 mm
(3.480 in.)

14.2

4th accumulator spring B

2.3 mm
(0.091 in.)

10.2 mm
(0.402 in.)

51.6 mm
(2.031 in.)

13.8

3rd accumulator spring A

2.8 mm
(0.110 in.)

17.5 mm
(0.689 in.)

94.3 mm
(3.713 in.)

15.6

3rd accumulator spring B

2.1 mm
(0.083 in.)

31.0 mm
(1.220 in.)

38.2 mm
(1.504 in.)

2.4

2nd accumulator spring C

2.2 mm
(0.087 in.)

14.5 mm
(0.571 in.)

68.0 mm
(2.677 in.)

13.9

2nd accumulator spring A

2.4 mm
(0.094 in.)

29.0 mm
(1.142 in.)

39.0 mm
(1.535 in.)

2.9

3rd sub accumulator spring

2.7 mm
(0.106 in.)

17.0 mm
(0.669 in.)

39.0 mm
(1.535 in.)

6.3

Lock-up shift valve spring

0.9 mm
(0.035 in.)

7.6 mm
(0.299 in.)

73.7 mm
(2.902 in.)

32.0

Lock-up timing valve spring

0.9 mm
(0.035 in.)

8.1 mm
(0.319 in.)

80.7 mm
(3.177 in.)

54.2

Servo body springs 1st accumulator spring


(see page 14-188)

Lock-up valve
body springs (see
page 14-189)

Standard or New

Item

Measurement

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 clearance

0.023-0.057 mm
(0.001-0.002 in.)

0.1 mm (0.004 in.)

Driveshaft contact area I.D.

26.025-26.045 mm
(1.0246-1.0254 in.)

Carrier-to-driveshaft clearance

0.045-0.086 mm
(0.002-0.003 in.)

0.12 mm
(0.005 in.)

Set ring-to-carrier bearing outer


race clearance

0-0.15 mm
(0-0.006 in.)

Adjust

Backlash

0.05-0.15 mm
(0.002-0.006 in.)

I.D.

18.042-18.066 mm
(0.7103-0.7113 in.)

Pinion gear-to-pinion shaft

0.055-0.095 mm

0.15 mm (0.006 in.)

A/T differential
pinion gear

Qualification

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Specifications - Standards and Service Limits


clearance

(0.0022-0.0037 in.)

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Specifications - Standards and Service Limits

2-15

Standards and Service Limits


Steering

Item

Measurement

Qualification

Standard or New

Service Limit

Steering wheel

Rotational play measure at


outside edge

With engine running

0-10 mm (0-0.39 in.)

Starting load measured at


outside edge

With engine running

29 N (3.0 kgf, 6.6 lbs)

20 Max.

Gearbox

Angle of rack guide screw


loosened from locked position

Pump

Output pressure with shut-off


valve closed

Engine speed at 3,000


rpm (min)

7,600-8,300 kPa (78-85 kgf/cm2, 1,110-1,210 psi)

Power steering
fluid

Capacity

Use Genuine Honda


power steering fluid

For reservoir capacity: 0.3 l (0.32 US qt, 0.26 Imp qt)

Power steering
pump belt NOTE:
Adjust a new belt
to the new belt
spec, run the
engine for 5
minutes, then
readjust it to the
used belt spec.

Deflection with 98 N (10 kgf, 22


lbs) applied mid-way between
pulleys

Used belt: 13.0-16.5 mm (0.51-0.65 in.)

Tension (measured with belt


tension gauge)

Used belt: 390-540 N (40-55 kgf, 88-121 lbs)

290-1,100 kPa (3-11 kgf/cm2, 43-156 psi)

For system capacity: 1.0 l (1.06 US qt, 0.88 Imp qt)

New belt: 9.0-11.0 mm (0.35-0.43 in.)

New belt: 740-880 N (75-90 kgf, 165-198 lbs)

Suspension
Item

Measurement

Wheel alignment Camber

Qualification

Standard or New

Front

000'+45

Service Limit

Rear

-045'+45'

Caster

Front

133'+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.)

Inside wheel

3800'2

Inspect: IN 2+3 mm (0.08+0.12 in.)


Front wheel turning angle
Aluminium wheel Runout
Steel wheel

Runout

Wheel bearings End play

Outside wheel

3000' (Reference)

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.)

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.)

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

2-16

Standards and Service Limits


Brakes

Item

Measurement

Qualification

Parking brake lever Distance travelled when pulled


with 196 N (20 kgf, 44 lbs) of
force
Brake pedal

Pedal height (Carpet removed)

Standard or New

Service Limit

Rear drum brake 6-7 clicks, Rear disc brake 7-8 clicks

M/T

184 mm (7.24 in.)

A/T

188 mm (7.40 in.)

Free play

0.4-3.0 mm (0.016-0.118 in.)

Master cylinder

Piston-to-pushrod clearance

0-0.4 mm (0-0.02 in.)

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.)

Thickness Front

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.

199.9-200.0 mm (7.870-7.874 in.)

201 mm (7.91 in.)

Brake shoes

Lining thickness

4.0 mm (0.16 in.)

2.0 mm (0.08 in.)

Brake booster
Vehicle with ABS

Characteristics at 196 N (20


kgf, 44 lbf) pedal force

N (kgf, lbf)

kPa (kgf/cm2, psi)

Brake pads

Brake booster
Vehicle without
ABS

Characteristics at 196 N (20


kgf, 44 lbf) pedal force

Vacuum
kPa (mmHg, inHg)

(1)

(2)

0 (0, 0)

0 (0, 0)

0 (0, 0)

98 (10, 22)
294 (30, 66)

1700 (17, 240) 1600 (16, 230)

66.7 (500, 19.7)

98 (10, 22)

4600 (47, 670) 4200 (43, 610)

294 (30, 66)

10500 (107,
1500)

N (kgf, lbf)

kPa (kgf/cm2, psi)

Vacuum
kPa (mmHg, inHg)

10300 (105,
1500)

(3)

(4)

0 (0, 0)

0 (0, 0)

0 (0, 0)

98 (10, 22)
294 (30, 66)

1700 (17, 240) 1600 (16, 230)

66.7 (500, 19.7)

98 (10, 22)

4400 (45, 640) 4100 (42, 600)

294 (30, 66)

10500 (107,
1500)

10300 (105,
1500)

(1) KK, KY, KX models(2) Except KK, KY, KX models(3) KK, KY, KX models
(4) Except KK, KY, KX models
Air Conditioning
Item

Measurement

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 or 38899-P13-A01)

Capacity of components

Compressor

Compressor belt
NOTE: Adjust a

Starter coil resistance

Qualification

Condenser

Standard or New

25 ml (5/6 fl oz, 0.9 Imp oz)

Evaporator

45 ml (1 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)

at 20C (68F)

3.05-3.35 ohms

Pulley-to-pressure plate
clearance

0.5+0.15 mm (0.02+0.006 in.)

Deflection with 98 N (10 kgf, 22


lbs) applied mid-way between

Used belt: 8.5-11.0 mm (0.33-0.43 in.)


New belt: 5.0-6.5 mm (0.20-0.26 in.)

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Specifications - Standards and Service Limits


new belt to the
pulleys
new belt spec.,
Tension (measured with belt
run the engine for tension gauge)
5 minutes, then
readjust it to the
used belt spec.

Used belt: 440-590 N (45-60 kgf, 100-130 lbs)


New belt: 930-1,125 N (95-115 kgf, 210-255 lbs)

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Specifications - Design Specifications

2-17

Design Specifications
Item

Measurement

Qualification

DIMENSIONS Overall length

Specification
4,440 mm (174.8 in.)

Overall width

1,695 mm (66.7 in.)

Overall height

1,415 mm (55.7 in.)*1


1,400 mm (55.1 in.)*2

Wheelbase
Track

2,620 mm (103.1 in.)


Front

1,465 mm (57.7 in.)

Rear

1,470 mm (57.9 in.)

Ground clearance

150 mm (5.9 in.)

Seating capacity
WEIGHT

Curb Weight

Max. permissible Weight

Five
(M/T)

1,103-1,171 kg (2,432-2,582 lbs)

(A/T)

1,128-1,196 kg (2,487-2,637 lbs)


1,575 kg (3,472 lbs)

*1: KK models
*2: Except KK models

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Specifications - Design Specifications

2-18

Design Specifications
(cont'd)
Item
ENGINE

Measurement
Type

Qualification

Specification

D17A2, D17A5, D17A9


engines

Water-cooled, 4-stroke SOHC VTEC engine

D17A8 engine

Water-cooled, 4-stroke SOHC engine

Cylinder arrangement

Inline 4-cylinder, transverse

Bore and stroke

75 x 94.4 mm (2.95 x 3.72 in.)

Displacement

1,668 cm3 (102 cu in.)

Compression ratio

D17A8, D17A5 engines

9.5

D17A2, D17A9 engines

9.9

Valve train

D17A2, D17A5, D17A9


engines

Belt driven, SOHC VTEC 4 valves per cylinder

D17A8 engine

Belt driven, SOHC 4 valves per cylinder

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Specifications - Design Specifications

2-19

Design Specifications
(cont'd)

Item

Measurement

ENGINE

Lubrication system

STARTER

CLUTCH

Qualification

Specification

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

KK model

UNLEADED gasoline with 91 research octane number or higher

KB, KE, KG, KR models

Premium UNLEADED gasoline with 95 research octane number or higher

KX model

UNLEADED gasoline with 91 research octane number or higher (RON of


95 UNLEADED gasoline may also be used)

KY model

LEADED gasoline with 91 research octane number or higher (RON of 91


UNLEADED gasoline may also be used)

Type

Gear reduction

Normal output

1.0 kW

Hour rating

30 seconds

Direction of rotation

Clockwise as viewed from gear end

Clutch

Clutch friction material surface


area
MANUAL TRANSMISSION

A/T

Torque converter

M/T

176 cm3 (102 sq in.)


Synchronised, 5-speed forward, 1 reverse
Direct 1:1

1st

3.461

2nd

1.869

3rd

1.241

4th

0.969

5th

0.805

Reverse

3.230

Type

Single helical gear

Gear ratio

4.411

Type

Electronically controlled automatic, 4-speed forward, 1 reverse

Primary reduction

Direct 1:1

Gear ratio

Final reduction

SUSPENSION

Single plate dry, diaphragm spring

Primary reduction

Final reduction

STEERING

M/T

Type

Gear ratio

AUTOMATIC
TRANS-MISSION

Forced, wet sump, with trochoid pump

1st

2.722

2nd

1.468

3rd

0.975

4th

0.674

Reverse

1.955

Type

Single helical gear

Gear ratio

4.357

Type

Rack and pinion, with electrical power assistance/hydraulic power


assistance

Overall ratio

14.49

Turns, lock-to-lock

2.83

Steering wheel diameter

380 mm (15.0 in.)

Type

Strut

Shock absorber

Rear

Double wishbone

Front and rear

Telescopic, hydraulic, nitrogen gas-filled

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Specifications - Design Specifications

2-20

Design Specifications
(cont'd)
Item
WHEEL
ALIGNMENT

BRAKE

Measurement
Camber

Qualification
Front

Rear

-045'

Caster

Front

133'

Total toe

Front

0 mm (0 in.)

Rear

In 2 mm (1/16 in.)

Type of service brake

Front

Power-assisted self-adjusting ventilated disc

Rear

Power-assisted self-adjusting solid disc or drum

Type of parking brake

TYRES

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)

Size of front and rear

KK, KX models

P185/65R 15 86H

KE, KG, KB, KR, KY


models

P195-60R 15 88H

KG, KB, KR, KX models

T125/70D 15 95M

Size of spare tyre


AIR
CONDITIONING

Specification

Cooling capacity
Compressor

3,870 kcal/h (15,400 BTU/h)


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-P13-003, 38898-P13-003 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)

Type

Dry, single plate, poly-V belt drive

Electrical power
consumption at 20C
(68F)

42 W maximum at 12 V

Type

HFC-134a (R-134a)

Quantity

500-550 g (17.5-19.5 oz)

Temperature clutch
Compressor clutch

Refrigerant

Air-mix type

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Specifications - Design Specifications

2-21

Design Specifications
(cont'd)
Item
ELECTRICAL
RATINGS

Measurement

Qualification

Battery

Specification
12 V - 36 AH/5 hours*1
12 V - 38 AH/5 hours*2

Starter

DENSO

12 V - 1.0 kW

MITSUBA

12 V - 1.2 kW

Alternator
Fuses

Light bulbs

12 V - 70 A
Under-hood fuse/relay
box

80 A, 60 A, 40 A, 30 A, 20 A, 15 A, 10 A, 7.5 A

Under-dash fuse/relay
box

30 A, 20 A, 15 A, 10 A, 7.5 A

Headlight high beam

12 V - 60 W

Headlight low beam

12 V - 55 W

Front turn signal/Front


side marker lights

12 V - 21 W/5 W

Front position lights

12 V - 5 W/3 CP (candlepower)

Front parking lights

12 V - 5 W

Side turn signal lights

12 V - 21 W

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

12 V - 5 W

Individual map light

12 V - 8 W

Spotlights

14 V - 8 W: without sunroof 12 V - 5 W: with sunroof

Gauge light

14 V - 1.4 W

Indicator light

12 V - 1.12 W

Front fog light

12 V - 55 W

Rear fog light

12 V - 21 W

Glove box light

12 V - 3.4 W

Side turn signal light

12 V - 5 W

*1: KK, KX models


*2: Except KK, KX models

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Body Specifications

Body Specifications

2-22

Unit: mm (in.)

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Maintenance - Maintenance

Maintenance

Lubricants and Fluids

3-2

Maintenance Schedule for Normal Conditions (For European Model)

3-4

Maintenance Schedule for Severe Conditions (For European Model)

3-6

Maintenance Schedule for Normal Conditions (Except European Models)

3-8

Maintenance Schedule for Severe Conditions (Except European Models)

3-10

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Maintenance - Lubricants and Fluids

*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

Lubricants and Fluids

3-2

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.
1

LUBRICATION POINTS
Engine

LUBRICANT
Always use fuel-efficient that says "API service SG, SH or SJ"
SAE Viscosity See chart below.

Transmission

Manual

Genuine Honda Manual Transmission Fluid (MTF) *1

Automatic

Genuine Honda ATF-Z1 (ATF) *2

Brake system (includes ABS line)

Brake fluid DOT 3 or DOT 4 *3

Clutch line

Brake fluid DOT 3 or DOT 4 *3

Power steering gearbox

Steering grease P/N 08733-B070E

Release fork (manual transmission)

Super High Temp Urea Grease (P/N 08798-9002)

Shift and select cable ends (Manual transmission)

Throttle cable end (dashboard lower panel hole)

Silicon grease

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

17

Hood hinges and latch

18

Trunk hinges and latch

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)

Honda White Lithium Grease

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

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Maintenance - Lubricants and Fluids

Lubricants and Fluids

3-3

(cont'd)

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Maintenance Schedule for Severe Conditions

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.
*1: Refer to shop manual: '01 CIVIC MAINTENANCE, REPAIR and CONSTRUCTION Code No. 62S5A00 on this CD.

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Maintenance - Maintenance Schedule for Normal Conditions

Maintenance Schedule for Normal


Conditions

3-4

(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 whichever comes


first.

km x 1,000

20 40 60 80 100 120 140 160 180 200

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

l l l l l

Replace engine oil filter

l l l l l

Replace air cleaner element

Every 40,000 km (24,000 miles)

Inspect valve clearance

Every 40,000 km (24,000 miles)

Replace fuel filter

Replace spark plugs

Every 40,000 km (24,000 miles)

Replace timing belt and inspect water pump

Every 120,000 km (72,000 miles) or 96 months

Inspect and adjust drive belts

Inspect idle speed

Replace engine coolant

200,000 km (120,000 miles) or 120 months,


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

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

Replace transmission fluid

Inspect front and rear brakes

l l l l l

Replace brake fluid

Every 36 months

Check parking brake adjustment

l l

Replace air conditioning filter

Every 30,000 km (18,000 miles) or 12 months

Check light alignment

l l l l l

Test drive (noise, stability, dashboard operation)

l l l l l

l l l l l

l
l

Visually inspect the following items:


Tie rod ends, steering gearbox and boots
Suspension components
Driveshaft boots
Brake hoses and lines (including ABS)
All fluid levels and condition of fluid
Exhaust system

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Maintenance - Maintenance Schedule for Normal Conditions


Fuel line and connections
Tyre condition

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Maintenance - Maintenance Schedule for Normal Conditions

Maintenance Schedule for Normal


Conditions

3-5

(European Model) (cont'd)

NOTES

SECTION and PAGE

(see page 8-3)

(see page 8-6) *1

(see page 11-147)*1 (see page 11-447)*1

Check the valve clearance.

(see page 6-8)

(see page 11-138)*1 (see page 11-296)*1


(see page 11-438)*1 (see page 11-571)*1

(see page 4-17)

Check water pump for signs of seal leakage.

Check for cracks and damage.


Check deflection and tension.

(see page 6-18)*1 (see page 6-22)*1 (see


page 10-7)*1
(see page 17-23)*1
(see page 11-125)*1 (see page 11-285)*1
(see page 11-425)*1 (see page 11-560)*1
(see page 11-71)

Check specific gravity for freezing point.

(see page 10-8)*1

Use genuine Honda MTF (Manual Transmission Fluid).

(see page 13-3)*1

Use genuine Honda AFT-Z1 (ATF).

Check
Check
Check
Check

the
the
the
the

brake pad and disc thickness. Check for damage or cracks.


wheel cylinder for leaks.
brake linings for cracking, glazing, wear or contamination.
callipers for damage, leaks and tightness.

(see page 14-122)*1


(see page 19-3)*1

Use only DOT 3 or DOT 4 brake fluid. (We recommend Genuine Honda Brake Fluid.) Check
that Brake fluid level is between the upper and lower marks on the reservoir.

(see page 19-7)*1

Check the parking brake operation.

(see page 19-6)*1

Check the position of the headlight.


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.

(see page 22-114)*1


-

Check rack grease and steering linkage. Check the boot for damage and
leaking grease.
Check the fluid line for damage and leaks.

(see page 17-5)*1

Check the bolts for tightness.


Check all the dust covers for deterioration and damage.

(see page 18-3)*1

Check the boot and boot band for cracks


Check rack grease.

(see page 16-3)*1

Check the master cylinder, proportioning control valve and ABS modulator and leakage.
Check for leaks.
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, leaks and
tightness.
Check fuel lines for loose connections, cracks and deterioration. Retighten loose connections
and replace any damaged parts
Check for pressure, puncture or cuts and irregular tread wear.

(see page 19-48)*1


(see page 9-3)
(see page 11-132)*1 (see page 11-290)*1
(see page 11-432)*1 (see page 11-565)*1
-

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Maintenance Schedule for Severe Conditions (European Model)

Maintenance Schedule for Severe


Conditions (European Model)

3-6

Listed by Distance/Time

Service at the indicated distance or time whichever comes


first.

km x 1,000

20 40 60 80 100 120 140 160 180 200

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

l l l l l l l l l

Replace air cleaner element

l l l l l l l l l

Inspect valve clearance

Every 40,000 km (24,000 miles)

Replace fuel filter

Replace spark plugs

Every 40,000 km (24,000 miles)

Replace timing belt and inspect water pump

Inspect and adjust drive belts

Inspect idle speed

Replace engine coolant

200,000 km (120,000 miles) or 120 months,


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

Manual Transmission

Every 60,000 km (36,000 miles) or 48


months

Automatic Transmission

60,000 km (36,000 miles) or 48 months,


thereafter every 40,000 km (24,000 miles) or
24 months

Replace transmission fluid

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

l l l l l l l l l

Replace air conditioning filter

Every 30,000 km (18,000 miles) or 12


months

Check light alignment

l l l l l l l l l

Test drive (noise, stability, dashboard operation)

l l l l l l l l l

Visually inspect the following items:


Tie rod ends, steering gearbox and boots
Suspension components

Every 10,000 km (6,000 miles) or 6 months

Driveshaft boots
Brake hoses and lines (including ABS)

l l l l l l l l l

All fluid levels and condition of fluid


Exhaust system
Fuel line and connections

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Maintenance Schedule for Severe Conditions (European Model)


Tyre condition

Follow the Servere 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 35C (95F) 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 Schedule for Severe Conditions

Maintenance Schedule for Severe


Conditions

3-7

(European Model) (cont'd)

NOTES

SECTION and PAGE

(see page 8-3)

(see page 8-6)*1

(see page 11-147)*1 (see page 11-447)*1

Check the valve clearance.

(see page 6-8)

(see page 11-138)*1 (see page 11-296)*1


(see page 11-438)*1 (see page 11-571)*1

(see page 4-17)

Check water pump for signs of seal leakage.

Check for cracks and damage.


Check deflection and tension.

(see page 6-18)*1 (see page 6-22)*1 (see


page 10-7)*1
(see page 17-23)*1
(see page 11-125)*1 (see page 11-285)*1
(see page 11-425)*1 (see page 11-560)*1
(see page 11-71)

Check specific gravity for freezing point.

(see page 10-8)*1

Use genuine Honda MTF (Manual Transmission Fluid).

(see page 13-3)*1

Use genuine Honda AFT-Z1 (ATF).

Check
Check
Check
Check

the
the
the
the

brake pad and disc thickness. Check for damage or cracks.


wheel cylinder for leaks.
brake linings for cracking, glazing, wear or contamination.
calipers for damage, leaks and tightness.

(see page 14-122)*1


(see page 19-3)

Use only DOT 3 or DOT 4 brake fluid. (We recommend Genuine Honda Brake Fluid.) Check
that Brake fluid level is between the upper and lower marks on the reservoir.

(see page 19-7)*1

Check the parking brake operation.

(see page 19-6)*1

Check the position of the headlight.


Check for road stability, noise, vibrations and dashboard operation.

(see page 22-114)*1


-

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 damage and
leaking grease.
Check the fluid line for damage and leaks.

(see page 17-5)*1

Check the bolts for tightness.


Check all dust covers for deterioration and damage.

(see page 18-3)*1

Check the boot and boot band for cracks


Check rack grease.

(see page 16-3)*1

Check the master cylinder, proportioning control valve and ABS modulator and leakage.
Check for leaks.
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, leaks and
tightness.
Check fuel lines for loose connections, cracks and deterioration. Retighten loose connections
and replace any damaged parts
Check for pressure, puncture or cuts and irregular tread wear.

(see page 19-48)*1


(see page 9-3)
(see page 11-132)*1 (see page 11-290)*1
(see page 11-432)*1 (see page 11-565)*1
-

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Maintenance - Maintenance Schedule for Normal Conditions (Except European Models)

Maintenance Schedule for Normal


Conditions (Except European Models)

3-8

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 time whichever comes
first.

km x 1,000

20 40 60 80 100 120 140 160 180 200

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
Unleaded type: Every 10,000 km (6,000
miles) or 12 months

Replace engine oil

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


or 6 months
Unleaded type: Every 20,000 km (12,000
miles) or 12 months

Replace engine oil filter

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)


with catalytic converter

Every 40,000 km (24,000 miles)

without catalytic converter

Every 20,000 km (12,000 miles)

Inspect valve clearance

Replace fuel filter

with catalytic converter

Every 40,000 km (24,000 miles)

without catalytic converter

Every 20,000 km (12, 000 miles)

Replace spark plugs

Inspect and adjust drive belts

with catalytic converter

without catalytic converter

Inspect idle speed

Replace timing belt and inspect water pump

200,000 km (120,000 miles) or 120 months,


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

Replace engine coolant

Manual Transmission

Automatic Transmission

Replace transmission fluid


Inspect front and rear brakes

every 100,000 km (60,000 miles)

Replace brake fluid

Every 36 months

Check parking brake adjustment

l l

Rotate tyre (Check tyre inflation and condition at least once per month)

Every 10,000 km (6,000 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

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Maintenance - Maintenance Schedule for Normal Conditions (Except European Models)


Brake hoses and lines (including ABS)

l l l l l l l l l l

All fluid levels and condition of fluid


Exhaust system
Fuel line and connections

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Maintenance - Maintenance Schedule for Normal Conditions (Except European Models)

Maintenance Schedule for Normal


Conditions (Except European Models)

3-9

Listed by Distance/Time (cont'd)

NOTES

SECTION and PAGE

(see page 8-3)

(see page 8-6)*1

(see page 11-147)*1 (see page 11-447)*1

Check the valve clearance.

(see page 6-8)

(see page 11-138)*1 (see page 11-296)*1


(see page 11-438)*1 (see page 11-571)*1

(see page 4-17)

Check water pump for signs of seal leakage.

Check for cracks and damage.


Check deflection and tension.

(see page 6-18)*1 (see page 6-22)*1 (see


page 10-7)*1
(see page 17-23)*1
(see page 11-125)*1 (see page 11-285)*1
(see page 11-425)*1 (see page 11-560)*1
(see page 11-71)

Check specific gravity for freezing point.

(see page 10-8)*1

Use genuine Honda MTF (Manual Transmission Fluid).

(see page 13-3)*1

Use genuine Honda AFT-Z1 (ATF).

Check
Check
Check
Check

the
the
the
the

brake pad and disc thickness. Check for damage or cracks.


wheel cylinder for leaks.
brake linings for cracking, glazing, wear or contamination.
calipers for damage, leaks and tightness

(see page 14-122)*1


(see page 19-3)*1

Use only DOT 3 or DOT 4 brake fluid. (We recommend Genuine Honda Brake Fluid.) Check
that Brake fluid level is between the upper and lower marks on the reservoir.

(see page 19-7)*1

Check the parking brake operation.

(see page 19-6)*1

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 damage and
leaking grease.
Check the fluid line for damage and leaks.

(see page 17-5)*1

Check the bolts for tightness.


Check all dust covers for deterioration and damage.

(see page 18-3)*1

Check the boot and boot band for cracks


Check rack grease.

(see page 16-3)*1

Check the master cylinder, proportioning control valve and ABS modulator and leakage.
Check for leaks.
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, leaks and
tightness.
Check fuel lines for loose connections, cracks and deterioration. Retighten loose connections
and replace any damaged parts

(see page 19-48)*1


(see page 9-3)
(see page 11-132)*1 (see page 11-290)*1
(see page 11-432)*1 (see page 11-565)*1

*1: Refer to shop manual: '01 CIVIC MAINTENANCE, REPAIR and CONSTRUCTION Code No. 62S5A00 on this CD.

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Maintenance - Maintenance Schedule for Severe Conditions (Except European Models)

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 35C (95F) 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 (Except European Models)

Maintenance Schedule for Severe


Conditions (Except European Models)

3-10

Listed by Distance/Time

Service at the indicated distance or time whichever comes


first.

km x 1,000

20 40 60 80 100 120 140 160 180 200

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

Every 20,000 km (12,000 miles)


with catalytic converter

Every 40,000 km (24,000 miles)

without catalytic converter

Every 20,000 km (12,000 miles)

Inspect valve clearance

Replace fuel filter

with catalytic converter

Every 40,000 km (24,000 miles)

without catalytic converter

Every 20,000 km (12,000 miles)

Replace spark plugs

Inspect and adjust drive belts

with catalytic converter

without catalytic converter

Inspect idle speed

Replace timing belt and inspect water pump

200,000 km (120,000 miles) or 120 months,


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

Replace engine coolant

Manual Transmission

Automatic Transmission

Replace transmission fluid

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

l l

Rotate tyre (Check tyre inflation and condition at least once per month)

Every 10,000 km (6,000 miles)

Visually inspect the following items:

Tie rod ends, steering gearbox and boots


Suspension components

Every 10,000 km (6,000 miles) or 6 months

Driveshaft boots
Brake hoses and lines (including ABS)

l l l l l l l l l l

All fluid levels and condition of fluid


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:

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Maintenance - Maintenance Schedule for Severe Conditions (Except European Models)

Maintenance Schedule for Severe


Conditions (Except European Models)

3-11

Listed by Distance/Time (cont'd)

NOTES

SECTION and PAGE

(see page 8-3)

(see page 8-6)*1

(see page 11-147)*1 (seepage 11-447)*1

Check the valve clearance.

(see page 6-8)

(see page 11-138)*1 (see page 11-296)*1


(see page 11-438)*1 (see page 11-571)*1

(see page 4-17)

Check water pump for signs of seal leakage.

Check for cracks and damage.


Check deflection and tension.

(see page 6-18)*1 (see page 6-22)*1 (see


page 10-7)*1
(see page 17-23)*1
(see page 11-125)*1 (see page 11-285)*1
(see page 11-425)*1 (see page 11-560)*1
(see page 11-71)

Check specific gravity for freezing point.

(see page 10-8)*1

Use genuine Honda MTF (Manual Transmission Fluid).

(see page 13-3)*1

Use genuine Honda AFT-Z1 (ATF).

Check
Check
Check
Check

the
the
the
the

brake pad and disc thickness. Check for damage or cracks.


wheel cylinder for leaks.
brake linings for cracking, glazing, wear or contamination.
calipers for damage, leaks and tightness.

(see page 14-122)*1


(see page 19-3)*1

Use only DOT 3 or DOT 4 brake fluid. (We recommend Genuine Honda Brake Fluid.) Check
that Brake fluid level is between the upper and lower marks on the reservoir.

(see page 19-7)*1

Check the parking brake operation.

(see page 19-6)*1

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 damage and
leaking grease.
Check the fluid line for damage and leaks.

(see page 17-5)*1

Check the bolts for tightness.


Check all dust covers for deterioration and damage.

(see page 18-3)*1

Check the boot and boot band for cracks


Check rack grease.

(see page 16-3)*1

Check the master cylinder, proportioning control valve and ABS modulator and leakage.
Check for leaks.
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, leaks and
tightness.
Check fuel lines for loose connections, cracks and deterioration. Retighten loose connections
and replace any damaged parts

(see page 19-48)*1


(see page 9-3)
(see page 11-132)*1 (see page 11-290)*1
(see page 11-432)*1 (see page 11-565)*1

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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Engine Electrical - Engine Electrical

Engine Electrical
Special Tools
Starting System

4-2

Component Location Index

4-3

Circuit Diagram

4-4

Starter Circuit Troubleshooting

4-5

Starter Performance Test

4-7

Starter Overhaul

4-8

Ignition System
Component Location Index

4-15

Circuit Diagram

4-16

Spark Plug Inspection

4-17

Charging System
Circuit Diagram

4-18

Cruise Control
Circuit Diagram

4-19

NOTE: Refer to the '01 Civic Shop Manual, P/N 62S5A00 on this CD for items not shown in this section.
Outline of Model Change
D17A8, D17A9 engines have been added.

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Engine Electrical - Engine Electrical

Engine Electrical

4-2

Special Tools
Number
1
2
3

Tool Number
07JGG-0010100
07746-0010400
07749-0010000

Description
Belt Tension Gauge
Driver Attachment, 52 x 55 mm
Handle Driver

Qty
1
1
1

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Engine Electrical - Starting System

Starting System

4-3

Component Location Index


1. STARTER CUT RELAY
Test, page 22-80 in the '01 Civic Shop
Manual on this CD
2. UNDER-DASH FUSE/RELAY BOX
3. CLUTCH INTERLOCK SWITCH (M/T)
Test, page 4-7 in the '01 Civic Shop Manual
on this CD
Switch Position Adjustment, page 12-4
in the '01 Civic Shop Manual on this CD
4. STARTER
Starter Circuit Troubleshooting, page 4-5
Solenoid Test, Page 4-7
in the '01 Civic Shop Manual on this CD
Performance Test, page 4-7
Replacement, page 4-9
in the '01 Civic Shop Manual on this CD
Overhaul, page 4-8
5. TRANSMISSION RANGE SWITCH (A/T)
Test, page 14-159
in the '01 Civic Shop Manual on this CD
Replacement, page 14-161
in the '01 Civic Shop Manual

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Engine Electrical - Starting System

Starting System

4-4

Circuit Diagram

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Engine Electrical - Starting System

Starting System

4-5

Starter Circuit Troubleshooting

NOTE:

1.

Air temperature must be between 59 and 100F (15


and 38F) during this procedure.
After this test, or any subsequent repair, reset the
Engine Control Module (ECM)/Powertrain Control
Module (PCM) to clear any Diagnostic Trouble Codes
(DTCs), refer to the '01 Civic Shop Manual on this
CD (see page 11-13).
Recommended Procedure:
Use a starter system tester.
Connect and operate the equipment in accordance
with the manufacturer's instructions.
Alternate Procedure
1.

4. Check the battery condition. Check electrical


connections at the battery and the starter for
looseness and corrosion. Then check the starter
again.
Did the starter crank the engine?
YES - The starting system is OK.
NO - Go to step 5.

2.

5. Make sure the transmission is in neutral, then


disconnect the BLK/WHT wire (A) from the starter
solenoid (B). Connect a jumper wire from the battery
positive terminal to the solenoid terminal.

1. Hook up the following equipment:


Ammeter, 0 - 400 A
Voltmeter, 0 - 20 V (accurate within 0.1 volt)
Tachometer, 0 - 1200 rpm

Did the starter crank the engine?


YES - Go to step 6.
NO - Remove the starter and diagnose its internal
problems.

2.

2. Remove the No. 46 (15 A) fuse from the under-dash


fuse/relay box.
3. With the shift lever in
or
(A/T), or the clutch
pedal pressed (M/T), turn the ignition switch to start
(III).
Did the starter crank the engine normally?
YES - The starting system is OK.
NO - If the starter will not crank at all, go to step 4. If it
cranks the engine erratically or too slowly, go to step 7. If it
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

Starting System

4-6

Starter Circuit Troubleshooting (cont'd)

1.

6. Check the following items are in the order listed until


you find the open circuit.
Check the BLK/WHT wire and connectors
between the starter cut relay and the ignition
switch and between the starter cut relay and the
starter.
Check the ignition switch (see page 22-83).
With A/T, check the transmission range switch
and connector. With M/T, check the clutch
interlock switch and connector, refer to the '01
Civic Shop manual on this CD (see page 4-7).
2.
7. Check engine speed during cranking.
Is the engine speed above 100 rmp?
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
3.
8. Check the cranking voltage and current draw.
Is cranking voltage no less than 8.0 volts and 200 amps?
YES - Go to step 9.
NO - Remove and disassemble the starter and check for
the following until you find the cause.

4.

Open circuit in starter armature commutator


segments
Starter armature dragging
Shorted armature winding
Excessive drag in engine
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

Starting System

4-7

Starter Performance Test

1.

1. Disconnect the wires from the S terminal and the M


terminal.

2.

2. Make a connection as described below using as


heavy a wire as possible (preferably equivalent to the
wire used for the vehicle).
3. Connect the battery as shown. If the starter pinion
pops out, it is working properly. To avoid damaging
the starter, do not leave the battery connected for
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.

1.

5. Also disconnect the battery from the body. If the


pinion retracts immediately, it is working properly. To
avoid damaging the starter, do not leave the battery
connected for more than 10 seconds.

2.

6. Clamp the starter firmly in a vice.


7. Connect the starter to the battery as described in the
diagram below and confirm that the motor starts and
keeps rotating.

3.

8. If the electric current and motor speed meet the


specifications when the battery voltage is at 11.5 V,
the starter is working properly.
Specifications:
Maker
DENSO

Electric current
90 A or less

Motor speed
3,000 rpm (min-1) or more

(1.0 Kw)

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Engine Electrical - Starting System

Starting System

4-8

Starter Overhaul

Disassembly/Reassembly - M/T
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

STARTER SOLENOID
MOLYBDENUM DISULPHIDE
SOLENOID LEVER
GEAR HOUSING
OVERRUNNING CLUTCH
ASSEMBLY
ARMATURE
ARMATURE HOUSING
MOLYBDENUM DISULPHIDE
MOLYBDENUM DISULPHIDE
BRUSH HOLDER
END COVER

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Engine Electrical - Starting System

Starting System

4-9

Starter Overhaul (cont'd)

Disassembly/Reassembly - A/T
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

STARTER SOLENOID
MOLYBDENUM DISULPHIDE
SOLENOID LEVER
GEAR HOUSING
OVERRUNNING CLUTCH
ASSEMBLY
ARMATURE
ARMATURE HOUSING
MOLYBDENUM DISULFIDE
MOLYBDENUM DISULFIDE
BRUSH HOLDER
END COVER

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Engine Electrical - Starting System

Starting System

4-10

Starter Overhaul (cont'd)

Armature Inspection and Test


1.
1. Remove the starter, refer to '01 Civic Shop Manual
(see page 4-9).
2. Disassemble the starter as shown at the beginning of
this procedure.
3. Inspect the armature for wear or damage from
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
within the following specifications, or recondition with
#500 or #600 sandpaper (B).

1.

5. Check the commutator diameter. If the diameter is


below the service limit, replace the armature.
Commutator Diameter
Standard (New):
27.9 - 28.0 mm (1.098 - 1.102 in.)
Service Limit:
27.0 mm (1.142 in.)

2.

6. Measure the commutator (A) runout.


If the commutator runout is within the
service 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
Standard (New):0.02 mm (0.001 in.) max.
Service Limit:0.05 mm (0.002 in.)

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Engine Electrical - Starting System

Starting System

4-11

Starter Overhaul (cont'd)

1.

2.

7. Check the mica depth (A). If the mica is too high (B),
undercut the mica with a hacksaw blade to the
proper depth. Cut away all the mica (C) between the
commutator segments. The undercut should not be
too shallow, too narrow, or V-shaped (D).
Commutator Mica Depth
Standard (New):
0.45 - 0.75 mm (0.018 - 0.030 in.)
Service Limit:
0.2 mm (0.008 in.)

8. Check for continuity between the segments of the


commutator. If an open circuit exists between any
segments, replace the armature.

1.

9. Place the armature (A) on an armature tester (B).


Hold a hacksaw blade (C) on the armature core. If
the blade is attracted to the core or vibrates while
the core is turned, the armature is shorted. Replace
the armature.

2.

10. Check with an ohmmeter that no continuity exists


between the commutator (A) and armature coil core
(B) and between the commutator and armature shaft
(C). If continuity exists, replace the armature.

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Engine Electrical - Starting System

Starting System

4-12

Starter Overhaul (cont'd)

Starter Brush Inspection


1.
11. Measure the brush length. If it is not within the
service limit, replace the armature housing assembly.
Brush Length
Standard (New):
M/T:14.0 - 14.5 mm (0.55 - 0.58 in.)
A/T:15.8 - 16.2 mm (0.62 - 0.64 in.)
Standard (New):
M/T:9.0 mm (0.35 in.)
A/T:11.0 mm (0.43 in.)

Starter Field Winding Test (M/T)


2.

12. Check for continuity between the brushes (A). If there


is no continuity, replace the armature housing (B).

3.

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

Starter Brush Holder Test


1.

14. Check that there is no continuity between the (+)


brush holder (A) and (-) brush holder (B). If there is
no continuity, replace the brush holder assembly.

2.

15. Insert the brush (A) into the brush holder and bring
the brush into contact with the commutator, then
attach a spring scale (B) to the spring (C). Measure
the spring tension at the moment the spring lifts off
the brush.
Spring Tension:
13.7 - 17.7 N (1.4 - 1.8 kgf, 3.07 - 3.97 lbf)

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Engine Electrical - Starting System

Starting System

4-13

Starter Overhaul (cont'd)

1.

16. 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.

17. 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 the armature. The
contact surface of the brushes will be sanded to the same
contour as the commutator.

1.

18. Install the starter end cover (A) to retain the brush
holder (B).

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Engine Electrical - Starting System

Starting System

4-14

Starter Overhaul (cont'd)

Overruning Clutch Inspection


1.

19. Slide the overrunning clutch along the shaft. Replace


it if it does not slide smoothly.
2.
20. Rotate the overrunning clutch (A) both ways.
Does it lock in one direction and rotate smoothly in
reverse? If it does not lock in either direction or it locks in
both directions, replace it.

3.

4.

21. 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,
22. Reassemble the starter in reverse order of
disassembly.

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Engine Electrical - Ignition System

Ignition System

4-15

Component Location Index


1. SPARK PLUG
Inspection, page 4-17
2. IGNITION COIL
Removal/Installation, page 4-20 in the '01
Civic Shop Manual on this CD

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Engine Electrical - Ignition System

Ignition System

4-16

Circuit Diagram

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Engine Electrical - Ignition System

Ignition System

4-17

Spark Plug Inspection

1.

1. Inspect the electrodes and ceramic insulator.


Burned or worn electrodes may be caused by:
Advanced ignition timing
Loose spark plug
Plug heat range too hot
Insufficient cooling
Fouled plug may be caused by:
Retarded ignition timing
Oil in combustion chamber
Incorrect spark plug gap
Plug heat range too cold
Excessive idling/low speed running
Clogged air cleaner element
Deteriorated ignition coils

1.

Engine Type

D17A2,
D17A9

3.

1.
2.
3.
4.

Spark Plug Type

D17A8, ZFR6J-11 (NGK)


ZFR7J-11 (NGK)
KJ20CR-L11 (DENSO)

D17A5

BKR6E-N-11 (NGK)
BKR7E-N-11 (NGK)
K20PR-L11 (DENSO)

2.

2.

3. Replace the plug at the specified interval, or if the


centre electrode is rounded (A). Use only the spark
plugs listed below.
Spark Plugs:

4. Apply a small quantity of anti-seize compound to the


plug threads and screw the plugs into the cylinder
head finger-tight. Then torque them to 18 Nm (1.8
kgf/m, 13 lbf/ft).

Worn or deformed electrodes


Damaged gasket
Cranked Insulator
Improper gap
Oil-fouling
Carbon deposits
Cranked centre electrode insulator

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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Charging System

Charging System

4-18

Circuit Diagram

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Cruise Control

Cruise Control

4-19

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Engine Mechanical - Engine Mechanical

Engine Mechanical

Engine Assembly
Engine Removal

5-2

Engine Installation

5-10

Cylinder Head

6-1

Engine Block

7-1

Engine Lubrication

8-1

Intake Manifold/Exhaust System

9-1

Engine Cooling

10-1

NOTE: Refer to the '01 Civic Shop Manual, P/N 62S5A00on this CD, for items not shown in this section.
Outline of Model Change
D17A8, D17A9 engines have been added.

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Engine Mechanical - Engine Assembly

Engine Assembly

5-2

Engine Removal

NOTE:

1.

1.
2.

3.
4.

Use fender covers to avoid damaging painted


surfaces.
To avoid damage, unplug the wiring connectors
carefully while holding the connector portion.
Mark all wiring and hoses to avoid misconnection.
Also, make sure that they do not contact other wiring
or hoses, or interfere with other parts.
Secure the hood in the wide open position (support
rod in the lower hole).
Make sure you have the anti-theft code for the radio,
then write down the frequencies for the radio's preset
buttons.
Disconnect the battery negative terminal first, then
the positive terminal.
Remove the intake resonator.

1.
2.

5. Remove the battery and battery base.


6. Remove the battery cables (A) from the fuse box and
remove the harness clamps (B).

3.

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

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Engine Mechanical - Engine Assembly

Engine Assembly

5-3

Engine Removal (cont'd)

1.

8. Remove the clutch slave cylinder (A) and clutch line


bracket mounting bolt (B) (M/T).

1.
2.

3.
2.

10. Relieve fuel pressure, refer to the '01 Civic Shop


Manual on this CD (see page 11-130).
11. Remove the evaporative emission (EVAP) canister
hose.

12. Remove the brake booster vacuum hose.

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


(M/T).

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Engine Mechanical - Engine Assembly

Engine Assembly

5-4

Engine Removal (cont'd)

1.

13. Remove the throttle cable (A) and cruise control


cable (B) by loosening the locknuts (C), then slipping
the cable ends out of the accelerator linkage. Take
care not to bend the cables when removing them.
Always replace any kinked cable with a new one.

2.

14. Remove the glove box stops, then open the glove
box.
15. Disconnect the Engine Control Module
(ECM)/Powertrain Control Module (PCM) connectors.

1.

16. Remove the harness clamps (A) and grommet (B),


then pull the engine wire harness through the
bulkhead.

2.

17. Remove the adjusting 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.

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Engine Mechanical - Engine Assembly

Engine Assembly

5-5

Engine Removal (cont'd)

1.
2.

3.

18. Remove the alternator, refer to the '01 Civic Shop


Manual on this CD (see page 4-31).
19. Remove the air conditioning (A/C) hose bracket (A)
and P/S hose bracket (B).

20. Remove the alternator lower bracket (A), then


remove the A/C compressor (B) without
disconnecting the A/C hoses.

1.
2.

21.
22.
23.
24.

Remove the radiator cap.


Raise the hoist to full height.
Remove the front tyres/wheels.
Remove the splash shield.

3.

25. Loosen the drain plug in the radiator, drain the


engine coolant, refer to the '01 Civic Shop Manual on
this CD (see page 10-8).
26. Drain the transmission fluid. Reinstall the drain plug
using a new washer with MTF, refer to the '01 Civic
Shop Manual on this CD (see page 13-3) or ATF,
refer to the '01 Civic Shop Manual on this CD (see
page 14-122).
27. Drain the engine oil. Reinstall the drain bolt using a
new washer (see page 8-3).

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Engine Mechanical - Engine Assembly

Engine Assembly

5-6

Engine Removal (cont'd)

1.

28. Disconnect the Primary Heated Oxygen Sensor


(primary HO2S) connector (A) and Secondary Heated
Oxygen Sensor (secondary HO2S) connector (B),
then remove the exhaust pipe A/Three Way Catalytic
Converter (TWC) (C) (Except D17A5 engine).

2.

29. Remove the shift cable covers (A), then remove the
shift control cable (B) (A/T).

3.

30. Disconnect the suspension lower arm ball joints and


stabiliser links, refer to the '01 Civic Shop Manual on
this CD (see page 18-32).
31. Remove the driveshafts, refer to the '01 Civic Shop
Manual on this CD (see page 16-3). Coat all
precision finished surfaces with clean engine oil. Tie
plastic bags over the driveshaft ends.

1.
2.

32. Lower the hoist.


33. Remove the ground cable (A), upper radiator hose
(B), lower radiator hose (C) and heater hose (D).

3.

34. Remove the heater hose.

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Engine Mechanical - Engine Assembly

Engine Assembly

5-7

Engine Removal (cont'd)

1.

35. Remove the ATF cooler hoses, then plug the ATF
cooler hoses and lines (A/T).

2.

36. Attach the chain hoist to the engine as shown.

1.

37. Remove the front mount mounting bolt.

2.

38. Remove the side engine mount bracket mounting


nuts.

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Engine Mechanical - Engine Assembly

Engine Assembly

5-8

Engine Removal (cont'd)

1.

39. Remove the transmission mount bracket mounting


bolt/nuts.
M/T:

1.
2.

40. Make sure the hoist brackets are positioned properly.


Raise the hoist to full height.
41. Remove the rear mount mounting bolts.

3.

42. Use a marker to make alignment marks on the


reference lines (A) that align with the centres of the
rear sub-frame mounting bolts (B).

4.

43. Remove the front sub-frame.

A/T:

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Engine Mechanical - Engine Assembly

Engine Assembly

5-9

Engine Removal (cont'd)

1.

44. Check that the engine/transmission is completely free


of vacuum hoses, fuel and coolant hoses and
electrical wiring.
45. Slowly lower the engine approximately 150 mm (6
in.). Check once again that all hoses and wires are
disconnected from the engine/transmission.
46. Lower the engine all the way. Remove the chain
hoist from the engine.
47. Remove the engine from under the vehicle.

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Engine Mechanical - Engine Assembly

Engine Assembly

5-10

Engine Installation

1.

1. Install the accessory brackets and tighten their bolts and nuts to the specified torques.
1. REAR STIFFENER
(D17A8, D17A9
engines M/T)
2. REAR STIFFENER
(D17A8, D17A9
engines A/T)
3. P/S PUMP BRACKET
4. ENGINE MOUNT
BRACKET
5. A/C COMPRESSOR
BRACKET
6. STIFFENER
(D17A2, D17A5,
D17A8, D17A9
engines A/T)
7. FRONT STIFFENER
(D17A8, D17A9
engines)

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Engine Mechanical - Engine Assembly

Engine Assembly

5-11

Engine Installation (cont'd)

1.

2. Position the engine under the vehicle. Attach the


chain hoist to the engine, then lift the engine into
position in the vehicle.

1.

4. Tighten the rear mount mounting bolts.

2.

5. Lower the hoist.


6. Tighten the side engine mount bracket mounting
nuts.

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.

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Engine Mechanical - Engine Assembly

Engine Assembly

5-12

Engine Installation (cont'd)

1.

7. Tighten the transmission mount bracket mounting


bolt/nuts.
M/T:

1.

2.

A/T:

8. Tighten the front mount mounting bolt.

9. Remove the chain hoist from the engine.


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, refer to the '01 Civic Shop Manual on
this CD (see page 18-18).
13. Install the shift control cable (A), then install the shift
cable covers (B) (A/T).

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Engine Mechanical - Engine Assembly

Engine Assembly

5-13

Engine Installation (cont'd)

1.

14. Install exhaust pipe A/TWC (A): use new gaskets (B)
and new self-locking nuts (C). Connect the primary
HO2S connector (D) and secondary HO2S connector
(E) (Except D17A5 engine).

2.

15. Install the splash shield.

3.

16. Install the front tyres/wheels.


17. Lower the hoist.

1.

18. Install the ATF cooler hoses (A/T).

2.

19. Install the heater hose.

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Engine Mechanical - Engine Assembly

Engine Assembly

5-14

Engine Installation (cont'd)

1.

20. Connect the upper radiator hose (A), lower radiator


hose (B), heater hose (C) and ground cable (D).

2.

21. Install the A/C compressor (A), then install the


alternator lower bracket (B).

1.

22. Install the A/C hose bracket (A) and P/S hose
bracket (B).

2.

23. Loosely install the alternator.


24. Adjust the alternator belt tension, refer to the '01
Civic Shop Manual on this CD (see page 4-38) or
the alternator-compressor belt tension, refer to the
'01 Civic Shop Manual on this CD (see page 4-37).
25. Loosely install the P/S pump belt and pump.
26. Adjust the P/S pump belt, refer to the '01 Civic Shop
Manual on this CD (see page 17-23).
27. Push the ECM/PCM connectors through the
bulkhead, then install the grommet (A).

3.

28. Install the harness clamps (B).

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Engine Mechanical - Engine Assembly

Engine Assembly

5-15

Engine Installation (cont'd)

1.

29. Connect the ECM/PCM connectors.


RHD models:

1.

2.

31. Install the cruise control cable, then adjust the cable,
refer to the '01 Civic Shop Manual on this CD (see
page 4-48).
32. Install the throttle cable, then adjust the cable, refer
to the '01 Civic Shop Manual on this CD (see page
11-149).
33. Install the brake booster vacuum hose.
RHD models:

LHD models:

LHD models:
2.

30. Install the glove box stops.

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Engine Mechanical - Engine Assembly

Engine Assembly

5-16

Engine Installation (cont'd)

1.

34. Install the EVAP canister hose.

2.

35. Install the select cable (A) and shift cable (B) using
the plastic washers (C), washers (D) and new cotter
pins (E) (M/T).

1.

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

2.

37. Install the battery base.


38. Install the intake air duct (A) and ground cable (B).

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Engine Mechanical - Engine Assembly

Engine Assembly

5-17

Engine Installation (cont'd)

1.

39. Install the battery cable (A) on the under-hood


fuse/relay box, then install the harness clamps (B).

2.

40. Install the intake resonator.

1.

41. Clean the battery posts and cable terminals with


sandpaper, then assemble them and apply grease to
prevent corrosion.
42. Move the shift lever to each gear and verify that the
A/T gear position indicator, follows the transmission
range switch (A/T).
43. Check that the transmission shifts into gear smoothly
(M/T).
44. 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.
45. Refill the engine with engine oil (see page 8-3).
46. Refill the transmission with MTF, refer to the '01
Civic Shop Manual on this CD (see page 13-3) or
ATF, refer to the '01 Civic Shop Manual on this CD
(see page 14-122).
47. Refill the radiator with engine coolant, and bleed air
from the cooling system with the heater valve open,
refer to the '01 Civic Shop Manual on this CD (see
page 10-8).
48. Check the wheel alignment, refer to the '01 Civic
Shop Manual on this CD (see page 18-4).
49. Enter the anti-theft code for the radio, then enter the
customer's radio station presets.

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Engine Mechanical - Engine Mechanical

Engine Mechanical

Cylinder Head
Special Tools

6-2

Component Location Index

6-3

VTEC Rocker Arm Test

6-7

Valve Clearance Adjustment

6-8

Cylinder Head Removal

6-11

Rocker Arms and Shafts Disassembly/Reassembly

6-16

Rocker Arms and Shafts Inspection

6-18

Camshaft Inspection

6-20

Valve Inspection

6-22

Valve Stem-to-Guide Clearance Inspection

6-23

Camshaft/Rocker Arms, Camshaft Seal and Pulley Installation

6-23

Cylinder Head Installation

6-24

NOTE: Refer to the 'CIVIC 4/5 D MAINTENANCE, REPAIR and CONSTRUCTION 01'the other part of this CD for the items not
shown in this section.
Outline of Model Change
D17A8, D17A9 engines have been added.

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Engine Mechanical - Cylinder Head

Cylinder Head

6-2

Special Tools

Ref. No
1
2
3
4
5
6
7
8
9
10
11
12
13

Tool Number
07HAH-PJ70100
07JAA-0010200
07JAB-0010200
07JAB-0010400
07LAJ-PR30101
07LAJ-PR30201
07MAB-PY30100
07NAJ-P070100
07PAD-0010000
07ZAJ-S5A0200
07406-0070001
07742-0010100
07757-0010000

Description
Valve Guide Reamer, 5.525 mm
Socket Wrench, 19 mm
Handle
Pulley Holder Attachment, HEX 50 mm
Valve Inspection Set
Air Stopper
Pulley Holder Attachment, HEX 50 mm
Oil Pressure Gauge Attachment
Stem Seal Driver
Hose, Oil Pressure
Low Pressure Gauge
Valve Guide Driver, 5.5 mm
Valve Spring Compressor

Qty
1
1
1
1
1
1
1
1
1
1
1
1
1

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Engine Mechanical - Cylinder Head

Cylinder Head

6-3

Component Location Index


1.
2.
3.
4.
5.
6.

7.
8.
9.

10.

11.
12.
13.
14.
15.

CYLINDER HEAD COVER


HEAD COVER GASKET
UPPER COVER
RUBBER SEAL
LOWER COVER
CRANKSHAFT PULLEY
Replacement, page 6-16 in the '01 Civic
Shop Manual on this CD
TDC SENSOR
CAMSHAFT PULLEY
CRANKSHAFT PULLEY BOLT
Replacement, 6-16 in the '01 Civic Shop
Manual on this CD
TIMING BELT
Removal, page 6-18 in the '01 Civic Shop
Manual on this CD
Inspection, page 6-18 in the '01 Civic
Shop Manual on this CD
Installation, page 6-22 in the '01 Civic
Shop Manual on this CD
AUTO-TENSIONER
TIMING BELT DRIVE PULLEY
Install with concave surface facing in
CKP SENSOR
SIDE ENGINE MOUNT BRACKET

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Engine Mechanical - Cylinder Head

Cylinder Head

6-4

Component Location Index (cont'd)


1.
2.
3.
4.
5.
6.

WATER PASSAGE
CYLINDER HEAD BOLT
DOWEL PIN
O-RING
CYLINDER HEAD GASKET
GASKET

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Engine Mechanical - Cylinder Head

Cylinder Head

6-5

Component Location Index (cont'd)

D17A2, D17A5, D17A9 engines:


1. CYLINDER HEAD PLUG
2. O-RING
3. ROCKER ARM ASSEMBLY
Overhaul, page 6-16
Inspection, 6-18
4. DOWEL PIN
5. CAMSHAFT
Inspection, page 6-20
6. INTAKE VALVE SPRING
7. SEAL
8. CAMSHAFT PULLEY
9. INTAKE VALVE SEAL
Replacement, page 6-42 in the '01
Civic Shop Manual on this CD
10. VALVE GUIDE
Replacement, page 6-44 in the '01
Civic Shop Manual on this CD
11. BACK COVER
12. RUBBER SEAL
13. EXHAUST VALVE
Inspection, page 6-22
Removal, page 6-42 in the '01 Civic
Shop Manual on this CD
Installation, page 6-48 in the '01
Civic Shop Manual on this CD
14. INTAKE VALVE
Inspection, page 6-22
Removal, page 6-42 in the '01 Civic
Shop Manual on this CD
Installation, page 6-48 in the '01
Civic Shop Manual on this CD
15. CYLINDER HEAD
Removal, page 6-11
Inspection, page 6-34 in the '01
Civic Shop Manual on this CD
Installation, page 6-50 in the '01
Civic Shop Manual on this CD
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

Cylinder Head

6-6

Component Location Index (cont'd)

D17A8 engine:
1. ROCKER ARM ASSEMBLY
Overhaul, page 6-17
Inspection, page 6-18
2. DOWEL PIN
3. CAMSHAFT
Inspection, page 6-20
4. VALVE SPRING
5. SEAL
6. CAMSHAFT PULLEY
7. INTAKE VALVE SEAL
Replacement, page 6-42 in the
'01 Civic Shop Manual on this
CD
8. VALVE GUIDE
Replacement, page 6-44 in the
'01 Civic Shop Manual on this
CD
9. BACK COVER
10. RUBBER SEAL
11. EXHAUST VALVE
Inspection, page 6-22
Removal, page 6-42 in the '01
Civic Shop Manual on this CD
Installation, page 6-48 in the '01
Civic Shop Manual on this CD
12. INTAKE VALVE
Inspection, page 6-22
Removal, page 6-42 in the '01
Civic Shop Manual on this CD
Installation, page 6-48 in the '01
Civic Shop Manual on this CD
13. CYLINDER HEAD
Removal, page 6-11
Inspection, page 6-34 in the '01
Civic Shop Manual on this CD
Installation, page 6-50 in the '01
Civic Shop Manual on this CD
14. VALVE GUIDE
15. VALVE SPRING SEAT
16. EXHAUST VALVE SEAL
17. VALVE SPRING
18. SPRING RETAINER
19. VALVE KEEPERS
20. OIL CONTROL ORIFICE
21. CYLINDER HEAD PLUG
22. O-RING

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Engine Mechanical - Cylinder Head

Cylinder Head

6-7

VTEC Rocker Arm Test

Special Tools Required

1.

1.
2.

3.

4.
5.
6.

2.

Air Stopper, 07LAJ-PR30201


Valve Inspection Set, 07LAJ-PR30101
Remove the resonator (see step 5 on page 6-11).
Remove the ignition coil cover, then remove the four
ignition coils, refer to the '01 Civic Shop Manual on
this CD (see page 4-24).
Remove the throttle cable clamps and harness
holder from the cylinder head cover (see step 21 on
page 6-14).
Remove the cylinder head cover (see step 22 on
page 6-14).
Set the No. 1 piston at TDC (see step 5 on page 68).
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, replace the
primary and secondary rocker arms as an assembly
and retest.
If the intake secondary rocker arm moves freely, go
to step 7.

1.

2.

3.

8. Check that the air pressure on the shop air


compressor gauge indicates over 400 kPa (4
kgf/cm2, 57 psi).
9. Inspect the valve clearance (see page 6-8}.
10. Cover the timing belt with a shop towel to protect the
belt.
11. Plug the relief hole with the air stopper.

12. Remove the sealing bolt (A) from the inspection hole
(B) and connect the valve inspection set.

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

Cylinder Head

6-8 Valve Clearance Adjustment

VTEC Rocker Arm Test (cont'd)

1.

13. Loosen the valve on the regulator and apply the


specified air pressure:
Specified Air Pressure:
250 kPa (2.5 kgf/cm2, 36 psi)
NOTE: If the synchronising piston does not move after
applying air pressure, move the primary or secondary 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 as an assembly
and retest.

3.

15. Remove the special tools.


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

NOTE: Adjust the valves only when the cylinder head


temperature is less than 100F (38C).
1.
1. Remove the ignition coil cover, then remove the four
ignition coils, refer top the '01 Civic Shop Manual on
this CD (see page 4-25).
2. Remove the throttle cable clamps and harness
holder from the cylinder head cover (see step 21 on
page 6-14).
3. Remove the cylinder head cover (see step 22 on
page 6-14).
4. Remove the grommet from the upper cover and
disconnect the TDC sensor connector. Remove the
upper cover, refer to the '01 Civic Shop Manual on
this CD (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.

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Engine Mechanical - Cylinder Head

Cylinder Head

6-9

Valve Clearance Adjustment (cont'd)

1.

2.

6. Select the correct thickness feeler gauge for the


valves you are going to check.
Intake:0.18 - 0.22 mm (0.007 - 0.009 in.)
Exhaust:0.23 - 0.27 mm (0.009 - 0.011 in.)
Adjusting screw location:
INTAKE

1.

8. If you feel too much or too little drag, loosen the


locknut (A) and turn the adjusting screw (B) until the
drag on the feeler gauge is correct.
D17A2, D17A5, D17A9 engines:

D17A8 engine:

EXHAUST
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.

2.

9. Tighten the locknut and recheck the clearance.


Repeat the adjustment if necessary.

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Engine Mechanical - Cylinder Head

Cylinder Head

6-10

Valve Clearance Adjustment (cont'd)

1.

10. Rotate the crankshaft 180 counter-clockwise


(camshaft pulley turns 90). The ''UP'' mark (A) on
the camshaft pulley should be toward the exhaust
side of the head.

2.

11. Check and if necessary, adjust the valve clearance


on No. 3 cylinder.
12. Rotate the crankshaft 180 counter-clockwise to bring
No. 4 piston to TDC. TDC marks (A) are visible
again.

3.

13. Check and if necessary, adjust the valve clearance


on No. 4 cylinder.

1.

14. Rotate the crankshaft 180 counter-clockwise to bring


No. 2 piston to TDC. The ''UP'' mark (A) should be
on the intake side of the head.

2.

15. Check and if necessary, adjust the valve clearance


on No. 2 cylinder.
16. Install the cylinder head cover, refer to the '01 Civic
Shop Manual on this CD on this CD (see page 655).

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Engine Mechanical - Cylinder Head

Cylinder Head

6-11

Cylinder Head Removal

NOTE:

1.

1.

2.
3.
4.

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 100F
(38C) before loosening the cylinder head bolts.
Mark all wiring and hoses to avoid misconnection.
Also, make sure that they do not contact other wiring
or hoses, or interfere with other parts.
Make sure you have the anti-theft code for the radio,
then write down the frequencies for the radio's preset
buttons.
Disconnect the battery negative terminal.
Drain the engine coolant, refer to the '01 Civic Shop
Manual on this CD (see page 10-8).
Remove the throttle cable (A) and cruise control
cable (B) by loosening the locknuts (C), then slipping
the cable ends out of the accelerator linkage. Take
care not to bend the cables when removing them.
Always replace any kinked cable with a new one.

1.

5. Remove the intake resonator.

2.

6. Disconnect the Intake Air Temperature (IAT) sensor


connector (A) and remove the breather hose, then
remove the air cleaner housing (B).

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Engine Mechanical - Cylinder Head

Cylinder Head

6-12

Cylinder Head Removal (cont'd)

1.

7. Remove the brake booster vacuum hose (A) and


positive crankcase ventilation (PCV) hose (B).

2.

8. Relieve fuel pressure, refer to the '01 Civic Shop


Manual on this CD (see page 11-130).
9. Remove the EVAP canister hose.

1.

10. Remove the ground cable (A), upper radiator hose


(B), lower radiator hose (C), heater hose (D) and
water bypass hose (E).

2.

11. Remove the two bolts securing the connecting pipe,


then remove the connecting pipe from the water
passage.

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Engine Mechanical - Cylinder Head

Cylinder Head

6-13

Cylinder Head Removal (cont'd)

1.

12. Remove the adjusting 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.

2.

13. Remove the alternator refer to the '01 Civic Shop


Manual on this CD (see page 4-31).
14. Remove the air conditioning (A/C) hose bracket (A)
and P/S hose bracket (B).

1.

2.

15. Remove the engine wire harness connectors and


wire harness clamps from the intake manifold.
Idle Air Control (IAC) valve connector
Throttle position sensor connector
Manifold Absolute Pressure (MAP) sensor
connector
Evaporative Emission (EVAP) canister purge
valve connector
Engine Coolant Temperature (ECT) sensor
connector
Radiator fan switch connector
CKP sensor connector
TDC sensor connector
Exhaust Gas Recirculation (EGR) connector
(D17A9 engine)
VTEC solenoid valve connector (Except D17A8
engine)
VTEC oil pressure switch connector (Except
D17A8 engine)
Oil pressure sensor connector
16. Support the engine with a jack and wood block
under the oil pan.
17. Remove the upper bracket.

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Engine Mechanical - Cylinder Head

Cylinder Head

6-14

Cylinder Head Removal (cont'd)

1.

18. Remove the cover (A), then remove the exhaust


manifold (B).

1.
2.

2.

20. Remove the four ignition coils refer to the '01 Civic
Shop Manual on this CD (see page 4-24).
21. Remove the throttle cable clamps (A) and harness
holder (B) from the cylinder head cover.

19. Remove the intake manifold.

3.

22. Remove the cylinder head cover.

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Engine Mechanical - Cylinder Head

Cylinder Head

6-15

Cylinder Head Removal (cont'd)

1.
2.

23. Remove the timing belt, refer to the '01 Civic Shop
Manual on this CD (see page 6-18).
24. Remove the camshaft pulley (A) and back cover (B).

3.

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:

4.

26. Remove the cylinder head.

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Engine Mechanical - Cylinder Head

Cylinder Head

6-16

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, refer to the '01 Civic Shop Manual on this CD (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.
D17A2, D17A5, D17A9 engines:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

RUBBER BAND
INTAKE ROCKER SHAFT
COLLAR B
INTAKE ROCKER ARM
ASSEMBLY
COLLAR A
No. 1 CAMSHAFT HOLDER
EXHAUST ROCKER ARM A
Letter "A" is stamped on the rocker
arm
EXHAUST ROCKER SHAFT
Letter "B" is stamped on the rocker
arm
SPRING
EXHAUST ROCKER ARM B
No. 5 CAMSHAFT HOLDER
No. 4 CAMSHAFT HOLDER
No. 3 CAMSHAFT HOLDER
No. 2 CAMSHAFT HOLDER

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Engine Mechanical - Cylinder Head

Cylinder Head

6-17

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, refer to the '01 Civic Shop Manual on this CD (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.
D17A8 engine:
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

Cylinder Head

6-18

Rocker Arms and Shafts Inspection

1.

1. Measure the diameter of the shaft at the first rocker


location.

2.

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

1.

3. Measure the inside diameter of the rocker arm and


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.

3.

1. Inspect rocker arm face for wear

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

Cylinder Head

6-19

Rocker Arms and Shafts Inspection (cont'd)

1.

5. Inspect the synchronising piston (s) (A) and timing


piston (B). Push it manually. If it does not move
smoothly, replace the rocker arm assembly.
NOTE:

1.

6. Assemble each timing plate (A) and return spring (B)


on its camshaft holder as shown (D16W8 engine).

When reassembling the primary rocker arm (C),


carefully apply air pressure to its oil passage.
Apply oil to the pistons when reassembling.
D17A2, D17A5, D17A9 engines:

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Engine Mechanical - Cylinder Head

6-20

Cylinder Head

Camshaft Inspection

NOTE:
Do not rotate the camshaft during inspection.
Remove the rocker arms and rocker shafts.
1.
1. Put the camshaft and the camshaft holders on the
cylinder head, then tighten the bolts to the specified
torque.
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.

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.)

1.

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


in a criss-cross pattern. Then remove the camshaft
holders from the cylinder head.
2.
5. Lift the camshaft out of the cylinder head, wipe it
clean, then inspect the lift ramps. Replace the
camshaft if any lobes are pitted, scored, or
excessively worn.
6. Clean the camshaft journal surfaces in the cylinder
head, then set the camshaft back in place. Place a
plastigauge strip across each journal.
7. Install the camshaft holders, then tighten the bolts to
the specified torque as shown in step 1.
8. Remove the camshaft holders. Measure the widest
portion of plastigauge on each journal.
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.)

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Engine Mechanical - Cylinder Head

6-21

Cylinder Head

Camshaft Inspection (cont'd)

1.

9. Check the total runout with the camshaft supported


on V-blocks.
If the total runout of the camshaft is within the
service limit, replace the cylinder head.
If the total runout is beyond the service limit,
replace the camshaft and recheck the camshaftto-holder oil clearance. If the oil clearance is still
out of tolerance, replace the cylinder head.
Camshaft Total Runout:
Standard (New):0.03 mm (0.001 in.) max.
Service Limit:0.04 mm (0.002 in.)

1.

10. Measure cam lobe height.


Cam Lobe Height Standard (New):
INTAKE

D17A2,
D17A5,
D17A9,
engines

D17A8 engine

PRI

38.604 mm
(1.5198 in.)

SEC

32.848 mm
(1.2932 in.)
35.299 mm
(1.3897 in.)

EXHAUST

38.784 mm
(1.5269 in.)

37.281 mm
(1.4678 in.)

PRI: PrimarySEC: Secondary


IN: IntakeEX: ExhaustT/B: Timing Belt

2.

1. Rotate camshaft while measuring

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Engine Mechanical - Cylinder Head

Cylinder Head

6-22

Valve Inspection

Measure the valve in these areas.

D17A5 engine:

D17A2, D17A8, D17A9 engines:

Intake Valve Dimensions

Intake Valve Dimensions

A Standard (New):29.90 - 30.10 mm

A Standard (New):29.85 - 30.15 mm

(1.177 - 1.185 in.)

(1.175 - 1.187 in.)

B Standard (New):118.27 - 118.87 mm

B Standard (New):118.27 - 118.87 mm

(4.656 - 4.680 in.)

(4.656 - 4.680 in.)

C Standard (New):5.480 - 5.490 mm

C Standard (New):5.480 - 5.490 mm

(0.2157 - 0.2161 in.)

(0.2157 - 0.2161 in.)

C Service Limit:5.45 mm (0.215 in.)

C Service Limit:5.45 mm (0.215 in.)

Exhaust Valve Dimensions

Exhaust Valve Dimensions

A Standard (New):25.90 - 26.10 mm

A Standard (New):25.85 - 26.15 mm

(1.020 - 1.028 in.)

(1.018 - 1.030 in.)

B Standard (New):115.65 - 116.25 mm

B Standard (New):115.65 - 116.25 mm

(4.553 - 4.577 in.)

(4.553 - 4.577 in.)

C Standard (New):5.450 - 5.460 mm

C Standard (New):5.450 - 5.460 mm

(0.2146 - 0.2150 in.)

(0.2146 - 0.2150 in.)

C Service Limit:5.42 mm (0.213 in.)

C Service Limit:5.42 mm (0.213 in.)

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Engine Mechanical - Cylinder Head

Cylinder Head

6-23

Valve Stem-to-Guide Clearance Inspection

1.

1. Slide the valve out of its guide about 10mm, then


measure the guide-to-stem clearance with a dial
indicator while rocking the stem in the direction of
normal thrust (wobble method).
If the measurement exceeds the service limit,
recheck it using a new valve.
If the measurement is now within the service limit,
reassemble using a new valve.
If the measurement with a new valve still exceeds
the service limit, go to step 2.
Intake Valve Stem-to-Guide Clearance:
Standard (New):0.04 - 0.10 mm
(0.002 - 0.004 in.)
Service Limit:0.16 mm (0.006 in.)
Exhaust Valve Stem-to-Guide Clearance:
Standard (New):0.10 - 0.16 mm
(0.004 - 0.006 in.)
Service Limit:0.22 mm (0.009 in.)

NOTE: To prevent the rocker arm assembly from coming apart,


leave the camshaft holder bolts in the holes.
1.
1. After wiping down the camshaft and the journals in
the cylinder head, lubricate both surfaces and install
the camshaft.
2. Clean and install the oil control orifice (A) with a new
O-ring (B) (D17A2, D17A5, D17A9 engines).

2.

2.

Camshaft/Rocker Arms, Camshaft Seal and


Pulley Installation

3. Clean and install the oil control orifice (C) (D17A8


engine).
4. Turn the camshaft until its keyway (D) is facing up
(No. 1 piston TDC).
5. Loosen all the valve adjusting screws.
6. Apply liquid gasket to the head mating surface
(shaded areas) of the No. 1 and No. 5 camshaft
holders.

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

Cylinder Head

6-24

Cylinder Head Installation

Camshaft/Rocker Arms, Camshaft Seal and Pulley


Installation (cont'd)

1.

7. Set the rocker arm assembly in place and loosely


install the bolts. Make sure that the rocker arms are
properly positioned on the valve stems.
2.
8. Tighten each bolt 2 turns at a time, in the sequence
shown below to ensure that the rockers do not bind
on the valves.
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)

Install the cylinder head in the reverse order of removal:


1.
1. Clean the cylinder head and block surface.
2. Install the cylinder head gasket (A) and dowel pins
(B) on the cylinder block. Always use a new cylinder
head gasket.

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

Cylinder Head

6-25

Cylinder Head Installation (cont'd)

1.

4. 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.

1.

6. Apply engine oil to the bolt threads and under the


bolt heads of all the cylinder head bolts.
2.
7. Tighten the cylinder head bolts sequentially in 3
steps.
1st step torque:20 Nm (2.0 kgf/m, 14 lbf/ft)
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

Cylinder Head

6-26

Cylinder Head Installation (cont'd)

1.

2.

8. Install the timing belt, refer to the '01 Civic Shop


Manual on this CD (see page 6-22).
9. Adjust the valve clearance (see page 6-8).
10. Install the cylinder head cover, refer to the '01 Civic
Shop Manual on this CD (see page 6-55).
11. Install the intake manifold (A) and tighten the
bolts/nuts in a criss-cross pattern in 2 or 3 steps,
beginning with the inner nut. Always use a new
intake manifold gasket (B).

1.

13. Install the new exhaust manifold gasket (A) and


exhaust manifold (B). Loosely install the new nuts,
then install the cover (C) and loosely install the new
bolts.

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).

12. Tighten the three nuts securing the intake manifold


and brackets.

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Engine Mechanical - Cylinder Head

6-27

Cylinder Head

Cylinder Head Installation (cont'd)

1.

16. Install the A/C hose bracket (A) and P/S hose
bracket (B).

1.

22. Install the ground cable (A), upper radiator hose (B),
lower radiator hose (C), heater hose (D) and water
bypass hose (E).

2.

17. Loosely install the alternator.


18. Adjust the alternator belt tension, refer to the '01
Civic Shop Manual on this CD (see page 4-38) or
the alternator-compressor belt tension, refer to the
'01 Civic Shop Manual on this CD (see page 4-37).
19. Loosely install the P/S pump belt and pump.
20. Adjust the P/S pump belt, refer to the '01 Civic Shop
Manual on this CD (see page 17-23).
21. Install the connecting pipe (A) with a new O-ring (B).

2.

23. Install the EVAP canister hose.

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Engine Mechanical - Cylinder Head

6-28

Cylinder Head

Cylinder Head Installation (cont'd)

1.

24. Install the brake booster vacuum hose (A) and PCV
hose (B).

2.

25. Install the air cleaner housing (A), then connect the
IAT sensor connector (B) and breather hose.

1.

26. Install the intake resonator.

2.

27. Install the cruise control cable, then adjust the cable,
refer to the '01 Civic Shop Manual on this CD (see
page 4-48).
28. Install the throttle cable, then adjust the cable, refer
to the '01 Civic Shop Manual on this CD (see page
11-149).
29. After installation, check that all tubes, hoses and
connectors are installed correctly.
30. Clean the battery posts and cable terminals with
sandpaper, then assemble them and apply grease to
prevent corrosion.
31. 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.
32. Refill the radiator with engine coolant and bleed air
from the cooling system with the heater valve open,
refer to the '01 Civic Shop Manual on this CD (see
page 10-8).
33. Enter the anti-theft code for the radio, then enter the
customer's radio station presets.

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Engine Mechanical - Engine Mechanical

Engine Mechanical

Engine Block
Special Tools

7-2

Component Location Index

7-3

Crankshaft Main Bearing Replacement

7-5

Connecting Rod Bearing Replacement

7-7

Piston Ring Replacement

7-9

Crankshaft Installation

7-11

NOTE: Refer to the '01 Civic Shop Manual, P/N 62S5A00 on this CD for items not shown in this section.
Outline of Model Change
D17A8, D17A9 engines have been added.

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Engine Mechanical - Engine Block

Engine Block

7-2

Special Tools

Ref. No.
1
2
3
4
5

Tool Number
07LBA-PV00100
07PAF-0010000
07PAF-0010650
07749-0010000
07948-SB00101

Description
Ring Gear Holder
Piston Pin Assembly Tool Set
Pilot Collar, O.D. 19 mm
Handle Driver
Driver Attachment, 96 mm

Qty
1
1
1
1
1

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Engine Mechanical - Engine Block

Engine Block

7-3

Component Location Index


1. DRAIN BOLT
2. WASHER
3. OIL PAN
Installation for Aluminium Type, page 7-24 in the '01
Civic Shop Manual on this CD
4. FLYWHEEL (M/T)
5. CRANKSHAFT
End play, page 7-6 in the '01 Civic Shop Manual on
this CD
Runout, page 7-13 in the '01 Civic Shop Manual on
this CD
Out-of-Round, page 7-13 in the '01 Civic Shop
Manual on this CD
Removal, page 7-11 in the '01 Civic Shop Manual on
this CD
Installation, page 7-11
6. CRANKSHAFT OIL SEAL, TRANSMISSION END
Installation, page 7-11
7. ENGINE BLOCK END COVER
8. DOWEL PIN
9. THRUST WASHERS
10. DOWEL PIN
11. O-RING
12. OIL PUMP
Overhaul, page 8-9 in the '01 Civic Shop Manual on
this CD
13. CRANKSHAFT OIL SEAL, PULLEY END
Installation, page 8-9 in the '01 Civic Shop Manual on
this CD
14. KNOCK SENSOR
Replacement, page 7-26 in the '01 Civic Shop Manual
on this CD
15. MAIN BEARINGS
Oil clearance, page 7-5
Selection, page 7-6
16. GASKET
17. OIL SCREEN
18. MAIN BEARING CAP BRIDGE
19. OIL PAN
Installation for Steel Type, page 7-25 in the '01 Civic
Shop Manual on this CD

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Engine Mechanical - Engine Block

Engine Block

7-4

Component Location Index (cont'd)


1. PISTON RINGS
Replacement, page 7-9
2. PISTON
Removal, page 7-11 in the '01 Civic Shop Manual on this CD
Measurement, page 7-14 in the '01 Civic Shop Manual on this CD
3. PISTON PIN
Removal, page 7-17 in the '01 Civic Shop Manual on this CD
Inspection, page 7-17 in the '01 Civic Shop Manual on this CD
Installation, page 7-17 in the '01 Civic Shop Manual on this CD
4. ENGINE BLOCK
Cylinder bore inspection, page 7-14 in the '01 Civic Shop Manual
on this CD
Warpage inspection, page 7-14 in the '01 Civic Shop Manual on
this CD
Cylinder bore honing, page 7-16 in the '01 Civic Shop Manual on
this CD
Ridge removal, page 7-11 in the '01 Civic Shop Manual on this CD
5. CONNECTING ROD BEARING CAP
6. CONNECTING ROD BEARINGS
Oil Clearance, page 7-7
Selection, page 7-8
7. CONNECTING ROD
End play, page 7-6 in the '01 Civic Shop Manual on this CD
Small end measurement, page 7-17 in the '01 Civic Shop Manual
on this CD

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Engine Mechanical - Engine Block

Engine Block

7-5

Crankshaft Main Bearing Replacement

Main Bearing Clearance Inspection


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

1.

2.

6. If the plastigauge measures too wide or too narrow,


(remove the engine if it is 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 plastigauge 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

Engine Block

7-6

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

Engine Block

7-7

Connecting Rod Bearing Replacement

Rod Bearing Clearance Inspection


1.
1. Remove the connecting rod cap and bearing half.
2. Clean the crankshaft rod journal and bearing half with
a clean shop towel.
3. Place a strip of plastigauge across the rod journal.
4. Reinstall the bearing half and cap and torque the
bolts to 32 Nm (3.3 kgf/m, 24 lbf/ft). Do not rotate the
crankshaft.
5. Remove the rod cap and bearing half and measure
the widest part of the plastigauge.
Connecting Rod Bearing-to-Journal Oil
Clearance:
Standard (New):0.024 - 0.042 mm
(0.0009 - 0.0017 in.)
Service Limit:0.05 mm (0.002 in.)

1.

2.

6. If the plastigauge measures too wide or too narrow,


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 plastigauge shows the clearance is still
incorrect, try the next larger or smaller bearing (the
colour listed above or below that one) and check
clearance 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

Engine Block

7-8

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 is 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: 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

Engine Block

7-9

Piston Ring Replacement

1.

1. Using a ring expander (A), remove the old piston


rings (B).

2.

2. Clean all ring grooves thoroughly with a squared-off


broken ring or ring groove cleaner with a blade to fit
the piston grooves.
The top ring groove is 1.0 mm (0.04 in.) wide. The second
ring groove is 1.2 mm (0.05 in.) wide. The oil ring groove is
2.8 mm (0.11 in.) wide (D17A5 engine) 2.0 mm (0.08 in.)
wide (D17A2, D17A8, D17A9 engines).
File down a blade if necessary.
Do not use a wire brush to clean the ring grooves, or cut
the ring grooves deeper with cleaning tools.
NOTE: If the piston is to be separated from the connecting
rod, do not install new rings yet.

1.

3. Using a piston, push a new ring (A) into the cylinder


bore 15 - 20 mm (0.6 - 0.8 in.) from the bottom.

2.

4. Measure the piston ring end-gap (B) with a feeler


gauge:
If the gap is too small, check to see if you have the
proper rings for your engine.
If the gap is too large, recheck the cylinder bore
diameter against the wear limits, refer to the '01 Civic
Shop Manual on this CD (see page 7-14).
If the bore is over the service limit, the cylinder block
must be rebored.
Piston Ring End-Gap:
Top Ring
Standard (New):0.15 - 0.30 mm
(0.006 - 0.012 in.)
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
D17A5 engine:
Standard (New):0.20 - 0.80 mm
(0.008 - 0.031 in.)
Service Limit:0.90 mm (0.035 in.)
D17A2, D17A8, D17A9 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

Engine Block

7-10

Piston Ring Replacement (cont'd)

1.

5. Install the top ring (A) and second ring (B) as shown.
The manufacturing marks (C) must be facing upward.

1.
2.

3.

6. Rotate the rings in their grooves to make sure they


do not bind.
7. Position the ring end gaps as shown:

8. After installing a new set of rings, measure the ringto-groove clearances:


Top Ring Clearance
D17A5 engine:
Standard (New):0.035 - 0.055 mm
(0.0014 - 0.0022 in.)
Service Limit:0.13 mm (0.005 in.)
D17A2, D17A8, D17A9 engines:
Standard (New):0.035 - 0.060 mm
(0.0014 - 0.0024 in.)
Service Limit:0.13 mm (0.005 in.)
Second Ring Clearance
Standard (New):0.030 - 0.055 mm
(0.0012 - 0.0022 in.)
Service Limit:0.13 mm (0.005 in.)

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Engine Mechanical - Engine Block

Engine Block

7-11

Crankshaft Installation

Special Tools Required


Handle Driver, 07749-0010000
Driver Attachment, 96 mm, 07948-SB00101
1.
1. Apply engine oil to the main bearings and rod
bearings.
2. Install the bearing halves in the cylinder block and
connecting rods.
3. Hold the crankshaft so rod journal No. 2 and rod
journal No. 3 are straight up and lower the crankshaft
into the block.
4. Install the thrust washers (A) on both edges of the
No. 4 main bearing recess.

1.

10. Check the main bearing clearance with plastigauge


(see page 7-5).
11. Install the bearing cap bridge. Coat the bolt threads
with engine oil.
12. Torque the cylinder head bolts sequentially in 2
steps.
1st step torque:25 Nm (2.5 kgf/m, 18 lbf/ft)
2nd step torque: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
plastigauge (see page 7-7).
9. Tighten the connecting rod bolts to 32 Nm (3.3 kgf/m,
24 lbf/ft).

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Engine Mechanical - Engine Block

Engine Block

7-12

Crankshaft Installation (cont'd)

1.

2.

3.

13. The seal mating surface on the engine block end


cover should be dry. Apply a light coat of grease to
the crankshaft and to the lip of the seal.
14. Drive the crankshaft oil seal squarely into the engine
block end cover.

1.

16. Clean and dry the engine block end cover mating
surfaces.
2.
17. Apply liquid gasket, part No. 08718-0001 or 087180003, evenly to the 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.

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

Engine Block

7-13

Crankshaft Installation (cont'd)

1.

19. Clean and dry the oil pump mating surfaces.


20. Install the oil pump (A).
1. Install a new crankshaft oil seal in the oil pump,
refer to the '01 Civic Shop Manual on this CD
(see step 12 on page 8-11).
2. Apply liquid gasket, part No. 08718-0001 or
08718-0003, evenly to the block mating surface of
the oil pump and to the inner threads of the bolt
holes.
3. Grease the lip of the oil seal and apply oil to the
new O-ring (B).
4. Install the dowel pins (C), then align the inner
rotor with the crankshaft and install the oil pump.
5. Clean the excess grease off the crankshaft and
check the seal for distortion.

2.

21. Install the oil screen (D) with a new gasket (E).
22. Install the oil pan, refer to the '01 Civic Shop Manual
on this CD (see page 7-24).

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Engine Mechanical - Engine Mechanical

Engine Mechanical

Engine Lubrication
Component Location Index

8-2

Engine Oil Replacement

8-3

NOTE: Refer to the '01 Civic Shop Manual, P/N 62S5A00 on this CD for items not shown in this section.
Outline of Model Change
D17A8, D17A9 engines have been added.

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Engine Mechanical - Engine Lubrication

Engine Lubrication

8-2

Component Location Index


1. DOWEL PIN
2. O-RING
3. OIL PRESSURE SWITCH
Circuit Diagram, page 22-88, in the '01 Civic Shop Manual
on this CD
Switch Test, page 8-4, in the '01 Civic Shop Manual on
this CD
Oil Pressure Test, page 8-4, in the '01 Civic Shop Manual
on this CD
Replacement, page 8-12, in the '01 Civic Shop Manual on
this CD
4. OIL FILTER
Replacement, page 8-6, in the '01 Civic Shop Manual on
this CD
5. OIL/AIR SEPARATOR
Installation, page 8-12, in the '01 Civic Shop Manual on
this CD
6. BREATHING PORT COVER
7. WASHER
8. DRAIN BOLT
Engine Oil Replacement, page 8-3
9. OIL PAN
Installation, for Aluminium Type page 7-24, in the '01 Civic
Shop Manual on this CD
10. OIL PAN
Installation, for Steel Type, page 7-25, in the '01 Civic
Shop Manual on this CD
11. BAFFLE PLATE
12. OIL SCREEN
13. GASKET
14. OIL PUMP
Overhaul, page 8-9, in the '01 Civic Shop Manual on this
CD

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/8-2.htm[8/25/2012 6:24:30 PM]

Engine Mechanical - Engine Lubrication

Engine Lubrication

8-3

Engine Oil Replacement

NOTE: Under normal conditions, the oil filter should be


replaced at every other oil change. Under severe conditions,
the oil filter should be replaced at each oil change.
Change interval
Every 10,000 miles (16,000 km) or 12 months
(Normal conditions)
Every 5,000 miles (8,000 km) or 6 months
(Severe conditions)
1.
1. Warm up the engine.
2. Remove the drain bolt (A) and drain the engine oil.
Except D17A8 engine:

1.

4. Refill with the recommended oil (see page 3-2).


Capacity
Except D17A8 engine:
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.
D17A8 engine:
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.
2.
5. Run the engine for more than 3 minutes then check
for oil leakage.

D17A8 engine:

2.

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

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/8-3.htm[8/25/2012 6:24:30 PM]

Engine Mechanical - Engine Mechanical

Engine Mechanical

Intake Manifold and Exhaust System


Exhaust Manifold Removal and Installation

9-2

Exhaust Pipe and Muffler Replacement

9-3

NOTE: Refer to the '01 Civic Shop Manual, P/N 62S5A00 on this CD for items not shown in this section.
Outline of Model Change
D17A8, D17A9 engines have been added.

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/9-1.htm[8/25/2012 6:24:30 PM]

Engine Mechanical - Intake Manifold and Exhaust System

Intake Manifold and Exhaust System

9-2

Exhaust Manifold Removal and Installation

NOTE: Use a new gasket when reassembling.


1.
2.
3.
4.

COVER
GASKET, Replace.
EXHAUST MANIFOLD
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

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/9-2.htm[8/25/2012 6:24:30 PM]

Engine Mechanical - Intake Manifold and Exhaust System

Intake Manifold and Exhaust System

9-3

Exhaust Pipe and Muffler Replacement

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


D17A2, D17A8, D17A9 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. HEAT SHIELD
5. 6 x 1.0 mm, 9.8 Nm (1.0 kgf/m, 7.2
lbf/ft)
6. EXHAUST PIPE B
7. GASKET, Replace.
8. EXHAUST PIPE A/THREE WAY
CATALYTIC CONVERTER
ASSEMBLY
9. PRIMARY HEATED OXYGEN
SENSOR (PRIMARY HO2S)
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. GASKET, Replace.
12. SECONDARY HEATED OXYGEN
SENSOR (SECONDARY HO2S)
44 Nm (4.5 kgf/m, 33 lbf/ft)
13. SELF-LOCKING NUT
10 x 1.25 mm, 33 Nm (3.4 kgf/m, 25
lbf/ft), Replace.

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/9-3.htm[8/25/2012 6:24:31 PM]

Engine Mechanical - Intake Manifold and Exhaust System

Intake Manifold and Exhaust System

9-4

Exhaust Pipe and Muffler Replacement (cont'd)

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


D17A5 engine:
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. HEAT SHIELD
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 Nm (3.4
kgf/m, 25 lbf/ft), Replace.

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/9-4.htm[8/25/2012 6:24:31 PM]

Engine Cooling - Engine Cooling

Engine Cooling
Cooling System

Component Location Index

10-2

Fan Controls
Circuit Diagram

10-5

NOTE: Refer to the '01 Civic Shop Manual, P/N62S5A00 on this CD for items not shown in this section.
Outline of Model Change
D17A8, D17A9 engines have been added.

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/10-1.htm[8/25/2012 6:23:23 PM]

Engine Cooling - Cooling System

Cooling System

10-2

Component Location Index

DENSO:
1. A/C CONDENSER FAN ASSEMBLY
Replacement, page 10-11 in the '01 CIVIC
Shop Manual on this CD
Fan Motor Test, page 10-6 in the '01 CIVIC
Shop Manual on this CD
2. O-RING
3. UPPER RADIATOR HOSE
4. RADIATOR CAP
5. RADIATOR
Replacement, page 10-11 in the '01 CIVIC
Shop Manual on this CD
6. COOLANT RESERVOIR
7. LOWER RADIATOR HOSE
8. ATF COOLER HOSES
9. DRAIN PLUG
10. RADIATOR FAN
Replacement, page 10-11 in the '01 CIVIC
Shop Manual on this CD
11. RADIATOR FAN SHROUD
Replacement, page 10-11 in the '01 CIVIC
Shop Manual on this CD
12. RADIATOR FAN MOTOR
Test, page 10-6 in the '01 CIVIC Shop Manual
on this CD
Replacement, page 10-11 in the '01 CIVIC
Shop Manual on this CD

TOYO RADIATOR:
1. A/C CONDENSER FAN ASSEMBLY
Replacement, page 10-11 in the '01 CIVIC
Shop Manual on this CD
Fan Motor Test, page 10-6 in the '01 CIVIC
Shop Manual on this CD
2. O-RING
3. UPPER RADIATOR HOSE
4. RADIATOR CAP
5. RADIATOR
Replacement, page 10-11 in the '01 CIVIC
Shop Manual on this CD
6. COOLANT RESERVOIR
7. LOWER RADIATOR HOSE
8. ATF COOLER HOSES
9. DRAIN PLUG
10. RADIATOR FAN
Replacement, page 10-11 in the '01 CIVIC
Shop Manual on this CD
11. RADIATOR FAN MOTOR
Test, page 10-6 in the '01 CIVIC Shop Manual
on this CD
Replacement, page 10-11 in the '01 CIVIC
Shop Manual on this CD
12. RADIATOR FAN SHROUD
Replacement, page 10-11 in the '01 CIVIC
Shop Manual on this CD

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/10-2.htm[8/25/2012 6:23:23 PM]

Engine Cooling - Cooling System

Cooling System

10-3

Component Location Index (cont'd)

RHD models:
1.
2.
3.
4.
5.

WATER BYPASS HOSE


WATER PASSAGE
CONNECTING PIPE
HEATER HOSES
HEATER VALVE

1.
2.
3.
4.
5.

WATER BYPASS HOSE


WATER PASSAGE
CONNECTING PIPE
HEATER VALVE
HEATER HOSES

LHD models:

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/10-3.htm[8/25/2012 6:23:23 PM]

Engine Cooling - Cooling System

Cooling System

10-4

Component Location Index (cont'd)


1. O-RING
2. GASKET
3. EXHAUST GAS RECIRCULATION (EGR)
VALVE, (D7A9 engine)
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
in the '01 CIVIC Shop Manual on this CD
Replacement, page 10-7
in the '01 CIVIC Shop Manual on this CD

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/10-4.htm[8/25/2012 6:23:23 PM]

Fan Controls

Fan Controls

10-5

Circuit Diagram

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/10-5.htm[8/25/2012 6:23:23 PM]

Fuel and Emissions - Fuel and Emissions

Fuel and Emissions


KB, KE, KG, KR models

11-1

KK, KX, KY models

11-75

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/11-0.htm[8/25/2012 6:23:24 PM]

KB, KE, KG, KR models

KB, KE, KG, KR models

Fuel and Emissions Systems


DTC Troubleshooting Index

11-2

Symptom Troubleshooting Index

11-5

System Descriptions

11-6

PGM-FI System
Component Location Index

11-51

DTC Troubleshooting

11-54

MIL Circuit Troubleshooting

11-56

Idle Control System


Component Location Index

11-68

PSP Switch Signal Circuit Troubleshooting

11-69

Idle Speed Adjustment

11-71

Fuel Supply System


Component Location Index

11-72

Fuel Tank Replacement

11-73

Refer to the 2001 Civic Shop Manual, P/N 62S5A000 on this CD [4-door (KB, KE, KG, TR models)], for items not shown in this
section.
Outline of Civic Coupe Model Change
D17A8, D17A9 engine has been added.

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/11-1.htm[8/25/2012 6:23:24 PM]

Fuel and Emissions - Fuel and Emissions Systems

11-2

Fuel and Emissions Systems


DTC Troubleshooting Index
Scan tool DTC

Honda DTC

Detection Item

Page

DTC

Temporary
DTC

DTC (MIL
Indication*)

Temporary
DTC

P0107

3-1 (3)

Manifold Absolute Pressure (MAP) Sensor


Circuit Low Voltage

Refer to the '01 Civic Shop


Manual on this CD (see page
11-59)

P0108

3-2 (3)

Manifold Absolute Pressure (MAP) Sensor


Circuit High Voltage

Refer to the '01 Civic Shop


Manual on this CD (see page
11-60)

P0112

10-1 (10)

Intake Air Temperature (IAT) Sensor Circuit


Low Voltage

Refer to the '01 Civic Shop


Manual on this CD (see page
11-61)

P0113

10-2 (10)

Intake Air Temperature (IAT) Sensor Circuit


High Voltage

Refer to the '01 Civic Shop


Manual on this CD (see page
11-62)

P0117

6-1 (6)

Engine Coolant Temperature (ECT) Sensor


Circuit Low Voltage

Refer to the '01 Civic Shop


Manual on this CD (see page
11-63)

P0118

6-2 (6)

Engine Coolant Temperature (ECT) Sensor


Circuit High Voltage

Refer to the '01 Civic Shop


Manual on this CD (see page
11-64)

P0122

7-1 (7)

Throttle Position (TP) Sensor Circuit Low


Voltage

Refer to the '01 Civic Shop


Manual on this CD (see page
11-65)

P0123

7-2 (7)

Throttle Position (TP) Sensor Circuit High


Voltage

Refer to the '01 Civic Shop


Manual on this CD (see page
11-67)

P0131

1-1 (1)

Primary Heated Oxygen Sensor (Primary


HO2S) (Sensor 1) Circuit Low Voltage

Refer to the '01 Civic Shop


Manual on this CD (see page
11-68)

P0132

1-2 (1)

Primary Heated Oxygen Sensor (Primary


HO2S) (Sensor 1) Circuit High Voltage

Refer to the '01 Civic Shop


Manual on this CD (see page
11-69)

P0133

P0133

61-1 (61)

T61-1

Primary Heated Oxygen Sensor (Primary


HO2S) (Sensor 1) Slow Response

Refer to the '01 Civic Shop


Manual on this CD (see page
11-70)

P0135

41-2 (41)

P0137

P0137

63-1 (63)

T63-1

Secondary Heated Oxygen Sensor


(Secondary HO2S) (Sensor 2) Circuit Low
Voltage

Refer to the '01 Civic Shop


Manual on this CD (see page
11-73)

P0138

P0138

63-2 (63)

T63-2

Secondary Heated Oxygen Sensor


(Secondary HO2S) (Sensor 2) Circuit High
Voltage

Refer to the '01 Civic Shop


Manual on this CD (see page
11-74)

P0139

P0139

63-3 (63)

T63-3

Secondary Heated Oxygen Sensor


(Secondary HO2S) (Sensor 2) Slow
Response

Refer to the '01 Civic Shop


Manual on this CD (see page
11-75)

Primary Heated Oxygen Sensor (Primary


Refer to the '01 Civic Shop
HO2S) (Sensor 1) Heater Circuit Malfunction Manual on this CD (see page
11-71)

*:These DTCs will be indicated by the blinking of the Malfunction Indicator Lamp (MIL) when SCS short connector is connected.

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/11-2.htm[8/25/2012 6:23:26 PM]

Fuel and Emissions - Fuel and Emissions Systems

**:The D indicator light and the Malfunction Indicator Lamp (MIL) may come on simultaneously.
*1:D17A9 engine
*2:A/T
*3:M/T

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/11-2.htm[8/25/2012 6:23:26 PM]

Fuel and Emissions - Fuel and Emissions Systems

11-3

Fuel and Emissions Systems

DTC Troubleshooting Index (cont'd)


Scan tool DTC

Honda DTC

Detection Item

Page

DTC

Temporary
DTC

DTC (MIL
Indication*)

Temporary
DTC

P0141

65-2 (65)

P0171

P0171

45-2 (45)

T45-2

Fuel system Too Lean

(see page 11-54)

P0172

P0172

45-1 (45)

T45-1

Fuel system Too Rich

(see page 11-54)

P0300 and
some of
P0301
P0302
P0303
P0304

71-1 (71)
72-1 (72)

Random Misfire

(see page 11-55)

P0301

P0301

71-1(71)

T71-1

No. 1 Cylinder Misfire

Refer to the '01 Civic Shop


Manual on this CD (see page
11-80)

P0302

P0302

72-1(72)

T72-1

No. 2 Cylinder Misfire

Refer to the '01 Civic Shop


Manual on this CD (see page
11-80)

P0303

P0303

73-1(73)

T73-1

No. 3 Cylinder Misfire

Refer to the '01 Civic Shop


Manual on this CD (see page
11-80)

P0304

P0304

74-1(74)

T74-1

No. 4 Cylinder Misfire

Refer to the '01 Civic Shop


Manual on this CD (see page
11-80)

P0325

23-1 (23)

Knock Sensor Circuit Malfunction

Refer to the '01 Civic Shop


Manual on this CD (see page
11-85)

P0335

4-1 (4)

Crankshaft Position (CKP) Sensor No Signal Refer to the '01 Civic Shop
Manual on this CD (see page
11-88)

P0336

4-2 (4)

Crankshaft Position (CKP) Sensor


Intermittent Interruption

P0401*1

P0401*1

80-1 (80)*1

T80-1*1

P0420

P0420

67-1 (67)

T67-1

P0443

92-4 (92)

Evaporative Emission (EVAP) Canister Purge Refer to the '01 Civic Shop
Valve Circuit Malfunction
Manual on this CD (see page
11-161)

P0500*3

17-1 (17)

Vehicle Speed Sensor (VSS) Circuit


Malfunction

Refer to the '01 Civic Shop


Manual on this CD (see page
11-90)

P0501*2

17-2*2

Vehicle Speed Sensor (VSS)


Range/Performance

Refer to the '01 Civic Shop


Manual on this CD (see page
11-90)

Refer to the '01 Civic Shop


Secondary Heated Oxygen Sensor
(Secondary HO2S) (Sensor 2) Heater Circuit Manual on this CD (see page
11-76)
Malfunction

73-1 (73)
74-1 (74)

Refer to the '01 Civic Shop


Manual on this CD (see page
11-88)

Exhaust Gas Recirculation (EGR) Insufficient Refer to the '01 Civic Shop
Flow
Manual on this CD (see page
11-154)
Catalyst System Efficiency Below Threshold

Refer to the '01 Civic Shop


Manual on this CD (see page
11-153)

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/11-3.htm[8/25/2012 6:23:29 PM]

Fuel and Emissions - Fuel and Emissions Systems

*: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:D17A9 engine
*2:A/T
*3:M/T

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/11-3.htm[8/25/2012 6:23:29 PM]

Fuel and Emissions - Fuel and Emissions Systems

11-4

Fuel and Emissions Systems

DTC Troubleshooting Index (cont'd)


Scan tool DTC

Honda DTC

Detection Item

Page

DTC

Temporary
DTC

DTC (MIL
Indication*)

Temporary
DTC

P0563

34-2 (34)

Engine Control Module (ECM)/Powertrain


Control Module (PCM) Power Source Circuit
Unexpected Voltage

Refer to the '01 Civic Shop


Manual on this CD (see page
11-91)

P0600

39-1 (39)

Serial Communication Link Malfunction

Refer to the Multiplex Control


System Troubleshooting,
refer to the '01 Civic Shop
Manual on this CD (see page
22-273).

P07xx** *2

70-2 (70)*2

Automatic Transaxle System Malfunction*2

Refer to the Automatic


Transmission DTC
Troubleshooting Index

P1107

13-1 (13)

Barometric Pressure (BARO) Sensor Circuit


Low Voltage

Refer to the '01 Civic Shop


Manual on this CD (see page
11-93)

P1108

13-2 (13)

Barometric Pressure (BARO) Sensor Circuit


High Voltage

Refer to the '01 Civic Shop


Manual on this CD (see page
11-93)

P1259*1

22-4 (22)*1

VTEC System Malfunction*1

Refer to the '01 Civic Shop


Manual on this CD (see page
11-94)

P1324

23-2 (23)

Knock Sensor Power Source Circuit Low


Voltage

Refer to the '01 Civic Shop


Manual on this CD (see page
11-87)

P1361

8-2 (8)

Top Dead Centre (TDC) Sensor Intermittent


Interruption

Refer to the '01 Civic Shop


Manual on this CD (see page
11-98)

P1362

8-1 (8)

Top Dead Centre (TDC) Sensor No Signal

Refer to the '01 Civic Shop


Manual on this CD (see page
11-98)

P1491*1

P1491*1

12-3 (12)*1

T12-3*1

Exhaust Gas Recirculation (EGR) Valve


Insufficient Lift

Refer to the '01 Civic Shop


Manual on this CD (see page
11-154)

P1498*1

12-2 (12)*1

Exhaust Gas Recirculation (EGR) Valve


Position Sensor Circuit High Voltage

Refer to the '01 Civic Shop


Manual on this CD (see page
11-158)

P1519

14-3 (14)

Idle Air Control (IAC) Valve Circuit


Malfunction

Refer to the '01 Civic Shop


Manual on this CD (see page
11-117)

P1607

0-2

Engine Control Module (ECM)/Powertrain


Control Module (PCM) Internal Circuit
Malfunction

Refer to the '01 Civic Shop


Manual on this CD (see page
11-99)

P17xx** *2

70-3 (70)*2

Automatic Transaxle System Malfunction*2

Refer to the Automatic


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.

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/11-4.htm[8/25/2012 6:23:31 PM]

Fuel and Emissions - Fuel and Emissions Systems

*1:D17A9 engine
*2:A/T

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/11-4.htm[8/25/2012 6:23:31 PM]

Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-5

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
Engine will not start
(MIL works OK, no DTCs set)

Diagnostic procedure

1. Test the battery, refer to the '01 Civic


Shop Manual on this CD (see page
22-79).
2. Test the starter, refer to the '01 Civic
Shop Manual on this CD (see page 48).
3. Troubleshoot the fuel pump circuit,
refer to the '01 Civic Shop Manual on
this CD (see page 11-127).

Also check for

Low compression
Intake air leaks
Locked up engine
Slipped/ broken timing belt
Contaminated fuel

Engine will not start (MIL comes on and stays Troubleshoot the MIL circuit (see page 11-56).
on, or never comes on at all, no DTCs set)
Engine will not start
(immobiliser indicator light comes on)
Hard starting
(MIL works OK, no DTCs set)

Cold fast idle too low


(MIL works OK, no DTCs set)
Cold fast idle too high
(MIL works OK, no DTCs set)

Idle speed fluctuates


(MIL works OK, no DTCs set)

After warming up idle speed is below


specifications with no load
(MIL works OK, no DTCs set)

After warming up idle speed is above


specifications with no load

Troubleshoot the immobiliser system, refer to the


'01 Civic Shop Manual on this CD (see page 22245).

1. Test the battery, refer to the '01 Civic


Shop Manual on this CD (see page
22-79).
2. Check the fuel pressure, refer to the
'01 Civic Shop Manual on this CD
(see page 11-131).

Low compression
Intake air leaks
Contaminated fuel

Check the idle speed, refer to the '01 Civic Shop


Manual on this CD (see page 11-125).

1. Check the idle speed (see page 1171).


2. Inspect/adjust the throttle cable, refer
to the '01 Civic Shop Manual on this
CD (see page 11-149).
3. Inspect and test the throttle body, refer
to the '01 Civic Shop Manual on this
CD (see page 11-145).
1. Check the idle speed (see page 11- Intake air leaks
71).
2. Inspect/adjust the throttle cable, refer
to the '01 Civic Shop Manual on this
CD (see page 11-149).
3. Inspect and test the throttle body, refer
to the '01 Civic Shop Manual on this
CD (see page 11-145).
1. Troubleshoot the ALT FR signal
Vacuum hose clogged/cracked/poor
connection
circuit, refer to the '01 Civic Shop
Manual on this CD (see page 11-120).
2. Inspect and test the throttle body, refer
to the '01 Civic Shop Manual on this
CD (see page 11-145).
Troubleshoot the ALT FR signal circuit, refer to
the '01 Civic Shop Manual on this CD (see page

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Fuel and Emissions - Fuel and Emissions Systems


(MIL works OK, no DTCs set)
Low power
(MIL works OK, no DTCs set)

Engine stalls
(MIL works OK, no DTCs set)

11-120).

1. Check the fuel pressure, refer to the Low compression


'01 Civic Shop Manual on this CD
(see page 11-131).
2. Inspect and test the throttle body, refer
to the '01 Civic Shop Manual on this
CD (see page 11-145).
3. Inspect/adjust the throttle cable, refer
to the '01 Civic Shop Manual on this
CD (see page 11-149).
1. Check the fuel pressure, refer to the
'01 Civic Shop Manual on this CD
(see page 11-131).
2. Check the idle speed (see page 1171).
3. Troubleshoot the brake pedal position
switch signal circuit, refer to the '01
Civic Shop Manual on this CD (see
page 11-123).

Intake air leaks


Faulty harness and sensor
connections

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-6

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

11-7

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 Value

Freeze Data

Diagnostic Trouble Code


(DTC)

If the ECM/PCM detects a problem, it will store it as a


code consisting of one letter and four numbers.
Depending on the problem, an SAE-defined code
(P0xxx) or a Honda-defined code (P1xxx) will be
output to the tester.

If no problem is detected,
there is no output.

YES

Engine Speed

The ECM/PCM computes engine speed from the


signals sent from the Crankshaft Position (CKP)
sensor. This data is used for determining the time and
amount of injected fuel.

Nearly the same as


tachometer indication

YES

Vehicle Speed

The ECM/PCM converts pulse signals from Vehicle


Speed Sensor (VSS).

Nearly the same as


speedometer indication

YES

Manifold Absolute
Pressure (MAP)

The absolute pressure caused in the intake manifold


by engine load and speed.

With engine stopped:


Nearly the same as
atmospheric pressure

YES

At idle speed: 700+50 rpm


(min-1)

At idle speed: about 20-34


kPa (150-260 mmHg, 6-10
in.Hg), 0.7-1.1 V
Engine Coolant
Temperature (ECT)

Primary Heated Oxygen


Sensor (Primary HO2S)
(Sensor 1), Secondary
Heated Oxygen Sensor
(Secondary HO2S)
(Sensor 2)

The ECT sensor converts coolant temperature into


voltage and signals the ECM/PCM. The sensor is a
thermistor whose internal resistance changes with
coolant temperature. The ECM/PCM uses the voltage
signals from the ECT sensor to determine the amount
of injected fuel.

With cold engine: Same as


ambient temperature and
IAT

YES

With engine warmed up:


about 80-100C (176212F), 0.5-0.8 V

The HO2S detects the oxygen content in the exhaust 0.0-1.25 V


gas and sends voltage signals to the ECM/PCM.
At idle speed: about 0.1Based on these signals, the ECM/PCM controls the air 0.9 V
fuel ratio. When the oxygen content is high (that is,
when the ratio is leaner than the stoichiometric ratio),
the voltage signal is lower. When the oxygen content is
low (that is, when the radio is richer than the
stoichiometric ratio), the voltage signal is higher.

NO

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-8

System Descriptions (cont'd)

ECM/PCM Data (cont'd)


Data
Fuel System Status

Description

Operating Value

Fuel system status is indicated as ''open'' or ''closed''. At idle speed: closed

Freeze Data
YES

Closed: Based on the HO2S output, the ECM/PCM


determines the air/fuel ratio and controls the amount
of injected fuel.
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 Fuel Trim

0.6-1.5

YES

0.8-1.2
Long term fuel trim is computed from short term fuel
trim and indicates changes occurring in the fuel supply
system over a long period.

YES

The air/fuel ratio correction coefficient for correcting


the amount of injected fuel when the 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 Fuel Trim

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 Temperature
(IAT)

The IAT sensor converts intake air temperature into


voltage and signals the ECM/PCM. When intake air
temperature is low, the internal resistance of the
sensor increases and the voltage signal is higher.

With cold engine:

Throttle Position

Based on the accelerator pedal position, the opening


angle of the throttle valve is indicated.

At idle speed:

Ignition Timing

YES

Same as ambient
temperature and ECT
YES

about 10 %

Ignition timing is the ignition advance angle set by the At idle speed: 8+2
ECM/PCM. The ECM/PCM matches ignition timing to BTDC when the SCS short
the driving conditions.
connector is connected

NO

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Fuel and Emissions - Fuel and Emissions Systems

11-9

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 colour
number
1

BLK/WHT

YEL/BLK

Terminal name
PO2SHTC (PRIMARY
HEATED OXYGEN
SENSOR (PRIMARY
HO2S) HEATER
CONTROL)

Description
Drives primary HO2S
heater

IGP2 (POWER SOURCE) Power source for the


ECM/PCM circuit

Signal
With ignition switch ON (II): battery voltage
With fully warmed up engine running: duty
controlled

With the ignition switch ON (II): battery


voltage
With the ignition switch OFF: about 0 V

YEL/BLK

IGP1 (POWER SOURCE) Power source for the


ECM/PCM circuit

With the ignition switch ON (II): battery


voltage
With the ignition switch OFF: about 0 V

BLK

PG2 (POWER GROUND)

Ground for the ECM/PCM Less than 1.0 V at all times


circuit

BLK

PG1 (POWER GROUND)

Ground for the ECM/PCM Less than 1.0 V at all times


circuit

WHT

PHO2S (PRIMARY
HEATED OXYGEN
SENSOR (PRIMARY
HO2S), SENSOR 1)

Detects primary HO2S


sensor (sensor 1) signal

With throttle fully opened from idle with fully


warmed up engine: about 0.6 V
With throttle quickly closed: below 0.4 V

BLU

CKP (CRANKSHAFT
POSITION (CKP)
SENSOR)

Detects CKP sensor


signal

With engine running: pulses

YEL

VCCR (SENSOR
VOLTAGE RETURN)

Detects sensor voltage

With ignition switch ON (II): about 5 V

KS (KNOCK SENSOR)

Detects knock sensor


signal

RED/BLU

10

GRN/YEL

11
12
13*1

With the ignition switch OFF: about 0 V


With engine knocking: pulses
With ignition switch ON (II): about 5 V

SG2 (SENSOR GROUND) Sensor ground

Less than 1.0 V at all times

GRN/WHT

SG1 (SENSOR GROUND) Sensor ground

Less than 1.0 V at all times

BLK/RED

IACV (IDLE AIR


CONTROL (IAC) VALVE)

Drives IAC valve

With engine running: duty controlled

EGRP (EXHAUST GAS


RECIRCULATION (EGR)
VALVE POSITION
SENSOR)

Detects EGR valve


position sensor signal

WHT/BLK

With ignition switch ON (II): about 5 V


With engine running: 1.2 V-2.0 V
(depending on EGR valve lift)

15

RED/BLK

TPS (THROTTLE
Detects TP sensor signal With throttle fully open: about 4.8 V
POSITION (TP) SENSOR)
With throttle fully closed: about 0.5 V

18

WHT/GRN

VSS (VEHICLE SPEED

Detects VSS signal

With ignition switch ON (II) and front wheels

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Fuel and Emissions - Fuel and Emissions Systems


SENSOR (VSS))

rotating: cycles 0 V-about 5 V or battery


voltage

*1:D17A9 engine
*2:A/T

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-10

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

19

GRN/RED

MAP (MANIFOLD
ABSOLUTE
PRESSURE (MAP)
SENSOR)

20

YEL/BLU

VCC2 (SENSOR
VOLTAGE)

Provides sensor
voltage

With ignition switch ON (II): about 5 V

VCC1 (SENSOR
VOLTAGE)

Provides sensor
voltage

With ignition switch ON (II): about 5 V

21

YEL/RED

Detects MAP sensor


signal

With ignition switch ON (II): about 3 V


At idle: about 1.0 V (depending on engine
speed)

With ignition switch OFF: about 0 V

With ignition switch OFF: about 0 V

23

BRN/YEL

LG2 (LOGIC GROUND)

Ground for the


ECM/PCM circuit

Less than 1.0 V at all times

24

BRN/YEL

LG1 (LOGIC GROUND)

Ground for the


ECM/PCM circuit

Less than 1.0 V at all times

26

GRN

TDC (TOP DEAD


CENTRE (TDC)
SENSOR)

Detects TDC sensor

With engine running: pulses

27

BRN

IGPLS4 (No. 4
Drives No. 4 ignition
IGNITION COIL PULSE) coil

28

WHT/BLU

IGPLS3 (No. 3
Drives No. 3 ignition
IGNITION COIL PULSE) coil

29

BLU/RED

IGPLS2 (No. 2
Drives No. 2 ignition
IGNITION COIL PULSE) coil

30

YEL/GRN

IGPLS1 (No. 1
Drives No. 1 ignition
IGNITION COIL PULSE) coil

With ignition switch ON (II): about 0 V


With engine running: pulses

*1:D17A9 engine
*2:A/T

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-11

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 colour
number

Terminal name

Description

Signal

YEL

INJ4 (No. 4 INJECTOR)

Drives No. 4 injector

With ignition switch ON (II): battery voltage

BLU

INJ3 (No. 3 INJECTOR)

Drives No. 3 injector

At idle: duty controlled

RED

INJ2 (No. 2 INJECTOR)

Drives No. 2 injector

BRN

INJ1 (No. 1 INJECTOR)

Drives No. 1 injector

GRN

FANC (RADIATOR FAN


CONTROL)

Drives radiator fan relay


Drives A/T pressure
control solenoid valve A

With radiator fan running: about 0 V


With radiator fan stopped: battery voltage
With the ignition switch ON (II): duty
controlled

7*2

RED/BLK

LSA + (A/T PRESSURE


CONTROL SOLENOID
VALVE A + SIDE

RED/WHT

ECT (ENGINE COOLANT Detects ECT sensor


signal
TEMPERATURE (ECT)
SENSOR)

With the ignition switch ON (II): about 0.1-4.8


V
At idle: about 0 V

(depending on engine coolant temperature)

9*1

BLU/BLK

VTPSW (VTEC OIL


PRESSURE SWITCH)

Detects VTEC oil


pressure switch signal

10

WHT/BLU

ALTL (ALTERNATOR L
SIGNAL)

Detects alternator L signal With ignition switch ON (II): about 0 V

ALTF (ALTERNATOR FR
SIGNAL)

Detects alternator FR
signal

With engine running: 0 V-5 V

EGR (EXHAUST GAS


RECIRCULATION (EGR)
VALVE)

Drives EGR valve

With EGR operating: duty controlled

13
14*1

WHT/RED
BLU/RED

With engine running: battery voltage


(depending on electrical load)
With EGR not operating: about 0 V

15*1

GRN/YEL

VTS (VTEC SOLENOID


VALVE)

Drives VTEC solenoid


valve

At idle: about 0 V

16*2

BLK/RED

LSB + (A/T PRESSURE


CONTROL SOLENOID
VALVE B + SIDE)

Drives A/T pressure


control solenoid valve B

With the ignition switch ON (II): duty


controlled

17

RED/YEL

IAT (INTAKE AIR


TEMPERATURE (IAT)
SENSOR)

Detects IAT sensor signal With ignition switch ON (II): about 0.1 V-4.8 V

PCS (EVAPORATIVE
EMISSION (EVAP)
CANISTER PURGE
VALVE)

Drives EVAP canister


purge valve

21

YEL/BLU

(depending on intake air temperature)


With engine running, engine coolant below
70C (158F): battery voltage
With engine running, engine coolant above
70C (158F): duty controlled

*1:D17A9 engine
*2:A/T

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-12

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 colour
number

Terminal name

Description

Signal

1*2

WHT/BLK

LSA- (A/T PRESSURE


CONTROL SOLENOID
VALVE A-SIDE

Ground for A/T pressure


control solenoid valve A

2*2

YEL/BLU

LC (TORQUE
CONVERTER CLUTCH
SOLENOID VALVE)

Drives torque converter


clutch solenoid valve

With lock-up ON: battery voltage

SHB (SHIFT SOLENOID


VALVE B)

Drives shift solenoid valve With engine running in 1st, 2nd gears: battery
B
voltage

4*2

GRN/WHT

With lock-up OFF: about 0 V

With engine running in 3rd, 4th gears: about


0V
6*2

BLU/BLK

SHA (SHIFT SOLENOID


VALVE A)

Drives shift solenoid valve With engine running in 2nd, 3rd gears:
A
battery voltage
With engine running in 1st, 4th gears: about
0V

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 SOLENOID
VALVE B-SIDE)

Ground for A/T pressure


control solenoid valve B

9*2

RED

ATPD3 (TRANSMISSION
RANGE SWITCH D3
POSITION)

Detects transmission
range switch D3 position
signal

In D3 position: about 0 V

ATPR (TRANSMISSION
RANGE SWITCH R
POSITION)

Detects transmission
range switch R position
signal

In R position: about 0 V

ATP2 (TRANSMISSION
RANGE SWITCH 2
POSITION)

Detects transmission
range switch 2 position
signal

In 2nd position: about 0 V

10*2

11*2

WHT

BLU

In any other position: about 5 V or battery


voltage
In any other position: about 5 V or battery
voltage
In any other position: about 5 V or battery
voltage

In Park or neutral: about 0 V


ATPNP (TRANSMISSION Detects transmission
range switch Neutral/Park In any other position: about 5 V or battery
RANGE SWITCH
position signal
NEUTRAL/PARK
voltage
POSITION)

12*2

BLU/WHT

14*2

GRN

NCSG (COUNTERSHAFT Ground for countershaft


speed sensor
SPEED SENSOR
GROUND)

15*2

BLU

NC (COUNTERSHAFT
SPEED SENSOR)

Detects countershaft
speed sensor signals

With ignition switch ON (II) and front wheels


rotating: battery voltage

19*2

BRN

ATP1 (TRANSMISSION

Detects transmission

In 1st position: about 0 V

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Fuel and Emissions - Fuel and Emissions Systems

20*2

21*2

YEL

WHT/GRN

RANGE SWITCH 1
POSITION)

range switch 1 position


signal

In any other position: about 5 V or battery


voltage

ATPD (TRANSMISSION
RANGE SWITCH D
POSITION)

Detects transmission
range switch D position
signal

In D position: about 0 V

NMSG (MAINSHAFT
SPEED SENSOR
GROUND)

Ground for mainshaft


speed sensor

In any other position: about 5 V or battery


voltage

*1:D17A8 engine
*2:A/T

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-13

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 colour
number

Terminal name

Description

Signal

GRN/YEL

IMO FPR (IMMOBILIZER


FUEL PUMP RELAY)

Drives PGM-FI main relay 0 V for 2 seconds after turning ignition switch
2
ON (II), then battery voltage

WHT/RED

SHO2S (SECONDARY
HEATED OXYGEN
SENSOR (SECONDARY
HO2S), SENSOR 2)

Detects secondary HO2S With throttle fully opened from idle with fully
(sensor 2) signal
warmed up engine: above 0.6 V

LG3 (LOGIC GROUND)

Ground for the ECM/PCM Less than 1.0 V at all times


control circuit

BRN/YEL

PNK

BLK/WHT

With throttle quickly closed: below 0.4 V

SG3 (SENSOR GROUND) Sensor ground

Less than 1.0 V at all times

SO2SHTC (SECONDARY Drives secondary HO2S


heater
HEATED OXYGEN
SENSOR (SECONDARY
HO2S) HEATER
CONTROL)

With ignition switch ON (II): battery voltage


With fully warmed up engine running: duty
controlled

RED/YEL

MRLY (PGM-FI MAIN


RELAY)

Drives PGM-FI main relay With ignition switch ON (II): about 0 V


1 Power source for the
With ignition switch OFF: battery voltage
DTC memory

YEL/BLK

IG1 (IGNITION SIGNAL)

Detects ignition signal

With ignition switch ON (II): battery voltage


With ignition switch OFF: about 0 V

16

18
22

LT GRN/BLK PSPSW (POWER


STEERING PRESSURE
SWITCH SIGNAL)
RED
WHT/BLK

Detects PSP switch signal At idle with steering wheel in straight ahead
position: about 0 V
At idle with steering wheel at full lock: battery
voltage

ACC (A/C CLUTCH


RELAY)

Drives A/C clutch relay

BKSW (BRAKE PEDAL


POSITION SWITCH)

Detects brake pedal


position switch signal

With compressor ON: about 0 V


With compressor OFF: battery voltage
With brake pedal released: about 0 V
With brake pedal pressed: battery voltage

23

LT BLU

K-LINE

Sends and receives scan With ignition switch ON (II): pulses or battery
tool signal
voltage

24

YEL

SEFMJ

Communicates with
multiplex control unit

With ignition switch ON (II): about 5 V


With engine running: pulses

With engine running under load: pulses

26

BLU

NEP (ENGINE SPEED


PULSE)

Outputs engine speed


pulse

27

RED/BLU

IMOCD (IMMOBILIZER
CODE)

Detects immobiliser signal

29

BRN

SCS (SERVICE CHECK


SIGNAL)

Detects service check


signal

With the service check signal shorted: about


0V

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Fuel and Emissions - Fuel and Emissions Systems


With the service check signal opened: about
5 V battery voltage
31

GRN/ORN

MIL (MALFUNCTION
INDICATOR LAMP)

Drives MIL

With MIL turned ON: about 0 V


With MIL turned OFF: battery voltage

*1:D17A9 engine
*2:A/T

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-14

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

Fuel and Emissions Systems

11-15

System Descriptions (cont'd)

Vacuum Distribution

1.

0. ENGINE COOLANT.
1. (D17A9 ENGINE)

(1)

PRIMARY HEATED OXYGEN SENSOR (PRIMARY HO2S) (13) FUEL PRESSURE REGULATOR
(SENSOR 1)

(2)

SECONDARY HEATED OXYGEN SENSOR (SECONDARY (15) FUEL TANK


HO2S) (SENSOR 2)

(16) AIR CLEANER

(3)

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

(17) RESONATOR

(14) FUEL PUMP

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Fuel and Emissions - Fuel and Emissions Systems


(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

(11)

FUEL PULSATION DAMPER

(23) EVAPORATIVE EMISSION (EVAP) TWO WAY VALVE

(12)

FUEL FILTER

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-16

System Descriptions (cont'd)

PGM-FI System

Engine Coolant Temperature (ECT) Sensor

The Programmed Fuel Injection (PGM-FI) system is a


sequential multiport fuel injection system.

The ECT sensor is a temperature dependent resistor


(thermistor). The resistor of the thermistor decreases as the
engine coolant temperature increases.

Air Conditioning (A/C) Compressor Clutch Relay


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
The BARO sensor is inside the ECM/PCM. It converts
atmospheric pressure into a voltage signal that modifies the
basic duration of the fuel injection discharge.
Crankshaft Position (CKP) Sensor
The CKP sensor detects engine speed and determines ignition
timing and timing for fuel injection of each cylinder.

1.

1. THERMISTOR

Ignition Timing Control


The ECM/PCM contains the memory for basic ignition timing at
various engine speeds and manifold absolute pressure. It also
adjusts the timing according to engine coolant temperature.
Injector Timing and Duration
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

Fuel and Emissions Systems

11-17

System Descriptions (cont'd)

Knock Sensor

Primary Heated Oxygen Sensor (Primary HO2S)

The knock control system adjusts the ignition timing to


minimise knock.

The primary HO2S detects the oxygen content in the exhaust


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
the ECM/PCM sets a DTC.

1.

1. WEIGHT
2. PIEZO ELEMENT

Manifold Absolute Pressure (MAP) Sensor


The MAP sensor converts manifold absolute pressure into
electrical signals to the ECM/PCM.

1.

1.
2.
3.
4.

ZIRCONIA ELEMENT
SENSOR TERMINALS
HEATER TERMINALS
HEATER

Secondary
HO2S)
2.

1. SENSOR UNIT

Heated

Oxygen

Sensor

(Secondary

The secondary HO2S detects the oxygen content in the


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.
2.
3.
4.

ZIRCONIA ELEMENT
SENSOR TERMINALS
HEATER TERMINALS
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

Fuel and Emissions Systems

11-18

System Descriptions (cont'd)

Throttle Position (TP) Sensor

Idle Control System

The TP sensor is a potentiometer connected to the throttle


valve shaft. As the throttle position changes, the sensor varies
the signal voltage to the ECM/PCM. The TP sensor is not
replaceable apart from the throttle body.

When the engine is cold, the A/C compressor is on, the


transmission is in gear, the brake pedal is pressed, the power
steering load is high, or the alternator is charging, the
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.
Idle Air Control (IAC) Valve
To maintain the proper idle speed, the IAC valve changes the
amount of air bypassing the throttle body in response to an
electrical signal from the ECM/PCM.

1.

1. ELEMENT
2. BRUSH HOLDER
3. BRUSH

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

Power Steering Pressure (PSP) Switch


The PSP switch signals the ECM/PCM when the power
steering load is high.
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

Fuel and Emissions Systems

11-19

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


system.

During deceleration with the throttle valve closed, current to the


injectors is cut off to improve fuel economy at speeds over 850
rpm (min-1). Fuel cut-off action also occurs when engine
speed exceeds 6,900 rpm (min-1) regardless of the 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).

Throttle Body
The throttle body is a single-barrel down draft type. The side
portion of the IAC valve is heated by engine coolant from the
cylinder head.

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 PGMFI 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
pump for 2 seconds when the ignition switch is turned ON (II)
and when the engine is running.

1.

1. TP SENSOR
2. IAC VALVE

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-20

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


system.

The TWC converts hydrocarbons (HC), carbon monoxide (CO),


and oxides of nitrogen (NOx) in the exhaust gas to carbon
dioxide (CO2), dinitrogen (N2), and water vapour.

EGR Valve
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.
2.
3.
4.
5.
6.

PCV HOSE
BREATHER PIPE
INTAKE MANIFOLD
PCV VALVE
BLOW BY VAPOUR
FRESH AIR

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-21

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 70C (158F),
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

Fuel and Emissions Systems

11-22

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

Fuel and Emissions Systems

11-23

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

Fuel and Emissions Systems

11-24

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 70C (158F).
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

Fuel and Emissions Systems

11-25

System Descriptions (cont'd)

ECM/PCM Circuit Diagram

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-26

System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-27

System Descriptions (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-28

System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-29

System Descriptions (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-30

System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-31

System Descriptions (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-32

System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-33

System Descriptions (cont'd)

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-34

System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)


LHD model:
1. ENGINE
COMPARTMENT
WIRE HARNESS
2. ENGINE WIRE
HARNESS

*1: D17A9 engine*2: A/T

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-35

System Descriptions (cont'd)

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

Fuel and Emissions Systems

11-36

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

Fuel and Emissions Systems

11-37

System Descriptions (cont'd)

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

Fuel and Emissions Systems

11-38

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

Fuel and Emissions Systems

11-39

System Descriptions (cont'd)

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.

*: Terminal side of female terminals

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-40

System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)


LHD model:
1. DASHBOARD WIRE
HARNESS A
2. ECM/PCM WIRE
HARNESS
3. FLOOR WIRE
HARNESS
4. ENGINE
COMPARTMENT
WIRE HARNESS

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-41

System Descriptions (cont'd)

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

Fuel and Emissions Systems

11-42

System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)


RHD model:
1. ENGINE
COMPARTMENT
WIRE HARNESS
2. ENGINE WIRE
HARNESS

*1:D17A9 engine*2:A/T

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-43

System Descriptions (cont'd)

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

Fuel and Emissions Systems

11-44

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

Fuel and Emissions Systems

11-45

System Descriptions (cont'd)

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

Fuel and Emissions Systems

11-46

System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)


RHD model:
1. DASHBOARD WIRE
HARNESS B
2. DASHBOARD WIRE
HARNESS A
3. ECM/PCM WIRE HARNESS
4. ENGINE COMPARTMENT
WIRE HARNESS

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-47

System Descriptions (cont'd)

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.

*: Terminal side of female terminals

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-48

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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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-49

System Descriptions (cont'd)

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

Fuel and Emissions Systems

11-50

System Descriptions (cont'd)

ECM/PCM Circuit Diagram (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 - PGM-FI System

PGM-FI System

11-51

Component Location Index (cont'd)


1. THROTTLE POSITION (TP) SENSOR
Troubleshooting, page 11-65 in the '01
Civic Shop Manual on this CD
2. INTAKE AIR TEMPERATURE (IAT)
SENSOR
Troubleshooting, page 11-61 in the '01
Civic Shop Manual on this CD
3. MANIFOLD ABSOLUTE PRESSURE
(MAP) SENSOR
Troubleshooting, page 11-59 in the '01
Civic Shop Manual on this CD
4. TOP DEAD CENTRE (TDC) SENSOR
Troubleshooting, page 11-98 in the '01
Civic Shop Manual on this CD
5. CRANKSHAFT POSITION (CKP)
SENSOR
Troubleshooting, page 11-88 in the '01
Civic Shop Manual on this CD
6. KNOCK SENSOR
Troubleshooting, page 11-85 in the '01
Civic Shop Manual on this CD
7. ENGINE COOLANT TEMPERATURE
(ECT) SENSOR
Troubleshooting, page 11-63 in the '01
Civic Shop Manual on this CD
8. SECONDARY HEATED OXYGEN
SENSOR (SECONDARY HO2S)
(SENSOR 2)
Troubleshooting, page 11-73 in the '01
Civic Shop Manual on this CD
Replacement, page 11-115 in the '01
Civic Shop Manual on this CD
9. PRIMARY HEATED OXYGEN
SENSOR (PRIMARY HO2S) (SENSOR
1)
Troubleshooting, page 11-68 in the '01
Civic Shop Manual on this CD
Replacement, page 11-115 in the '01
Civic Shop Manual on this CD

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Fuel and Emissions - PGM-FI System

PGM-FI System

11-52

Component Location Index (cont'd)


1. INJECTORS
Replacement, page 11-113 in the '01 Civic
Shop Manual on this CD

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Fuel and Emissions - PGM-FI System

PGM-FI System

11-53

Component Location Index (cont'd)


1. DATA LINK CONNECTOR (DLC)
General Troubleshooting Information, page 11-3 in the '01 Civic
Shop Manual on this CD

*: The illustration shows LHD model.


1. ENGINE CONTROL MODULE/POWERTRAIN CONTROL
MODULE (ECM/PCM)
General Troubleshooting Information, page 11-3 in the '01 Civic
Shop Manual on this CD
Troubleshooting, page 11-99 in the '01 Civic Shop Manual on
this CD
2. PGM-FI MAIN RELAY 1
Troubleshooting, page 11-56

*: The illustration shows LHD model.

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Fuel and Emissions - PGM-FI System

PGM-FI System

11-54

DTC Troubleshooting

DTC P0171: Fuel System Too Lean


DTC P0172: Fuel System Too Rich
NOTE: If some of the DTCs listed below are stored at the
same time as DTC P0171 and/or P0172, troubleshoot those
DTCs first, then recheck for P0171 and/or P0172.

1.

5. With a vacuum pump (A), apply vacuum to the


evaporative emission (EVAP) canister purge valve
(B) from the intake manifold side.

P0107, P0108: Manifold Absolute Pressure (MAP) sensor


P0135: Primary Heated Oxygen Sensor (Primary HO2S)
(Sensor 1) heater
P0137, P0138: Secondary HO2S (Sensor 2)
P0141: Secondary HO2S (Sensor 2) heater
P0401 P1491, P1498: Exhaust Gas Recirculation (EGR)
system*
P1259: VTEC system*
*: D17A9 engine
1.

1. Check the fuel pressure, refer to the '01 Civic Shop


Manual on this CD (see page 11-131).
Is fuel pressure OK?

YES - Go to step 2.
NO - Check these items:
If the pressure is too high, replace the fuel
pressure regulator, refer to the '01 Civic Shop
Manual on this CD (see page 11-138).
If the pressure is too low, check the fuel pump,
the fuel feed pipe, the fuel filter and replace the
fuel pressure regulator, refer to the '01 Civic Shop
Manual on this CD (see page 11-138).
2.
2. Start the engine. Hold the engine at 3,000 rpm with
no load (in Park or neutral) until the radiator fan
comes on.
3. Check the primary HO2S (Sensor 1) output with the
scan tool.
Does it stay at less than 0.3 V or more than 0.6 V?

Does it hold vacuum?


YES - Go to step 6.
NO - Replace the EVAP canister purge valve.
2.
6. Turn the ignition switch ON (II).
7. Check the manifold pressure with the scan tool.
Does it indicate atmospheric pressure?
YES - Go to step 8.
NO - Replace the MAP sensor.
3.
8. Start the engine.
9. Check the MAP with the scan tool.
Is a MAP of 40.0 kPa (300 mmHg, 12.0 in.Hg) or less
indicated within 1 second after starting the engine?
YES - Check the valve clearances and adjust if necessary.
If the valve clearances are OK, replace the injectors.
NO - Replace the MAP sensor.

YES - Replace the primary HO2S (Sensor 1).


NO - Go to step 4.
3.
4. Turn the ignition switch OFF.

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Fuel and Emissions - PGM-FI System

PGM-FI System

11-55

DTC Troubleshooting (cont'd)

DTC P0300: Random misfire and any Combination of the Following:


DTC P0301: No. 1 Cylinder Misfire
DTC P0302: No. 2 Cylinder Misfire
DTC P0303: No. 3 Cylinder Misfire
DTC P0304: No. 4 Cylinder Misfire
NOTE:

1.

If the misfiring is frequent enough to trigger detection of increased emissions during two consecutive driving cycles, the
MIL will come on and DTC P0300 (and some combination of P0301 through P0304) will be stored.
If the misfiring is frequent enough to damage the catalyst, the MIL will blink whenever the misfiring occurs and DTC
P0300 (and some combination of P0301 through P0304) will be stored. When the misfiring stops, the MIL will remain on.
1. Troubleshoot the following DTCs first if any of them were stored along with the random misfire DTC(s):
P0107, P0108: Manifold Absolute Pressure (MAP) sensor
P0131, P0132: Primary Heated Oxygen Sensor
P0171, P0172: Fuel system
P0335, P0336: Crankshaft Position (CKP) sensor
P0401, P1491, P1498: Exhaust Gas Recirculation (EGR) system*
P0505: Idle control system
P1259: VTEC system*
P1361, P1362: Top Dead Centre (TDC) sensor
P1519: Idle Air Control (IAC) valve
*: D17A9 engine
2. Test-drive the vehicle to verify the symptom.
3. Find the symptom in the chart below and do the related procedures in the order listed until you find the cause.
Symptom

Procedure(s)

Also check for:

Low compression.
Low quality fuel.

Random misfire only at low RPM


and under load

Check fuel pressure, refer to the '01 Civic Shop


Manual on this CD (see page 11-131).

Random misfire only during


acceleration

Check fuel pressure, refer to the '01 Civic Shop


Manual on this CD (see page 11-131).

Malfunction in the VTEC system


(D17A9 engine), refer to the '01
Civic Shop Manual on this CD (see
page 6-9).

Random misfire at high RPM,


under load, or under random
conditions

Check fuel pressure, refer to the '01 Civic Shop


Manual on this CD (see page 11-131).

Correct valve clearance, refer to the


'01 Civic Shop Manual on this CD
(see page 6-14).

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Fuel and Emissions - PGM-FI System

PGM-FI System

11-56

MIL Circuit Troubleshooting

1.

1. Turn the ignition switch ON (II) and watch the


Malfunction Indicator Lamp (MIL).
Does the MIL come on and stay on?

1.

2. Turn the ignition switch OFF.


3. Turn the ignition switch ON (II).
Is the low oil pressure light on?

YES - If the MIL always comes on and stays on, go to step


63. But if the MIL sometimes works normally, first check for
these problems.
An intermittent short in the wire between the
ECM/PCM (E29) and the Data Link Connector
(DLC).
An intermittent short in the wire between the
ECM/PCM (E31) and the gauge assembly.
NO - If the MIL is always off, go to step 2. But if the MIL
sometimes works normally, first check for these problems.
A loose No. 10 METER (7.5A) fuse in the underdash fuse/relay box.
A loose No. 20 IG (40A) fuse in the under-hood
fuse/relay box.
A loose No. 6 ECU (ECM/PCM) (15A) fuse in the
under-hood fuse/relay box.
A loose No. 17 FUEL PUMP (15A) fuse in the
under-dash fuse/relay box.
A poor connection at ECM/PCM terminal E31.
An intermittent open in the GRN/ORN wire
between the ECM/PCM (E31) and the gauge
assembly.
An intermittent short in the wire between the
ECM/PCM (A21) and the manifold absolute
pressure (MAP) sensor.
An intermittent short in the wire between the
ECM/PCM (A20) and the throttle position (TP)
sensor, knock sensor, exhaust gas recirculation
(EGR) valve position sensor.
An intermittent short in the wire between the
ECM/PCM (A8) and the knock sensor.

YES - Go to step 6.
NO - Go to step 4.
2.
4. Inspect the No. 10 METER (7.5 A) fuse in the underdash fuse/relay box.
Is the fuse OK?
YES - Go to step 5.
NO - Repair short in the wire between No. 10 METER
(7.5A) fuse and the gauge assembly. Also replace the No.
10 METER (7.5A) fuse.
3.
5. Inspect the No. 20 IG1 (40A) fuse in the under-hood
fuse/relay box.
Is the fuse OK?
YES - Repair open in the wire between the No. 20 IG
(40A) fuse and the gauge assembly. If the wires are OK,
test the ignition switch, refer to the '01 Civic Shop Manual
on this CD (see page 22-83).
NO - Repair short in the wire between No. 20 IG (40A) fuse
and the under-dash fuse/relay box. Also replace the No. 20
IG (40A) fuse.
4.
6. Try to start the engine.
Does the engine start?
YES - Go to step 7.
NO - Go to step 10.
5.
7. Turn the ignition switch OFF.

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Fuel and Emissions - PGM-FI System

PGM-FI System

11-57

MIL Circuit Troubleshooting (cont'd)

1.

8. Connect ECM/PCM connector terminal E31 and body


ground with a jumper wire.
ECM/PCM CONNECTOR E (31P)

Wire side of female terminals


2.

1.
2.

10. Turn the ignition switch OFF.


11. Inspect the No. 6 ECU (ECM/PCM) (15A) fuse in the
under-hood fuse/relay box.
Is the fuse OK?

YES - Go to step 18.


NO - Go to step 12.
3.
12. Remove the blown No. 6 ECU (ECM/PCM) (15A)
fuse in the under-dash fuse/relay box.
13. Remove the PGM-FI main relay 1 (A).
LHD model:

9. Turn the ignition switch ON (II).


Is the MIL on?
YES - Substitute a known-good ECM/PCM and recheck,
refer to the '01 Civic Shop Manual on this CD (see page 116). If symptom/indication goes away, replace the original
ECM/PCM.
NO - Check for an open in the wire between the ECM/PCM
(E31) and the gauge assembly. Also check for a blown MIL
bulb. If the wires and the bulb are OK, replace the gauge
assembly.

RHD model:

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Fuel and Emissions - PGM-FI System

PGM-FI System

11-58

MIL Circuit Troubleshooting (cont'd)

1.

14. Check for continuity between body ground and the


PGM-FI main relay 14P connector terminals No. 2
and No. 4 individually.

Is there continuity?
YES - Go to step 16.
NO - Replace the component that made continuity to body
ground go away when disconnected. If the item is the
ECM/PCM, substitute a known-good ECM/PCM and
recheck, refer to the '01 Civic Shop Manual on this CD (see
page 11-6). If symptom/indication goes away, replace the
original ECM/PCM.
Also replace the No. 6 ECU (ECM/PCM) (15 A) fuse.
1.

Wire side of female terminals


Is there continuity?
YES - Repair short in the wire between the No. 6 ECU
(ECM/PCM) (15A) fuse and the PGM-FI main relay 1. Also
replace the No. 6 ECU (ECM/PCM) (15A) fuse.
NO - Go to step 15.
2.
15. Disconnect each of the components or the
connectors below, one at a time and check for
continuity between the PGM-FI main relay 1 4P
connector terminal No. 1 and body ground.
PGM-FI main relay 2
ECM/PCM connector A (31P)
Each injector 2P connector
Idle air control (IAC) valve 3P connector
Top dead centre (TDC) sensor 3P connector
Crankshaft position (CKP) sensor 3P connector

2.

16. Disconnect the connectors of all these components.


PGM-FI main relay 2
ECM/PCM connector A (31P)
Injectors
Idle air control (IAC) valve
Top dead centre (TDC) sensor
Crankshaft position (CKP) sensor
17. Check for continuity between the PGM-FI main relay
1 4P connector terminal No. 2 and body ground.

Wire side of female terminals


Is there continuity?
YES - Repair short in the wire between the PGM-FI main
relay 1 and each item. Also replace the No. 6 ECU
(ECM/PCM) (15A) fuse.
NO - Replace the PGM-FI main relay 1. Also replace the
No 6 ECU (ECM/PCM) (15A) fuse.

Wire side of female terminals

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Fuel and Emissions - PGM-FI System

PGM-FI System

11-59

MIL Circuit Troubleshooting (cont'd)

1.

18. Inspect the No. 17 FUEL PUMP (15A) fuse in the


under-dash fuse/relay box.
Is the fuse OK?

YES - Go to step 30.


NO - Go to step 19.
2.
19. Remove the blown No. 17 FUEL PUMP (15A) fuse in
the under-dash fuse/relay box.
20. Disconnect ECM/PCM connector E (31P).
21. Check for continuity between ECM/PCM connector
terminal E9 and body ground.
ECM/PCM CONNECTOR E (31P)

1.
22. Remove the PGM-FI main relay 2 (A).
LHD model:

RHD model:

Wire side of female terminals


Is there continuity?
YES - Go to step 22.
NO - Replace the No. 17 FUEL PUMP (15 A) fuse, and
substitute a known-good ECM/PCM and recheck, refer to
the '01 Civic Shop Manual on this CD (see page 11-6). If
symptom/indication goes away, replace the original
ECM/PCM.

2.

23. Check for continuity between ECM/PCM connector


terminal E9 and body ground.
ECM/PCM CONNECTOR E (31P)

Wire side of female terminals


Is there continuity?
YES - Repair short in the wire between the No. 17 FUEL
PUMP (15A) fuse and the ECM/PCM (E9), or the No. 17
FUEL PUMP (15 A) fuse and the PGM-FI main relay 2.
Also replace the No. 17 FUEL PUMP (15A) fuse.
NO - Go to step 24.
3.
24. Remove the rear seat cushion, refer to the '01 Civic
Shop Manual on this CD (see page 20-95).

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Fuel and Emissions - PGM-FI System

PGM-FI System

11-60

MIL Circuit Troubleshooting (cont'd)

1.
2.

25. Remove the access panel from the floor.


26. Disconnect the fuel pump 5P connector.
27. Check for continuity between the fuel pump 5P
connector terminal No. 5 and body ground.
FUEL PUMP 5P CONNECTOR

1.

29. Check for continuity between the fuel pump 5P


connector terminal No. 5 and body ground.
FUEL PUMP 5P CONNECTOR

Wire side of female terminals


Wire side of female terminals
Is there continuity?
YES - Repair short in the wire between the fuel pump and
the PGM-FI main relay 2. Also replace the No. 17 FUEL
PUMP (15A) fuse.
NO - Go to step 26.
3.
28. Reinstall the PGM-FI main relay 2 (A).
LHD model:

Is there continuity?
YES - Replace the PGM-FI main relay 2. Also replace the
No. 17 FUEL PUMP (15A) fuse.
NO - Check the fuel pump and replace it as necessary.
Also replace the No. 17 FUEL PUMP (15A) fuse.
2.
30. Disconnect ECM/PCM connector E (31P).
31. Turn the ignition switch ON (II).
32. Measure voltage between ECM/PCM connector
terminals E9 and body ground.
ECM/PCM CONNECTOR E (31P)

Wire side of female terminals


RHD model:

Is there battery voltage?


YES - Go to step 33.
NO - Repair open in the wire between the No. 17 FUEL
PUMP (15A) fuse and the ECM/PCM (E9).

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Fuel and Emissions - PGM-FI System

PGM-FI System

11-61

MIL Circuit Troubleshooting (cont'd)

1.
2.

33. Turn the ignition switch OFF.


34. Measure voltage between ECM/PCM connector
terminal E7 and body ground.
ECM/PCM CONNECTOR E (31P)

1.

36. Measure voltage between the PGM-FI main relay 1


4P connector terminal No. 4 and body ground.

Wire side of female terminals


Is there battery voltage?
YES - Go to step 38.
NO - Go to step 35.
3.
35. Remove the PGM-FI main relay 1 (A).
LHD model:

Wire side of female terminals


Is there battery voltage?
YES - Go to step 37.
NO - Repair open in the wire between the No. 6 ECU
(ECM/PCM) (15 A) fuse and the PGM-FI main relay 1.
2.
37. Check for continuity between the PGM-FI main relay
1 4P connector terminal No. 3 and ECM/PCM
connector terminal E7.

RHD model:

Wire side of female terminals


Is there continuity?
YES - Test the PGM-FI main relay 1, refer to the '01 Civic
Shop Manual on this CD (see page 22-80). If the relay is
OK, substitute a known-good ECM/PCM and recheck, refer
to the '01 Civic Shop Manual on this CD (see page 11-6). If
symptom/indication goes away, replace the original
ECM/PCM.
NO - Repair open in the wire between the PGM-FI main
relay 1 and the ECM/PCM (E7).

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Fuel and Emissions - PGM-FI System

PGM-FI System

11-62

MIL Circuit Troubleshooting (cont'd)

1.
2.

38. Reconnect ECM/PCM connector E (31P).


39. Turn the ignition switch ON (II).
40. Measure voltage between body ground and
ECM/PCM connector terminals A2 and A3
individually.
ECM/PCM CONNECTOR A (31P)

1.
2.

43. Turn the ignition switch ON (II).


44. Measure voltage between the PGM-FI main relay 1
4P connector terminal No. 2 and body ground.

Wire side of female terminals


Is there battery voltage?
YES - Go to step 47.
NO - Go to step 41.
3.
41. Turn the ignition switch OFF.
42. Remove the PGM-FI main relay 1 (A).
LHD model:

Wire side of female terminals


Is there battery voltage?
YES - Go to step 45.
NO - Repair open in the wire between the No. 6 ECU
(ECM/PCM) (15A) fuse and the PGM-FI main relay 1.
3.
45. Turn the ignition switch OFF.
46. Check for continuity between the PGM-FI main relay
1 4P connector terminal No. 1 and ECM/PCM
connector terminals A2 and A3 individually.

RHD model:

Wire side of female terminals


Is there continuity?
YES - Replace the PGM-FI main relay 1.
NO - Repair open in the wire between the PGM-FI main
relay 1 and the ECM/PCM (A2, A3).

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Fuel and Emissions - PGM-FI System

PGM-FI System

11-63

MIL Circuit Troubleshooting (cont'd)

1.

47. Measure voltage between body ground and


ECM/PCM connector terminals A4, A5, A23 and A24
individually.
ECM/PCM CONNECTOR A (31P)

1.
2.

49. Turn the ignition switch OFF.


50. Disconnect the manifold absolute pressure (MAP)
sensor 3P connector.
51. Turn the ignition switch ON (II).
52. Measure voltage between body ground and
ECM/PCM connector terminal A21.
ECM/PCM CONNECTOR A (31P)

Wire side of female terminals


Is there less than 1.0 V?
YES - Repair open in the wire (s) between that had more
than 1.0 V between G101 and the ECM/PCM (A4, A5, A23,
A24).
NO - Go to step 48.
2.
48. Measure voltage between body ground and
ECM/PCM connector terminal A21.
ECM/PCM CONNECTOR A (31P)

Wire side of female terminals


Is there about 5 V?
YES - Replace the MAP sensor.
NO - Go to step 53.
3.
53. Turn the ignition switch OFF.
54. Disconnect ECM/PCM connector A (31P).

Wire side of female terminals


Is there about 5 V?
YES - Go to step 56.
NO - Go to step 49.

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Fuel and Emissions - PGM-FI System

PGM-FI System

11-64

MIL Circuit Troubleshooting (cont'd)

1.

55. Check for continuity between ECM/PCM connector


terminal A21 and body ground.
ECM/PCM CONNECTOR A (31P)

1.
2.

57. Turn the ignition switch OFF.


58. Disconnect the 3P connector from each of these
sensors, one at a time and measure voltage between
body ground and ECM/PCM connector terminal A20
with the ignition switch ON (II).
Exhaust gas recirculation (EGR) valve position
sensor
Knock sensor
Throttle position (TP) sensor
ECM/PCM CONNECTOR A (31P)

Wire side of female terminals


Is there continuity?
YES - Repair short in the wire between the ECM/PCM
(A21) and the MAP sensor.
NO - Substitute a known-good ECM/PCM and recheck,
refer to the '01 Civic Shop Manual on this CD (see page 116). If symptom/indication goes away, replace the original
ECM/PCM.
2.
56. Measure voltage between body ground and
ECM/PCM connector terminal A20.
ECM/PCM CONNECTOR A (31P)

Wire side of female terminals


Is there about 5 V?

Wire side of female terminals


Is there about 5 V?
YES - Replace the sensor that restored about 5 V when
disconnected.
NO - Go to step 66.
3.
59. Turn the ignition switch OFF.
60. Disconnect the 3P connectors from the following
sensors.
Exhaust gas recirculation (EGR) valve position
sensor
Knock sensor
Throttle position (TP) sensor
4.
61. Disconnect ECM/PCM connector A (31P).

YES - Substitute a known-good ECM/PCM and recheck,


refer to the '01 Civic Shop Manual on this CD (see page 116). If symptom/indication goes away, replace the original
ECM/PCM.
NO - Go to step 57.

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Fuel and Emissions - PGM-FI System

PGM-FI System

11-65

MIL Circuit Troubleshooting (cont'd)

1.

62. Check for continuity between ECM/PCM connector


terminal A20 and body ground.
ECM/PCM CONNECTOR A (31P)

Wire side of female terminals


Is there continuity?
YES - Repair short in the wire between the ECM/PCM
(A20) and the EGR valve position sensor, knock sensor or
TP sensor, or repair short in the wire between the
ECM/PCM (A8) and the knock sensor.
NO - Substitute a known-good ECM/PCM and recheck,
refer to the '01 Civic Shop Manual on this CD (see page 116). If symptom/indication goes away, replace the original
ECM/PCM.

1.
2.

63. Turn the ignition switch OFF.


64. Connect a scan tool/Honda PGM Tester, refer to the
'01 Civic Shop Manual on this CD (see page 11-3).
65. Turn the ignition switch ON (II) and read the scan
tool/Honda PGM Tester.
Does the scan tool/Honda PGM Tester communicate with
the ECM/PCM?

YES - Go to step 70.


NO - Go to step 66.
3.
66. Turn the ignition switch OFF.
67. Disconnect ECM/PCM connector E (31P).
68. Check for continuity between body ground and Data
Link Connector (DLC) terminal No. 7.
DATA LINK CONNECTOR (DLC)

Terminal side of male terminals


Is there continuity?
YES - Repair short in the wire between the DLC and the
ECM/PCM (E23). After repairing it, check the DTC with the
scan tool/Honda PGM Tester and go to the DTC
Troubleshooting Index.
NO - Go to step 69.

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Fuel and Emissions - PGM-FI System

PGM-FI System

11-66

MIL Circuit Troubleshooting (cont'd)

1.

69. Check for continuity between ECM/PCM connector


terminal E23 and DLC terminal No. 7.
DATA LINK CONNECTOR (DLC)

1.

73. Measure voltage between ECM/PCM connector


terminal E29 and body ground.
ECM/PCM CONNECTOR E (31P)

Wire side of female terminals


Is there about 5 V (or battery voltage)?
Wire side of female terminals
Is there continuity?
YES - Substitute a known-good ECM/PCM and recheck,
refer to the '01 Civic Shop Manual on this CD (see page 116). If symptom/indication goes away, replace the original
ECM/PCM.
NO - Repair open in the wire between the DLC and the
ECM/PCM (E23). After repairing it, check the DTC with the
scan tool/Honda PGM Tester and go to the DTC
Troubleshooting Index.
2.
70. Check the scan tool/Honda PGM Tester for DTCs.
Are any DTCs indicated?

YES - Go to step 77.


NO - Go to step 74.
2.
74. Turn the ignition switch OFF.
75. Disconnect ECM/PCM connector E (31P).

YES - Go to the DTC Troubleshooting Index.


NO - Go to step 71.
3.
71. Turn the ignition switch OFF.
72. Turn the ignition switch ON (II).

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Fuel and Emissions - PGM-FI System

PGM-FI System

11-67

MIL Circuit Troubleshooting (cont'd)

1.

76. Check for continuity between ECM/PCM connector


terminal E29 and body ground.
ECM/PCM CONNECTOR E (31P)

Wire side of female terminals


Is there continuity?
YES - Repair short in the wire between the service check
connector and the ECM/PCM (E29).
NO - Substitute a known-good ECM/PCM and recheck,
refer to the '01 Civic Shop Manual on this CD (see page 116). If symptom/indication goes away, replace the original
ECM/PCM.
2.
77. Turn the ignition switch OFF.
78. Disconnect ECM/PCM connector E (31P).
79. Turn the ignition switch ON (II).
Is the MIL on?
YES - Repair short in the wire between the gauge
assembly and the ECM/PCM (E31). If the wires are OK,
replace the gauge assembly.
NO - Substitute a known-good ECM/PCM and recheck,
refer to the '01 Civic Shop Manual on this CD (see page 116). If symptom/indication goes away, replace the original
ECM/PCM.

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Fuel and Emissions - Idle Control System

Idle Control System

11-68

Component Location Index


1. POWER STEERING (PSP) SWITCH
Troubleshooting, page 11-69
2. IDLE AIR CONTROL (IAC) VALVE
Troubleshooting, page 11-117 in the '01 Civic Shop
Manual on this CD

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Fuel and Emissions - Idle Control System

Idle Control System

11-69

PSP Switch Signal Circuit Troubleshooting

1.
2.

1. Turn the ignition switch ON (II).


2. Measure voltage between ECM/PCM connector
terminals A24 and E16.
ECM/PCM CONNECTORS

1.

9. At the harness side, connect the PSP switch 2P


connector terminals No. 1 and No. 2 with a jumper
wire.
PSP SWITCH 2P CONNECTOR

Wire side of female terminals


2.

Wire side of female terminals


Is there less than 1.0 V?
YES - Go to step 3.
NO - Go to step 6.
3.
3. Start the engine.
4. Turn the steering wheel to the full lock position.
5. Measure voltage between ECM/PCM connector
terminals A24 and E16.
Is there battery voltage?

10. Measure voltage between ECM/PCM connector


terminals A24 and E16.
Is there less than 1.0 V?

YES - Replace the PSP switch.


NO - Check for these problems:
An open in the wire between the ECM/PCM (E16)
and the PSP switch.
An open in wire between the PSP switch and
G201.
3.
11. Turn the ignition switch OFF.
12. Disconnect the PSP switch 2P connector.
13. Turn the ignition switch ON (II).

YES - The PSP switch signal is OK.


NO - Go to step 11.
4.
6. Turn the ignition switch OFF.
7. Disconnect the PSP switch 2P connector.
8. Turn the ignition switch ON (II).

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Fuel and Emissions - Idle Control System

Idle Control System

11-70

PSP Switch Signal Circuit Troubleshooting


(cont'd)

1.

14. Measure voltage between ECM/PCM connector


terminals A24 and E16.
ECM/PCM CONNECTORS

Wire side of female terminals


Is there battery voltage?
YES - Replace the PSP switch.
NO - Go to step 15.
2.
15. Turn the ignition switch OFF.
16. Disconnect ECM/PCM connector E (31P).
17. Check for continuity between body ground and
ECM/PCM connector terminal E16.
ECM/PCM CONNECTOR E (31P)

Wire side of female terminals


Is there continuity?
YES - Repair short in the wire between ECM/PCM (E16)
and the PSP switch.
NO - Substitute a known-good ECM/PCM and recheck for
immobiliser information, refer to the '01 Civic Shop Manual
(see page 11-6). If the symptom/indication goes away,
replace the original ECM/PCM.

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Fuel and Emissions - Idle Control System

Idle Control System

11-71

Idle Speed Inspection

NOTE:

1.

6. Idle the engine for 1 minute with heater fan switch


on HI and air conditioner on, then check the idle
speed.
Idle speed should be:
M/T
750+50 rpm (min-1)
A/T
750+50 rpm (min-1)
(in Park or neutral)
NOTE: If the idle speed in not within specification, see
Symptom Chart.

2.

7. Reconnect the EVAP canister purge valve 2P


connector.

Leave the Idle Air Control (IAC) valve connected.


Before checking the idle speed, check these items:
The Malfunction Indicator Lamp (MIL) has not been
reported on.
Ignition timing
Spark plugs
Air cleaner
PCV system
2.

1. Disconnect the Evaporative Emission (EVAP)


canister purge valve 2P connector.
2. Connect a tachometer (A) to the test tachometer
connector (B).

3.

3. Start the engine. Hold the engine at 3,000 rpm (min1) with no load (in Park or neutral) until the radiator
fan comes on, then let it idle.
4. Turn the ignition switch OFF.
5. Start the engine.Check the idle speed with no-load
conditions: headlights, blower fan, rear defogger,
radiator fan, and air conditioner are not operating.
Idle speed should be:
M/T
700+50 rpm (min -1 )
A/T

700+50 rpm (min -1 )


(in Park or neutral)
NOTE:ECM/PCM might control to raise the idle speed 750
rpm (min -1 ) in case of the battery performance,etc. In this
case, idle speed is OK.Go to step 6.

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Fuel and Emissions - Fuel Supply System

Fuel Supply System

11-72

Component Location Index


1. FUEL PUMP
Troubleshooting, page 11-127 in the '01 Civic Shop
Manual on this CD
Replacement, page 11-139 in the '01 Civic Shop
Manual on this CD
FUEL FILTER
Replacement, page 11-138 in the '01 Civic Shop
Manual on this CD
FUEL GAUGE SENDING UNIT
Test/Replacement, page 11-141 in the '01 Civic
Shop Manual on this CD
FUEL PRESSURE REGULATOR
Replacement, page 11-138 in the '01 Civic Shop
Manual on this CD
2. FUEL FILL CAP
3. FUEL TANK
Replacement, page 11-140 in the '01 Civic Shop
Manual on this CD
4. FUEL TUBE/QUICK-CONNECT FITTINGS
Precautions, page 11-134 in the '01 Civic Shop
Manual on this CD
Removal, page 11-135 in the '01 Civic Shop Manual
on this CD
Installation, page 11-136 in the '01 Civic Shop
Manual on this CD
5. FUEL VAPOUR PIPE
6. PGM-FI MAIN RELAY 2
Troubleshooting, page 11-127 in the '01 Civic Shop
Manual on this CD
7. PGM-FI MAIN RELAY 1
8. FUEL FEED PIPE
9. FUEL RAIL

*: The illustration shows LHD model.

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Fuel and Emissions - Fuel Supply System

Fuel Supply System

11-73

Fuel Tank Replacement

1.

2.

1. Relieve the fuel pressure, refer to the '01 Civic Shop Manual on this CD (see page 11-130).
2. Drain the fuel tank: Remove the fuel pump, refer to the '01 Civic Shop Manual on this CD (see page 11-139). Using a
hand pump, hose and container suitable for gasoline, draw the fuel from the fuel tank.
3. Jack up the vehicle and support it with jackstands.
4. Remove the fuel pipe cover (A). Disconnect the fuel vapour hose and quick-connect fittings.
Disconnect the hoses. Slide back the clamps, then twist the hoses as you pull to avoid damaging them.

5.
6.
7.
8.

Place a jack or other support, under the tank.


Remove the strap bolts and let the strap (B) fall free.
Remove the fuel tank (C). If it sticks to the undercoat on its mount, carefully pry it off the mount.
Install the remaining parts in the reverse order of removal.

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KK, KX, KY models

KK, KX, KY models

Fuel and Emissions Systems


System Descriptions

11-76

PGM-FI System
Component Location Index

11-85

Idle Control System


Component Location Index

11-88

Fuel Supply System


Component Location Index

11-89

Fuel Tank Replacement

11-90

Refer to the 2001 Civic Shop Manual, P/N 62S5A000 on this CD [4-door (Except KB, KE, KG, TR models)], for items not shown in
this section.
Outline of Civic Coupe Model Change
This Coupe has been added in the body type.

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-76

System Descriptions

ECM/PCM Circuit Diagram


1. ENGINE
COMPARTMENT
WIRE HARNESS
2. ENGINE WIRE
HARNESS

*1: A/T

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-77

System Descriptions (cont'd)

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

Fuel and Emissions Systems

11-78

System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)


1. ENGINE WIRE
HARNESS

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-79

System Descriptions (cont'd)

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

Fuel and Emissions Systems

11-80

System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)


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

Fuel and Emissions Systems

11-81

System Descriptions (cont'd)

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.

*: Terminal side of female terminals

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-82

System Descriptions (cont'd)

ECM/PCM Circuit Diagram (cont'd)


1. DASHBOARD
WIRE HARNESS
A
2. ECM/PCM WIRE
HARNESS
3. FLOOR WIRE
HARNESS
4. ENGINE
COMPARTMENT
WIRE HARNESS

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Fuel and Emissions - Fuel and Emissions Systems

Fuel and Emissions Systems

11-83

System Descriptions (cont'd)

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

Fuel and Emissions Systems

11-84

System Descriptions (cont'd)

ECM/PCM Circuit Diagram (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 - PGM-FI System

PGM-FI System

11-85

Component Location Index


1. THROTTLE POSITION (TP) SENSOR
Troubleshooting, page 11-232 in the '01 Civic Shop
Manual on this CD
2. INTAKE AIR TEMPERATURE (IAT) SENSOR
Troubleshooting, page 11-235 in the '01 Civic Shop
Manual on this CD
3. MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
Troubleshooting, page 11-226 in the '01 Civic Shop
Manual on this CD
4. TOP DEAD CENTRE (TDC) SENSOR
Troubleshooting, page 11-234 in the '01 Civic Shop
Manual on this CD
5. CRANKSHAFT POSITION (CKP) SENSOR
Troubleshooting, page 11-228 in the '01 Civic Shop
Manual on this CD
6. KNOCK SENSOR
Troubleshooting, page 11-245 in the '01 Civic Shop
Manual on this CD
7. ENGINE COOLANT TEMPERATURE (ECT) SENSOR
Troubleshooting, page 11-229 in the '01 Civic Shop
Manual on this CD
8. PRIMARY HEATED OXYGEN SENSOR (PRIMARY
HO2S) (SENSOR 1)
Troubleshooting, page 11-225 in the '01 Civic Shop
Manual on this CD
Replacement, page 11-279 in the '01 Civic Shop
Manual on this CD

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Fuel and Emissions - PGM-FI System

PGM-FI System

11-86

Component Location Index (cont'd)


1. INJECTORS
Test, page 11-276 in the '01 Civic Shop
Manual on this CD
Replacement, page 11-113 in the '01 Civic
Shop Manual on this CD

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Fuel and Emissions - PGM-FI System

PGM-FI System

11-87

Component Location Index (cont'd)


1. DATA LINK CONNECTOR (DLC)
General Troubleshooting Information, page 11-167 in the '01 Civic
Shop Manual on this CD
2. ENGINE CONTROL MODULE/POWERTRAIN CONTROL
MODULE (ECM/PCM)
General Troubleshooting Information, page 11-167 in the '01 Civic
Shop Manual on this CD
3. PGM-FI MAIN RELAY 1
Troubleshooting, page 11-264 in the '01 Civic Shop Manual on
this CD
4. IDLE MIXTURE ADJUSTER (IMA) (Without TWC model)
Troubleshooting, page 11-237 in the '01 Civic Shop Manual

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Fuel and Emissions - Idle Control System

Idle Control System

11-88

Component Location Index


1. POWER STEERING (PSP) SWITCH
Troubleshooting, page 11-283 in the '01 Civic Shop
Manual on this CD
2. IDLE AIR CONTROL (IAC) VALVE
Troubleshooting, page 11-281 in the '01 Civic Shop
Manual on this CD

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Fuel and Emissions - Fuel Supply System

Fuel Supply System

11-89

Component Location Index


1. FUEL PUMP
Troubleshooting, page 11-287 in the '01 Civic Shop
Manual on this CD
Replacement, page 11-139 in the '01 Civic Shop
Manual on this CD
2. FUEL FILL CAP
3. FUEL FILTER
Replacement, page 11-296 in the '01 Civic Shop
Manual on this CD
4. FUEL TANK
Replacement, page 11-90
5. FUEL TUBE/QUICK-CONNECT FITTINGS
Precautions, page 11-292 in the '01 Civic Shop
Manual on this CD
Removal, page 11-293 in the '01 Civic Shop Manual
on this CD
Installation, page 11-294 in the '01 Civic Shop
Manual on this CD
6. PGM-FI MAIN RELAY 2
Troubleshooting, page 11-287 in the '01 Civic Shop
Manual on this CD
7. PGM-FI MAIN RELAY 1
8. FUEL VAPOUR PIPE
9. FUEL FEED PIPE
10. FUEL RAIL

*: The illustration shows LHD model.

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Fuel and Emissions - Fuel Supply System

Fuel Supply System

11-90

Fuel Tank Replacement

1.

2.

1. Relieve the fuel pressure, refer to the '01 Civic Shop Manual on this CD (see page 11-130).
2. Drain the fuel tank: Remove the fuel pump, refer to the '01 Civic Shop Manual on this CD (see page 11-139). Using a
hand pump, hose and container suitable for gasoline, draw the fuel from the fuel tank.
3. Jack up the vehicle and support it with jackstands.
4. Remove the fuel pipe cover (A). Disconnect the fuel vapour hose and quick-connect fittings.
Disconnect the hoses. Slide back the clamps, then twist the hoses as you pull to avoid damaging them.

5.
6.
7.
8.

Place a jack, or other support, under the tank.


Remove the strap bolts and let the strap (B) fall free.
Remove the fuel tank (C). If it sticks to the undercoat on its mount, carefully pry it off the mount.
Install the remaining parts in the reverse order of removal.

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Automatic Transmission - Automatic Transmission

Automatic Transmission

Road Test
Shift Schedule

14-2

Outline of Model Change


Shift schedule has been added to suit the CIVIC Coupe.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If body maintenance is required)
This model has an SRS which includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above
the glove box, seat belt tensioners in the front seat retractors, seat belt buckle tensioners in the front seat belt buckles and side
airbags in the front seat-backs. Information necessary to safely service the SRS is included in the '01 Civic Shop Manual, P/N
62S5A00 on this CD. 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 be done only by an
authorised Honda dealer.
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 and/or side airbags.
Do not bump the SRS unit. Otherwise, the system may fail in a collision, or airbags may deploy when the ignition switch
is ON (II).
SRS electrical wiring connectors are identified by yellow colour coding. Related components are located in the steering
column, front console, dashboard, dashboard lower panel, in the dashboard above the glove box, in the front seats, and
around the floor. Do not use electrical test equipment on these circuits.

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Automatic Transmission - Automatic Transmission

Automatic Transmission

14-2

Road Test

Shift Schedule
position
Upshift
Throttle Opening
Throttle position sensor voltage:
0.75 V
Throttle position sensor voltage:
2.25 V
Fully-opened throttle, Throttle
position sensor voltage: 4.5 V

Unit of Speed

1st - 2nd

2nd - 3rd

3rd - 4th

Lock-up ON

mph

9-12

19-22

29-34

14-18

km/h

15-19

30-35

47-54

23-28

mph

22-26

42-48

60-66

68-74

km/h

36-42

68-76

96-105

110-119

mph

34-40

67-76

103-114

103-114

km/h

55-63

108-121

166-183

166-183

Unit of Speed

3rd - 2nd

2nd - 1st

Downshift
Lock-up OFF

4th - 3rd

Throttle position sensor voltage:


0.5 V

Throttle Opening

mph

13-17

17-20

6-10 (3rd - 1st)

km/h

21-26

27-32

10-15 (3rd - 1st)

Fully-opened throttle, Throttle


position sensor voltage: 4.5 V

mph

93-104

85-96

55-62

25-30

km/h

150-166

137-153

89-100

40-48

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Body - Body

Body

Doors
Component Location Index

20-2

Door Panel Removal/Installation

20-4

Door Outer Handle Replacement

20-5

Door Latch Replacement

20-7

Door Glass and Regulator Replacement

20-9

Door Sash Trim Replacement

20-11

Door Glass Outer Weatherstrip Replacement

20-11

Door Weatherstrip Replacement

20-12

Door Upper Seal Replacement

20-12

Door Side Sill Seal Replacement

20-13

Door Channel Tape Replacement Process

20-14

Door Outer Channel Tape Replacement

20-15

Mirrors
Power Mirror Replacement

20-16

Glass
Component Location Index

20-17

Windshield Replacement

20-18

Rear Window Replacement

20-24

Quarter Glass Replacement

20-29

Interior Trim
Component Location Index

20-33

Trim Removal/Installation-Door Area

20-34

Trim Removal/Installation-Seat Side and Rear Shelf Area

20-35

Trim Removal/Installation-Trunk Area

20-36

Headliner Removal/Installation

20-37

Seats
* Front Seat Disassembly/Reassembly-Passenger's

20-40

Rear Seat-back Lock Cylinder Replacement

20-41

Rear Seat-back Cover Replacement

20-41

Bumpers
Rear Bumper Removal/Installation

20-43

Exterior Trim
Front Grille Replacement

20-44

Rear License Trim Replacement

20-44

Emblem Replacement

20-45

Openers
* Trunk Lid Opener/Fuel Fill door Opener Cable Replacement

20-46

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Body - Body

Frame
* Frame Repair Chart

20-48

NOTE: Refer to the '01 CIVIC Shop Manual, P/N 62S5A00 on this CD, for the items not shown in this section.
Outline of 2-door Model Change
The Civic 2-door model has been added.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If body maintenance is required)
This model has an SRS which includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above
the glove box, seat belt tensioners in the front seat belt retractors, seat belt buckle tensioners in the front seat belt buckles and
side airbags in the front seat-backs. Information necessary to safely service the SRS is included in the '01 Civic Shop Manual, P/N
62S5A00 on this CD. 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 be done only by an
authorised Honda dealer.
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 and/or side airbags.
Do not bump the SRS unit. Otherwise, the system may fail in a collision, or airbags may deploy when the ignition switch
is ON (II).
SRS electrical wiring connectors are identified by yellow colour coding. Related components are located in the steering
column, front console, dashboard, dashboard lower panel, in the dashboard above the glove box, in the front seats and
around the floor. Do not use electrical test equipment on these circuits.

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Body - Doors

Doors

20-2

Component Location Index - Front Door


1. DOOR PANEL SHOULDER PAD
(For some models)
2. DOOR SKIN SHOULDER PAD
(For some models)
3. DOOR SASH TRIM
Replacement, page 20-11
4. DOOR UPPER SEAL
Replacement, page 20-12
5. DOOR OUTER CHANNEL TAPE
Replacement process, page 20-14
Installation, page 20-15
6. DOOR GLASS OUTER WEATHERSTRIP
Replacement, page 20-11
7. DOOR
8. HINGE
9. DETENT ROD
10. HINGE
11. DOOR SIDE SILL SEAL
Replacement, page 20-13
12. SPEAKER
13. DOOR GLASS INNER WEATHERSTRIP
14. DOOR PANEL
Removal/Installation, page 20-4
15. POWER WINDOW SWITCH
16. POWER WINDOW SWITCH PANEL
17. ARMREST
18. DOOR WEATHERSTRIP
Replacement, page 20-12
19. PLASTIC COVER

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Body - Doors

Doors

20-3

Component Location Index - Front Door (cont'd)


1. CENTRE LOWER CHANNEL
2. IMMOBILISER LABEL
3. GLASS
Replacement, page 20-9
4. GLASS RUN CHANNEL
5. FRONT LOWER CHANNEL
6. OUTER HANDLE
Replacement, page 20-5
7. RETAINER CLIP
8. LOCK KNOB
9. KNOB BRACKET
10. INNER HANDLE ROD
11. POWER DOOR LOCK SWITCH
(Driver's for some models)
12. INNER HANDLE
13. COVER
14. LOCK CABLE
15. CABLE PROTECTOR
(For some models)
16. LATCH
(Without Super Locking)
Replacement, page 20-7
17. POWER DOOR LOCK ACTUATOR
(Without Super Locking)
18. LATCH PROTECTOR
(With Super Locking)
19. POWER DOOR LOCK ACTUATOR
(Without Super Locking)
20. LATCH
(With Super Locking)
Replacement, page 20-7
21. STRIKER
22. CYLINDER SWITCH
(For some models)
23. LOCK CYLINDER
24. OUTER HANDLE PROTECTOR
25. REGULATOR
Replacement, page 20-9

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Body - Doors

20-4

Doors

Door Panel Removal/Installation

Special Tools Required

1.

3. Remove the switch panel (A).


1. Using a flat-tip screwdriver wrapped with
protective tape, pry the cap (B), then remove the
screw (C).
2. Pry out the panel or pocket to release the clips
(D).
3. Release the clip (E) by pulling the cover or pocket
forward.
4. Disconnect the power window switch connector
(F).

Trim pad remover, Snap-on # A 177 or equivalent,


commercially available.
1.

1. Remove the inner handle (A). Take care not to


scratch the door panel.
1. Pry out on the upper portion of the cover (B) to
release the hooks (C and D), then remove the
cover.
2. Remove the screws.
3. Pull the inner handle forward and out half-way to
release the hook (E).
4. Disconnect the inner handle rod (F) and power
door lock switch connector (G) (driver's for some
models).

Fastener Locations
C

Fastener Locations

: Screw, 1D

: Clip, 2 or 1G

: Screw, 2

Power window model:

: Screw, 2

2.

3. Remove the screws (G) securing the door panel.

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Body - Doors

Doors

20-5

Door Outer Handle Replacement

Door Panel Removal/Installation (cont'd)

1.

4. Remove the mirror mount cover (see step 2 on page


20-16).
2.
5. Release the clips that hold the door panel (A) with a
commercially available trim pad remover (B), then
remove the door panel by pulling it upward. Remove
the door panel with as little bending as possible to
avoid creasing or breaking it.
Fastener Locations

NOTE: Put on gloves to protect your hands.


1.

2.

1. Raise the glass fully.


2. Remove these items:
Door panel (see page 20-4)
Plastic cover, as necessary
3. Release the retainer clip (A), then remove the lock
cylinder (B). Disconnect the cylinder rod (C).

: Clip, 9

3.

4. With cylinder switch: Remove the screw, then


separate the lock cylinder (A) and cylinder switch (B).
Fastener Location
: Screw, 1

3.

6. Install the door panel in the reverse order of removal


and note these items:
Replace any damaged clips.
Make sure the connectors are plugged in properly
and the rod is connected properly.

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Body - Doors

20-6

Doors

Door Outer Handle Replacement (cont'd)

1.

5. With cylinder switch: Disconnect the cylinder switch


connector (A) and detach the harness clips (B), then
remove the cylinder switch (C).

1.

7. Remove the maintenance hole (A). Disconnect the


outer handle rod (B) and remove the nuts, then
remove the outer handle protector (C) from the outer
handle (D).
Fastener Locations
: Nut, 2

2.

6. Pull the glass run channel (A) away as necessary.

2.

8. Pull out the outer handle (A) in the numbered


sequence and remove it.

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Body - Doors

Doors

20-7

Door Latch Replacement

Door Outer handle Replacement (cont'd)

1.

9. Install the handle in the reverse order of removal and


note these items:
Make sure the door locks and opens properly.
Make sure each rod is connected securely.
Make sure the door locks and opens properly.
When installing the lock cylinder, leave the outer
door handle bolts loose so the inner protector
does not interfere with the lock cylinder, then
tighten the handle bolts.
Install the lock cylinder retaining clip on the
handle, then install the lock cylinder. Be sure the
clip is fully seated in the slot on the lock cylinder.

NOTE: Put on gloves to protect your hands.


1.

1. Raise the glass fully.


2. Remove these items:
Door panel (see page 20-4)
Plastic cover, as necessary
2.
3. Disconnect the cylinder rod from the lock cylinder
(see step 3 on page 20-5) and disconnect the outer
handle rod from the outer handle (see step 7 on
page 20-6).
4. For some models: Remove the screw and release
the clip (A) and hook (B) while pulling the cable
protector (C) forward, then remove it from the latch
(D) and door.
Fastener Location
: Screw, 1

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Body - Doors

20-8

Doors

Door Latch Replacement (cont'd)

1.

5. Pull the glass run channel (A) away as necessary


and remove the bolts, then remove the centre lower
channel (B) by pulling it downward.
Fastener Location
: Bolt, 1

1.

6. Release the lock knob (A) from the knob bracket (B)
and detach the inner handle rod (C) from the rod
holder (D). Detach the harness clip (E) and
disconnect (and detach) the actuator connector(s)
(F).
Without Super Locking:

Without Super Locking:

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Body - Doors

Doors

20-9

Door Glass and Regulator Replacement

Door Latch Replacement (cont'd)

1.

7. Remove the screws, then remove the latch (A)


through the hole in the door. Take care not to bend
the outer handle rod (B), cylinder rod (C), inner
handle rod (D) and lock cable (E). Without Super
Locking model is shown, with Super Locking model is
similar.
Fastener Locations
: Screw, 3

NOTE: Put on gloves to protect your hands.


1.
1. Remove these items:
Door panel (see page 20-4)
Plastic cover, as necessary
2.
2. Carefully raise the glass (A) until you can see the
bolts, then remove them. Carefully pull the glass out
through the window slot. Take care not to drop the
glass inside the door.
Fastener Locations
: Bolt, 2

2.

8. If necessary, disconnect the lock cable (A) from the


latch (B). Without Super Locking model is shown with
Super Locking model is similar.

3.

9. Install the latch in the reverse order of removal and


note these items:
Make sure the actuator connectors are
plugged in property and each rod is
connected securely.
Make sure the door locks and opens
property.

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Body - Doors

Doors

20-10

Door Glass and Regulator Replacement (cont'd)

1.

3. Disconnect and detach the connector (A) and


harness clip (B) from the door.
Fastener Locations
C

2.

: Bolt, 3D

: Bolt, 4

1.

6. Install the glass and regulator in the reverse order of


removal and note these items:
Roll the glass up and down to see if it moves
freely without binding.
Make sure that there is no clearance between the
glass and glass run channel when the glass is
closed.
Adjust the position of the glass as necessary.

4. Remove the bolts (C) and loosen the bolts (D), then
remove the regulator (E) through the hole in the
door. Power window is shown, manual window is
similar.
5. Grease all the sliding surfaces of the regulator (A)
where shown.

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Body - Doors

Doors

Door Glass Outer Weatherstrip Replacement

20-11

Door Sash Trim Replacement

NOTE: Take care not to scratch the door.


1.
1. Remove the door glass outer weatherstrip.
2. Pull back the door weatherstrip (A) at the rear upper
corner and remove the screw.
Fastener Location
: Screw, 1

NOTE:
Put on gloves to protect your hands.
Take care not to scratch the door.
1.
1. Remove the power mirror (see page 20-16).
2. Starting at the front, pry the door glass outer
weatherstrip (A) up to detach the clips (B) and
release the weatherstrip from the door sash trim (C),
then remove the weatherstrip.
Fastener Locations
B

2.

3. Lift up the door sash trim (B) to release the hooks


(C), then remove the trim.
4. Install the trim in the reverse order of removal.

2.

: Clip, 4

3. Install the weatherstrip in the reverse order of


removal and replace any damaged clips.

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Body - Doors

Door Upper Seal Replacement

20-12

Doors

Door Weatherstrip Replacement

NOTE:

NOTE:

Take care not to scratch the door.


Use a clip remover to remove the clips.
1.
1. At the front-pillar, remove the door stop mounting
bolt (A).
Fastener Location

Take care not to scratch the door.


Use a clip remover to remove the clips.
1.
1. Remove these items:
Power mirror, as necessary (see page 20-16)
Door sash trim (see page 20-11)
2.
2. Detach the door weatherstrip clips (A, B), then
remove the door upper seal (C).
Fastener Location

: Bolt, 1B

: Clip, 1C

: Clip, 17

3.

2.

2. Detach the clips (B, C), then remove the door


weatherstrip (D).
3. Install the weatherstrip in the reverse order of
removal and note these items:
Replace any damaged clips.
Make sure the weatherstrip is installed in the holder
(E) securely.
Apply liquid thread lock to door stop mounting bolt
before installation.
Check for water leaks, refer to the '01 CIVIC Shop
Manual, P/N 62S5A00 on this CD (see step 7 on
page 20-25).

: Clip, 1B

: Clip, 2

3. Install the seal in the reverse order of removal and


note these items:
Replace the clip if it is damaged.
Make sure the upper seal is installed in the holder
(D) securely.
Check for water leaks, refer to the '01 CIVIC Shop
Manual, P/N 62S5A00 on this CD (see step 7 on
page 20-25).

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Body - Doors

Doors

20-13

Door Side Sill Seal Replacement

NOTE:
Take care not to scratch the door.
Use a clip remover to remove the clips.
1.
1. Detach the clips, then remove the door side sill seal
(A).
Fastener Locations
: Clip, 9

2.

2. Install the seal in the reverse order of removal and


replace any damaged clips.

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Body - Doors

Doors

20-14

Door Channel Tape Replacement Process

NOTE:

1.

This procedure is a general description of the door


channel tape replacement process. For details about
installation, door outer channel tape (see page 2015).
Keep dust away from the working area.
When working at lower temperatures, heat the door
channel and door channel tape with a hair dryer.
Door channel: about 15C (59F).
Door channel tape: about 30C (86F).
When heating the door channel tape, heat it evenly
and gradually to prevent deformation.
When pressing the door channel tape, slowly press it
from the corner to prevent air bubbles and wrinkles.
If there are air bubbles (A) in the door channel tape
(B), prick them with a pin (C), then release the air
with your finger or a plastic squeegee.
If the air bubble is more than 10 mm (0.4 in.) in
diameter, peel up the door channel tape, then
reapply it.

1.

1. The following tools are required to replace the door


channel tape:
Plastic squeegee
Alcohol
Sponge or Shop towel
Hair dryer
Pin

2. Remove these items:


Door outer channel tape replacement
Power mirror (see page 20-16)
Door glass outer weatherstrip (see page 20-11)
Glass run channel, as necessary (see page 20-2)
Sash trim (see page 20-11)
Upper seal (see page 20-12)
2.
3. Slowly peel up the old door channel tape while
heating it with a hair dryer.
4. Clean the door channel bonding surface with a
sponge dampened in alcohol. After cleaning, keep
oil, grease and water from getting on the surface.
5. Attach the door channel tape:
1. Peel the edge of the adhesive backing from the
channel tape.
2. Fit the door channel tape to the door channel.
3. Apply the door channel tape to the door channel
while peeling the adhesive backing from it a little
at a time. Check that the channel tape is parallel
with the door channel.
4. Push firmly on the door channel tape with a
plastic squeegee (felt side).
NOTE: To prevent air bubbles, slowly press the
door channel tape around the door frame corner.

3.

6. As necessary, repeat the preceding steps.


7. Reinstall all remaining removed parts.
8. Check that the body colour on the door channel is
covered by the door channel tape.
9. Check for water leaks, refer to '01 CIVIC Shop
Manual, P/N 62S5A00 on this CD (see step 7 on
page 20-25).

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Body - Doors

Doors

20-15

Door Outer Channel Tape Installation

NOTE: Familiarise yourself with the channel tape replacement process (see page 20-14).
Attachment Point (Reference):
a.

a. FRONT DOOR
OUTER CHANNEL
TAPE
b. DOOR OUTER
CHANNEL TAPE
c. FRONT DOOR
OUTER CHANNEL
TAPE
d. Align.
e. Outside
f. FRONT DOOR
OUTER CHANNEL
TAPE

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Mirrors

Mirrors

20-16

Power Mirror Replacement

1.
2.

1. Lower the door glass fully.


2. Carefully pry out the mirror mount cover (A) by hand
in the sequence shown.
Fastener Location

1.

7. While holding the mirror, push out the connector clip


(A) and remove the mirror (B). Take care not to
scratch the door.

2.

8. Install the mirror in the reverse order of removal and


make sure the connector is plugged in properly.

: Clip, 1

3.

3. Remove the door panel (see page 20-4).


4. If equipped with a tweeter, pull the plastic cover (A)
back as necessary and disconnect the connector (B),
then remove the mirror mount cover (C) with the
tweeter.
Fastener Locations
: Nut, 3

4.

4. Disconnect the connector (D).


5. While holding the mirror, remove the nuts securing
the mirror.

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Body - Glass

Glass

20-17

Component Location Index


1. CLIP, 2
(Self-adhesive-type, glass side)
2. CLIP, 2
(Clip-type, body side)
3. WINDSHIELD MOULDING
4. WINDSHIELD SIDE TRIM
5. RETAINER, 10
Navy Blue
6. CLIP, 2
Green
7. SIDE RUBBER DAM
8. LOWER RUBBER DAM
9. PASSENGER'S AIRBAG CAUTION
LABEL
(For some models)
10. WINDSHIELD
Replacement, page 20-18
11. CLIP, 2
(Self-adhesive-type, glass side)
12. CLIP, 2
(Clip-type, body side)
13. QUARTER GLASS
Replacement, page 20-29
14. REAR WINDOW
Replacement, page 20-24
15. FASTENER, 2
(Self-adhesive-type, body side)
16. FASTENER, 2
(Self-adhesive-type, glass side)

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Body - Glass

Glass

20-18

Windshield Replacement

NOTE:

1.

2.

1.

3. Remove the moulding (A) from the upper edge of the


windshield (B). If necessary, cut the moulding with a
utility knife.

2.

4. If the old windshield is to be reinstalled, make


alignment marks across the glass and body with a
grease pencil.
5. Pull down the front portion of the headliner (see
page 20-37). Take care not to bend the headliner
excessively, or you may crease or break it.
6. Apply protective tape along the edge of the
dashboard and body. Using an awl, make a hole
through the rubber dam and adhesive from inside the
vehicle at the corner portion of the windshield. Push
a piece of piano wire through the hole and wrap
each end around a piece of wood.

Put on gloves to protect your hands.


Wear eye protection when removing the glass with
piano wire.
Use seat covers to avoid damaging the seats.
1. Pull up the side trim (A) to release the clips (B and
C) from the retainers (D), then remove the trim from
each side of the windshield.

2. Remove these items:


Windshield wiper arms, refer to the '01
CIVIC Shop Manual, P/N 62S5A00 on this
CD (see page 22-179).
Cowl covers, refer to the '01 CIVIC Shop
Manual, P/N 62S5A00 on this CD (see
page 20-114).

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Body - Glass

Glass

20-19

Windshield Replacement (cont'd)

1.

7. With a helper on the outside, pull the piano wire (A)


back and forth in a sawing motion. Hold the piano
wire as close to the windshield (B) as possible to
prevent damage to the body and dashboard.
Carefully cut through the rubber dam and adhesive (C)
around the entire windshield.

1.

2.

Cutting portions:

2.

9. With a knife, scrape the old adhesive smooth to a


thickness of about 2 mm (0.08 in.) on the bonding
surface around the entire windshield opening flange:
Do not scrape down to the painted surface of the
body; damaged paint will interfere with proper
bonding.
Remove the rubber dam, clips and fasteners from
the body.
10. Clean the body bonding surface with a sponge
dampened in alcohol. After cleaning, keep oil, grease
and water from getting on the clean surface.
11. If the old windshield is to be reinstalled, use a putty
knife to scrape off all of the old adhesive, the
fasteners, the clips and the rubber dam from the
windshield. Clean the inside face and the edge of the
windshield with alcohol where new adhesive is to be
applied. Make sure the bonding surface is kept free
of water, oil and grease.

8. Carefully remove the windshield.

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Body - Glass

Glass

20-20

Windshield Replacement (cont'd)

1.

12. Glue the side rubber dams (A), lower rubber dam (B)
and fasteners (C) to the inside face of the windshield
(D) as shown:
Be sure the rubber dam and fasteners and
dashboard seal line up with the alignment marks
(E).
Be careful not to touch the windshield where
adhesive will be applied.

1.

13. Glue the moulding (A) with adhesive tape (B) to the
upper edge of the windshield (C):
Be sure the alignment mark (D) of the moulding
lines up with the alignment mark (E) of the
windshield.
Be careful not to touch the windshield where
adhesive will be applied.

2.

14. After installing the moulding, glue the seal (F) on


each side of the moulding. Be sure the seal lines up
with the edge of the rubber dam (G).
15. Install the clips (A) and retainers (B) to the body.
Fastener Locations
A

: Clip, 2B

: Retainer, 10

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Body - Glass

Glass

20-21

Windshield Replacement (cont'd)

1.

2.

16. Set the windshield in the opening and centre it.


Make alignment marks (A) across the windshield and body
with a grease pencil at the four points shown. Be careful not
to touch the windshield where adhesive will be applied.

1.

18. With a sponge, apply a light coat of glass primer


around the edge of the windshield (A) between the
dams (B) and moulding (C) as shown, then lightly
wipe it off with gauze or cheesecloth:
Apply glass primer to the moulding.
Do not apply body primer to the windshield and
do not get body and glass primer sponges mixed
up.
Never touch the primed surfaces with your hands.
If you do, the adhesive may not bond to the
windshield properly, causing a leak after the
windshield is installed.
Keep water, dust and abrasive materials away
from the primed surface.
Cross-hatched area: Apply primer here

17. Remove the windshield.

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Body - Glass

Glass

20-22

Windshield Replacement (cont'd)

1.

19. With a sponge, apply a light coat of body primer to


the original adhesive remaining around the
windshield opening flange. Let the body primer dry
for at least 10 minutes:
Do not apply glass primer to the body and be
careful not to mix up glass and body primer
sponges.
Never touch the primed surfaces with your hands.
Mask off the dashboard before painting the
flange.
Cross-hatched area: Apply body primer here

2.

20. Before filling a cartridge, cut a ''V'' in the end of the


nozzle (A) as shown.

1.

21. Pack adhesive into the cartridge without air pockets


to ensure continuous delivery. Put the cartridge in a
caulking gun and run a bead of adhesive (A) around
the edge of the windshield (B) between the dams (C)
and moulding (D) as shown. Apply the adhesive
within 30 minutes after applying the glass primer.
Make a slightly thicker bead at each corner.

2.

22. Use suction cups to hold the windshield over the


opening, align it with the alignment marks made in
step 16 and set it down on the adhesive. Lightly
push on the windshield until its edges are fully
seated on the adhesive all the way around. Do not
open or close the doors until the adhesive is dry.

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Body - Glass

Glass

20-23

Windshield Replacement (cont'd)

1.

23. Scrape or wipe the excess adhesive off with a putty


knife or towel. To remove adhesive from a painted
surface or the windshield, wipe with a soft shop towel
dampened with alcohol.
24. Let the adhesive dry for at least 1 hour, then spray
water over the windshield and check for leaks. Mark
leaking areas and let the windshield dry, then seal
with sealant:
Let the vehicle stand for at least 4 hours after
windshield installation. If the vehicle has to be
used within the first 4 hours, it must be driven
slowly.
Keep the windshield dry for the first hour after
installation.
25. Reinstall the cowl covers.
26. Install the clip (A) on both side mouldings (B). If the
clip portions (C) of the moulding are damaged,
replace the moulding.

2.

3.

4.

1.

27. On both sides of the windshield, set the bottom edge


of the side moulding (A) under the cowl cover (B),
then align the clips (C and D) with the retainers (E)
and push on the clip portions of the moulding until
the moulding is fully seated on the windshield.

2.

28. Reinstall all remaining removed parts. Advise the


customer not to do the following things for 2 to 3
days:
Slam the doors with all the windows rolled up.
Twist the body excessively (such as when going
in and out of driveways at an angle or driving
over rough, uneven roads).

1. Top of moulding

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Body - Glass

Glass

20-24

Rear Window Replacement

NOTE:

1.

2.

1.

Put on gloves to protect your hands.


Wear eye protection when removing the glass with
piano wire.
Use seat covers to avoid damaging any surfaces.
Do not damage the rear window defogger grid lines,
window antenna grid lines and terminals.
1. Remove these items:
Trunk lid
Rear shelf (see page 20-35)
2. Disconnect the window antenna connector (A) and
rear window defogger connectors (B).

2.

3.

3. If the old rear window is to be reinstalled, make


alignment marks across the glass and body with a
grease pencil.

4. Pull down the rear portion of the headliner (A) by


detaching the clips (B). Take care not to bend the
headliner excessively, or you may crease or break it.
Fastener Locations
: Clip, 2

5. Apply protective tape along the inside and outside


edges of the body. Using an awl, make a hole
through the adhesive from inside the vehicle at the
corner portion of the rear window. Push a piece of
piano wire through the hole and wrap each end
around a piece of wood.

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Body - Glass

Glass

20-25

Rear Window Replacement (cont'd)

1.

6. With a helper on the outside, pull the piano wire (A)


back and forth in a sawing motion. Hold the piano
wire as close to the rear window (B) as possible to
prevent damage to the body and carefully cut
through the adhesive (C) around the entire rear
window:
If the rear window is to be reinstalled, take care
not to damage the moulding (D).
If the moulding is damaged, replace the rear
window and moulding as an assembly.

1.

2.

8. With a putty knife, scrape the old adhesive smooth


to a thickness of about 2 mm (0.08 in.) on the
bonding surface around the entire rear window
opening flange:
Do not scrape down to the painted surface of the
body; damaged paint will interfere with proper
bonding.
Remove the clips and fasteners from the body.
9. Clean the body bonding surface with a sponge
dampened in alcohol. After cleaning, keep oil, grease
and water from getting on the surface.
10. If the old rear window is to be reinstalled, use a putty
knife to scrape off all of the old adhesive, the clips
and the fasteners from the rear window. Clean the
inside face and the edge of the rear window with
alcohol where new adhesive is to be applied. Make
sure the bonding surface is kept free of water, oil
and grease.

Cutting positions:

2.

7. Carefully remove the rear window.

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Body - Glass

Glass

20-26

Rear Window Replacement (cont'd)

1.

11. Glue the clips (A) and fasteners (B) to the inside face
of the rear window (C) as shown:
Be sure the clips and fasteners line up with the
alignment marks (D).
Be careful not to touch the rear window where
adhesive will be applied.

1.

12. Install the clips (A) to the rear window opening


flange (B) and glue the fasteners (C) to the offset
area of the rear shelf (D).
Fastener Locations
A

: Clip, 2B

: Fastener, 2

2.

13. Set the rear window in the opening and centre it.
Make alignment marks (A) across the rear window
and body with a grease pencil at the 4 points shown.
Be careful not to touch the rear window where
adhesive will be applied.

3.

14. Remove the rear window.

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Body - Glass

Glass

20-27

Rear Window Replacement (cont'd)

1.

15. With a sponge, apply a light coat of glass primer


along the edge of the rear window (A) and moulding
(B) as shown, then lightly wipe it off with gauze or
cheesecloth:
Do not apply body primer to the rear window and
do not get body and glass primer sponges mixed
up.
Never touch the primed surfaces with your hands.
If you do, the adhesive may not bond to the rear
window properly, causing a leak after the rear
window is installed.
Keep water, dust and abrasive materials away
from the primed surface.
Cross-hatched area: Apply glass primer here

1.

16. With a sponge, apply a light coat of body primer to


the original adhesive remaining around the rear
window opening flange. Let the body primer dry for
at least 10 minutes:
Do not apply glass primer to the body and be
careful not to mix up glass and body primer
sponges.
Never touch the primed surfaces with your hands.
Cross-hatched area: Apply body primer here

2.

17. Before filling a cartridge, cut a ''V'' in the end of the


nozzle (A) as shown.

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Body - Glass

Glass

20-28

Rear Window Replacement (cont'd)

1.

18. Pack adhesive into the cartridge without air pockets


to ensure continuous delivery. Put the cartridge in a
caulking gun and run a bead of adhesive (A) around
the edge of the rear window (B) and mouldings (C)
as shown.
Apply the adhesive within 30 minutes after applying the
glass primer. Make a slightly thicker bead at each corner.

1.

19. Use suction cups to hold the rear window over the
opening, align it with the alignment marks you made
in step 13 and set it down on the adhesive. Lightly
push on the rear window until its edges are fully
seated on the adhesive all the way around. Do not
open or close the doors until the adhesive is dry.
20. Scrape or wipe the excess adhesive off with a putty
knife or towel. To remove adhesive from a painted
surface or the rear window, use a soft shop towel
dampened with alcohol.
21. Let the adhesive dry for at least 1 hour, then spray
water over the rear window and check for leaks.
Mark the leaking areas, let the rear window dry, then
seal with sealant. Let the vehicle stand for at least 4
hours after rear window installation. If the vehicle
has to be used within the first 4 hours, it must be
driven slowly.
22. Reinstall all remaining removed parts. Advise the
customer not to do the following things for 2 to 3
days:
Slam the doors with all the windows rolled up.
Twist the body excessively (such as when going
in and out of driveways at an angle or driving
over rough, uneven roads).

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Body - Glass

Glass

20-29

Quarter Glass Replacement

NOTE:

1.

2.

Put on gloves to protect your hands.


Use seat covers to avoid damaging any surface.
1. Remove these items:
Rear pillar trim and side trim panel (see page 2035).
Centre pillar upper trim (see page 20-34).
2. Apply protective tape along the inside and outside
edges of the body and along the edge of the
headliner. Using an awl, make a hole through the
adhesive from inside the vehicle. Push a piece of
piece of piano wire through the hole and wrap each
end around a piece of wood.
3. With a helper on the outside, pull the piano wire (A)
back and forth in a sawing motion. Hold the piano
wire as close to the quarter glass (B) as possible to
prevent damage to the body and carefully cut
through the adhesive (C) around the entire quarter
glass:
If the quarter glass is to be reinstalled, take care
not to damage the moulding (D).
If the moulding is damaged, replace the quarter
glass, moulding fastener (E) and clips (F) as an
assembly.
If any of the clips and fastener are broken, the
quarter glass can be reinstalled using butyl tape
(refer to step 8).

Cutting positions:

1.

2.

4. Carefully remove the quarter glass.


5. With a putty knife, scrape the old adhesive smooth
to a thickness of about 2 mm (0.08 in.) on the
bonding surface around the entire quarter glass
opening flange:
Do not scrape down to the painted surface of the
body, damaged paint will interfere with proper
bonding.
Remove the clips and fastener from the body.
6. Clean the body bonding surface with a sponge
damaged in alcohol. After cleaning, keep oil, grease
and water from getting on the surface.
7. If the old quarter glass is to be reinstalled, use a
putty knife to scrape off all of the old adhesive, any
broken clips and the fastener from the glass. Clean
the inside face and the edge of the glass with
alcohol where new adhesive is to be applied. Make
sure the bonding surface is kept free of water, oil
and grease.

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Body - Glass

Glass

20-30

Quarter Glass Replacement (cont'd)

1.

8. If the old quarter glass is to be reinstalled (and either


clip is broken off the moulding), apply a light coat of
primer (C-100, or equivalent), then apply butyl tapes
(A) and (B) to the moulding (C) as shown:
Be careful not to touch the quarter glass where
adhesive will be applied.
Do not peel the separator off the butyl tapes.

2.

9. If the new quarter glass is to be installed, glue the


fastener (A) to the body:
Be sure the fastener lines up with the alignment
marks (B).

1.

10. If the old quarter glass is to be reinstalled (and either


clip is broken off the moulding), seal the body holes
with pieces of urethane tape (A). Then set the
quarter glass upright in the opening and make
alignment marks (B) across the quarter glass and
body with a grease pencil at the stet points shown.
Be careful not to touch the quarter glass where
adhesive will be applied.

2.

11. Remove the quarter glass.

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Body - Glass

Glass

20-31

Quarter Glass Replacement (cont'd)

1.

12. With a sponge, apply a light coat of glass primer to


the inside face of the quarter glass (A) as shown,
then lightly wipe it off with gauze or cheesecloth:
Do not apply body primer to the quarter glass and
do not get body and glass primer sponges mixed
up.
Never touch the primed surfaces with your hands.
If you do the adhesive may not bond to the
quarter glass properly, causing a leak after the
quarter glass is installed.
Keep water, dust and abrasive materials away
from the primed surface.
Cross-hatched area: Apply glass primer here

1.

13. With a sponge, apply a light coat of body primer to


the original adhesive remaining around the quarter
glass opening flange. Let the body primer dry for at
least 10 minutes:
Do not apply glass primer to the body and be
careful not to mix up glass and body primer
sponges.
Never touch the primed surfaces with your hands.
Mask off the dashboard before painting the
flange.
Cross-hatched area: Apply body primer here

2.

14. Before filling a cartridge, cut a ''V'' in the end of the


nozzle (A) as shown.

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Body - Glass

Glass

20-32

Quarter Glass Replacement (cont'd)

1.

15. Park adhesive into the cartridge without air pockets


to ensure continuous delivery. Put the cartridge in a
caulking gun and run a bead of adhesive (A) around
the edge of the quarter glass (B) as shown:
After applying the adhesive, peel the separator off
the butyl tape.
Apply the adhesive within 30 minutes after
applying the glass primer. Make slightly thicker
bead at each corner.

1.

16. Use suction cups (A) to hold the quarter glass (B)
over the opening, align the clips or the alignment
marks (C) made in step 10 and set it down on the
adhesive. Lightly push on the quarter glass until its
edges are fully seated on the adhesive all the way
around. Do not open or close the doors until the
adhesive is dry.

2.

17. Scrape or wipe the excess adhesive off with a putty


knife or towel. To remove adhesive from a painted
surface or the quarter glass, wipe with a soft shop
towel damaged with alcohol.
18. Let the adhesive dry for at least 1 hour, then spray
water over the quarter glass and check for leaks.
Mark the leaking areas and let the quarter glass dry,
then seal with sealant. Let the vehicle stand for at
least 4 hours after quarter glass installation. If the
vehicle has to be used within the first 4 hours, it
must be driven slowly.
19. Reinstall all remaining removed parts. Advise the
customer not to do the following things for 2 to 3
days:
Slam the doors with all the windows rolled up.
Twist the body excessively (such as when going
in and out of driveways at an angle or driving
over rough, uneven roads).

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Body - Interior Trim

Interior Trim

20-33

Component Location Index


1. FRONT PILLAR TRIM
page 20-34
2. DOOR OPENING TRIM
page 20-34
3. CENTRE PILLAR UPPER TRIM
page 20-34
4. REAR PILLAR TRIM
page 20-35
5. REAR SHELF
page 20-35
6. TRUNK REAR TRIM PANEL
page 20-36
7. TRUNK SIDE TRIM PANEL
page 20-36
8. TRUNK FLOOR MAT
page 20-36
9. TRUNK FLOOR SIDE SPACER
page 20-36
10. TRUNK CENTRE SPACER
page 20-36
11. SPARE TYRE LID
page 20-36
12. HEADLINER
Removal and Installation, page 20-37
13. SIDE TRIM PANEL
page 20-35
14. DOOR SILL TRIM
page 20-34
15. CARPET
16. KICK PANEL
page 20-34

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Body - Interior Trim

Interior Trim

20-34

Trim Removal/Installation - Door Area

NOTE:
Put on gloves to protect your hands.
When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage.
Take care not to bend or scratch the trim and panels.
LHD is shown, RHD is symmetrical.
Remove the trim as shown. To remove the door sill trim and centre-pillar upper trim, remove the side trim panel as necessary (see
page 20-35).
Install the trim in the reverse order of removal and note these items:
Replace any damaged clips.
Before installing the anchor bolts, make sure there are no twists or kinks in the belts.
Fastener Locations
A
: Clip, 2B : Clip, 3C
(Black)(White)

: Clip, 7
1.
2.
3.
4.

5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

15.

CENTRE PILLAR UPPER TRIM


To headliner
PIN
FRONT SEAT BELT UPPER
ANCHOR BOLT
7/16 - 20 UNF
32 Nm (3.3 kgf/m, 24 lbf/ft)
To headliner
FRONT PILLAR TRIM
PIN
DOOR OPENING TRIM
UPPER ANCHOR COVER
OPENER LOCK CYLINDER
(For some models)
FRONT SIDE CAP
KICK PANEL
DOOR SILL TRIM
FRONT SEAT BELT LOWER
ANCHOR BOLTS
7/16 - 20 UNF
32 Nm (3.3 kgf/m, 24 lbf/ft)
SIDE TRIM PANEL

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Body - Interior Trim

Interior Trim

20-35

Trim Removal/Installation - Seat Side and Rear


Shelf Area

NOTE:
Put on gloves to protect your hands.
When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage.
Take care not to bend or scratch the trim and panels.
Remove the trim as shown. To remove the side trim panel, remove the rear seat-back, refer to the '01 CIVIC Shop Manual, P/N
62S5A00 on this CD (see page 20-95).
Install the trim in the reverse order of removal and note these items:
Before installing the rear shelf, remove the clips from the body and install them to the rear shelf.
Replace any damaged clips.
When installing the rear shelf, slip the rear seat belts and centre belt through the slits in the rear shelf.
Make sure the high mount brake light connector is plugged in properly.
Fastener Locations
A
: Clip, 9B
(White)

: Clip, 1C

: Clip, 7
1. HIGH MOUNT BRAKE
LIGHT CONNECTOR
2. HOOK
3. REAR SHELF
4. REAR CENTRE BELT
5. REAR PILLAR TRIM
6. SLIT
7. REAR SEAT BELT
8. CENTRE PILLAR UPPER
TRIM
9. CAP
10. DOOR SILL TRIM
11. FRONT SEAT BELT
LOWER ANCHOR BOLTS
7/16 - 20 UNF
32 Nm (3.3 kgf/m, 24 lbf/ft)
12. SIDE TRIM PANEL
13. HOOK
14. HOOKS
15. SLIT
16. CLIP
(Three places)
17. HOOK
18. REAR SEAT BELT
19. SLIT

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Body - Interior Trim

Interior Trim

20-36

Trim Removal/Installation - Trunk Area

NOTE:
Put on gloves to protect your hands.
When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage.
Take care not to bend or scratch the trim and panels.
Remove the trim as shown. To remove the trunk side trim panel, remove the side trim panel as necessary (see page 20-35).
Install the trim in the reverse order of removal and replace any damaged clips.
Fastener Locations
A

: Clip, 4B

: Clip, 2C

: Clip, 6
1. LEFT TRUNK SIDE TRIM
PANEL
2. SPARE TYRE LID
3. TRUNK FLOOR MAT
4. Without trunk floor spacer:
5. To body
6. HOOKS
7. HOOKS
8. To body.
9. RIGHT TRUNK FLOOR SIDE
SPACER
(For some models)
10. RIGHT TRUNK SIDE TRIM
PANEL
11. TRUNK FLOOR CENTRE
SPACER
(For some models)
12. TRUNK REAR TRIM PANEL
13. LEFT TRUNK FLOOR SIDE
SPACER
(For some models)

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Body - Interior Trim

Interior Trim

20-37

Headliner Removal/Installation

NOTE:

1.

2.

1.

When prying with a flat-tip screwdriver, wrap it with


protective tape to prevent damage.
Take care not to bend and scratch the headliner.
Be careful not to damage the dashboard and other
interior trim.
1. Remove these items:
Front-pillar trim, both sides (see page 20-34)
Centre-pillar trim, both sides (see page 20-34)
Centre-pillar upper trim, one side (see page 2034)
Rear view mirror, refer to the '01 CIVIC Shop
Manual, P/N 62S5A00 on this CD (see page 2036).
Spotlights/ceiling light, with sunroof, refer to the
'01 CIVIC Shop Manual, P/N 62S5A00 on this CD
(see page 22-137).
Spotlights, without sunroof, refer to the '01 CIVIC
Shop Manual, P/N 62S5A00 on this CD (see page
22-138).
Ceiling light, refer to the '01 CIVIC Shop Manual,
P/N 62S5A00 on this CD (see page 22-138).
2. From both sides, remove the caps (A) and remove
the self-tapping ET screws, then remove the
sunvisor (B) and holder (C).
Fastener Locations

3. On front passenger's side: Lower the grab handle,


then remove the caps (A). Remove the self-tapping
ET screws, then remove the grab handle (B).
Fastener Locations
: Screw, 6

2.

4. On left rear passenger's side: Remove the screw,


then remove the coat hanger (A).
Fastener Locations
: Screw, 1

: Screw, 4

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Body - Interior Trim

Interior Trim

20-38

Headliner Removal/Installation (cont'd)

1.

5. Remove the headliner.


With sunroof:

1.

1. Remove the socket plug (A).


2. Remove the upper portion of the centre-pillar
upper trim (B) from one side (see page 20-34).
3. Remove the remaining door opening trim (C) from
each roof portion.
4. Detach the clips (D) and release the fasteners (E)
by pulling the front portion of the headliner (F)
down.
5. With the help of an assistant, release the clips (G)
of the headliner from the sunroof frame (H) and
release the headliner from the clips (I) by sliding
the headliner forward and lowering the headliner.
6. Remove the headliner through the passenger's
door opening.
Fastener Locations
D

: Clip, 3G

: Clip, 2I

6. Remove the headliner.


Without sunroof:
1. Remove the upper portion of the centre-pillar
upper trim (A) from one side (see page 20-34).
2. Remove the remaining door opening trim (B) from
each roof portion.
3. With the help of an assistant, release the
headliner (C) from the clips (D) by sliding the
headliner forward and lowering the headliner.
4. Remove the cushion tape (E), then remove the
roof harness (F) from the headliner. LHD is
shown, RHD is symmetrical.
5. Remove the headliner through the passenger's
door opening.
Fastener Locations
D

: Clip, 2E

: Cushion tape, 5 or 3

: Clip, 2

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Body - Interior Trim

Interior Trim

20-39

Headliner Removal/Installation (cont'd)

1.

7. If necessary, remove the bolts, then remove the grab


handle bracket (A).
Fastener Locations
: Bolt, 2

2.

8. Install the headliner in the reverse order of removal


and note these items:
When reinstalling the headliner through the door
opening, be careful not to fold or bend it. Also, be
careful not to scratch the body.
If the threads on a visor and grab handle screws
are worn out, use an oversized self-tapping ET
screw made specifically for this application.
Check that both sides of the headliner are
securely attached to the trim.

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Body - Seats

Seats

20-40

Front Seat Disassembly/Reassembly Passenger's

SRS components are located in this area. Review the SRS component locations, precautions and procedures in the SRS section
before performing repairs or service. Refer to the '01 CIVIC Shop Manual, P/N 62S5A00 on this CD.
NOTE:
Take care not to tear the seams or damage the seat covers.
Put on gloves to protect your hands.
When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage.
Disassemble the seat as shown.
Reassemble the seat in the reverse order of disassembly and note these items:
Apply multipurpose grease to the moving portion of the seat track.
To prevent wrinkles in the seat cushion cover, stretch the material evenly over the pad.
Make sure the rear seat access cable is connected properly on each side.
Replace any damaged clips and replace the wire ties with new ones.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.

SEAT-BACK
HEADREST
SIDE AIRBAG HARNESS
HANGER SPRING
HOOKS
Release the seat cushion cover
from the cushion frame spring
HOOKS
HOOKS
(Five places)
OPDS HARNESS
CENTRE COVER
CLIP
SEAT CUSHION FRAME/SEAT
TRACKS
SLIDE LEVER
HOOK
CLIP
CLIP
RECLINE COVER
HOOK
RECLINE KNOB
REAR SEAT ACCESS KNOB
SCREW
REAR SEAT ACCESS CABLE
WIRE TIE

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Body - Seats

Seats

Rear Seat-back Cover Replacement

20-41

Rear Seat-back Lock Cylinder Replacement

NOTE: Take care not to scratch the interior trim.


1.
1. Remove the rear shelf (see page 20-35).
2. Disconnect the cylinder rods from both seat-back
latches.
3. Remove the screws, then remove the seat-back lock
cylinder (A) and cylinder rods (B).
Fastener Locations
: Screw, 2

NOTE:
Take care not to tear the seams or damage the
seat covers.
Put on gloves to protect your hands.
1.
1. Remove the seat back, refer to the '01 M CIVIC
Shop Manual, P/N. 625A00 on this CD (see page
20-95).
2. On the left seat-back: Remove the screw, then
remove the centre belt guide (A).
Fastener Location
: Screw, 1

2.
2.

4. Install the lock cylinder in the reverse order of


removal and note these items:
Make sure the cylinder rod is connected securely.
Make sure the seat-back opens properly.

3. Release the hook (A) and unzip the seat-back cover


(B). The left seat-back is shown, the right seat-back
is similar.

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Body - Seats

Seats

20-42

Rear Seat-back Cover Replacement (cont'd)

1.

4. Pull back the seat-back cover (A) and remove the


clips (B) and release the hooks (C).
Fastener Locations

1.

: ClipLeft, 6
B
Right, 3

6. Pull back the edge of the seat-back cover (A) all the
way around and remove the clips (B), then remove
the seat-back cover.
Left seat back:

Left seat back:

Right seat back:

Right seat back:

2.

2.

7. Install the cover in the reverse order of removal and


note these items:
To prevent wrinkles when installing a seat-back
cover, make sure the material is stretched evenly
over the pad before securing the hooks and clips.
Replace any clips you removed with new ones.
Install them with commercially available upholstery
ring pliers.

5. Remove the seat-back cover and pad (D) from the


seat-back frame (E).

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Bumpers

Bumpers

20-43

Rear Bumper Removal/Installation

NOTE:
Have an assistant help you when removing and installing the rear bumper.
Take care not to scratch the rear bumper and body.
When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage.
Put on gloves to protect your hands.
Remove the rear bumper as shown. LHD with rear fog light is shown, RHD with fog light is symmetrical.
Install the bumper in the reverse order of removal and note these items:
If equipped, make sure the rear fog light connector is plugged in properly.
Make sure the rear bumper engages the hooks of the side spacers, upper spacers and upper brackets on both sides
securely.
Replace any damaged clips.
Fastener Locations
A

: Bolt, 2B

: Screw, 2C

: Screw, 2D

: Clip, 2
1. CAP
2. ABSORBER
3. REAR FOG LIGHT
CONNECTOR
(For some models)
4. UPPER BRACKET
5. HOOKS
6. HOOKS
7. UPPER SPACER
8. HOOKS
9. SIDE SPACER
10. HOOKS
(Six places)
11. REAR BUMPER
12. CAP

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Body - Exterior Trim

20-44

Exterior Trim

Rear License Trim Replacement

Front Grille Replacement

1.
2.

1. Remove the front bumper.


2. Remove the screws (A) and clips (B) and remove the
front grille (C) from the front bumper (D) by pulling it
out. Take care not to scratch the front bumper.
Fastener Locations
A

3.

: Screw, 2B

1.

: Clip, 4

1. On the inside of the trunk lid, remove the nuts (A)


and release the clips (B), then remove the rear
license trim (C). Take care not to scratch the trunk
lid.
Fastener Locations
A

: Nut, 3B

: Clip, 2

3. Remove the screws, then remove the front grille


cover (A) from the front grille (B).
Fastener Locations
: Screw, 9
2.

4.

2. Install the trim in the reverse order of removal and


replace any damaged clips.

4. Install the grille in the reverse order of removal and


replace any damaged clips.

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Body - Exterior Trim

Exterior Trim

20-45

Emblem Replacement

NOTE: When removing the emblems, take care not to scratch the body.
1.

1. Clean the body surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water from getting on
the surface.
2. Apply the emblem where shown.
1. HONDA EMBLEM (KG, KB, KR
models)/VTEC EMBLEM (KY model)
2. VERSION EMBLEM (KB, KK, KX,
KY models)/VTEC EMBLEM (KE,
KG, KR model)
3. CIVIC EMBLEM

Unit: mm (in.)

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Body - Openers

Openers

20-46

Trunk Lid Opener/Fuel Fill Door Opener Cable


Replacement

SRS components are located in this area. Review the SRS component locations and the precautions and procedures in the SRS
section before performing repairs or service. Refer to the '01 CIVIC Shop Manual, P/N 62S5A00 on this CD.
NOTE:

1.

2.

Put on gloves to protect your hands.


Take care not to scratch the body and related parts.
1. Remove these items:
Front door sill trim (see page 20-34)
Side trim panel, left side (see page 20-35)
RHD: Side trim panel, right side as necessary (see page 20-35)
Trunk side trim panel, left side (see page 20-36)
2. Pull the carpet back as necessary, refer to the '01 CIVIC Shop Manual on this CD (see page 20-70).
3. Disconnect the trunk lid opener/fuel fill door opener cable (A) from the opener (B), refer to the '01 CIVIC Shop Manual on
this CD (see step 3 on page 20-129).
Fastener Location
C
: ClipD : Cushion Tape
LHD, 1LHD, 2
RHD, 4

3.

4. Release the opener cable from the clip (LHD) (C). Remove the cushion tape (D).

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Body - Openers

Openers

20-47

Trunk Lid Opener/Fuel Fill Door Opener Cable


Replacement (cont'd)

1.

5. Remove the cushion tape (A) and detach the clip (B) with a clip remover. Remove the fuel fill door latch (C) by turning it
90 and detach the opener cable junction box (D) from the body.
Fastener Locations
A

2.

: Cushion tape, 1B and G

: Clip, 2H

: Clip, 3

6. Disconnect the trunk lid opener cable (E) from the trunk lid latch (F), refer to the '01 CIVIC Shop Manual, P/N 62S5A00
on this CD (see page 20-130).
7. Using a clip remover, detach the clip (G) from the body and detach the clips (H) from the trunk lid hinge.
8. Remove the trunk lid opener/fuel fill door opener cable from the vehicle. Take care not to bend the cable.
9. Install the opener cable in the reverse order of removal and note these items:
Align the mark on the cable with the clip on the bottom portion of the trunk lid hinge.
Replace any damaged clips.

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Body - Frame

Frame

20-48

Frame Repair Chart

Top View
Unit : mm (in)

For sub-frame 15 (0.59)

For sub-frame 11 (0.43)

: Inner diameter

For engine mount 13 (0.51)

For
damper
(0.45)

mount

11.5

For engine mount 13 (0.51)

For
damper
(0.45)

mount

11.5

For engine mount 13 (0.51)

Damper centre 78 (3.07)

For transmission mount 13 (0.51) m

For sub-frame 15 (0.59)

For transmission mount 13 (0.51) n

Locating hole 25 (0.98)

For transmission mount 13 (0.51) o

Locating hole 50 (1.97)

For damper mount 11.5 (0.45)

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Body - Frame

Frame

20-49

Frame Repair Chart (cont'd)

Locating hole 25 (0.98)

For upper arm bracket centre 15 (0.98)

For trailing arm 13 (0.51)

y1, y2

Locating hole 13 (0.51)

Locating hole 25 (0.98)

For upper arm 13 (0.51)

Locating hole 20 (0.79)

a1

For rear lower arm centre

Trailing arm centre

b1

Locating hole 50 (1.97)

Rear damper centre 73 x 68 (Slot)

c1

Locating hole 20 (0.79)

For upper arm 13 (0.51)

For trailing arm 23 (0.51)

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Frame 50

Frame 50

20-50

Frame Repair Chart (cont'd)

Side View
Unit : mm (in)

For sub-frame 15 (0.59)

For sub-frame 11 (0.43)

: Inner diameter

For engine mount 13 (0.51)

For
damper
(0.45)

mount

11.5

For engine mount 13 (0.51)

For
damper
(0.45)

mount

11.5

For engine mount 13 (0.51)

Damper centre 78 (3.07)

For transmission
(0.51)

mount

13 m

For sub-frame 15 (0.59)

For transmission
(0.51)

mount

13 n

Locating hole 25 (0.98)

For transmission
(0.51)

mount

13 o

Locating hole 50 (1.97)

For damper mount 11.5 (0.45)

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Body - Frame

Frame

20-51

Frame Repair Chart (cont'd)

Locating hole 25 (0.98)

For upper arm bracket centre 15 (0.98)

For trailing arm 13 (0.51)

y1, y2

Locating hole 13 (0.51)

Locating hole 25 (0.98)

For upper arm 13 (0.51)

Locating hole 20 (0.79)

a1

For rear lower arm centre

Trailing arm centre

b1

Locating hole 50 (1.97)

Rear damper centre 73 x 68 (Slot)

c1

Locating hole 20 (0.79)

For upper arm 13 (0.51)

For trailing arm 23 (0.51)

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Body Electrical - Relay and Control Unit Locations

Body Electrical
Wire Harnesses and Ground Locations
Power Distribution

22-2

Fuse to Components Index

22-6

Circuit Identification

22-8

Ground Distribution
Ground to Identification

22-16

Exterior Lights
Taillights Replacement

22-26

Interior Lights
Circuit Diagram-With Sunroof

22-27

Stereo Sound System


Component Location Index

22-28

Circuit Diagram

22-29

Audio Unit Connector Replacement

22-30

Speaker Replacement

22-31

Window Antenna Test

22-32

Window Antenna Repair

22-32

Power Window
Component Location Index

22-33

Circuit Diagram

22-34

Master Switch Input Test

22-36

Master Switch Test/Replacement

22-40

Passenger's Switch Test/Replacement

22-41

Rear Window Defogger


Component Location Index

22-42

Circuit Diagram

22-43

Antenna Module Test

22-44

Function Test

22-45

Defogger Wire Repair

22-45

Outline of Model Changes


Coupe model has been added; related information is included.
The information in which differs from the '01 CIVIC Shop Manual has been included.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If electrical maintenance is required)
This model has an SRS which includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above
the glove box, seat belt tensioners in the front seat belt retractors, seat belt buckle tensioners in the front seat belt buckles, and
side airbags in the front seat-backs. Information necessary to safely service the SRS is included in the '01 Civic Shop Manual, P/N
62S5A00 on this CD. 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 be done only by an
authorised Honda dealer.

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Body Electrical - Relay and Control Unit Locations

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 and/or side airbags.
Do not bump the SRS unit. Otherwise, the system may fail in a collision, or airbags may deploy when the ignition switch
is ON (II).
SRS electrical wiring connectors are identified by yellow colour coding. Related components are located in the steering
column, front console, dashboard, dashboard lower panel, in the dashboard above the glove box, in the front seats and
around the floor. Do not use electrical test equipment on these circuits.

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Floor

Relay and Control Unit Locations

22-2

Floor

1. FLOOR WIRE HARNESS

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Body Electrical - Relay and Control Unit Locations

Relay and Control Unit Locations

22-3

Rear

1. REAR WINDOW DEFOGGER GROUND


WIRE
2. REAR WIRE HARNESS

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Body Electrical - Relay and Control Unit Locations

Relay and Control Unit Locations

22-4

Door

NOTE: LHD type is shown, RHD type is similar.


KG and KE models:
1. DRIVER'S DOOR WIRE HARNESS

Except KG and KE models:


1. DRIVER'S DOOR WIRE HARNESS

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Body Electrical - Relay and Control Unit Locations

Relay and Control Unit Locations

22-5

Door (cont'd)

NOTE: LHD type is shown, RHD type is similar.


KG and KE models:
1. PASSENGER'S DOOR
WIRE HARNESS

Except KG and KE models:


1. PASSENGER'S DOOR
WIRE HARNESS

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Body Electrical - Power Distribution

Power Distribution

22-6

Fuse to Components Index

Under-hood Fuse/Relay Box


Fuse

Amps

Wire
Colour

20 A

BLU/YEL

Condenser fan motor

BLU/RED

A/C compressor clutch

15 A

WHT/GRN Climate control unit, Dash lights, Front parking lights, Front side marker lights, Heater control
panel, License plate lights, Taillights

Number

Component(s) or Circuit(s) Protected

7.5 A

WHT/BLU

Ceiling light, Spotlights, Trunk light

20 A

BLU/BLK

Radiator fan motor

10 A

WHT/BLK

Turn signal/hazard relay, Turn signal lights

15 A

WHT/BLK

CKP sensor, ECM/PCM, Injectors, IAC valve, Immobiliser control unit-receiver, PGM-FI main
relay 1 and 2, TDC sensor

15 A

WHT/GRN Horn, Brake lights, Brake signals (to ABS modulator-control unit, Cruise control unit,
ECM/PCM, Multiplex control unit)

20 A

WHT/GRN ABS modulator unit

10 A

WHT/RED Data link connector (DLC), Gauge assembly, Immobiliser control unit-receiver, Keyless
receiver unit, Multiplex control unit, Security control unit, Audio unit

10

40 A

WHT/RED ABS modulator unit

11

30 A

BLK/YEL

Rear window defogger, Antenna module

12

40 A

BLU/WHT

Blower motor

13

40 A

WHT/BLK

No. 7 fuse (in the under-dash fuse/relay box), Power window relay

14

40 A

WHT/RED No. 3, and 16 fuses (in the under-dash fuse/relay box)

15

15 A

RED/YEL

16

20 A

WHT

Multiplex control unit

17

15 A

RED

Right headlight

18

Not used
Battery, Power distribution

19

80 A

20

50 A*1

WHT

High beam indicator light, Left headlight

Ignition switch (BAT)

40 A*2

*1: KG, KE, KR


*2: KB, KK, KX, KY

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-6.htm[8/25/2012 6:24:07 PM]

Body Electrical - Power Distribution

: Spare Fuse

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-6.htm[8/25/2012 6:24:07 PM]

Body Electrical - Power Distribution

Power Distribution

22-7

Fuse to Components Index (cont'd)

Under-dash Fuse/Relay Box


Fuse
Number

Amps

Wire
Colour

15 A

BLK/WHT

Component(s) or Circuit(s) Protected


Ignition coils
Not used

10 A

RED/BLU

Multiplex control unit

10 A

BLK/ORN

Alternator, Cruise control unit, Evaporative emission (EVAP) canister purge valve, Primary
and secondary HO2S, Vehicle speed sensor (VSS)

7.5 A

Fuse/relay Multiplex control unit (KG)


box socket

7.5 A

YEL/GRN

20 A

GRN

7.5 A

YEL/RED

Sunroof open and close relays, Power window relay, Headlight adjuster unit
Sunroof motor
Audio unit, Multiplex control unit

10 A

GRN

OPDS unit

10

7.5 A

YEL

A/T reverse relay, Back-up lights, Gauge assembly, Keyless receiver unit, Multiplex control
unit, Security control unit, Shift lock solenoid

11

7.5 A

BLK/ORN

ABS modulator-control unit (IG2)

12

7.5 A

YEL/RED

Multiplex control unit (KG)

13

10 A

PNK

14

10 A

BLK/YEL

A/C compressor fan relay, Heater control panel/climate control unit, Condenser fan relay,
Blower motor relay, Power mirror actuators, Radiator fan relay, Recirculation control motor,
Rear window defogger relay

15

30 A

RED/YEL

Headlight washer control unit (KG, KR)

16

20 A

RED/BLK

Seat heaters

17

15 A

BLK/YEL

ECM/PCM, SRS unit

18

15 A

YEL/GRN

Cigarette lighter

19

7.5 A

YEL/BLK

Turn signal/hazard relay

20

20 A

GRN/BLK

Multiplex control unit, Windshield washer motor, Windshield wiper motor

SRS unit

21

22

20 A

GRN/BLK

Not used

23

20 A

GRN/WHT Driver's power window motor

Passenger's power window motor

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-7.htm[8/25/2012 6:24:07 PM]

Body Electrical - Power Distribution

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-7.htm[8/25/2012 6:24:07 PM]

Body Electrical - Power Distribution

Power Distribution

22-8

Circuit Identification

4 - door:

To get to the pages referenced on the above diagram, click on the following:
22-13
22-14

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-8.htm[8/25/2012 6:24:07 PM]

Body Electrical - Power Distribution

22-15

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-8.htm[8/25/2012 6:24:07 PM]

Body Electrical - Power Distribution

Power Distribution

22-9

Circuit Identification (cont'd)

file:///C|/...20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-9.htm[8/25/2012 6:24:07 PM]

Body Electrical - Power Distribution

Power Distribution

22-10

Circuit Identification (cont'd)

To get to the pages referenced on the above diagram, click on the following:
22-11
22-13
22-15

file:///C|/...0EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-10.htm[8/25/2012 6:23:58 PM]

Body Electrical - Power Distribution

Power Distribution

22-11

Circuit Identification (cont'd)

To get to the pages referenced on the above diagram, click on the following:
22-9
22-12

file:///C|/...0EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-11.htm[8/25/2012 6:23:58 PM]

Body Electrical - Power Distribution

22-13

file:///C|/...0EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-11.htm[8/25/2012 6:23:58 PM]

Body Electrical - Power Distribution

Power Distribution

22-12

Circuit Identification (cont'd)

file:///C|/...0EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-12.htm[8/25/2012 6:23:58 PM]

Body Electrical - Power Distribution

Power Distribution

22-13

Circuit Identification (cont'd)

file:///C|/...0EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-13.htm[8/25/2012 6:23:59 PM]

Body Electrical - Power Distribution

Power Distribution

22-14

Circuit Identification (cont'd)

file:///C|/...0EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-14.htm[8/25/2012 6:23:59 PM]

Body Electrical - Power Distribution

Power Distribution

22-15

Circuit Identification (cont'd)

file:///C|/...0EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-15.htm[8/25/2012 6:23:59 PM]

Body Electrical - Ground Distribution

Ground Distribution

22-16

Circuit Identification

file:///C|/...0EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-16.htm[8/25/2012 6:23:59 PM]

Body Electrical - Ground Distribution

Ground Distribution

22-17

Circuit Identification (cont'd)

file:///C|/...0EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-17.htm[8/25/2012 6:23:59 PM]

Body Electrical - Ground Distribution

Ground Distribution

22-18

Circuit Identification (cont'd)

file:///C|/...0EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-18.htm[8/25/2012 6:24:00 PM]

Body Electrical - Ground Distribution

Ground Distribution

22-19

Circuit Identification (cont'd)

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Body Electrical - Ground Distribution

Ground Distribution

22-20

Circuit Identification (cont'd)

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Body Electrical - Ground Distribution

Ground Distribution

22-21

Circuit Identification (cont'd)

file:///C|/...0EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-21.htm[8/25/2012 6:24:01 PM]

Body Electrical - Ground Distribution

Ground Distribution

22-22

Circuit Identification (cont'd)

file:///C|/...0EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-22.htm[8/25/2012 6:24:01 PM]

Body Electrical - Ground Distribution

Ground Distribution

22-23

Circuit Identification (cont'd)

file:///C|/...0EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-23.htm[8/25/2012 6:24:01 PM]

Body Electrical - Ground Distribution

Ground Distribution

22-24

Circuit Identification (cont'd)

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Body Electrical - Ground Distribution

Ground Distribution

22-25

Circuit Identification (cont'd)

file:///C|/...0EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-25.htm[8/25/2012 6:24:02 PM]

Exterior Lights

Exterior Lights

22-26

Taillight Replacement

Taillights:
1.
1. Open the trunk lid.
2. Disconnect each connector from the taillight.
Brake/Taillight:21/5 W
Back-up Light18 W
Turn Signal Light:27 W
Side Marker Light
(KK, KX, KY):3.8 W

2.

3. Remove the four nuts and taillight.


4. Install in the reverse order of removal.
5. When installing the taillight check the gasket; if it is
distorted or stays compressed, replace it.
6. After installing the taillight run water over the taillight
to make sure it does not leak.

file:///C|/...0EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-26.htm[8/25/2012 6:24:02 PM]

Interior Lights

Interior Lights

22-27

Circuit Diagram - With Sunroof

file:///C|/...0EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-27.htm[8/25/2012 6:24:02 PM]

Body Electrical - Stereo Sound System

Stereo Sound System

22-28

Component Location Index

[ ]: RHD type
1. WINDOW ANTENNA
(AM antenna grid)
Wire Test, page 22-32
Wire Repair, page 22-32
2. LEFT TWEETER (KK, KX)
Replacement, page 22-31
3. DRIVER'S [PASSENGER'S] DOOR
SPEAKER
Replacement, page 22-213 in the '01 Civic
Shop Manual on this CD
4. SUB ANTENNA LEAD
5. RIGHT TWEETER (KK, KX)
Replacement, page 22-31
6. PASSENGER'S [DRIVER'S] DOOR
SPEAKER
Replacement, page 22-213 in the '01 Civic
Shop Manual on this CD
7. AUDIO UNIT
Removal, page 22-212 in the '01 Civic
Shop Manual on this CD
Connector Replacement, page 22-30
8. ANTENNA LEAD
9. ANTENNA MODULE
Input Test, page 22-44
10. REAR WINDOW DEFOGGER
(FM antenna, grid)
Antenna Wire Test, page 22-32
Defogger Function, page 22-45
Defogger Wire Repair, page 22-45
11. REAR SPEAKERS
Replacement, page 22-31

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Body Electrical - Stereo Sound System

Stereo Sound System

22-29

Circuit Diagram

file:///C|/...0EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-29.htm[8/25/2012 6:24:02 PM]

Body Electrical - Stereo Sound System

22-30

Stereo Sound System

Audio Unit Connector Replacement

Cavity

Wire

Connects to

YEL/GRN

Antenna module

YEL/RED

ACC (Main stereo power supply)

Not used

Not used

PNK

BLU/WHT

Left rear speaker (+)

GRN/YEL

Passenger's door speaker (+), Right tweeter (+)

GRN/BLK

Driver's door speaker (+), Left tweeter (+)

RED/BLK

Lights-on signal

10

WHT/RED

Constant power

11

Not used

12

Not used

13

Not used

14

Not used

15

BLU/YEL

Right rear speaker (-)

16

BLU/BLK

Left rear speaker (-)

17

GRY/RED

Passenger's door speaker (-), Right tweeter (-)

18

LT GRN

19

RED

Dash lights brightness controller

20

BLK

Ground (G503)

Right rear speaker (+)

Driver's door speaker (-), Left tweeter (-)

AUDIO UNIT 20P CONNECTOR

file:///C|/...0EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-30.htm[8/25/2012 6:24:03 PM]

Body Electrical - Stereo Sound System

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Body Electrical - Stereo Sound System

Stereo Sound System

22-31

Speaker Replacement

Tweeter:
1.
1. Remove the door panel (see page 20-4).
2. Disconnect the 2P connector (A) from the tweeter
(B).

2.

Rear Speaker:
1.
1. Remove the rear shelf (see page 20-35).
2. Remove the four screws, and disconnect the 2P
connector (A) from the speaker (B).

3. Remove the mirror garnish (C).


4. Remove the screw and tweeter from the mirror
garnish.

file:///C|/...0EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-31.htm[8/25/2012 6:24:03 PM]

Body Electrical - Stereo Sound System

Stereo Sound System

22-32

Window Antenna Repair

Window Antenna Test

1.

1. Wrap Aluminium foil (A) around the tip of the tester


probe (B) as shown.

2.

2. Touch one tester probe to the window antenna


terminal (A) and move the other tester probe along
the antenna wires to check that continuity exists.

NOTE: To make an effective repair, the broken section must


be no longer than 1 inch.
1.
1. Lightly rub the area around the broken section (A)
with fine steel wool, then clean it with alcohol.

2.

2. Carefully mask above and below the broken portion


of the window antenna wire (B) with transparent tape
(C).
3. Using a small brush, apply a heavy coat of silver
conductive paint (A) extending about 1/8" on both
sides of the break. Allow 25 minutes to dry.
Thoroughly mix the paint before use.

3.

4. Check for continuity in the repaired wire.


5. Apply a second coat of paint in the same way. Let it
dry 3 hours before removing the tape

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Body Electrical - Power Windows

Power Windows

22-33

Component Location Index


1. UNDER-DASH FUSE/RELAY BOX
2. POWER WINDOW RELAY
Test, page 22-80 in the '01 CIVIC Shop
Manual on this CD
3. PASSENGER'S WINDOW MOTOR
Test, page 22-198 in the '01 CIVIC Shop
Manual on this CD
4. PASSENGER'S WINDOW SWITCH
Test, page 22-41
Replacement, page 22-41
5. POWER WINDOW MASTER SWITCH
Input Test, page 22-36
Test, page 22-40
Replacement, page 22-40
6. DRIVER'S WINDOW MOTOR
Test, page 22-196 in the '01 CIVIC Shop
Manual on this CD

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Body Electrical - Power Windows

Power Windows

22-34

Circuit Diagram

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Body Electrical - Power Windows

Power Windows

22-35

Circuit Diagram (cont'd)

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Body Electrical - Power Windows

Power Windows

22-36

Master Switch Input Test

KY model
NOTE: The power window control unit is built into the power window master switch, and it only controls the driver's window
operations.
1.

1. Remove the power window master switch (A) (see page 22-40)
2. Disconnect the 14P connector (B) from the master switch.

2.

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, make the following input tests at the connector.
If a test indicates a problem, find and correct the cause, then recheck the system.
If all the input tests prove OK, go to step 4.

file:///C|/...0EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CHtml/22-36.htm[8/25/2012 6:24:04 PM]

Body Electrical - Power Windows

Power Windows

22-37

Master Switch Input Test (cont'd)

1.

4. With the connector still disconnected, make these input tests at the connector.
If any test indicates a problem, find and correct the cause, then recheck the system.
If all the input tests prove OK, go to step 5.

Cavity

Wire

10

BLK

Test condition
Under all conditions

Test: Desired result


Check for continuity to ground:
There should be continuity.

14
11

GRN/WHT Under all conditions

Check for voltage to ground:


There should be battery voltage.

12

YEL/GRN Ignition switch ON (II)

Check for voltage to ground:

GRN/BLK

There should be battery voltage.

RED/YEL Connect the No. 11 and


RED/BLK No. 7 terminals, and the
No. 4 and No. 14
terminals, and turn the
ignition switch ON (II).

Check for driver's window motor


operation:

BLU/RED Connect the No. 2 and


BLU/WHT No. 1 terminals, and the
No. 3 and No. 10
terminals, and turn the
ignition switch ON (II).

Check for front passenger's


window motor operation:

3
1

2.

Possible cause if result is not


obtained

Poor ground (G501)


An open in the wire
Blown No. 23 (20A) fuse in the
under-dash fuse/relay box
An open in the wire
Blown No. 6 (7.5 A) fuse in the
under-dash fuse/relay box
Blown No. 22 (20 A) fuse in the
under-dash fuse/relay box
Faulty power window relay
An open in the wire
Faulty driver's window motor
An open in the wire

It should run (the driver's window


moves down).

It should run (the front


passenger's window moves
down).

Faulty passenger's window


motor
Faulty passenger's window
switch
An open in the wire.

5. Reconnect the 14P connector to the switch, and perform the following input tests.
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 the power window master switch.

Cavity
5

Wire

Test condition

RED/WHT Ignition switch ON (II)

Test: Desired result


Check for voltage to ground:
There should be battery voltage.

LT GRN

Under all conditions

Check for voltage to ground:

Possible cause if result is not


obtained

Faulty power window master


switch
An open in the wire
An open in the wire

There should be battery voltage.


13

BLU

Check for voltage between the No.


Ignition switch ON (II),
and the driver's window 13 and No. 6 terminals:
switch AUTO DOWN
There should be 0 V - about 5 V 0 V - about 5 V repeatedly.

ORN

Check for voltage between the No.


Ignition switch ON (II),
and the driver's window 8 and No. 6 terminals:
switch AUTO DOWN
There should be 0 V - about 5 V 0 V - about 5 V repeatedly.

Blown No. 6 (7.5 A) fuse in the


under-dash fuse/relay box
Blown No. 23 (20 A) fuse in the
under-dash fuse/relay box
Faulty power window relay
Faulty power window master
switch
An open in the wire

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Body Electrical - Power Windows

Power Windows

22-38

Master Switch Input Test (cont'd)

Except KY
NOTE: The power window control unit is built into the power window master switch, and it only controls the driver's window
operations.
1.

1. Remove the power window master switch (A) (see page 22-40).
2. Disconnect the 14P connector (B) from the master switch.

2.

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, make the following input tests at the connector.
If a test indicates a problem, find and correct the cause, then recheck the system.
If all the input tests prove OK, go to step 4.

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Body Electrical - Power Windows

Power Windows

22-39

Master Switch Input Test (cont'd)

1.

4. With the connector still disconnected, make these input tests at the connector.
If any test indicates a problem, find and correct the cause, then recheck the system.
If all the input tests prove OK, go to step 5.

Cavity

Wire

10

BLK

Test condition
Under all conditions

Test: Desired result


Check for continuity to ground:
There should be continuity.

14
11

GRN/WHT Ignition switch ON (II)

Check for voltage to ground:

GRN/BLK

There should be battery voltage.

RED/BLK Connect the No. 11 and


RED/YEL No. 7 [No. 3] terminals,
and the No. 4 [No. 1]
and No. 14 terminals,
and turn the ignition
switch ON (II).

Check for driver's window motor


operation:

BLU/RED Connect the No. 2 and


BLU/WHT No. 1 [No. 7] terminals,
and the No. 3 [No. 4]
and No. 10 terminals,
and turn the ignition
switch ON (II).

Check for passenger's window


motor operation:

4 [1]
7 [3]

3 [4]
1 [7]

2.

Possible cause if result is not


obtained

Poor ground (G501)


An open in the wire
Blown No. 6 (7.5 A) fuse in the
under-dash fuse/relay box
Blown No. 22 or 23 (20 A) fuse
in the under-dash fuse/relay
box
Faulty power window relay
An open in the wire
Faulty driver's window motor
An open in the wire

It should run (the driver's window


moves down).

It should run (the passenger's


window moves down).

Faulty passenger's window


motor
Faulty passenger's window
switch
An open in the wire.

5. Reconnect the 14P connector to the switch, and perform the following input tests.
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 the power window master switch.

Cavity

Wire

Test condition

Test: Desired result

13

BLU

Connect the No. 11 and


No. 7 [No. 3] terminals,
and the No. 4 [No. 1]
and No. 14 terminals,
and turn the ignition
switch ON (II).

Check for voltage between the No.


13 and No. 14 terminals:

Possible cause if result is not


obtained

Faulty driver's window motor


An open in the wire

About 6 V should be indicated


while the driver's window motor
running.

[ ]: RHD type

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Body Electrical - Power Windows

Power Windows

22-40

Master Switch Test/Replacement

1.

2.

1. Remove the screw and the power window master


switch (A) from the door panel.

1.

3. Check for continuity between the terminals in each


switch position according to the table.
Driver's Switch:
The driver's switch is combined with the control unit so you
cannot isolate the switch to test it. Instead, run the master
switch input test procedures on page 22-36. If the tests are
normal, the driver's switch must be faulty.

2.

4. If the switch is faulty, remove the two screws and


replace the switch.

2. Disconnect the 14P connector (B) from the switch.

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Body Electrical - Power Windows

Power Windows

22-41

Passenger's Window Switch Test/Replacement

1.

1. Remove the screw and passenger's power window


switch (A) from the door panel.

2.

2. Disconnect the 5P connector (B) from the switch.


3. Check for continuity between the terminals in each
switch position according to the table.

3.

4. If the switch is faulty, remove the two screws and


replace the switch.

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Body Electrical - Rear Window Defogger

Rear Window Defogger

22-42

Component Location Index

*: Rear window defogger switch is built into the heater control panel.
1. REAR WINDOW
DEFOGGER SWITCH*
2. UNDER-HOOD
FUSE/RELAY BOX
3. REAR WINDOW
DEFOGGER RELAY
Test, page 22-80 in the '01
Civic Shop Manual on this
CD
4. ANTENNA MODULE
Input Test, page 22-44
5. REAR WINDOW
DEFOGGER
Function Test, page 22-45
Defogger Wire Repair, page
22-45

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Body Electrical - Rear Window Defogger

Rear Window Defogger

22-43

Circuit Diagram

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Body Electrical - Rear Window Defogger

Rear Window Defogger

22-44

Antenna Module Input Test

1.
2.

1. Remove the right C-Pillar trim (see page 20-35)


2. Make sure the antenna module mounting bolt (A) is
torqued to 9.8 Nm (1.0 kgf/m, 7.2 lbf/ft).
Wire side of female terminals

1.

7. Disconnect the rear window defogger (+B OUT)


connector (C) from the antenna module.
2.
8. Check for continuity between the rear window
defogger negative terminal connector and body
ground.
There should be continuity.
If there is no continuity, check for.
An open in the BLK wire.
An open in the rear window defogger wire (see
page 22-45).
Poor ground (G701).

3.

3. Disconnect the 2P connector from the antenna


module (B).
4. Turn the ignition switch ON (II), and turn the rear
window defogger switch ON.
5. Check for voltage between the No. 2 terminal and
body ground. There should be battery voltage.
If there is no voltage, check for.

Faulty rear window defogger relay.


Blown No. 11 (40 A) fuse in the under-hood
fuse/relay box.
An open in the BLK/YEL wire.
4.
6. Check for continuity between No. 1 terminal and
audio unit 20P connector No. 1 terminal. There
should be continuity.
If there is no continuity, check for an open in the YEL/GRN
wire.

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Body Electrical - Rear Window Defogger

Rear Window Defogger

22-45

Defogger Wire Repair

Function Test

NOTE:
Be careful not to scratch or damage the defogger
wires with the tester probe.
Before testing, check the No. 11 (40 A) fuse in the
under-hood fuse/relay box and No. 14 (10 A) fuse in
the under-dash fuse/relay box.
1.
1. Check for voltage between the positive terminal (A)
and body ground with the ignition switch and
defogger switch ON.
There should be battery voltage.

NOTE: To make an effective repair, the broken section must


be no longer than one inch.
1.
1. Lightly rub the area around the broken section (A)
with fine steel wool, then clean it with alcohol.

If there is no voltage, check for:


faulty defogger relay.
faulty antenna module.
an open in the wire between the defogger relay
and positive terminal.
3.

faulty defogger switch.


2. Check for continuity between the negative terminal
(B) and body ground.
If there is no continuity, check for:

2.

2. Carefully mask above and below the broken portion


of the defogger wire (B) with transparent tape (C).
3. Using a small brush, apply a heavy coat of silver
conductive paint extending about 1/8" on both sides
of the break. Allow 25 minutes to dry. Thoroughly
mix the paint before use.

3.

4. Check for continuity in the repaired wire.


5. Apply a second coat of paint in the same way. Let it
dry 3 hours before removing the tape.

an open in the BLK wire.


Poor body ground at the window antenna coil
mounting bolt.
Poor ground (G701)
4.
3. Touch the voltmeter positive probe to the halfway
point of each defogger wire, and the negative probe
to the negative terminal.
There should be about 6 V with the ignition switch and the
defogger switch ON.
If the voltage is as specified, the defogger wire is
OK.
If the voltage is not as specified, repair the
defogger wire.
If it is more than 6 V, there is a break in the
negative half of the wire.
If it is less than 6 V, there is a break in the
positive half of the wire.

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Restraints - Restraints

Restraints

Seat Belts
Front Seat Belt Replacement

23-2

Inspection

23-4

SRS (Supplemental Restraint System)


Side Impact Sensor Replacement

23-5

NOTE: Refer to the 'CIVIC 4/5 D MAINTENANCE, REPAIR and CONSTRUCTION 01'the other part of this CD for the items not
shown in this section.

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Restraints - Seat Belts

Seat Belts

23-2

Front Seat Belt Replacement

SRS components are located in this area. Review the SRS


component location, precautions and procedures in the SRS
section before performing repairs or service. Refer to the '01
Civic Shop Manual, P/N 62S5A00 on this CD NOTE:

1.

6. Remove the upper anchor cap (A) and remove the


upper anchor bolt (B).

2.

7. Disconnect the seat belt tensioner connector (A).


Remove the retractor mounting self-tapping ET
screw (B) and the retractor bolt (C), then remove the
front seat belt (D) and retractor (E).

NOTE: Check the front seat belts for damage, and replace
them if necessary. Be careful not to damage them during
removal and installation.
Front Seat Belt
1.

2.

1. If equipped, make sure you have the anti-theft code


for the radio, then write down the frequencies for the
preset buttons.
2. Disconnect the negative battery cable, and wait at
least 3 minutes before beginning work.
3. Slide the front seat forward fully.
4. Remove the lower anchor bolts, then remove the
slide bar (A).

5. Remove the slide trim panel refer to '01 Civic Shop


Manual on this CD (see page 20-35).

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Restraints - Seat Belts

Seat Belts

23-3

Front Seat Belt Replacement (cont'd)

Install the belt in the reverse order of removal and note these
items:
If the threads on the retractor mounting selftapping ET screw are worn out, use an oversized
self-tapping ET screw made specifically for this
application.
Check that the retractor locking mechanism
functions (see page 23-4).
Assemble the washers, collars and bushing on
the upper and lower anchor bolts as shown.
Before installing the anchor bolts, make sure
there are no twists or kinks in the front seat belt.
Make sure the seat belt tensioner connector is
plugged in properly.
Reconnect the negative cable to the battery.
If equipped, enter the anti-theft code for the radio,
then enter the customer's radio station presets.
Upper anchor bolt construction:

Lower anchor bolt construction:

1.

1.
2.
3.
4.
5.
6.
7.

BUSHING
UPPER ANCHOR
WASHERS
TOOTHED LOCK WASHER
COLLARS
SPRING WASHER
UPPER ANCHOR BOLT

LOWER ANCHOR BOLT


TOOTHED LOCK WASHER
COLLAR
LOWER ANCHOR

Retractor bolt:

2.
1.

1.
2.
3.
4.

1.
2.
3.
4.
5.

RETRACTOR BOLT
COLLAR
SPRING WASHER
TOOTHED LOCK WASHER
RETRACTOR

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Restraints - Seat Belts

Seat Belts

23-4

Inspection

For front seat belt retractor with seat belt tensioner, review the
SRS component locations, precautions and procedures in the
SRS section before performing repairs or service. Refer to the
'01 Civic Shop Manual, P/N 62S5A00 on this CD.
Retractor
1.

1. Before installing the retractor, check that the seat belt


can be pulled out freely.
2. Make sure that the seat belt does not lock when the
retractor (A) is leaned slowly up to 15 from the
mounted position. The seat belt should lock when the
retractor is leaned over 40. Do not attempt to
disassemble the retractor.
Front:

2.

3. Replace the seat belt with a new assembly if there is


any abnormality. Do not disassemble any part of the
seat belt for any reason.

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SRS

SRS

23-5

Side Impact Sensor Replacement

Removal

Installation

CAUTION

Removal of the airbag must be performed


according to the precautions/procedures
described before.
Before disconnecting the side impact
sensor 2P connector(s), disconnect the
side airbag 2P connector(s).
Do not turn the ignition switch ON (II) and
do not connect the battery cable while
replacing the side impact sensor.
1.

2.

1. Disconnect the negative battery cable and wait at


least 3 minutes before beginning work.
2. Slide the front seat forward.
3. Remove these items:
Rear seat-backs
Rear seat cushion
4. Remove the front seat belt lower anchor slide bar
(see page 23-2).
5. Remove the side trim panel refer to '01 Civic Shop
Manual on this CD (see page 20-35).
6. Remove the middle cross-member gusset.
7. Disconnect the floor wire harness 2P connector from
the side impact sensor.
8. Remove the Torx bolt (A) using a Torx T30 bit, then
remove the side impact sensor (B).

CAUTION

Be sure to install the harness wires so that


they are not pinched or interfering with
other parts.
Do not turn the ignition switch ON (II) and
do not connect the battery cable while
replacing the side impact sensor.
Install the side impact sensor in the reverse order of removal,
and note these items:
Replace the Torx bolt with a new one.
After installing the side impact sensor, confirm proper
system operation: Turn the ignition switch ON (II):
the SRS indicator light should come on for about 6
seconds and then go off.

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