Professional Documents
Culture Documents
Introduction
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.
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.
General Information
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Abbreviations 1-9
List of automotive abbreviations, which may be used in shop manual. EPR Evaporator Pressure Regulator
ABS Anti-lock Brake System EPS Electrical Power Steering
A/C Air Conditioning, Air Conditioner EVAP Evaporative
ACL Air Cleaner EX Exhaust
A/F Air Fuel Ratio F Front
ALR Automatic Locking Retractor FIA Fuel Injection Air
ALT Alternator FL Front Left
AMP Ampere(s) FP Fuel Pump
ANT Antenna FR Front Right
API American Petroleum Institute FSR Fail Safe Relay
APPROX. Approximately FWD Front Wheel Drive
ASSY Assembly GAL Gallon
A/T Automatic Transmission GND Ground
ATDC After Top Dead Centre GPS Global Positioning System
ATF Automatic Transmission Fluid H/B Hatchback
ATT Attachment HC Hydrocarbons
ATTS Active Torque Transfer System HID High Intensity Discharge
AUTO Automatic HO2S Heated Oxygen Sensor
AUX Auxiliary IAB Intake Air Bypass
BARO Barometric IAC Idle Air Control
BAT Battery IACV Idle Air Control Valve
BDC Bottom Dead Centre IAR Intake Air Resonator
BTDC Before Top Dead Centre IAT Intake Air Temperature
CARB Carburettor ICM Ignition Control Module
CAT Catalytic Converter ID Identification
or CATA ID or I.D. Inside Diameter
CHG Charge IG or IGN Ignition
CKF Crankshaft Speed Fluctuation IMA Idle Mixture Adjustment
CKP Crankshaft Position Integrated Motor Assist
I.D. 18.042-18.066 mm -
(0.7103-0.7113 in.)
Hydraulic pressure Forward clutch pressure At 1,500 rpm (min-1) in 1.4-1.75 MPa
position (14.3-17.8 kgf/cm2, 203-253 psi)
Torque converter Stall speed Check with vehicle on D15Y4 engine in position 2,500 rpm (min-1) 2,350-2,650 rpm (min-1)
level ground
D15Y4 engine in , 3,000 rpm (min-1) 2,800-3,100 rpm (min-1)
and positions
ATF pump ATF pump drive gear shaft O.D. 9.98-9.99 mm (0.3929-0.3933 in.) When worn or damaged
ATF pump driven gear shaft O.D. 9.98-9.99 mm (0.3929-0.3933 in.) When worn or damaged
ATF pump body bushing I.D. Drive gear shaft 10.0-10.015 mm (0.3937-0.3944 in.) When worn or damaged
Driven gear shaft 10.0-10.015 mm (0.3937-0.3944 in.) When worn or damaged
ATF pump gear side clearance 0.015-0.035 mm (0.0006-0.0014 in.) -
ATF pump gear-to-body clearance Drive gear 0.035-0.0505 mm (0.0014-0.0020 in.) -
Driven gear 0.035-0.0505 mm (0.0014-0.0020 in.) -
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Clutch return spring free length Forward clutch 30.5 mm (1.20 in.) 28.5 mm (1.12 in.)
Start clutch 40.9 mm (1.61 in.) 38.9 mm (1.53 in.)
Reverse brake 29.4 mm (1.16 in.) 27.4 mm (1.08 in.)
Clutch disc thickness Forward clutch 1.94 mm (0.076 in.) -
Start clutch 1.94 mm (0.076 in.) -
Reverse brake 2.00 mm (0.079 in.) -
Clutch plate thickness Forward clutch 2.00 mm (0.079 in.) When discoloured
Start clutch 2.3 mm (0.091 in.) When discoloured
Reverse brake 1.35 mm (0.053 in.) When discoloured
Forward clutch end plate Mark 14 3.4 mm (0.134 in.) When discoloured
Mark 15 3.5 mm (0.138 in.) When discoloured
Mark 16 3.6 mm (0.142 in.) When discoloured
Mark 17 3.7 mm (0.146 in.) When discoloured
Mark 18 3.8 mm (0.150 in.) When discoloured
Mark 19 3.9 mm (0.154 in.) When discoloured
Mark 20 4.0 mm (0.157 in.) When discoloured
Mark 21 4.1 mm (0.161 in.) When discoloured
Mark 22 4.2 mm (0.165 in.) When discoloured
Mark 23 4.3 mm (0.169 in.) When discoloured
Mark 24 4.4 mm (0.173 in.) When discoloured
Mark 25 4.5 mm (0.177 in.) When discoloured
Mark 26 4.6 mm (0.181 in.) When discoloured
Mark 27 4.7 mm (0.185 in.) When discoloured
Reverse brake end plate Mark 1 3.6 mm (0.142 in.) When discoloured
Mark 2 3.8 mm (0.150 in.) When discoloured
Mark 3 4.0 mm (0.157 in.) When discoloured
Mark 4 4.2 mm (0.165 in.) When discoloured
Mark 5 4.4 mm (0.173 in.) When discoloured
Mark 6 4.6 mm (0.181 in.) When discoloured
Mark 7 4.8 mm (0.189 in.) When discoloured
Mark 8 5.0 mm (0.197 in.) When discoloured
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Feed pipe O.D. Drive pulley feed pipe 6.97-6.98 mm 6.95 mm (0.274 in.)
(0.274-0.275 in.)
Feed pipe bushing I.D. Drive pulley feed pipe 7.00-7.015 mm 7.030 mm (0.277 in.)
(0.2756-0.2762 in.)
Thrust shim, 22 x 28 mm thickness (ATF pump driven C 1.15 mm (0.045 in.) When worn or damaged
sprocket hub)
D 1.40 mm (0.055 in.) When worn or damaged
E 1.65 mm (0.065 in.) When worn or damaged
F 1.90 mm (0.075 in.) When worn or damaged
G 2.15 mm (0.085 in.) When worn or damaged
H 2.40 mm (0.095 in.) When worn or damaged
Thrust shim, 25 x 31 mm thickness (Planetary carrier) A 1.050 mm (0.041 in.) When worn or damaged
B 1.12 mm (0.044 in.) When worn or damaged
C 1.19 mm (0.047 in.) When worn or damaged
D 1.26 mm (0.050 in.) When worn or damaged
E 1.33 mm (0.052 in.) When worn or damaged
F 1.40 mm (0.055 in.) When worn or damaged
G 1.47 mm (0.058 in.) When worn or damaged
H 1.54 mm (0.061 in.) When worn or damaged
I 1.61 mm (0.063 in.) When worn or damaged
J 1.68 mm (0.066 in.) When worn or damaged
K 1.75 mm (0.069 in.) When worn or damaged
L 1.82 mm (0.072 in.) When worn or damaged
M 1.085 mm (0.0427 in.) When worn or damaged
N 1.155 mm (0.0454 in.) When worn or damaged
O 1.225 mm (0.0482 in.) When worn or damaged
P 1.295 mm (0.0510 in.) When worn or damaged
Q 1.365 mm (0.0537 in.) When worn or damaged
R 1.435 mm (0.0565 in.) When worn or damaged
Driven pulley shaft Diameter of needle bearing contact area Start clutch side 43.981-43.991 mm When worn or damaged
(1.7315-1.7319 in.)
Driven pulley shaft feed pipe O.D. 11.47-11.48 mm 11.45 mm (0.451 in.)
(0.4516-0.4520 in.)
Start clutch feed pipe bushing I.D. End cover side 7.00-7.015 mm 7.030 mm (0.277 in.)
(0.2756-0.2762 in.)
Driven pulley shaft feed pipe bushing I.D. 11.50-11.518 mm 11.533 mm (0.454 in.)
(0.4528-0.4535 in.)
I.D. 18.042-18.066 mm -
(0.7103-0.7113 in.)
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Suspension
Item Measurement Qualification Standard or New Service Limit
Wheel alignment Camber Front 0°00'+45°
Rear -0°45'+45'
Caster Front 1°33'+1°
Total Toe Front 0+3 mm (0+0.12 in.)
Rear Adjust: IN 2 +2/-1 mm (0.08 +0.08/-0.04 in.)
Inspect: IN 2+3 mm (0.08+0.12 in.)
Aluminium wheel Runout Axial 0-0.7 mm (0-0.03 in.) 2.0 mm (0.08 in.)
Radial 0-0.7 mm (0-0.03 in.) 1.5 mm (0.06 in.)
Steel wheel Runout Axial 0-1.0 mm (0-0.04 in.) 2.0 mm (0.08 in.)
Radial 0-1.0 mm (0-0.04 in.) 1.5 mm (0.06 in.)
Wheel bearings End play Front 0-0.05 mm (0-0.002 in.)
Rear 0-0.05 mm (0-0.002 in.)
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Brake booster Vehicle Characteristics at 196 N (20 kgf, Vacuum N (kgf, lbf) kPa (kgf/cm2, psi)
without ABS 44 lbf) pedal force kPa (mmHg, inHg)
(3) (4) (5)
0 (0, 0) 98 (10, 22) 0 (0, 0) 0 (0, 0) 0 (0, 0)
294 (30, 66) 1700 (17, 240) 1600 (16, 230) 1800 (18, 260)
66.7 (500, 19.7) 98 (10, 22) 4400 (45, 640) 4100 (42, 600) 4800 (49, 700)
294 (30, 66) 10500 10300 9800
(107, 1500) (105, 1500) (100, 1400)
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3-4
Listed by Distance/Time
Service at the indicated distance or time km x 1,000 20 40 60 80 100 120 140 160 180 200
whichever comes first.
miles x 1,000 12 24 36 48 60 72 84 96 108 120
months 12 24 36 48 60 72 84 96 108 120
Replace engine oil Every 10,000 km (6,000 miles) or 6 months
Replace engine oil filter
Replace air cleaner element
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
Replace transmission fluid 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
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
Replace air conditioning filter Every 30,000 km (18,000 miles) or 12 months
Check light alignment
Test drive (noise, stability, dashboard operation)
Visually inspect the following items:
Tie rod ends, steering gearbox and boots Every 10,000 km (6,000 miles) or 6 months
Suspension components
Driveshaft boots
Brake hoses and lines (including ABS)
All fluid levels and condition of fluid
Exhaust system
Fuel line and connections
Tyre condition
Follow the Severe Conditions Maintenance Schedule if the customer's vehicle is driven MAINLY under one or more of the following conditions:
● Driving less than 8km (5 miles) per trip or, in freezing temperatures, driving less than 16km (10 miles) per trip.
● Driving in extremely hot over 35°C (95°F) conditions.
● Extensive idling of long periods of stop-and-go driving.
● Trailer towing, driving with a car-top carrier, or driving in mountainous conditions.
● Driving on muddy, dusty, or de-iced roads.
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● Check the brake pad and disc thickness. Check for damage or cracks. (see page 19-3)*1
● Check the wheel cylinder for leaks.
● Check the brake linings for cracking, glazing, wear or contamination.
● Check the calipers for damage, leaks and tightness.
Use only DOT 3 or DOT 4 brake fluid. (We recommend Genuine Honda Brake Fluid.) Check that Brake (see page 19-7)*1
fluid level is between the upper and lower marks on the reservoir.
Check the parking brake operation. (see page 19-6)*1
-
Check the position of the headlight. (see page 22-114)*1
Check for road stability, noise, vibrations and dashboard operation. -
● Check for correct installation and position, check for cracks, deterioration rust and leaks. -
● Check tightness of screws, nuts and joints. If necessary, retighten.
● Check rack grease and steering linkage. Check the boot for damage and leaking grease. (see page 17-5)*1
● Check the fluid line for damage and leaks.
● Check the bolts for tightness. (see page 18-3)*1
● Check all dust covers for deterioration and damage.
● Check the boot and boot band for cracks (see page 16-3)*1
● Check rack grease.
Check the master cylinder, proportioning control valve and ABS modulator and leakage. (see page 19-48)*1
Check for leaks. -
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, leaks and tightness. (see page 9-3)*2
Check fuel lines for loose connections, cracks and deterioration. Retighten loose connections and (see page 11-132)*1 (see page 11-290)*1 (see page 11-432)
replace any damaged parts *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 3-2 and 3-3.
*1: Refer to shop manual: 2001 CIVIC MAINTENANCE, REPAIR and CONSTRUCTION Code No. 62S5A00
*2: Refer to shop manual: 2001 CIVIC COUPE SUPPLEMENT Code No. 62S5A20
Listed by Distance/Time
Follow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe Conditions Maintenance Schedule on 3-8 and
3-9 do not apply.
Service at the indicated distance or time km x 1,000 20 40 60 80 100 120 140 160 180 200
whichever comes first.
miles x 1,000 12 24 36 48 60 72 84 96 108 120
months 12 24 36 48 60 72 84 96 108 120
Replace engine oil Every 10,000km (6,000 miles) or 12 months
Replace engine oil filter
Replace air cleaner element
Inspect valve clearance
Replace fuel filter
Replace spark plugs
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
Replace transmission fluid Manual Transmission
Automatic Transmission 120,000 km (72,000 miles) or 96 months, thereafter every 80,000 km (48,000 miles) or
48 months
Inspect front and rear brakes
Replace brake fluid Every 36 months
Check parking brake adjustment
Check light alignment
Test drive (noise, stability, dashboard operation)
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
Fuel line and connections
Tyre condition
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Use genuine Honda All Season Antifreeze/Coolant Type 2 (see page 10-8)*1
Use genuine Honda MTF (Manual Transmission Fluid). (see page 13-3)*1
Use genuine Honda AFT-Z1 (ATF). (see page 14-122)*1
● Check the brake pad and disc thickness. Check for damage or cracks. (see page 19-3)*1
● Check the wheel cylinder for leaks.
● Check the brake linings for cracking, glazing, wear or contamination.
● Check the calipers for damage, leaks and tightness
Use only DOT 3 brake fluid. (We recommend Genuine Honda Brake Fluid.) Check that Brake fluid level (see page 19-7)*1
is between the upper and lower marks on the reservoir.
Check the parking brake operation. (see page 19-6)*1
Check the position of the headlight. (see page 22-114)*1
Check for road stability, noise, vibrations and dashboard operation. -
● Check for correct installation and position, check for cracks, deterioration rust and leaks. -
● Check tightness of screws, nuts and joints. If necessary, retighten.
● Check rack grease and steering linkage. Check the boot for damage and leaking grease. (see page 17-5)*1
● Check the fluid line for damage and leaks.
● Check the bolts for tightness. (see page 18-3)*1
● Check all dust covers for deterioration and damage.
● Check the boot and boot band for cracks (see page 16-3)*1
● Check rack grease.
Check the master cylinder, proportioning control valve and ABS modulator and leakage. (see page 19-48)*1
Check for leaks. -
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, leaks and tightness. (see page 9-3)*2
Check fuel lines for loose connections, cracks and deterioration. Retighten loose connections and (see page 11-132)*1 (see page 11-290)*1 (see page 11-432)
replace any damaged parts *1 (see page 11-565)*1
*1: Refer to shop manual: 2001 CIVIC MAINTENANCE, REPAIR and CONSTRUCTION Code No. 62S5A00
*2: Refer to shop manual: 2001 CIVIC COUPE SUPPLEMENT Code No. 62S5A20
Listed by Distance/Time
Service at the indicated distance or time km x 1,000 20 40 60 80 100 120 140 160 180 200
whichever comes first.
miles x 1,000 12 24 36 48 60 72 84 96 108 120
months 12 24 36 48 60 72 84 96 108 120
Replace engine oil Every 5,000 km (3,000 miles) or 6 months
Replace engine oil filter Every 10,000 km (6,000 miles) or 6 months
Replace air cleaner element
Inspect valve clearance
Replace fuel filter
Replace spark plugs
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
Replace transmission fluid Manual Transmission
Automatic Transmission
Inspect front and rear brakes Every 10,000km (6,000 miles) or 6 months
Replace brake fluid Every 36 months
Check parking brake adjustment
Check light alignment
Test drive (noise, stability, dashboard operation)
Visually inspect the following items:
Tie rod ends, steering gearbox and boots Every 10,000km (6,000 miles) or 6 months
Suspension components
Driveshaft boots
Brake hoses and lines (including ABS)
All fluid levels and condition of fluid
Exhaust system
Fuel line and connections
Tyre condition
Follow the Severe Conditions Maintenance Schedule if the customer's vehicle is driven MAINLY under one or more of the following conditions:
● Driving less than 8 km (5 miles) per trip or, in freezing temperatures, driving less than 16 km (10 miles) per trip.
● Driving in extremely hot over 35°C (95°F) conditions.
● Extensive idling of long periods of stop-and-go-driving.
● Trailer towing, driving with a car-top carrier, or driving in mountainous conditions.
● Driving on muddy, dusty, or de-iced roads.
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● Check the brake pad and disc thickness. Check for damage or cracks. (see page 19-3)*1
● Check the wheel cylinder for leaks.
● Check the brake linings for cracking, glazing, wear or contamination.
● Check the calipers for damage, leaks and tightness.
Use only DOT 3 brake fluid. (We recommend Genuine Honda Brake Fluid.) Check that Brake fluid (see page 19-7)*1
level is between the upper and lower marks on the reservoir.
Check the parking brake operation. (see page 19-6)*1
Check the position of the headlight. (see page 22-114)*1
Check for road stability, noise, vibrations and dashboard operation. -
● Check for correct installation and position, check for cracks, deterioration rust and -
leaks.
● Check tightness of screws, nuts and joints. If necessary, retighten.
● Check rack grease and steering linkage. Check the boot for damage and leaking (see page 17-5)*1
grease.
● Check the fluid line for damage and leaks.
● Check the bolts for tightness. (see page 18-3)*1
● Check all dust covers for deterioration and damage.
● Check the boot and boot band for cracks (see page 16-3)*1
● Check rack grease.
Check the master cylinder, proportioning control valve and ABS modulator and leakage. (see page 19-48)*1
Check for leaks. -
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, leaks and tightness. (see page 9-3)*2
Check fuel lines for loose connections, cracks and deterioration. Retighten loose connections and (see page 11-132)*1 (see page 11-290)*1 (see page 11-432)*1
replace any damaged parts (see page 11-565)*1
Check for pressure, puncture or cuts and irregular tread wear. -
NOTE: If the customer's vehicle is driven OCCASIONALLY under severe conditions, you should follow the Normal Condition Maintenance Schedule on
pages 3-6 and 3-7.
*1: Refer to shop manual: 2001 CIVIC MAINTENANCE, REPAIR and CONSTRUCTION Code No. 62S5A00
*2: Refer to shop manual: 2001 CIVIC COUPE SUPPLEMENT Code No. 62S5A20
Listed by Distance/Time
Follow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe Conditions Maintenance Schedule on 3-12
and 3-13 do not apply.
Service at the indicated distance or time km x 1,000 20 40 60 80 100 120 140 160 180 200
whichever comes first.
miles x 1,000 12 24 36 48 60 72 84 96 108 120
months 12 24 36 48 60 72 84 96 108 120
Replace engine oil Unleaded type: Every 10,000 km (6,000 miles) or 12 months
Leaded type: Every 5,000 km (3,000 miles) or 6 months
Replace engine oil filter Unleaded type: Every 20,000 km (12,000 miles) or 12 months
Leaded type: Every 10,000 km (6,000 miles) or 6 months
● Check the brake pad and disc thickness. Check for damage or cracks. (see page 19-3)*1
● Check the wheel cylinder for leaks.
● Check the brake linings for cracking, glazing, wear or contamination.
● Check the callipers for damage, leaks and tightness.
Use only DOT 3 brake fluid. (We recommend Genuine Honda Brake Fluid.) Check that Brake fluid (see page 19-7)*1
level is between the upper and lower marks on the reservoir.
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 (see page 17-5)*1
grease,
● Check the fluid line for damage and leaks.
● Check the bolts for tightness (see page 18-3)*1
● Check all the dust covers for deterioration and damage.
● Check the boot and boot band for cracks (see page 16-3)*1
● Check rack grease.
Check the master cylinder, proportioning control valve and ABS modulator and leakage. (see page 19-48)*1
Check for leaks. -
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, leaks and tightness. (see page 9-3)*2
Check fuel lines for loose connections, cracks and deterioration. Retighten loose connections and (see page 11-132)*1 (see page 11-290)*1 (see page 11-432)*1
replace any damaged parts. (see page 11-565)*1
*1: Refer to shop manual: 2001 CIVIC MAINTENANCE, REPAIR and CONSTRUCTION Code No. 62S5A00
*2: Refer to shop manual: 2001 CIVIC COUPE SUPPLEMENT Code No. 62S5A20
Listed by Distance/Time
Service at the indicated distance or time km x 1,000 20 40 60 80 100 120 140 160 180 200
whichever comes first.
miles x 1,000 12 24 36 48 60 72 84 96 108 120
months 12 24 36 48 60 72 84 96 108 120
Replace engine oil Every 5,000 km (3,000 miles) or 6 months
Replace engine oil filter Every 10,000 km (6,000 miles) or 6 months
Clean or replace air cleaner element Every 20,000 km (12,000 miles)
Inspect valve clearance with catalytic converter Every 40,000 km (24,000 miles)
without catalytic converter Every 20,000 km (12,000 miles)
Replace fuel filter
Replace spark plugs Non-Platinum with catalytic converter Every 40,000 km (24,000 miles)
type
without catalytic Every 20,000 km (12,000 miles)
converter
Platinum type Every 100,000 km (60,000 miles)
Replace timing belt, and inspect water pump
Inspect and adjust drive belts
Inspect idle speed with catalytic converter
without catalytic converter
Replace engine coolant 200,000 km (120,000 miles) or 120 months, thereafter every 100,000 km (60,000 miles)
or 60 months
Replace transmission fluid Manual Transmission
Automatic Transmission
Honda Multi Matic
Inspect front and rear brakes Every 100,000 km (60,000 miles) or 6 months
Replace brake fluid Every 36 months
Check parking brake adjustment
Rotate tyre (Check tyre inflation and condition at lease once per month) Every 100,000 km (60,000 miles)
Visually inspect the following items:
Tie rod ends, steering gearbox and boots Every 10,000 km (6,000 miles) or 6 months
Suspension components
Driveshaft boots
Brake hoses and lines (including ABS)
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:
● Driving less than 8 km (5 miles) per trip or, in freezing temperatures, driving less than 16 km (10 miles) per trip.
● Driving in extremely hot over 35°C (95°F) conditions.
● Extensive idling of long periods of stop-and-go-driving.
Use genuine Honda All Season Antifreeze/Coolant Type 2 (see page 10-8)*1
Use genuine Honda MTF (Manual Transmission Fluid). (see page 13-3)*1
Use genuine Honda AFT-Z1 (ATF). (see page 14-122)*1
Use genuine Honda AFT-Z1 (ATF). (see page 14-320)*1
● Check the brake pad and disc thickness. Check for damage or cracks. (see page 19-3)*1
● Check the wheel cylinder for leaks.
● Check the brake linings for cracking, glazing, wear or contamination.
● Check the calipers for damage, leaks and tightness.
Use only DOT 3 brake fluid. (We recommend Genuine Honda Brake Fluid.) Check that Brake fluid level (see page 19-7)*1
is between the upper and lower marks on the reservoir.
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. (see page 17-5)*1
● Check the fluid line for damage and leaks.
● Check the bolts for tightness. (see page 18-3)*1
● Check all dust covers for deterioration and damage.
● Check the boot and boot band for cracks (see page 16-3)*1
● Check rack grease.
Check the master cylinder, proportioning control valve and ABS modulator and leakage. (see page 19-48)*1
Check for leaks. -
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, leaks and tightness. (see page 9-3)*2
Check fuel lines for loose connections, cracks and deterioration. Retighten loose connections and (see page 11-132)*1 (see page 11-290)*1 (see page 11-432)
replace any damaged parts *1 (see page 11-565)*1
NOTE: If the customer's vehicle is driven OCCASIONALLY under severe condition, you should follow Normal Condition Maintenance Schedule on pages 3-
10 and 3-11
*1: Refer to shop manual: 2001 CIVIC MAINTENANCE, REPAIR and CONSTRUCTION Code No. 62S5A00
*2: Refer to shop manual: 2001 CIVIC COUPE SUPPLEMENT Code No. 62S5A20
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.
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.
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A Few Words about Safety
IMPORTANT SAFETY
A Few Words about Safety PRECAUTIONS
Service Information
The service and repair information contained in ● Make sure you have a clear understanding of
this manual is intended for use by qualified, all basic shop safety practices and that you are
professional technicians. Attempting service or wearing appropriate clothing and using safety
repairs without the proper training, tools and equipment. When performing any service task,
equipment could cause injury to you or others. It be especially careful of the following:
could also damage the vehicle or create an ● Read all of the instructions before you begin
unsafe condition. and make sure you have the tools, the
This manual describes the proper methods and replacement or repair parts and the skills
procedures for performing service, maintenance required to perform the tasks safely and
and repairs. Some procedures require the use of completely.
● Protect your eyes by using proper safety
specially designed tools and dedicated
equipment. Any person who intends to use a glasses, goggles or face shields any time you
replacement part, service procedure or a tool that hammer, drill, grind or work around
is not recommended by Honda, must determine pressurised air or liquids and springs or other
the risks to their personal safety and the safe stored-energy components. If there is any
operation of the vehicle. doubt, put on eye protection.
● Use other protective wear when necessary,
If you need to replace a part, use genuine Honda for example gloves or safety shoes. Handling
parts with the correct part number or an hot or sharp parts can cause severe burns or
equivalent part. We strongly recommend that you cuts. Before you grab something that looks
do not use replacement parts of inferior quality. like it can hurt you, stop and put on gloves.
FOR YOUR CUSTOMER'S SAFETY ● Protect yourself and others whenever you
Proper service and maintenance are essential to have the vehicle up in the air. Any time you lift
the customer's safety and the reliability of the the vehicle, either with a hoist or a jack, make
vehicle. Any error or oversight while servicing a sure that it is always securely supported. Use
vehicle can result in faulty operation, damage to jack stands.
the vehicle, or injury to others. ● Make sure the engine is off before you begin
any servicing procedures, unless the instruction
WARNING tells you to do otherwise. This will help
Improper service or repairs can create an eliminate several potential hazards:
● Carbon monoxide poisoning from engine
unsafe condition that can cause your
customer or others to be seriously hurt or exhaust. Be sure there is adequate ventilation
killed. whenever you run the engine.
● Burns from hot parts or coolant. Let the
Follow the procedures and precautions in engine and exhaust system cool before
this manual and other service materials working in those areas.
carefully. ● Injury from moving parts. If the instruction tells
received shop safety training or do not feel ● Use only a non-flammable solvent, not
confident about your knowledge of safe servicing gasoline to clean parts.
practices, we recommend that you do not attempt ● Never drain or store gasoline in an open
to perform the procedures described in this container.
manual. ● Keep all cigarettes, sparks and flames away
from the battery and all fuel-related parts.
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.
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 DESCRIPTION 2001 MODEL REFERENCE
SECTION
General ● Coupe model added O -
● D17A8, D17A9 engines added
Engine Electrical D17A8, D17A9 engine added O 4
Engine D17A8, D17A9 engines added O -
Fuel and Emissions Coupe model added O 11
Automatic Transmission Shift schedule added O 14
Body Coupe model added O 20
Body Electrical Coupe model added O 22
Restraints Coupe model added O 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
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General Information - General Information
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General Information - General Information
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General Information - General Information
List of automotive abbreviations, which may be used in shop manual. EPR Evaporator Pressure Regulator
ABS Anti-lock Brake System EPS Electrical Power Steering
A/C Air Conditioning, Air Conditioner EVAP Evaporative
ACL Air Cleaner EX Exhaust
A/F Air Fuel Ratio
ALR Automatic Locking Retractor F Front
ALT Alternator FIA Fuel Injection Air
AMP Ampere(s) FL Front Left
ANT Antenna FP Fuel Pump
API American Petroleum Institute FR Front Right
APPROX. Approximately FSR Fail Safe Relay
ASSY Assembly FWD Front Wheel Drive
A/T Automatic Transmission
ATDC After Top Dead Centre GAL Gallon
ATF Automatic Transmission Fluid GND Ground
ATT Attachment GPS Global Positioning System
ATTS Active Torque Transfer System
AUTO Automatic H/B Hatchback
AUX Auxiliary HC Hydrocarbons
HID High Intensity Discharge
BARO Barometric HO2S Heated Oxygen Sensor
BAT Battery
BDC Bottom Dead Centre IAB Intake Air Bypass
BTDC Before Top Dead Centre IAC Idle Air Control
IACV Idle Air Control Valve
CARB Carburettor IAR Intake Air Resonator
CAT Catalytic Converter IAT Intake Air Temperature
or CATA ICM Ignition Control Module
CHG Charge ID Identification
CKF Crankshaft Speed Fluctuation ID or I.D. Inside Diameter
CKP Crankshaft Position IG or IGN Ignition
CO Carbon Monoxide IMA Idle Mixture Adjustment
COMP Complete Integrated Motor Assist
CPB Clutch Pressure Back up IMMOBI. Immobiliser (Immobiliser)
CPC Clutch Pressure Control IN Intake
CPU Central Processing Unit INJ Injection
CVT Continuously Variable Transmission INT Intermittent
CYL Cylinder
CYP Cylinder Position KS Knock Sensor
Specifications
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
Alternator belt Deflection with 98 N (10 Without A/C (with A/ Used belt: 8.5-11.0 mm (0.33-0.43 in.)
NOTE: Adjust kgf, 22 lbs) applied midway C, see "Compressor
a new belt to between pulleys belt" in the A/C table)
New belt: 6.5-8.5 mm (0.26-0.33 in.)
the new belt
spec., run the
engine for 5 Tension (measured with Without A/C (with A/ Used belt: 340-490 N (35-55 kgf, 77-110 lbs)
minutes, then belt tension gauge) C, see "Compressor
readjust it to belt" in the A/C table)
the used belt New belt: 540-740 N (55-75 kgf, 120-170 lbs)
spec.
Engine Assembly
Item Measurement Qualification Standard or New Service Limit
Compression Pressure check at 250 rpm Minimum 930 kPa (9.5 kgf/cm2, 135 psi) -
(min-1) with wide open
throttle. (see Design Specs Maximum variation 200 kPa (2.0 kgf/cm2, 28 psi) -
for ratio.)
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Specifications - Standards and Service Limits
Valve springs Free length D17A2, VTEC intake 56-49 mm (2.224 in.) -
D17A5, D17A9 engines
VTEC exhaust 58-70 mm (2.31 in.) -
Free length D17A8 Intake 58.70 mm (2.311 in.) -
engine
Exhaust 58.70 mm (2.311 in.) -
Valve guides I.D. Intake 5.51-5.53 mm 5.55 mm (0.219 in.)
(0.217-0.218 in.)
Exhaust 18-65-19.15 mm -
(0.734-0.754 in.)
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Specifications - Standards and Service Limits
Crankshaft Main bearing-to-journal No. 1 journal 0.018-0.036 mm (0.0007-0.0014 0.05 mm (0.002 in.)
bearings oil clearance for in.)
No. 5 journal
D117A2, D17A5, D17A8,
D17A9 engines No. 2 journal 0.024-0.042 mm (0.0009-0.0017 0.05 mm (0.002 in.)
in.)
No. 3 journal
No. 4 journal
Rod bearing clearance 0.024-0.042 mm (0.0009-0.0017 0.05 mm (0.002 in.)
in.)
Engine Lubrication
Item Measurement Qualification Standard or New Service Limit
Engine oil Capacity D17A2, D17A5, D17A9 4.2 l (4.4 US qt, 3.7 Imp qt) for engine overhaul
engines
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 At idle 70 kPa (0.7kgf/cm2, 10 psi) min.
80°C (176°F)
at 3,000 rpm (min-1) 340 kPa (3.5 kgf/cm2, 50 psi) min.
Cooling
Item Measurement Qualification Standard or New Service Limit
Radiator Coolant capacity (Includes engine, M/T: engine overhaul 5.1 l (5.4 US qt, 4.5 lmp qt)
heater, hoses and reservoir)
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)
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 76-80°C (169-176°F)
Fully open 90°C (194°F)
Valve lift at fully open 8.0 mm (0.31 in.) min.
Radiator fan switch Thermoswitch "ON" temperature 91-95°C (196-203°F)
Thermoswitch "OFF" temperature Subtract 3-8°C (5-15°F) from actual "ON" temperature
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Specifications - Standards and Service Limits
Clutch
Item Measurement Qualification Standard or New Service Limit
Clutch pedal Height from the floor 198 mm (7.8 in.) -
Stroke 130-140 mm (5.1-5.5 in.) -
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Specifications - Standards and Service Limits
Length A 51.97-52.03 mm -
(2.046-2.048 in.)
B 24.03-24.06 mm -
(0.946-0.947 in.)
Synchro ring Ring-to-gear clearance Ring pushed against gear 0.85-1.10 mm 0.4 mm
(0.033-0.043 in.) (0.016 in.)
Dual cone synchro Outer synchro ring-to-synchro cone clearance Ring pushed against gear 0.5-1.0 mm 0.3 mm
(0.02-0.04 in.) (0.01 in.)
Outer synchro ring-to-gear cone clearance Ring pushed against gear 0.95-1.68 mm 0.6 mm
(0.037-0.066 in.) (0.02 in.)
Reverse shift fork Pawl groove width 13.8-14.1 mm 15.5 mm (0.610 in.)
(0.543-0.555 in.)
I.D. 18.042-18.066 mm -
(0.7103-0.7113 in.)
3rd clutch pressure At 2,000 rpm (min- 850-900 kPa 800 kPa
1) in position (8.7-9.2 kgf/cm2, 120-130 psi) (8.2 kgf/cm2, 120 psi)
2nd clutch pressure At 2,000 rpm (min- 850-900 kPa 800 kPa
1) in position (8.7-9.2 kgf/cm2, 120-130 psi) (8.2 kgf/cm2 120 psi)
1st clutch pressure At 2,000 rpm (min- 880-930 kPa 830 kPa
1) in position (9.0-9.5 kgf/cm2, 120-130 psi) (8.5 kgf/cm2, 120 psi)
1st-hold clutch pressure At 2,000 rpm (min- 880-930 kPa 830 kPa
1) in position (9.0-9.5 kgf/cm2, 120-130 psi) (8.5 kgf/cm2, 120 psi)
Torque Stall speed D14Z5 engine 2,550 rpm (min-1) 2,400-2,700 rpm (min-1)
converter Check with vehicle on D15Y2, D15Y3, 2,650 rpm (min-1) 2,500-2,800 rpm (min-1)
level ground D15Y5, D15Y6
engines
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 2,800 rpm (min-1) 2,650-2,950 rpm (min-1)
engine
D17A2, D17Z5 2,800 rpm (min-1) 2,650-2,950 rpm (min-1)
engine
Valve body Stator shaft needle Torque converter 27.000-27.021 mm (1.063-1.064 When worn or damaged
bearing contact I.D. side in.)
ATF pump side 29.000-29.013 mm (1.1417- When worn or damaged
1.1422 in.)
ATF pump gear thrust 0.03-0.06 mm (0.001-0.002 in.) 0.07 mm (0.003 in.)
clearance
ATF pump gear-to-body Drive gear 0.105-0.1325 mm (0.004-0.005 -
clearance in.)
Driven gear 0.0350-0.0625 mm (0.001-0.002 -
in.)
ATF pump driven gear I. 14.016-14.034 mm (0.5518- When worn or damaged
D. 0.5525 in.)
ATF pump driven gear 13.980-13.990 mm (0.5504- When worn or damaged
shaft O.D. 0.5508 in.)
Reverse shift Fork finger thickness 5.90-6.00 mm (0.232-0.236 in.) 5.4 mm (0.213 in.)
fork
Park gear and When worn or damaged
pawl
Servo body Shift fork shaft bore I.D. 14.000-14.010 mm (0.5512- -
0.5516 in.)
Shift fork shaft valve 37.000-37.039 mm (1.4567- 37.045 mm (1.4585 in.)
bore I.D. 1.4582 in.)
Regulator Sealing ring contact I.D. 35.000-35.025 mm (1.3780- 35.050 mm (1.3799 in.)
valve body 1.3782 in.)
Stator shaft Diameter of needle ATF pump side 29.000-29.013 mm (1.1417- When worn or damaged
bearing contact area 1.1422 in.)
Torque converter 27.000-27.021 mm (1.0630- When worn or damaged
side 1.0638 in.)
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Specifications - Standards and Service Limits
1st-hold 0.5-0.8 mm
(0.020-0.031 in.)
Clutch return spring free length 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.)
Clutch disc thickness 1.94 mm (0.076 in.) -
Clutch plate thickness 1st, 1st-hold 1.6 mm (0.06 in.) When discoloured
2nd, 3rd and 4th 2.0 mm (0.079 in.)
1st, 2nd, 3rd and 4th clutches end Mark 1 2.1 mm (0.083 in.)
plate thickness
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.)
1st-hold clutch end plate thickness 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.)
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Specifications - Standards and Service Limits
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Specifications - Standards and Service Limits
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Specifications - Standards and Service Limits
Sub-shaft Diameter of needle bearing at transmission housing 25.991-26.000 mm When worn or damaged
contact area (1.023-1.024 in.)
1st-clutch feed pipe O.D. at 15 mm (0.6 in.) from end 7.97-7.98 mm 7.95 mm (0.313 in.)
(0.3138-0.3142 in.)
Servo body springs 1st accumulator spring 2.1 mm 16.0 mm 89.1 mm 16.2
(see page 14-188) (0.083 in.) (0.630 in.) (3.508 in.)
Lock-up valve body Lock-up shift valve spring 0.9 mm 7.6 mm 73.7 mm 32.0
springs (see page 14- (0.035 in.) (0.299 in.) (2.902 in.)
189)
Lock-up timing valve spring 0.9 mm 8.1 mm 80.7 mm 54.2
(0.035 in.) (0.319 in.) (3.177 in.)
I.D. 18.042-18.066 mm -
(0.7103-0.7113 in.)
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Specifications - Standards and Service Limits
Suspension
Item Measurement Qualification Standard or New Service Limit
Wheel alignment Camber Front 0°00'+45°
Rear -0°45'+45'
Caster Front 1°33'+1°
Total Toe Front 0+3 mm (0+0.12 in.)
Rear Adjust: IN 2+2-1 mm (0.08+0.08-0.04 in.)
Inspect: IN 2+3 mm (0.08+0.12 in.)
Front wheel turning angle Inside wheel 38°00'±2°
Outside wheel 30°00' (Reference)
Aluminium wheel Runout Axial 0-0.7 mm (0-0.03 in.) 2.0 mm (0.08 in.)
Radial 0-0.7 mm (0-0.03 in.) 1.5 mm (0.06 in.)
Steel wheel Runout Axial 0-1.0 mm (0-0.04 in.) 2.0 mm (0.08 in.)
Radial 0-1.0 mm (0-0.04 in.) 1.5 mm (0.06 in.)
Wheel bearings End play Front 0-0.05 mm (0-0.002 in.)
Rear 0-0.05 mm (0-0.002 in.)
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Specifications - Standards and Service Limits
(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 Qualification Standard or New
Refrigerant Type HFC-134 a (R-134 a)
Compressor belt Deflection with 98 N (10 kgf, 22 Used belt: 8.5-11.0 mm (0.33-0.43 in.)
NOTE: Adjust a lbs) applied mid-way between
new belt to the pulleys New belt: 5.0-6.5 mm (0.20-0.26 in.)
new belt spec.,
run the engine for Tension (measured with belt Used belt: 440-590 N (45-60 kgf, 100-130 lbs)
5 minutes, then tension gauge)
readjust it to the New belt: 930-1,125 N (95-115 kgf, 210-255 lbs)
used belt spec.
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Specifications - Design Specifications
Design Specifications 2-
17
Item Measurement Qualification Specification
DIMENSIONS Overall length 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 2,620 mm (103.1 in.)
Track Front 1,465 mm (57.7 in.)
Rear 1,470 mm (57.9 in.)
Ground clearance 150 mm (5.9 in.)
Seating capacity Five
WEIGHT Curb Weight (M/T) 1,103-1,171 kg (2,432-2,582 lbs)
(A/T) 1,128-1,196 kg (2,487-2,637 lbs)
Max. permissible Weight 1,575 kg (3,472 lbs)
*1: KK models
*2: Except KK models
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Specifications - Design Specifications
Design Specifications 2-
(cont'd)
18
Item Measurement Qualification Specification
ENGINE Type D17A2, D17A5, Water-cooled, 4-stroke SOHC VTEC engine
D17A9 engines
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 9.5
engines
D17A2, D17A9 9.9
engines
Valve train D17A2, D17A5, Belt driven, SOHC VTEC 4 valves per cylinder
D17A9 engines
D17A8 engine Belt driven, SOHC 4 valves per cylinder
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Specifications - Design Specifications
Design Specifications 2-
(cont'd)
19
Item Measurement Qualification Specification
ENGINE Lubrication system Forced, wet sump, with trochoid pump
Oil pump displacement at 6,000 engine rpm 36.4 l (38.5 US qt, 32.0 imp qt)/minute
Water pump displacement at 6,000 engine rpm 130 l (137 US qt, 114 imp qt)/minute
Fuel required 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)
STARTER Type Gear reduction
Normal output 1.0 kW
Hour rating 30 seconds
Direction of rotation Clockwise as viewed from gear end
CLUTCH Clutch M/T Single plate dry, diaphragm spring
A/T Torque converter
Clutch friction material surface area M/T 176 cm3 (102 sq in.)
MANUAL TRANS- Type Synchronised, 5-speed forward, 1 reverse
MISSION
Primary reduction Direct 1:1
Gear ratio 1st 3.461
2nd 1.869
3rd 1.241
4th 0.969
5th 0.805
Reverse 3.230
Final reduction Type Single helical gear
Gear ratio 4.411
AUTOMATIC Type Electronically controlled automatic, 4-speed forward, 1 reverse
TRANS-MISSION
Primary reduction Direct 1:1
Gear ratio 1st 2.722
2nd 1.468
3rd 0.975
4th 0.674
Reverse 1.955
Final reduction Type Single helical gear
Gear ratio 4.357
STEERING 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.)
SUSPENSION Type Strut
Rear Double wishbone
Shock absorber Front and rear Telescopic, hydraulic, nitrogen gas-filled
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Specifications - Design Specifications
Design Specifications 2-
(cont'd)
20
Item Measurement Qualification Specification
WHEEL Camber Front 0°
ALIGNMENT
Rear -0°45'
Caster Front 1°33'
Total toe Front 0 mm (0 in.)
Rear In 2 mm (1/16 in.)
BRAKE Type of service brake Front Power-assisted self-adjusting ventilated disc
Rear Power-assisted self-adjusting solid disc or drum
Type of parking brake Mechanical actuating, rear wheels
Pad friction surface area Front 35 cm2 x 2 (5.4 sq in. x 2)
Shoe friction surface area Rear 67 cm2 x 2 (10.3 sq in. x 2)
TYRES Size of front and rear KK, KX models P185/65R 15 86H
KE, KG, KB, KR, KY P195-60R 15 88H
models
Size of spare tyre KG, KB, KR, KX models T125/70D 15 95M
AIR Cooling capacity 3,870 kcal/h (15,400 BTU/h)
CONDITIONING
Compressor Type/manufacturer Scroll/SANDEN
Number of cylinders -
Capacity 85.7 ml/rev. (5.23 cu in./rev.)
Maximum speed 12,000 rpm
Lubricant capacity 130 ml (4 1/3 fl oz)
Lubricant type SP-10 (P/N 38897-P13-003, 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)
Temperature clutch Air-mix type
Compressor clutch Type Dry, single plate, poly-V belt drive
Electrical power 42 W maximum at 12 V
consumption at 20°C
(68°F)
Refrigerant Type HFC-134a (R-134a)
Quantity 500-550 g (17.5-19.5 oz)
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Specifications - Design Specifications
Design Specifications 2-
(cont'd)
21
Item Measurement Qualification Specification
ELECTRICAL Battery 12 V - 36 AH/5 hours*1
RATINGS
12 V - 38 AH/5 hours*2
Starter DENSO 12 V - 1.0 kW
MITSUBA 12 V - 1.2 kW
Alternator 12 V - 70 A
Fuses Under-hood fuse/ 80 A, 60 A, 40 A, 30 A, 20 A, 15 A, 10 A, 7.5 A
relay box
Under-dash fuse/ 30 A, 20 A, 15 A, 10 A, 7.5 A
relay box
Light bulbs Headlight high beam 12 V - 60 W
Headlight low beam 12 V - 55 W
Front turn signal/ 12 V - 21 W/5 W
Front side marker
lights
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 12 V - 21W/5 W
side marker light
Rear for light 12 V - 21 W
Inner taillight 12 V - 5 W
High mount brake 12 V - 21 W
light
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
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Body Specifications
Body Specifications 2-
22
Unit: mm (in.)
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Maintenance - Maintenance
Maintenance
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Maintenance - Lubricants and Fluids
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.
*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 - Maintenance Schedule for Normal Conditions
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.
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Maintenance - Maintenance Schedule for Normal Conditions
*1: Refer to shop manual: '01 CIVIC MAINTENANCE, REPAIR and CONSTRUCTION Code No. 62D5A00 on this CD.
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.
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.
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Maintenance - Maintenance Schedule for Normal Conditions (Except European Models)
*1: Refer to shop manual: '01 CIVIC MAINTENANCE, REPAIR and CONSTRUCTION Code No. 62S5A00 on this CD.
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 (see page 6-
of seal leakage. 18)*1 (see
page 6-22)*1
(see page 10-
7)*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.
*1: Refer to shop manual: '01 CIVIC MAINTENANCE, REPAIR and CONSTRUCTION Code No. 692S5A00 on this CD.
Engine Electrical
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-
Special Tools
2
Number Tool Number Description Qty
1 07JGG-0010100 Belt Tension Gauge 1
2 07746-0010400 Driver Attachment, 52 x 55 mm 1
3 07749-0010000 Handle Driver 1
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Engine Electrical - Starting System
Starting System 4-
Component Location Index
3
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
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Engine Electrical - Starting System
NOTE: 4. Check the battery condition. Check electrical connections at the battery and the
● Air temperature must be between 59° and 100°F (15° and 38°F) during this starter for looseness and corrosion. Then check the starter again.
procedure. Did the starter crank the engine?
● After this test, or any subsequent repair, reset the Engine Control Module (ECM)/ YES - The starting system is OK.
Powertrain Control Module (PCM) to clear any Diagnostic Trouble Codes (DTCs), NO - Go to step 5.
refer to the '01 Civic Shop Manual on this CD (see page 11-13).
5. Make sure the transmission is in neutral, then disconnect the BLK/WHT wire (A)
Recommended Procedure:
from the starter solenoid (B). Connect a jumper wire from the battery positive
● Use a starter system tester. terminal to the solenoid terminal.
● Connect and operate the equipment in accordance with the manufacturer's
instructions.
Alternate Procedure
1. Hook up the following equipment:
● Ammeter, 0 - 400 A
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
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).
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
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
1. Disconnect the wires from the S terminal and the M terminal. 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.
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 Electric current Motor speed
DENSO 90 A or less 3,000 rpm (min-1) or more
(1.0 Kw)
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Engine Electrical - Starting System
Disassembly/Reassembly - M/T
1. STARTER SOLENOID
2. MOLYBDENUM DISULPHIDE
3. SOLENOID LEVER
4. GEAR HOUSING
5. OVERRUNNING CLUTCH ASSEMBLY
6. ARMATURE
7. ARMATURE HOUSING
8. MOLYBDENUM DISULPHIDE
9. MOLYBDENUM DISULPHIDE
10. BRUSH HOLDER
11. END COVER
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Engine Electrical - Starting System
Disassembly/Reassembly - A/T
1. STARTER SOLENOID
2. MOLYBDENUM DISULPHIDE
3. SOLENOID LEVER
4. GEAR HOUSING
5. OVERRUNNING CLUTCH ASSEMBLY
6. ARMATURE
7. ARMATURE HOUSING
8. MOLYBDENUM DISULFIDE
9. MOLYBDENUM DISULFIDE
10. BRUSH HOLDER
11. END COVER
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Engine Electrical - Starting System
Starting System 4-
Starter Overhaul (cont'd)
10
Armature Inspection and Test 5. Check the commutator diameter. If the diameter is below the service limit, replace
1. Remove the starter, refer to '01 Civic Shop Manual (see page 4-9). the armature.
2. Disassemble the starter as shown at the beginning of this procedure. Commutator Diameter
3. Inspect the armature for wear or damage from contact with the permanent magnet. Standard (New):
If there is wear or damage, replace the armature. 27.9 - 28.0 mm (1.098 - 1.102 in.)
Service Limit:
27.0 mm (1.142 in.)
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).
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-
Starter Overhaul (cont'd)
11
7. Check the mica depth (A). If the mica is too high (B), undercut the mica with a 9. Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the
hacksaw blade to the proper depth. Cut away all the mica (C) between the armature core. If the blade is attracted to the core or vibrates while the core is
commutator segments. The undercut should not be too shallow, too narrow, or V- turned, the armature is shorted. Replace the armature.
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.)
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.
8. Check for continuity between the segments of the commutator. If an open circuit
exists between any segments, replace the armature.
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Engine Electrical - Starting System
Starting System 4-
Starter Overhaul (cont'd)
12
Starter Brush Inspection Starter Brush Holder Test
11. Measure the brush length. If it is not within the service limit, replace the armature 14. Check that there is no continuity between the (+) brush holder (A) and (-) brush
housing assembly. holder (B). If there is no continuity, replace the brush holder 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.)
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)
13. Check for continuity between each brush (A) and the armature housing (B). If
there is continuity, replace the armature housing.
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Engine Electrical - Starting System
Starting System 4-
Starter Overhaul (cont'd)
13
16. Pry back each brush spring with a screwdriver, then position the brush about 18. Install the starter end cover (A) to retain the brush holder (B).
halfway out of its holder, and release the spring to hold it there.
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.
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Engine Electrical - Starting System
Starting System 4-
Starter Overhaul (cont'd)
14
Overruning Clutch Inspection
19. Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly.
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.
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-
Component Location Index
15
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-
Circuit Diagram
16
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Engine Electrical - Ignition System
Ignition System 4-
Spark Plug Inspection
17
1. Inspect the electrodes and ceramic insulator. 3. Replace the plug at the specified interval, or if the centre electrode is rounded (A).
Burned or worn electrodes may be caused by: Use only the spark plugs listed below.
● Advanced ignition timing Spark Plugs:
● Loose spark plug Engine Type Spark Plug Type
● Plug heat range too hot
D17A2, D17A8, ZFR6J-11 (NGK)
● Insufficient cooling
D17A9 ZFR7J-11 (NGK)
Fouled plug may be caused by:
KJ20CR-L11 (DENSO)
● Retarded ignition timing
● Oil in combustion chamber D17A5 BKR6E-N-11 (NGK)
● Incorrect spark plug gap BKR7E-N-11 (NGK)
Plug heat range too cold
K20PR-L11 (DENSO)
●
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).
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-
Circuit Diagram
18
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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
7. Remove the intake air duct (A) and ground cable (B).
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Engine Mechanical - Engine Assembly
8. Remove the clutch slave cylinder (A) and clutch line bracket mounting bolt (B) (M/ 10. Relieve fuel pressure, refer to the '01 Civic Shop Manual on this CD (see page 11-
T). 130).
11. Remove the evaporative emission (EVAP) canister hose.
9. Remove the shift cable (A) and select cable (B) (M/T).
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Engine Mechanical - Engine Assembly
13. Remove the throttle cable (A) and cruise control cable (B) by loosening the 16. Remove the harness clamps (A) and grommet (B), then pull the engine wire
locknuts (C), then slipping the cable ends out of the accelerator linkage. Take care harness through the bulkhead.
not to bend the cables when removing them. Always replace any kinked cable with
a new one.
14. Remove the glove box stops, then open the glove box.
15. Disconnect the Engine Control Module (ECM)/Powertrain Control Module (PCM)
connectors. 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
18. Remove the alternator, refer to the '01 Civic Shop Manual on this CD (see page 4- 21. Remove the radiator cap.
31). 22. Raise the hoist to full height.
19. Remove the air conditioning (A/C) hose bracket (A) and P/S hose bracket (B). 23. Remove the front tyres/wheels.
24. Remove the splash shield.
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).
20. Remove the alternator lower bracket (A), then remove the A/C compressor (B)
without disconnecting the A/C hoses. 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
28. Disconnect the Primary Heated Oxygen Sensor (primary HO2S) connector (A) 32. Lower the hoist.
and Secondary Heated Oxygen Sensor (secondary HO2S) connector (B), then 33. Remove the ground cable (A), upper radiator hose (B), lower radiator hose (C)
remove the exhaust pipe A/Three Way Catalytic Converter (TWC) (C) (Except and heater hose (D).
D17A5 engine).
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.
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Engine Mechanical - Engine Assembly
35. Remove the ATF cooler hoses, then plug the ATF cooler hoses and lines (A/T). 37. Remove the front mount mounting bolt.
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Engine Mechanical - Engine Assembly
39. Remove the transmission mount bracket mounting bolt/nuts. 40. Make sure the hoist brackets are positioned properly. Raise the hoist to full height.
M/T: 41. Remove the rear mount mounting bolts.
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).
A/T:
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Engine Mechanical - Engine Assembly
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-
Engine Installation
10
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-
Engine Installation (cont'd)
11
2. Position the engine under the vehicle. Attach the chain hoist to the engine, then lift 4. Tighten the rear mount mounting bolts.
the engine into position in the vehicle.
Reinstall the mounting bolts/support nuts in the sequence given. Failure to follow
this sequence may cause excessive noise and vibration and reduce bushing life.
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-
Engine Installation (cont'd)
12
7. Tighten the transmission mount bracket mounting bolt/nuts. 8. Tighten the front mount mounting bolt.
M/T:
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Engine Mechanical - Engine Assembly
Engine Assembly 5-
Engine Installation (cont'd)
13
14. Install exhaust pipe A/TWC (A): use new gaskets (B) and new self-locking nuts 18. Install the ATF cooler hoses (A/T).
(C). Connect the primary HO2S connector (D) and secondary HO2S connector (E)
(Except D17A5 engine).
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Engine Mechanical - Engine Assembly
Engine Assembly 5-
Engine Installation (cont'd)
14
20. Connect the upper radiator hose (A), lower radiator hose (B), heater hose (C) and 22. Install the A/C hose bracket (A) and P/S hose bracket (B).
ground cable (D).
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Engine Mechanical - Engine Assembly
Engine Assembly 5-
Engine Installation (cont'd)
15
29. Connect the ECM/PCM connectors. 31. Install the cruise control cable, then adjust the cable, refer to the '01 Civic Shop
RHD models: 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:
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Engine Mechanical - Engine Assembly
Engine Assembly 5-
Engine Installation (cont'd)
16
34. Install the EVAP canister hose. 36. Install the clutch slave cylinder (A) and clutch line bracket mounting bolt (B) (M/T).
35. Install the select cable (A) and shift cable (B) using the plastic washers (C),
washers (D) and new cotter pins (E) (M/T).
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Engine Mechanical - Engine Assembly
Engine Assembly 5-
Engine Installation (cont'd)
17
39. Install the battery cable (A) on the under-hood fuse/relay box, then install the 41. Clean the battery posts and cable terminals with sandpaper, then assemble them
harness clamps (B). 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).
40. Install the intake resonator. 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
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Engine Mechanical - Cylinder Head
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Engine Mechanical - Cylinder Head
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Engine Mechanical - Cylinder Head
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Engine Mechanical - Cylinder Head
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
Special Tools Required 8. Check that the air pressure on the shop air compressor gauge indicates over 400
● Air Stopper, 07LAJ-PR30201 kPa (4 kgf/cm2, 57 psi).
● Valve Inspection Set, 07LAJ-PR30101 9. Inspect the valve clearance (see page 6-8}.
1. Remove the resonator (see step 5 on page 6-11). 10. Cover the timing belt with a shop towel to protect the belt.
2. Remove the ignition coil cover, then remove the four ignition coils, refer to the '01 11. Plug the relief hole with the air stopper.
Civic Shop Manual on this CD (see page 4-24).
3. Remove the throttle cable clamps and harness holder from the cylinder head cover
(see step 21 on page 6-14).
4. Remove the cylinder head cover (see step 22 on page 6-14).
5. Set the No. 1 piston at TDC (see step 5 on page 6-8).
6. Verify that the intake secondary rocker arm (A) moves independently of the intake
primary rocker arm (B).
● If the intake secondary rocker arm does not move, remove the primary and
secondary rocker arms as an assembly and check that the pistons in the
secondary and primary rocker arms move smoothly. If any rocker arm needs
replacing, replace the primary and secondary rocker arms as an assembly and
retest. 12. Remove the sealing bolt (A) from the inspection hole (B) and connect the valve
● If the intake secondary rocker arm moves freely, go to step 7. 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
13. Loosen the valve on the regulator and apply the specified air pressure: NOTE: Adjust the valves only when the cylinder head temperature is less than 100°F
Specified Air Pressure: (38°C).
250 kPa (2.5 kgf/cm2, 36 psi) 1. Remove the ignition coil cover, then remove the four ignition coils, refer top the '01
NOTE: If the synchronising piston does not move after applying air pressure, move Civic Shop Manual on this CD (see page 4-25).
the primary or secondary rocker arm up and down manually by rotating the 2. Remove the throttle cable clamps and harness holder from the cylinder head cover
crankshaft counter-clockwise. (see step 21 on page 6-14).
3. Remove the cylinder head cover (see step 22 on page 6-14).
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. 4. Remove the grommet from the upper cover and disconnect the TDC sensor
● If the intake primary rocker arm does not move, remove the primary and secondary
connector. Remove the upper cover, refer to the '01 Civic Shop Manual on this CD
rocker arms as an assembly and check that the piston in the secondary and (see step 1 on page 6-57).
primary rocker arms move smoothly. If any rocker arm needs replacing, replace the 5. Set the No. 1 piston at TDC. The ''UP'' mark (A) on the camshaft pulley should be
primary and secondary rocker arms as an assembly and retest. 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
6. Select the correct thickness feeler gauge for the valves you are going to check. 8. If you feel too much or too little drag, loosen the locknut (A) and turn the adjusting
Intake:0.18 - 0.22 mm (0.007 - 0.009 in.) screw (B) until the drag on the feeler gauge is correct.
Exhaust:0.23 - 0.27 mm (0.009 - 0.011 in.) D17A2, D17A5, D17A9 engines:
Adjusting screw location:
INTAKE
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.
9. Tighten the locknut and recheck the clearance. Repeat the adjustment if necessary.
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Valve Clearance Adjustment (cont'd)
10
10. Rotate the crankshaft 180° counter-clockwise (camshaft pulley turns 90°). The 14. Rotate the crankshaft 180° counter-clockwise to bring No. 2 piston to TDC. The
''UP'' mark (A) on the camshaft pulley should be toward the exhaust side of the ''UP'' mark (A) should be on the intake side of the head.
head.
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
11. Check and if necessary, adjust the valve clearance on No. 3 cylinder. this CD (see page 6-55).
12. Rotate the crankshaft 180° counter-clockwise to bring No. 4 piston to TDC. TDC
marks (A) are visible again.
13. Check and if necessary, adjust the valve clearance on No. 4 cylinder.
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Engine Mechanical - Cylinder Head
they do not contact other wiring or hoses, or interfere with other parts.
1. Make sure you have the anti-theft code for the radio, then write down
the frequencies for the radio's preset buttons.
2. Disconnect the battery negative terminal.
3. Drain the engine coolant, refer to the '01 Civic Shop Manual on this CD
(see page 10-8).
4. 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.
6. Disconnect the Intake Air Temperature (IAT) sensor connector (A) and
remove the breather hose, then remove the air cleaner housing (B).
Cylinder Head 6-
Cylinder Head Removal (cont'd)
12
7. Remove the brake booster vacuum hose (A) and positive crankcase ventilation 10. Remove the ground cable (A), upper radiator hose (B), lower radiator hose (C),
(PCV) hose (B). heater hose (D) and water bypass hose (E).
8. Relieve fuel pressure, refer to the '01 Civic Shop Manual on this CD (see page 11- 11. Remove the two bolts securing the connecting pipe, then remove the connecting
130). pipe from the water passage.
9. Remove the EVAP canister hose.
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Cylinder Head Removal (cont'd)
13
12. Remove the adjusting plate mounting bolt (A), locknut (B) and mounting bolt (C), 15. Remove the engine wire harness connectors and wire harness clamps from the
then remove the power steering (P/S) pump belt (D) and pump without intake manifold.
disconnecting the P/S hoses. ● Idle Air Control (IAC) valve connector
16. Support the engine with a jack and wood block under the oil pan.
17. Remove the upper bracket.
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).
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Cylinder Head Removal (cont'd)
14
18. Remove the cover (A), then remove the exhaust manifold (B). 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.
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Cylinder Head Removal (cont'd)
15
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).
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:
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Rocker Arms and Shafts Disassembly/
Reassembly
16
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.
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Rocker Arms and Shafts Disassembly/
Reassembly (cont'd)
17
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-
Rocker Arms and Shafts Inspection
18
1. Measure the diameter of the shaft at the first rocker location. 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.)
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-
Rocker Arms and Shafts Inspection (cont'd)
19
5. Inspect the synchronising piston (s) (A) and timing piston (B). Push it manually. If it 6. Assemble each timing plate (A) and return spring (B) on its camshaft holder as
does not move smoothly, replace the rocker arm assembly. shown (D16W8 engine).
NOTE:
● When reassembling the primary rocker arm (C), carefully apply air pressure to its
oil passage.
● Apply oil to the pistons when reassembling.
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Camshaft Inspection
20
NOTE: 4. Unscrew the camshaft holder bolts 2 turns at a time, in a criss-cross pattern. Then
● Do not rotate the camshaft during inspection. remove the camshaft holders from the cylinder head.
● Remove the rocker arms and rocker shafts. 5. Lift the camshaft out of the cylinder head, wipe it clean, then inspect the lift ramps.
1. Put the camshaft and the camshaft holders on the cylinder head, then tighten the Replace the camshaft if any lobes are pitted, scored, or excessively worn.
bolts to the specified torque. 6. Clean the camshaft journal surfaces in the cylinder head, then set the camshaft
Specified torque: back in place. Place a plastigauge strip across each journal.
8 mm bolts:20 Nm (2.0 kgf/m, 14 lbf/ft) 7. Install the camshaft holders, then tighten the bolts to the specified torque as shown
Apply engine oil to the bolt threads. in step 1.
8. Remove the camshaft holders. Measure the widest portion of plastigauge on each
6 mm bolts:12 Nm (1.2 kgf/m, 8.7 lbf/ft) journal.
Apply engine oil to the bolt threads. ● If the camshaft-to-holder clearance is within limits, go to step 10.
6 mm bolts:(11), (12), (13), (14) ● If the camshaft-to-holder clearance is beyond the service limit and the camshaft
2. Seat the camshaft by pushing it away from the camshaft pulley end of the cylinder
head.
3. Zero the dial indicator against the end of the camshaft, then push the camshaft
back and forth and read the end play.
Camshaft End Play:
Standard (New):0.05 - 0.15 mm
(0.002 - 0.006 in.)
Service Limit:0.5 mm (0.02 in.)
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Camshaft Inspection (cont'd)
21
9. Check the total runout with the camshaft supported on V-blocks. 10. Measure cam lobe height.
● If the total runout of the camshaft is within the service limit, replace the cylinder Cam Lobe Height Standard (New):
head.
INTAKE EXHAUST
● If the total runout is beyond the service limit, replace the camshaft and recheck
the camshaft-to-holder oil clearance. If the oil clearance is still out of tolerance, D17A2, D17A5, PRI 38.604 mm 38.784 mm
replace the cylinder head. D17A9, engines (1.5198 in.) (1.5269 in.)
Camshaft Total Runout:
SEC 32.848 mm
Standard (New):0.03 mm (0.001 in.) max. (1.2932 in.)
Service Limit:0.04 mm (0.002 in.)
D17A8 engine 35.299 mm 37.281 mm
(1.3897 in.) (1.4678 in.)
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Valve Inspection
22
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
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
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-
Cylinder Head Installation (cont'd)
25
4. Clean the camshaft pulley and set it to TDC. 6. Apply engine oil to the bolt threads and under the bolt heads of all the cylinder head
1. The ''UP'' mark (A) on the camshaft pulley should be at the top. bolts.
2. Align the TDC marks (B) on the camshaft pulley with the top edge of the head. 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:
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Cylinder Head Installation (cont'd)
26
8. Install the timing belt, refer to the '01 Civic Shop Manual on this CD (see page 6- 13. Install the new exhaust manifold gasket (A) and exhaust manifold (B). Loosely
22). install the new nuts, then install the cover (C) and loosely install the new bolts.
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).
12. Tighten the three nuts securing the intake manifold and brackets.
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Cylinder Head Installation (cont'd)
27
16. Install the A/C hose bracket (A) and P/S hose bracket (B). 22. Install the ground cable (A), upper radiator hose (B), lower radiator hose (C),
heater hose (D) and water bypass hose (E).
17. Loosely install the alternator. 23. Install the EVAP canister hose.
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).
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Cylinder Head Installation (cont'd)
28
24. Install the brake booster vacuum hose (A) and PCV hose (B). 26. Install the intake resonator.
25. Install the air cleaner housing (A), then connect the IAT sensor connector (B) and
breather hose.
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
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Engine Mechanical - Engine Block
Engine Block 7-
Component Location Index
3
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-
Component Location Index (cont'd)
4
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
Main Bearing Clearance Inspection 6. If the plastigauge measures too wide or too narrow, (remove the engine if it is still
1. To check main bearing-to-journal oil clearance, remove the main caps and bearing in the car), remove the crankshaft and remove the upper half of the bearing. Install
halves. a new, complete bearing with the same colour code and recheck the clearance. Do
2. Clean each main journal and bearing half with a clean shop towel. not file, shim, or scrape the bearings or the caps to adjust clearance.
3. Place one strip of plastigauge across each main journal. 7. If the plastigauge shows the clearance is still incorrect, try the next larger or
NOTE: If the engine is still in the car when you bolt the main cap down to check the smaller bearing (the colour listed above or below that one) and check again. If the
clearance, the weight of the crankshaft and drive plate will flatten the plastigauge proper clearance cannot be obtained by using the appropriate larger or smaller
further than just the torque on the cap bolt and give you an incorrect reading. For bearings, replace the crankshaft and start over.
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.)
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Engine Mechanical - Engine Block
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Engine Mechanical - Engine Block
Rod Bearing Clearance Inspection 6. If the plastigauge measures too wide or too narrow, remove the upper half of the
1. Remove the connecting rod cap and bearing half. bearing, install a new, complete bearing with the same colour code and recheck
2. Clean the crankshaft rod journal and bearing half with a clean shop towel. the clearance. Do not file, shim, or scrape the bearings or the caps to adjust
3. Place a strip of plastigauge across the rod journal. clearance.
4. Reinstall the bearing half and cap and torque the bolts to 32 Nm (3.3 kgf/m, 24 lbf/ 7. If the plastigauge shows the clearance is still incorrect, try the next larger or
ft). Do not rotate the crankshaft. smaller bearing (the colour listed above or below that one) and check clearance
5. Remove the rod cap and bearing half and measure the widest part of the again. If the proper clearance cannot be obtained by using the appropriate larger or
plastigauge. smaller bearings, replace the crankshaft and start over.
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.)
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Engine Mechanical - Engine Block
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
1. Using a ring expander (A), remove the old piston rings (B). 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. Clean all ring grooves thoroughly with a squared-off broken ring or ring groove 4. Measure the piston ring end-gap (B) with a feeler gauge:
cleaner with a blade to fit the piston grooves. ● If the gap is too small, check to see if you have the proper rings for your engine.
The top ring groove is 1.0 mm (0.04 in.) wide. The second ring groove is 1.2 mm ● If the gap is too large, recheck the cylinder bore diameter against the wear limits,
(0.05 in.) wide. The oil ring groove is 2.8 mm (0.11 in.) wide (D17A5 engine) 2.0 refer to the '01 Civic Shop Manual on this CD (see page 7-14).
mm (0.08 in.) wide (D17A2, D17A8, D17A9 engines).
If the bore is over the service limit, the cylinder block must be rebored.
File down a blade if necessary.
Piston Ring End-Gap:
Do not use a wire brush to clean the ring grooves, or cut the ring grooves deeper Top Ring
with cleaning tools.
Standard (New):0.15 - 0.30 mm
NOTE: If the piston is to be separated from the connecting rod, do not install new
(0.006 - 0.012 in.)
rings yet.
Service Limit:0.60 mm (0.024 in.)
Second Ring
Standard (New):0.30 - 0.45 mm
(0.012 - 0.018 in.)
Service Limit:0.60 mm (0.024 in.)
Oil Ring
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-
Piston Ring Replacement (cont'd)
10
5. Install the top ring (A) and second ring (B) as shown. The manufacturing marks (C) 6. Rotate the rings in their grooves to make sure they do not bind.
must be facing upward. 7. Position the ring end gaps as shown:
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Engine Mechanical - Engine Block
Engine Block 7-
Crankshaft Installation
11
Special Tools Required 10. Check the main bearing clearance with plastigauge (see page 7-5).
● Handle Driver, 07749-0010000 11. Install the bearing cap bridge. Coat the bolt threads with engine oil.
● Driver Attachment, 96 mm, 07948-SB00101 12. Torque the cylinder head bolts sequentially in 2 steps.
1. Apply engine oil to the main bearings and rod bearings. 1st step torque:25 Nm (2.5 kgf/m, 18 lbf/ft)
2. Install the bearing halves in the cylinder block and connecting rods. 2nd step torque:51 Nm (5.2 kgf/m, 38 lbf/ft)
3. Hold the crankshaft so rod journal No. 2 and rod journal No. 3 are straight up and
NOTE: Whenever any crankshaft or connecting rod bearing is replaced, it is
lower the crankshaft into the block.
necessary after reassembly to run the engine at idling speed until it reaches normal
4. Install the thrust washers (A) on both edges of the No. 4 main bearing recess.
operating temperature, then continue to run it for approximately 15 minutes.
BEARING CAP BOLTS TIGHTENING SEQUENCE:
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Engine Mechanical - Engine Block
Engine Block 7-
Crankshaft Installation (cont'd)
12
13. The seal mating surface on the engine block end cover should be dry. Apply a light 16. Clean and dry the engine block end cover mating surfaces.
coat of grease to the crankshaft and to the lip of the seal. 17. Apply liquid gasket, part No. 08718-0001 or 08718-0003, evenly to the block
14. Drive the crankshaft oil seal squarely into the engine block end cover. 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.)
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-
Crankshaft Installation (cont'd)
13
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.
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-
Component Location Index
2
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
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Engine Mechanical - Engine Lubrication
NOTE: Under normal conditions, the oil filter should be replaced at every other oil 4. Refill with the recommended oil (see page 3-2).
change. Under severe conditions, the oil filter should be replaced at each oil change. Capacity
Change interval Except D17A8 engine:
Every 10,000 miles (16,000 km) or 12 months 3.3 l (3.5 US qt, 2.9 Imp qt) at oil change.
(Normal conditions) 3.5 l (3.7 US qt, 3.1 Imp qt) at oil change
Every 5,000 miles (8,000 km) or 6 months including filter.
(Severe conditions) 4.2 l (4.4 US qt, 3.7 Imp qt) after engine overhaul.
1. Warm up the engine. D17A8 engine:
2. Remove the drain bolt (A) and drain the engine oil. 3.0 l (3.2 US qt, 2.6 Imp qt) at oil change.
Except D17A8 engine:
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.
5. Run the engine for more than 3 minutes then check for oil leakage.
D17A8 engine:
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Engine Mechanical - Engine Mechanical
Engine Mechanical
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 - Intake Manifold and Exhaust System
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Engine Mechanical - Intake Manifold and Exhaust System
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Engine Mechanical - Intake Manifold and Exhaust System
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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.
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Engine Cooling - Cooling System
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
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Engine Cooling - Cooling System
RHD models:
1. WATER BYPASS HOSE
2. WATER PASSAGE
3. CONNECTING PIPE
4. HEATER HOSES
5. HEATER VALVE
LHD models:
1. WATER BYPASS HOSE
2. WATER PASSAGE
3. CONNECTING PIPE
4. HEATER VALVE
5. HEATER HOSES
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Engine Cooling - Cooling System
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Fan Controls
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Fuel and Emissions - Fuel and Emissions
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KB, KE, KG, KR models
PGM-FI System
Component Location Index 11-51
DTC Troubleshooting 11-54
MIL Circuit Troubleshooting 11-56
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.
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Fuel and Emissions - Fuel and Emissions Systems
*:These DTCs will be indicated by the blinking of the Malfunction Indicator Lamp (MIL) when SCS short connector is connected.
**:The D indicator light and the Malfunction Indicator Lamp (MIL) may come on simultaneously.
*1:D17A9 engine
*2:A/T
*3:M/T
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Fuel and Emissions - Fuel and Emissions Systems
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 Refer to the '01 Civic Shop
Interruption Manual on this CD (see page
11-88)
P0401*1 P0401*1 80-1 (80)*1 T80-1*1 Exhaust Gas Recirculation (EGR) Insufficient Flow Refer to the '01 Civic Shop
Manual on this CD (see page
11-154)
P0420 P0420 67-1 (67) T67-1 Catalyst System Efficiency Below Threshold Refer to the '01 Civic Shop
Manual on this CD (see page
11-153)
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)
*: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
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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
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Fuel and Emissions - Fuel and Emissions Systems
When the vehicle has one of these symptoms, check the Diagnostic Trouble Code (DTC) with the scan tool. If there is no DTC, do the diagnostic procedure for the symptom, in the
sequence listed, until you find the cause.
Symptom Diagnostic procedure Also check for
Engine will not start 1. Test the battery, refer to the '01 Civic Shop Manual ● Low compression
(MIL works OK, no DTCs set) on this CD (see page 22-79). ● Intake air leaks
2. Test the starter, refer to the '01 Civic Shop Manual ● Locked up engine
on this CD (see page 4-8). ● Slipped/ broken timing belt
3. Troubleshoot the fuel pump circuit, refer to the '01 ● Contaminated fuel
Civic Shop Manual on this CD (see page 11-127).
Engine will not start (MIL comes on and stays on, or never Troubleshoot the MIL circuit (see page 11-56).
comes on at all, no DTCs set)
Engine will not start Troubleshoot the immobiliser system, refer to the '01 Civic Shop
(immobiliser indicator light comes on) Manual on this CD (see page 22-245).
Hard starting 1. Test the battery, refer to the '01 Civic Shop Manual ● Low compression
(MIL works OK, no DTCs set) on this CD (see page 22-79). ● Intake air leaks
2. Check the fuel pressure, refer to the '01 Civic Shop ● Contaminated fuel
Manual on this CD (see page 11-131).
Cold fast idle too low Check the idle speed, refer to the '01 Civic Shop Manual on this CD
(MIL works OK, no DTCs set) (see page 11-125).
Cold fast idle too high 1. Check the idle speed (see page 11-71).
(MIL works OK, no DTCs set) 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).
Idle speed fluctuates 1. Check the idle speed (see page 11-71). Intake air leaks
(MIL works OK, no DTCs set) 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).
After warming up idle speed is below specifications with no 1. Troubleshoot the ALT FR signal circuit, refer to the Vacuum hose clogged/cracked/poor connection
load '01 Civic Shop Manual on this CD (see page 11-120).
(MIL works OK, no DTCs set) 2. Inspect and test the throttle body, refer to the '01
Civic Shop Manual on this CD (see page 11-145).
After warming up idle speed is above specifications with no Troubleshoot the ALT FR signal circuit, refer to the '01 Civic Shop
load Manual on this CD (see page 11-120).
(MIL works OK, no DTCs set)
Low power 1. Check the fuel pressure, refer to the '01 Civic Shop Low compression
(MIL works OK, no DTCs set) 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).
Engine stalls 1. Check the fuel pressure, refer to the '01 Civic Shop ● Intake air leaks
(MIL works OK, no DTCs set) Manual on this CD (see page 11-131). ● Faulty harness and sensor connections
2. Check the idle speed (see page 11-71).
3. Troubleshoot the brake pedal position switch signal
circuit, refer to the '01 Civic Shop Manual on this CD
(see page 11-123).
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Fuel and Emissions - Fuel and Emissions Systems
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 If no problem is detected, there is YES
of one letter and four numbers. Depending on the problem, an SAE- no output.
defined code (P0xxx) or a Honda-defined code (P1xxx) will be output
to the tester.
Engine Speed The ECM/PCM computes engine speed from the signals sent from Nearly the same as tachometer YES
the Crankshaft Position (CKP) sensor. This data is used for indication
determining the time and amount of injected fuel. At idle speed: 700+50 rpm (min-1)
Vehicle Speed The ECM/PCM converts pulse signals from Vehicle Speed Sensor Nearly the same as speedometer YES
(VSS). indication
Manifold Absolute Pressure The absolute pressure caused in the intake manifold by engine load With engine stopped: Nearly the YES
(MAP) and speed. same as atmospheric pressure
At idle speed: about 20-34 kPa
(150-260 mmHg, 6-10 in.Hg), 0.7-
1.1 V
Engine Coolant Temperature The ECT sensor converts coolant temperature into voltage and With cold engine: Same as YES
(ECT) signals the ECM/PCM. The sensor is a thermistor whose internal ambient temperature and IAT
resistance changes with coolant temperature. The ECM/PCM uses With engine warmed up: about 80-
the voltage signals from the ECT sensor to determine the amount of 100°C (176-212°F), 0.5-0.8 V
injected fuel.
Primary Heated Oxygen Sensor The HO2S detects the oxygen content in the exhaust gas and sends 0.0-1.25 V NO
(Primary HO2S) (Sensor 1), voltage signals to the ECM/PCM. Based on these signals, the ECM/ At idle speed: about 0.1-0.9 V
Secondary Heated Oxygen PCM controls the air fuel ratio. When the oxygen content is high (that
Sensor (Secondary HO2S) is, when the ratio is leaner than the stoichiometric ratio), the voltage
(Sensor 2) 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.
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Fuel and Emissions - Fuel and Emissions Systems
Short Term Fuel Trim The air/fuel ratio correction coefficient for correcting the amount of 0.6-1.5 YES
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 Long term fuel trim is computed from short term fuel trim and 0.8-1.2 YES
indicates changes occurring in the fuel supply system over a long
period.
If long term fuel trim is higher than 1.00, the amount of injected fuel
must be increased. If it is lower than 1.00, the amount of injected fuel
must be reduced.
Intake Air Temperature (IAT) The IAT sensor converts intake air temperature into voltage and With cold engine: YES
signals the ECM/PCM. When intake air temperature is low, the Same as ambient temperature
internal resistance of the sensor increases and the voltage signal is and ECT
higher.
Throttle Position Based on the accelerator pedal position, the opening angle of the At idle speed: YES
throttle valve is indicated. about 10 %
Ignition Timing Ignition timing is the ignition advance angle set by the ECM/PCM. At idle speed: 8°+2° NO
The ECM/PCM matches ignition timing to the driving conditions. BTDC when the SCS short
connector is connected
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Fuel and Emissions - Fuel and Emissions Systems
3 YEL/BLK IGP1 (POWER SOURCE) Power source for the ECM/PCM With the ignition switch ON (II): battery voltage
circuit With the ignition switch OFF: about 0 V
4 BLK PG2 (POWER GROUND) Ground for the ECM/PCM circuit Less than 1.0 V at all times
5 BLK PG1 (POWER GROUND) Ground for the ECM/PCM circuit Less than 1.0 V at all times
6 WHT PHO2S (PRIMARY HEATED Detects primary HO2S sensor With throttle fully opened from idle with fully warmed up
OXYGEN SENSOR (PRIMARY (sensor 1) signal engine: about 0.6 V
HO2S), SENSOR 1) With throttle quickly closed: below 0.4 V
7 BLU CKP (CRANKSHAFT POSITION Detects CKP sensor signal With engine running: pulses
(CKP) SENSOR)
8 YEL VCCR (SENSOR VOLTAGE Detects sensor voltage With ignition switch ON (II): about 5 V
RETURN) With the ignition switch OFF: about 0 V
9 RED/BLU KS (KNOCK SENSOR) Detects knock sensor signal With engine knocking: pulses
With ignition switch ON (II): about 5 V
10 GRN/YEL SG2 (SENSOR GROUND) Sensor ground Less than 1.0 V at all times
11 GRN/WHT SG1 (SENSOR GROUND) Sensor ground Less than 1.0 V at all times
12 BLK/RED IACV (IDLE AIR CONTROL (IAC) Drives IAC valve With engine running: duty controlled
VALVE) With ignition switch ON (II): about 5 V
13*1 WHT/BLK EGRP (EXHAUST GAS Detects EGR valve position With engine running: 1.2 V-2.0 V
RECIRCULATION (EGR) VALVE sensor signal (depending on EGR valve lift)
POSITION SENSOR)
15 RED/BLK TPS (THROTTLE POSITION (TP) Detects TP sensor signal With throttle fully open: about 4.8 V
SENSOR) With throttle fully closed: about 0.5 V
18 WHT/GRN VSS (VEHICLE SPEED SENSOR Detects VSS signal With ignition switch ON (II) and front wheels rotating:
(VSS)) 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
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Fuel and Emissions - Fuel and Emissions Systems
7*2 RED/BLK LSA + (A/T PRESSURE Drives A/T pressure control With the ignition switch ON (II): duty controlled
CONTROL SOLENOID VALVE A solenoid valve A
+ SIDE
8 RED/WHT ECT (ENGINE COOLANT Detects ECT sensor signal With the ignition switch ON (II): about 0.1-4.8 V
TEMPERATURE (ECT) SENSOR) (depending on engine coolant temperature)
9*1 BLU/BLK VTPSW (VTEC OIL PRESSURE Detects VTEC oil pressure At idle: about 0 V
SWITCH) switch signal
10 WHT/BLU ALTL (ALTERNATOR L SIGNAL) Detects alternator L signal With ignition switch ON (II): about 0 V
With engine running: battery voltage
13 WHT/RED ALTF (ALTERNATOR FR SIGNAL) Detects alternator FR signal With engine running: 0 V-5 V
(depending on electrical load)
14*1 BLU/RED EGR (EXHAUST GAS Drives EGR valve With EGR operating: duty controlled
RECIRCULATION (EGR) VALVE) With EGR not operating: about 0 V
15*1 GRN/YEL VTS (VTEC SOLENOID VALVE) Drives VTEC solenoid valve At idle: about 0 V
16*2 BLK/RED LSB + (A/T PRESSURE Drives A/T pressure control With the ignition switch ON (II): duty controlled
CONTROL SOLENOID VALVE B solenoid valve B
+ SIDE)
17 RED/YEL IAT (INTAKE AIR Detects IAT sensor signal With ignition switch ON (II): about 0.1 V-4.8 V
TEMPERATURE (IAT) SENSOR) (depending on intake air temperature)
21 YEL/BLU PCS (EVAPORATIVE EMISSION Drives EVAP canister purge With engine running, engine coolant below 70°C (158°F):
(EVAP) CANISTER PURGE valve battery voltage
VALVE) With engine running, engine coolant above 70°C (158°
F): duty controlled
*1:D17A9 engine
*2:A/T
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Fuel and Emissions - Fuel and Emissions Systems
4*2 GRN/WHT SHB (SHIFT SOLENOID VALVE Drives shift solenoid valve B With engine running in 1st, 2nd gears: battery voltage
B) With engine running in 3rd, 4th gears: about 0 V
6*2 BLU/BLK SHA (SHIFT SOLENOID VALVE Drives shift solenoid valve A With engine running in 2nd, 3rd gears: battery voltage
A) With engine running in 1st, 4th gears: about 0 V
7*2 WHT/RED NM (MAINSHAFT SPEED Detects mainshaft speed sensor With engine running: pulses
SENSOR) signals
8*2 BRN/WHT LSB- (A/T PRESSURE CONTROL Ground for A/T pressure control
SOLENOID VALVE B-SIDE) solenoid valve B
9*2 RED ATPD3 (TRANSMISSION RANGE Detects transmission range In D3 position: about 0 V
SWITCH D3 POSITION) switch D3 position signal In any other position: about 5 V or battery voltage
10*2 WHT ATPR (TRANSMISSION RANGE Detects transmission range In R position: about 0 V
SWITCH R POSITION) switch R position signal In any other position: about 5 V or battery voltage
11*2 BLU ATP2 (TRANSMISSION RANGE Detects transmission range In 2nd position: about 0 V
SWITCH 2 POSITION) switch 2 position signal In any other position: about 5 V or battery voltage
12*2 BLU/WHT ATPNP (TRANSMISSION RANGE Detects transmission range In Park or neutral: about 0 V
SWITCH NEUTRAL/PARK switch Neutral/Park position In any other position: about 5 V or battery voltage
POSITION) signal
14*2 GRN NCSG (COUNTERSHAFT SPEED Ground for countershaft speed
SENSOR GROUND) sensor
15*2 BLU NC (COUNTERSHAFT SPEED Detects countershaft speed With ignition switch ON (II) and front wheels rotating:
SENSOR) sensor signals battery voltage
19*2 BRN ATP1 (TRANSMISSION RANGE Detects transmission range In 1st position: about 0 V
SWITCH 1 POSITION) switch 1 position signal In any other position: about 5 V or battery voltage
20*2 YEL ATPD (TRANSMISSION RANGE Detects transmission range In D position: about 0 V
SWITCH D POSITION) switch D position signal 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
16 LT GRN/BLK PSPSW (POWER STEERING Detects PSP switch signal At idle with steering wheel in straight ahead position:
PRESSURE SWITCH SIGNAL) about 0 V
At idle with steering wheel at full lock: battery voltage
18 RED ACC (A/C CLUTCH RELAY) Drives A/C clutch relay With compressor ON: about 0 V
With compressor OFF: battery voltage
22 WHT/BLK BKSW (BRAKE PEDAL Detects brake pedal position With brake pedal released: about 0 V
POSITION SWITCH) switch signal With brake pedal pressed: battery voltage
23 LT BLU K-LINE Sends and receives scan tool With ignition switch ON (II): pulses or battery voltage
signal
24 YEL SEFMJ Communicates with multiplex With ignition switch ON (II): about 5 V
control unit With engine running under load: pulses
26 BLU NEP (ENGINE SPEED PULSE) Outputs engine speed pulse With engine running: pulses
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 0 V
With the service check signal opened: about 5 V battery
voltage
31 GRN/ORN MIL (MALFUNCTION INDICATOR Drives MIL With MIL turned ON: about 0 V
LAMP) With MIL turned OFF: battery voltage
*1:D17A9 engine
*2:A/T
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
0. ENGINE COOLANT.
1. (D17A9 ENGINE)
(1) PRIMARY HEATED OXYGEN SENSOR (PRIMARY HO2S) (SENSOR 1) (13) FUEL PRESSURE REGULATOR
(14) FUEL PUMP
(2) SECONDARY HEATED OXYGEN SENSOR (SECONDARY HO2S) (15) FUEL TANK
(SENSOR 2)
(16) AIR CLEANER
(3) MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR (17) RESONATOR
(4) ENGINE COOLANT TEMPERATURE (ECT) SENSOR (18) EXHAUST GAS RECIRCULATION (EGR) VALVE and POSITION SENSOR
(5) INTAKE AIR TEMPERATURE (IAT) SENSOR
(6) CRANKSHAFT POSITION (CKP) SENSOR (19) POSITIVE CRANKCASE VENTILATION (PCV) VALVE
(7) KNOCK SENSOR (20) THREE WAY CATALYTIC CONVERTER
(8) IDLE AIR CONTROL (IAC) VALVE (21) EVAPORATIVE EMISSION (EVAP) CANISTER
(9) THROTTLE BODY (22) EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VALVE
(10) INJECTOR
(11) FUEL PULSATION DAMPER (23) EVAPORATIVE EMISSION (EVAP) TWO WAY VALVE
(12) FUEL FILTER
1. MAGNET
1. THERMISTOR
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Fuel and Emissions - Fuel and Emissions Systems
1. WEIGHT
2. PIEZO ELEMENT
1. ZIRCONIA ELEMENT
2. SENSOR TERMINALS
3. HEATER TERMINALS
4. HEATER
1. SENSOR UNIT
1. ZIRCONIA ELEMENT
2. SENSOR TERMINALS
3. HEATER TERMINALS
4. HEATER
Starting Control
When the engine is started, the ECM/PCM provides a rich mixture by increasing injector
duration.
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Fuel and Emissions - Fuel and Emissions Systems
1. ELEMENT
2. BRUSH HOLDER
3. BRUSH
1. VALVE
2. From AIR CLEANER
3. To INTAKE MANIFOLD
1. MAGNET
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Fuel and Emissions - Fuel and Emissions Systems
1. TP SENSOR
2. IAC VALVE
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Fuel and Emissions - Fuel and Emissions Systems
1. HOUSING
2. FRONT OF VEHICLE
3. THREE WAY CATALYSTS
1. PCV HOSE
2. BREATHER PIPE
3. INTAKE MANIFOLD
4. PCV VALVE
5. BLOW BY VAPOUR
6. FRESH AIR
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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
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Fuel and Emissions - Fuel and Emissions Systems
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
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Fuel and Emissions - Fuel and Emissions Systems
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
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Fuel and Emissions - Fuel and Emissions Systems
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
*1:D17A9 engine*2:A/T
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Fuel and Emissions - Fuel and Emissions Systems
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
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Fuel and Emissions - Fuel and Emissions Systems
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
file:///C|/Users/Navindra/Desktop/Civic_2001-2005_english_...onda%20Civic%202001-2005(english)/EngCivic/CHtml/11-46.htm7/5/2011 10:47:32 PM
Fuel and Emissions - Fuel and Emissions Systems
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
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Fuel and Emissions - Fuel and Emissions Systems
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
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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:
Random misfire only at low RPM and under Check fuel pressure, refer to the '01 Civic Shop Manual on this CD ❍ Low compression.
load (see page 11-131). ❍ Low quality fuel.
Random misfire only during acceleration Check fuel pressure, refer to the '01 Civic Shop Manual on this CD Malfunction in the VTEC system (D17A9
(see page 11-131). engine), refer to the '01 Civic Shop Manual on
this CD (see page 6-9).
Random misfire at high RPM, under load, or Check fuel pressure, refer to the '01 Civic Shop Manual on this CD Correct valve clearance, refer to the '01 Civic
under random conditions (see page 11-131). Shop Manual on this CD (see page 6-14).
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
● Injectors
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Fuel and Emissions - PGM-FI System
RHD model:
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
RHD model:
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Fuel and Emissions - PGM-FI System
RHD model:
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
● Knock sensor
NO - 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 Wire side of female terminals
original ECM/PCM.
Is there about 5 V?
56. Measure voltage between body ground and ECM/PCM connector terminal A20.
ECM/PCM CONNECTOR A (31P) YES - Replace the sensor that restored about 5 V when disconnected.
NO - Go to step 66.
59. Turn the ignition switch OFF.
60. Disconnect the 3P connectors from the following sensors.
● Exhaust gas recirculation (EGR) valve position sensor
● Knock sensor
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - Idle Control System
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Fuel and Emissions - Idle Control System
Is there less than 1.0 V? ● An open in wire between the PSP switch and G201.
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Fuel and Emissions - Idle Control System
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Fuel and Emissions - Idle Control System
● Spark plugs
A/T 750+50 rpm (min-1)
● Air cleaner
(in Park or neutral)
● PCV system NOTE: If the idle speed in not within specification, see Symptom Chart.
1. Disconnect the Evaporative Emission (EVAP) canister purge valve 2P connector. 7. Reconnect the EVAP canister purge valve 2P connector.
2. Connect a tachometer (A) to the test tachometer connector (B).
3. Start the engine. Hold the engine at 3,000 rpm (min-1) 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
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Fuel and Emissions - Fuel Supply System
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KK, KX, KY models
PGM-FI System
Component Location Index 11-85
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
*1: A/T
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Fuel and Emissions - Fuel and Emissions Systems
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
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Fuel and Emissions - Fuel and Emissions Systems
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
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Fuel and Emissions - Fuel and Emissions Systems
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
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Fuel and Emissions - Fuel and Emissions Systems
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
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - Idle Control System
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Fuel and Emissions - Fuel Supply System
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Fuel and Emissions - Fuel Supply System
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Automatic Transmission - Automatic Transmission
Automatic Transmission
Road Test
Shift Schedule 14-2
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Automatic Transmission - Automatic Transmission
Shift Schedule
position
Upshift
Throttle Opening Unit of Speed 1st - 2nd 2nd - 3rd 3rd - 4th Lock-up ON
Throttle position sensor voltage: 0.75 V mph 9-12 19-22 29-34 14-18
km/h 15-19 30-35 47-54 23-28
Throttle position sensor voltage: 2.25 V mph 22-26 42-48 60-66 68-74
km/h 36-42 68-76 96-105 110-119
Fully-opened throttle, Throttle position mph 34-40 67-76 103-114 103-114
sensor voltage: 4.5 V
km/h 55-63 108-121 166-183 166-183
Downshift
Throttle Opening Unit of Speed Lock-up OFF 4th - 3rd 3rd - 2nd 2nd - 1st
Throttle position sensor voltage: 0.5 V mph 13-17 17-20 6-10 (3rd - 1st)
km/h 21-26 27-32 10-15 (3rd - 1st)
Fully-opened throttle, Throttle position mph 93-104 85-96 55-62 25-30
sensor voltage: 4.5 V
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
Frame
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.
Doors 20-
Component Location Index - Front Door
2
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-
Component Location Index - Front Door (cont'd)
3
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
Doors 20-4
Door Panel Removal/Installation
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Body - Doors
4. Remove the mirror mount cover (see step 2 on page 20-16). NOTE: Put on gloves to protect your hands.
5. Release the clips that hold the door panel (A) with a commercially available trim pad 1. Raise the glass fully.
remover (B), then remove the door panel by pulling it upward. Remove the door 2. Remove these items:
panel with as little bending as possible to avoid creasing or breaking it. ● Door panel (see page 20-4)
Fastener Locations ● Plastic cover, as necessary
: Clip, 9 3. Release the retainer clip (A), then remove the lock cylinder (B). Disconnect the
cylinder rod (C).
4. With cylinder switch: Remove the screw, then separate the lock cylinder (A) and
cylinder switch (B).
Fastener Location
: Screw, 1
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
Doors 20-6
Door Outer Handle Replacement (cont'd)
5. With cylinder switch: Disconnect the cylinder switch connector (A) and detach the 7. Remove the maintenance hole (A). Disconnect the outer handle rod (B) and remove
harness clips (B), then remove the cylinder switch (C). the nuts, then remove the outer handle protector (C) from the outer handle (D).
Fastener Locations
: Nut, 2
8. Pull out the outer handle (A) in the numbered sequence and remove it.
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Body - Doors
9. Install the handle in the reverse order of removal and note these items: NOTE: Put on gloves to protect your hands.
● Make sure the door locks and opens properly.
1. Raise the glass fully.
● Make sure each rod is connected securely.
2. Remove these items:
● Make sure the door locks and opens properly.
● Door panel (see page 20-4)
● When installing the lock cylinder, leave the outer door handle bolts loose so the
● Plastic cover, as necessary
inner protector does not interfere with the lock cylinder, then tighten the handle
3. Disconnect the cylinder rod from the lock cylinder (see step 3 on page 20-5) and
bolts.
disconnect the outer handle rod from the outer handle (see step 7 on page 20-6).
● 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. 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
Doors 20-8
Door Latch Replacement (cont'd)
5. Pull the glass run channel (A) away as necessary and remove the bolts, then 6. Release the lock knob (A) from the knob bracket (B) and detach the inner handle rod
remove the centre lower channel (B) by pulling it downward. (C) from the rod holder (D). Detach the harness clip (E) and disconnect (and detach)
Fastener Location the actuator connector(s) (F).
Without Super Locking:
: Bolt, 1
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Body - Doors
7. Remove the screws, then remove the latch (A) through the hole in the door. Take NOTE: Put on gloves to protect your hands.
care not to bend the outer handle rod (B), cylinder rod (C), inner handle rod (D) and 1. Remove these items:
lock cable (E). Without Super Locking model is shown, with Super Locking model is ● Door panel (see page 20-4)
Fastener Locations 2. Carefully raise the glass (A) until you can see the bolts, then remove them. Carefully
: Screw, 3 pull the glass out through the window slot. Take care not to drop the glass inside the
door.
Fastener Locations
: Bolt, 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.
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-
Door Glass and Regulator Replacement (cont'd)
10
3. Disconnect and detach the connector (A) and harness clip (B) from the door. 6. Install the glass and regulator in the reverse order of removal and note these items:
Fastener Locations ● 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
C : Bolt, 3D : Bolt, 4
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
2. Pull back the door weatherstrip (A) at the rear upper corner and remove the screw. ● Take care not to scratch the door.
3. Lift up the door sash trim (B) to release the hooks (C), then remove the trim. 3. Install the weatherstrip in the reverse order of removal and replace any damaged
4. Install the trim in the reverse order of removal. clips.
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Body - Doors
● Use a clip remover to remove the clips. ● Use a clip remover to remove the clips.
1. At the front-pillar, remove the door stop mounting bolt (A). 1. Remove these items:
Fastener Location ● Power mirror, as necessary (see page 20-16)
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
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.
● 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
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Body - Doors
Doors 20-
Door Side Sill Seal Replacement
13
NOTE:
● Take care not to scratch the door.
1. Detach the clips, then remove the door side sill seal (A).
Fastener Locations
: Clip, 9
2. Install the seal in the reverse order of removal and replace any damaged clips.
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Body - Doors
Doors 20-
Door Channel Tape Replacement Process
14
NOTE: 2. Remove these items:
● This procedure is a general description of the door channel tape replacement Door outer channel tape replacement
process. For details about installation, door outer channel tape (see page 20-15). ● Power mirror (see page 20-16)
● Keep dust away from the working area. ● Door glass outer weatherstrip (see page 20-11)
● When working at lower temperatures, heat the door channel and door channel tape
● Glass run channel, as necessary (see page 20-2)
with a hair dryer.
● Sash trim (see page 20-11)
Door channel: about 15°C (59°F).
● Upper seal (see page 20-12)
Door channel tape: about 30°C (86°F).
3. Slowly peel up the old door channel tape while heating it with a hair dryer.
● When heating the door channel tape, heat it evenly and gradually to prevent 4. Clean the door channel bonding surface with a sponge dampened in alcohol. After
deformation. cleaning, keep oil, grease and water from getting on the surface.
● When pressing the door channel tape, slowly press it from the corner to prevent air 5. Attach the door channel tape:
bubbles and wrinkles.
1. Peel the edge of the adhesive backing from the channel tape.
If there are air bubbles (A) in the door channel tape (B), prick them with a pin (C),
2. Fit the door channel tape to the door channel.
●
● Hair dryer
● Pin
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Body - Doors
Doors 20-
Door Outer Channel Tape Installation
15
NOTE: Familiarise yourself with the channel tape replacement process (see page 20-14).
Attachment Point (Reference):
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-
Power Mirror Replacement
16
1. Lower the door glass fully. 7. While holding the mirror, push out the connector clip (A) and remove the mirror (B).
2. Carefully pry out the mirror mount cover (A) by hand in the sequence shown. Take care not to scratch the door.
Fastener Location
: Clip, 1
3. Remove the door panel (see page 20-4). 8. Install the mirror in the reverse order of removal and make sure the connector is
4. If equipped with a tweeter, pull the plastic cover (A) back as necessary and plugged in properly.
disconnect the connector (B), then remove the mirror mount cover (C) with the
tweeter.
Fastener Locations
: Nut, 3
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Body - Glass
Glass 20-
Component Location Index
17
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-
Windshield Replacement
18
NOTE: 3. Remove the moulding (A) from the upper edge of the windshield (B). If necessary,
● Put on gloves to protect your hands. cut the moulding with a utility knife.
● Wear eye protection when removing the glass with piano wire.
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.
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.
page 20-114).
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Body - Glass
Glass 20-
Windshield Replacement (cont'd)
19
7. With a helper on the outside, pull the piano wire (A) back and forth in a sawing 9. With a knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in.)
motion. Hold the piano wire as close to the windshield (B) as possible to prevent on the bonding surface around the entire windshield opening flange:
damage to the body and dashboard. ● Do not scrape down to the painted surface of the body; damaged paint will
Carefully cut through the rubber dam and adhesive (C) around the entire windshield. 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.
Cutting portions:
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Body - Glass
Glass 20-
Windshield Replacement (cont'd)
20
12. Glue the side rubber dams (A), lower rubber dam (B) and fasteners (C) to the 13. Glue the moulding (A) with adhesive tape (B) to the upper edge of the windshield
inside face of the windshield (D) as shown: (C):
● Be sure the rubber dam and fasteners and dashboard seal line up with the ● Be sure the alignment mark (D) of the moulding lines up with the alignment mark
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-
Windshield Replacement (cont'd)
21
16. Set the windshield in the opening and centre it. 18. With a sponge, apply a light coat of glass primer around the edge of the windshield
Make alignment marks (A) across the windshield and body with a grease pencil at (A) between the dams (B) and moulding (C) as shown, then lightly wipe it off with
the four points shown. Be careful not to touch the windshield where adhesive will be gauze or cheesecloth:
applied. ● Apply glass primer to the moulding.
● Do not apply body primer to the windshield and do not get body and glass primer
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.
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Body - Glass
Glass 20-
Windshield Replacement (cont'd)
22
19. With a sponge, apply a light coat of body primer to the original adhesive remaining 21. Pack adhesive into the cartridge without air pockets to ensure continuous delivery.
around the windshield opening flange. Let the body primer dry for at least 10 minutes: Put the cartridge in a caulking gun and run a bead of adhesive (A) around the edge
● Do not apply glass primer to the body and be careful not to mix up glass and of the windshield (B) between the dams (C) and moulding (D) as shown. Apply the
body primer sponges. adhesive within 30 minutes after applying the glass primer. Make a slightly thicker
● Never touch the primed surfaces with your hands. bead at each corner.
● Mask off the dashboard before painting the flange.
20. Before filling a cartridge, cut a ''V'' in the end of the nozzle (A) as shown.
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-
Windshield Replacement (cont'd)
23
23. Scrape or wipe the excess adhesive off with a putty knife or towel. To remove 27. On both sides of the windshield, set the bottom edge of the side moulding (A) under
adhesive from a painted surface or the windshield, wipe with a soft shop towel the cowl cover (B), then align the clips (C and D) with the retainers (E) and push on
dampened with alcohol. the clip portions of the moulding until the moulding is fully seated on the windshield.
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
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
1. Top of moulding
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Body - Glass
Glass 20-
Rear Window Replacement
24
NOTE: 4. Pull down the rear portion of the headliner (A) by detaching the clips (B). Take care
● Put on gloves to protect your hands. not to bend the headliner excessively, or you may crease or break it.
● Wear eye protection when removing the glass with piano wire. Fastener Locations
● Use seat covers to avoid damaging any surfaces.
B : Clip, 2
● Do not damage the rear window defogger grid lines, window antenna grid lines and
terminals.
1. Remove these items:
● Trunk lid
2. Disconnect the window antenna connector (A) and rear window defogger connectors
(B).
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.
3. If the old rear window is to be reinstalled, make alignment marks across the glass
and body with a grease pencil.
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Body - Glass
Glass 20-
Rear Window Replacement (cont'd)
25
6. With a helper on the outside, pull the piano wire (A) back and forth in a sawing 8. With a putty knife, scrape the old adhesive smooth to a thickness of about 2 mm
motion. Hold the piano wire as close to the rear window (B) as possible to prevent (0.08 in.) on the bonding surface around the entire rear window opening flange:
damage to the body and carefully cut through the adhesive (C) around the entire ● Do not scrape down to the painted surface of the body; damaged paint will
● If the moulding is damaged, replace the rear window and moulding as an 9. Clean the body bonding surface with a sponge dampened in alcohol. After cleaning,
assembly. 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:
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Body - Glass
Glass 20-
Rear Window Replacement (cont'd)
26
11. Glue the clips (A) and fasteners (B) to the inside face of the rear window (C) as 12. Install the clips (A) to the rear window opening flange (B) and glue the fasteners (C)
shown: to the offset area of the rear shelf (D).
● Be sure the clips and fasteners line up with the alignment marks (D). Fastener Locations
● Be careful not to touch the rear window where adhesive will be applied.
A : Clip, 2B : Fastener, 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.
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Body - Glass
Glass 20-
Rear Window Replacement (cont'd)
27
15. With a sponge, apply a light coat of glass primer along the edge of the rear window 16. With a sponge, apply a light coat of body primer to the original adhesive remaining
(A) and moulding (B) as shown, then lightly wipe it off with gauze or cheesecloth: around the rear window opening flange. Let the body primer dry for at least 10
● Do not apply body primer to the rear window and do not get body and glass minutes:
primer sponges mixed up. ● Do not apply glass primer to the body and be careful not to mix up glass and
● Never touch the primed surfaces with your hands. If you do, the adhesive may body primer sponges.
not bond to the rear window properly, causing a leak after the rear window is ● Never touch the primed surfaces with your hands.
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-
Rear Window Replacement (cont'd)
28
18. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. 19. Use suction cups to hold the rear window over the opening, align it with the
Put the cartridge in a caulking gun and run a bead of adhesive (A) around the edge alignment marks you made in step 13 and set it down on the adhesive. Lightly push
of the rear window (B) and mouldings (C) as shown. on the rear window until its edges are fully seated on the adhesive all the way
Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly around. Do not open or close the doors until the adhesive is dry.
thicker bead at each corner. 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
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Body - Glass
Glass 20-
Quarter Glass Replacement
29
NOTE: Cutting positions:
● Put on gloves to protect your hands.
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).
4. Carefully remove the quarter glass.
● If the moulding is damaged, replace the quarter glass, moulding fastener (E) and
5. With a putty knife, scrape the old adhesive smooth to a thickness of about 2 mm
clips (F) as an assembly. (0.08 in.) on the bonding surface around the entire quarter glass opening flange:
● If any of the clips and fastener are broken, the quarter glass can be reinstalled
● Do not scrape down to the painted surface of the body, damaged paint will
using butyl tape (refer to step 8). 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-
Quarter Glass Replacement (cont'd)
30
8. If the old quarter glass is to be reinstalled (and either clip is broken off the moulding), 10. If the old quarter glass is to be reinstalled (and either clip is broken off the
apply a light coat of primer (C-100, or equivalent), then apply butyl tapes (A) and (B) moulding), seal the body holes with pieces of urethane tape (A). Then set the quarter
to the moulding (C) as shown: glass upright in the opening and make alignment marks (B) across the quarter glass
● Be careful not to touch the quarter glass where adhesive will be applied. and body with a grease pencil at the stet points shown. Be careful not to touch the
● Do not peel the separator off the butyl tapes. quarter glass where adhesive will be applied.
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).
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Body - Glass
Glass 20-
Quarter Glass Replacement (cont'd)
31
12. With a sponge, apply a light coat of glass primer to the inside face of the quarter 13. With a sponge, apply a light coat of body primer to the original adhesive remaining
glass (A) as shown, then lightly wipe it off with gauze or cheesecloth: around the quarter glass opening flange. Let the body primer dry for at least 10
● Do not apply body primer to the quarter glass and do not get body and glass minutes:
primer sponges mixed up. ● Do not apply glass primer to the body and be careful not to mix up glass and
● Never touch the primed surfaces with your hands. If you do the adhesive may not body primer sponges.
bond to the quarter glass properly, causing a leak after the quarter glass is ● Never touch the primed surfaces with your hands.
● Keep water, dust and abrasive materials away from the primed surface. Cross-hatched area: Apply body primer here
Cross-hatched area: Apply glass primer here
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-
Quarter Glass Replacement (cont'd)
32
15. Park adhesive into the cartridge without air pockets to ensure continuous delivery. 16. Use suction cups (A) to hold the quarter glass (B) over the opening, align the clips
Put the cartridge in a caulking gun and run a bead of adhesive (A) around the edge or the alignment marks (C) made in step 10 and set it down on the adhesive. Lightly
of the quarter glass (B) as shown: push on the quarter glass until its edges are fully seated on the adhesive all the way
● After applying the adhesive, peel the separator off the butyl tape. around. Do not open or close the doors until the adhesive is dry.
● Apply the adhesive within 30 minutes after applying the glass primer. Make
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
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Body - Interior Trim
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Body - Interior Trim
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 : Clip, 7
(Black)(White)
1. CENTRE PILLAR UPPER TRIM
2. To headliner
3. PIN
4. FRONT SEAT BELT UPPER
ANCHOR BOLT
7/16 - 20 UNF
32 Nm (3.3 kgf/m, 24 lbf/ft)
5. To headliner
6. FRONT PILLAR TRIM
7. PIN
8. DOOR OPENING TRIM
9. UPPER ANCHOR COVER
10. OPENER LOCK CYLINDER
(For some models)
11. FRONT SIDE CAP
12. KICK PANEL
13. DOOR SILL TRIM
14. FRONT SEAT BELT LOWER
ANCHOR BOLTS
7/16 - 20 UNF
32 Nm (3.3 kgf/m, 24 lbf/ft)
15. SIDE TRIM PANEL
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Body - Interior Trim
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 : Clip, 1C : Clip, 7
(White)
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
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
● Rear view mirror, refer to the '01 CIVIC Shop Manual, P/N 62S5A00 on this CD
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
4. On left rear passenger's side: Remove the screw, then remove the coat hanger (A).
: Screw, 4 Fastener Locations
: Screw, 1
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Body - Interior Trim
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Body - Interior Trim
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
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Body - Seats
Seats 20-
Front Seat Disassembly/Reassembly -
Passenger's
40
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.
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Body - Seats
3. Release the hook (A) and unzip the seat-back cover (B). The left seat-back is
shown, the right seat-back is similar.
4. Install the lock cylinder in the reverse order of removal and note these items:
● Make sure the cylinder rod is connected securely.
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Body - Seats
Seats 20-
Rear Seat-back Cover Replacement (cont'd)
42
4. Pull back the seat-back cover (A) and remove the clips (B) and release the hooks 6. Pull back the edge of the seat-back cover (A) all the way around and remove the
(C). clips (B), then remove the seat-back cover.
Fastener Locations Left seat back:
B : ClipLeft, 6
Right, 3
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
5. Remove the seat-back cover and pad (D) from the seat-back frame (E).
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Bumpers
Bumpers 20-
Rear Bumper Removal/Installation
43
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.
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
3. Remove the screws, then remove the front grille cover (A) from the front grille (B).
Fastener Locations
: Screw, 9
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
Unit: mm (in.)
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Body - Openers
Openers 20-
Trunk Lid Opener/Fuel Fill Door Opener Cable
Replacement
46
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:
● 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)
● RHD: Side trim panel, right side as necessary (see page 20-35)
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
4. Release the opener cable from the clip (LHD) (C). Remove the cushion tape (D).
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Body - Openers
Openers 20-
Trunk Lid Opener/Fuel Fill Door Opener Cable
Replacement (cont'd)
47
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 : 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.
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Body - Frame
Frame 20-
Frame Repair Chart
48
Top View
Unit : mm (in) a For sub-frame Ø15 (0.59) i For sub-frame Ø11 (0.43)
Ø: Inner diameter b For engine mount Ø13 (0.51) j For damper mount Ø11.5 (0.45)
c For engine mount Ø13 (0.51) k For damper mount Ø11.5 (0.45)
d For engine mount Ø13 (0.51) l Damper centre Ø78 (3.07)
e For transmission mount Ø13 (0.51) m For sub-frame Ø15 (0.59)
f For transmission mount Ø13 (0.51) n Locating hole Ø25 (0.98)
g For transmission mount Ø13 (0.51) o Locating hole Ø50 (1.97)
h For damper mount Ø11.5 (0.45)
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Body - Frame
Frame 20-
Frame Repair Chart (cont'd)
49
p Locating hole Ø25 (0.98) x For upper arm bracket centre Ø15 (0.98)
q For trailing arm Ø13 (0.51) y1, y2 Locating hole Ø13 (0.51)
r Locating hole Ø25 (0.98) z For upper arm Ø13 (0.51)
s Locating hole Ø20 (0.79) a1 For rear lower arm centre
t Trailing arm centre b1 Locating hole Ø50 (1.97)
u Rear damper centre 73 x 68 (Slot) c1 Locating hole Ø20 (0.79)
v For upper arm Ø13 (0.51)
w For trailing arm Ø23 (0.51)
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Frame 50
Frame 50 20-
Frame Repair Chart (cont'd)
50
Side View
Unit : mm (in) a For sub-frame Ø15 (0.59) i For sub-frame Ø11 (0.43)
Ø: Inner diameter b For engine mount Ø13 (0.51) j For damper mount Ø11.5 (0.45)
c For engine mount Ø13 (0.51) k For damper mount Ø11.5 (0.45)
d For engine mount Ø13 (0.51) l Damper centre Ø78 (3.07)
e For transmission mount Ø13 m For sub-frame Ø15 (0.59)
(0.51)
f For transmission mount Ø13 n Locating hole Ø25 (0.98)
(0.51)
g For transmission mount Ø13 o Locating hole Ø50 (1.97)
(0.51)
h For damper mount Ø11.5 (0.45)
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Body - Frame
Frame 20-
Frame Repair Chart (cont'd)
51
p Locating hole Ø25 (0.98) x For upper arm bracket centre Ø15 (0.98)
q For trailing arm Ø13 (0.51) y1, y2 Locating hole Ø13 (0.51)
r Locating hole Ø25 (0.98) z For upper arm Ø13 (0.51)
s Locating hole Ø20 (0.79) a1 For rear lower arm centre
t Trailing arm centre b1 Locating hole Ø50 (1.97)
u Rear damper centre 73 x 68 (Slot) c1 Locating hole Ø20 (0.79)
v For upper arm Ø13 (0.51)
w For trailing arm Ø23 (0.51)
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Body Electrical - Relay and Control Unit Locations
Body Electrical
Ground Distribution
Ground to Identification 22-16
Exterior Lights
Taillights Replacement 22-26
Interior Lights
Circuit Diagram-With Sunroof 22-27
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
● 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 Electrical - Relay and Control Unit Locations
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Body Electrical - Relay and Control Unit Locations
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Body Electrical - Power Distribution
: Spare Fuse
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Body Electrical - Power Distribution
4 - door:
To get to the pages referenced on the above diagram, click on the following:
22-13
22-14
22-15
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Body Electrical - Power Distribution
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Body Electrical - Power Distribution
To get to the pages referenced on the above diagram, click on the following:
22-11
22-13
22-15
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Body Electrical - Power Distribution
To get to the pages referenced on the above diagram, click on the following:
22-9
22-12
22-13
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Body Electrical - Power Distribution
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Body Electrical - Power Distribution
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Body Electrical - Power Distribution
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Body Electrical - Power Distribution
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Body Electrical - Ground Distribution
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Body Electrical - Ground Distribution
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Body Electrical - Ground Distribution
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Body Electrical - Ground Distribution
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Body Electrical - Ground Distribution
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Body Electrical - Ground Distribution
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Body Electrical - Ground Distribution
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Body Electrical - Ground Distribution
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Body Electrical - Ground Distribution
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Body Electrical - Ground Distribution
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Exterior Lights
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Interior Lights
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Body Electrical - Stereo Sound System
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Body Electrical - Stereo Sound System
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Body Electrical - Stereo Sound System
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Body Electrical - Stereo Sound System
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.
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.
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Body Electrical - Power Windows
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Body Electrical - Power Windows
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Body Electrical - Power Windows
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Body Electrical - Power Windows
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.
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Body Electrical - Power Windows
Cavity Wire Test condition Test: Desired result Possible cause if result is not
obtained
10 BLK Under all conditions Check for continuity to ground: ● Poor ground (G501)
14 There should be continuity. ● An open in the wire
11 GRN/WHT Under all conditions Check for voltage to ground: ● Blown No. 23 (20A) fuse in the under-dash fuse/
There should be battery voltage. relay box
● An open in the wire
12 YEL/GRN Ignition switch ON (II) Check for voltage to ground: ● Blown No. 6 (7.5 A) fuse in the under-dash fuse/
There should be battery voltage. relay box
● Blown No. 22 (20 A) fuse in the under-dash fuse/
2 GRN/BLK relay box
● Faulty power window relay
● An open in the wire
7 RED/YEL Connect the No. 11 and No. 7 Check for driver's window motor operation: ● Faulty driver's window motor
terminals, and the No. 4 and It should run (the driver's window moves ● An open in the wire
4 RED/BLK No. 14 terminals, and turn the down).
ignition switch ON (II).
3 BLU/RED Connect the No. 2 and No. 1 Check for front passenger's window motor ● Faulty passenger's window motor
terminals, and the No. 3 and operation: ● Faulty passenger's window switch
No. 10 terminals, and turn the It should run (the front passenger's window An open in the wire.
1 BLU/WHT ●
ignition switch ON (II). moves down).
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 Possible cause if result is not
obtained
5 RED/WHT Ignition switch ON (II) Check for voltage to ground: ● Faulty power window master switch
There should be battery voltage. ● An open in the wire
6 LT GRN Under all conditions Check for voltage to ground: ● An open in the wire
There should be battery voltage.
13 BLU Ignition switch ON (II), and the Check for voltage between the No. 13 and ● Blown No. 6 (7.5 A) fuse in the under-dash fuse/
driver's window switch AUTO No. 6 terminals: relay box
DOWN There should be 0 V - about 5 V - 0 V - ● Blown No. 23 (20 A) fuse in the under-dash fuse/
about 5 V repeatedly. relay box
8 ORN Ignition switch ON (II), and the Check for voltage between the No. 8 and
● Faulty power window relay
driver's window switch AUTO No. 6 terminals: ● Faulty power window master switch
DOWN An open in the wire
There should be 0 V - about 5 V - 0 V -
●
about 5 V repeatedly.
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Body Electrical - Power Windows
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.
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Body Electrical - Power Windows
Cavity Wire Test condition Test: Desired result Possible cause if result is not
obtained
10 BLK Under all conditions Check for continuity to ground: ● Poor ground (G501)
14 There should be continuity. ● An open in the wire
11 GRN/WHT Ignition switch ON (II) Check for voltage to ground: ● Blown No. 6 (7.5 A) fuse in the under-dash fuse/
There should be battery voltage. relay box
● Blown No. 22 or 23 (20 A) fuse in the under-
2 GRN/BLK dash fuse/relay box
● Faulty power window relay
● An open in the wire
4 [1] RED/BLK Connect the No. 11 and No. 7 Check for driver's window motor operation: ● Faulty driver's window motor
[No. 3] terminals, and the No. 4 It should run (the driver's window moves ● An open in the wire
[No. 1] and No. 14 terminals, down).
7 [3] RED/YEL and turn the ignition switch ON
(II).
3 [4] BLU/RED Connect the No. 2 and No. 1 Check for passenger's window motor ● Faulty passenger's window motor
[No. 7] terminals, and the No. 3 operation: ● Faulty passenger's window switch
[No. 4] and No. 10 terminals, It should run (the passenger's window An open in the wire.
1 [7] BLU/WHT
●
and turn the ignition switch ON moves down).
(II).
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 Possible cause if result is not
obtained
13 BLU Connect the No. 11 and No. 7 Check for voltage between the No. 13 and ● Faulty driver's window motor
[No. 3] terminals, and the No. 4 No. 14 terminals: ● An open in the wire
[No. 1] and No. 14 terminals, About 6 V should be indicated while the
and turn the ignition switch ON driver's window motor running.
(II).
[ ]: RHD type
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Body Electrical - Power Windows
4. If the switch is faulty, remove the two screws and replace the switch.
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Body Electrical - Power Windows
4. If the switch is faulty, remove the two screws and replace the switch.
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Body Electrical - Rear Window Defogger
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Body Electrical - Rear Window Defogger
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Body Electrical - Rear Window Defogger
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
Function Test
45
NOTE: NOTE: To make an effective repair, the broken section must be no longer than one
● Be careful not to scratch or damage the defogger wires with the tester probe. inch.
● Before testing, check the No. 11 (40 A) fuse in the under-hood fuse/relay box and 1. Lightly rub the area around the broken section (A) with fine steel wool, then clean it
No. 14 (10 A) fuse in the under-dash fuse/relay box. with alcohol.
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.
● 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.
2. Check for continuity between the negative terminal (B) and body ground.
If there is no continuity, check for:
● an open in the BLK wire.
● Poor body ground at the window antenna coil mounting bolt.
● Poor ground (G701)
3. Touch the voltmeter positive probe to the halfway point of each defogger wire, and
2. Carefully mask above and below the broken portion of the defogger wire (B) with
the negative probe to the negative terminal.
transparent tape (C).
There should be about 6 V with the ignition switch and the defogger switch ON.
3. Using a small brush, apply a heavy coat of silver conductive paint extending about
● If the voltage is as specified, the defogger wire is OK. 1/8" on both sides of the break. Allow 25 minutes to dry. Thoroughly mix the paint
● If the voltage is not as specified, repair the defogger wire. before use.
● If it is more than 6 V, there is a break in the negative half of the wire.
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Restraints - Restraints
Restraints
Seat Belts
Front Seat Belt Replacement 23-2
Inspection 23-4
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
SRS components are located in this area. Review the SRS component location, 6. Remove the upper anchor cap (A) and remove the upper anchor bolt (B).
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:
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. 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).
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).
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
Install the belt in the reverse order of removal and note these items: Lower anchor bolt construction:
● If the threads on the retractor mounting self-tapping 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
● If equipped, enter the anti-theft code for the radio, then enter the customer's radio
station presets.
Upper anchor bolt construction:
1. LOWER ANCHOR BOLT
2. TOOTHED LOCK WASHER
3. COLLAR
4. LOWER ANCHOR
Retractor bolt:
1. BUSHING
2. UPPER ANCHOR
3. WASHERS
4. TOOTHED LOCK WASHER
5. COLLARS
6. SPRING WASHER
7. UPPER ANCHOR BOLT
1. RETRACTOR BOLT
2. COLLAR
3. SPRING WASHER
4. TOOTHED LOCK WASHER
5. RETRACTOR
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Restraints - Seat Belts
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. 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:
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 CAUTION
● Removal of the airbag must be performed according ● Be sure to install the harness wires so that they are
to the precautions/procedures described before. not pinched or interfering with other parts.
● Before disconnecting the side impact sensor 2P ● Do not turn the ignition switch ON (II) and do not
connector(s), disconnect the side airbag 2P connector connect the battery cable while replacing the side
(s). impact sensor.
● Do not turn the ignition switch ON (II) and do not
connect the battery cable while replacing the side Install the side impact sensor in the reverse order of removal, and note these items:
impact sensor.
● Replace the Torx bolt with a new one.
● After installing the side impact sensor, confirm proper system operation: Turn the
1. Disconnect the negative battery cable and wait at least 3 minutes before beginning ignition switch ON (II): the SRS indicator light should come on for about 6 seconds
work. and then go off.
2. Slide the front seat forward.
3. Remove these items:
● Rear seat-backs
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).
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How to Use This Manual
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 preceded by a
symbol. The purpose of this message is to help prevent damage to
your vehicle, other property, or the environment.
First Edition 11/2000 364 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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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 and some models include side airbags in the front seat-backs. Information necessary to safely service the SRS is included in this 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.
WARNING
● To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe
frontal collision, all SRS service work must be performed by an authorised Honda dealer.
● Improper service procedures, including incorrect removal and installation of the SRS, could lead to personal
injury caused by unintentional deployment of the airbags.
● Do not bump the SRS unit. Otherwise, the system may fail in a collision, or airbags may deploy when the ignition
switch is ON (ll).
● SRS electrical wiring harnesses are identified by yellow colour coding. Related components are located in the
steering column, front console, dashboard, dashboard lower panel and in the dashboard above the glove box. Do
not use electrical test equipment on these circuits.
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A Few Words about Safety
IMPORTANT
A Few Words about Safety SAFETY
Service Information PRECAUTIONS
The service and repair information contained in this manual ● Make sure you have a clear understanding of all basic
is intended for use by qualified, professional technicians. shop safety practices and that you are wearing
Attempting service or repairs without the proper training, appropriate clothing and using safety equipment. When
tools and equipment could cause injury to you or others. It performing any service task, be especially careful of the
could also damage the vehicle or create an unsafe condition. following:
● Read all of the instructions before you begin and make
This manual describes the proper methods and procedures
for performing service, maintenance and repairs. Some sure you have the tools, the replacement or repair parts
procedures require the use of specially designed tools and and the skills required to perform the tasks safely and
dedicated equipment. Any person who intends to use a completely.
● Protect your eyes by using proper safety glasses,
replacement part, service procedure or a tool that is not
recommended by Honda, must determine the risks to their goggles or face shields any time you hammer, drill,
personal safety and the safe operation of the vehicle. grind, or work around pressurised air or liquids and
springs or other stored-energy components. If there is
If you need to replace a part, use genuine Honda parts with any doubt, put on eye protection.
the correct part number or an equivalent part. We strongly ● Use other protective wear when necessary, for example
recommend that you do not use replacement parts of inferior gloves or safety shoes. Handling hot or sharp parts can
quality. cause severe burns or cuts. Before you grab something
FOR YOUR CUSTOMER'S SAFETY that looks like it can hurt you, stop and put on gloves.
● Protect yourself and others whenever you have the
Proper service and maintenance are essential to the
customer's safety and the reliability of the vehicle. Any error vehicle up in the air. Any time you lift the vehicle, either
or oversight while servicing a vehicle can result in faulty with a hoist or a jack, make sure that it is always
operation, damage to the vehicle, or injury to others. securely supported. Use jack stands.
● Make sure the engine is off before you begin any
WARNING servicing procedures, unless the instruction tells you to do
Improper service or repairs can create otherwise. This will help eliminate several potential
an unsafe condition that can cause hazards:
● Carbon monoxide poisoning from engine exhaust. Be
your customer or others to be
seriously hurt or killed. sure there is adequate ventilation whenever you run the
engine.
Follow the procedures and ● Burns from hot parts or coolant. Let the engine and
precautions in this manual and other exhaust system cool before working in those areas.
service materials carefully. ● Injury from moving parts. If the instruction tells you to
procedures described in this manual. ● Keep all cigarettes, sparks and flames away from the
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.
Introduction
Outline of Model Changes
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General Information - General Information
General Information
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General Information - General Information
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General Information - General Information
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General Information - General Information
General Information 1-
Identification Number Locations
4
1. Vehicle Identification Number (VIN)
2. Built Data and Vehicle Type
(Except KY model)
3. Engine Number
4. Certification Plate
(KY model)
5. Transmission Number
(Automatic)
6. Transmission Number
(Manual)
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General Information - General Information
General Information 1-
Warning/Caution Lables Locations
5
1. PASSENGER AIRBAG CHILD SEAT CAUTION
(KE model)
2. SRS INFORMATION
(Except KE model)
3. SRS INFORMATION
(KE model)
4. PASSENGER AIRBAG CHILD SEAT CAUTION
(KG model)
5. FRONT PASSENGER MODULE DANGER
6. FRONT SEATBELT TENSIONER WARNING
7. SIDE AIRBAG INFORMATION
NOTE: Located on driver's and passenger's door
jamb (not shown)
8. PASSENGER AIRBAG CHILD SEAT CAUTION
NOTE: LHD model is shown, RHD model is
symmetrical
9. DRIVE MODULE DANGER
10. CABLE REEL CAUTION
11. MONITOR NOTICE
12. STEERING COLUMN NOTICE
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General Information - General Information
General Information 1-
Warning/Caution Lable Locations (Cont'd)
6
1. SRS WARNING
2. COOLANT INFORMATION
3. AIR CONDITIONING INFORMATION
4. RHD model:
5. TYRE INFORMATION
6. LHD model:
7. RADIATOR CAP CAUTION
8. BATTERY CAUTION
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General Information - General Information
List of automotive abbreviations, which may be used in shop manual. EPR Evaporator Pressure Regulator
ABS Anti-lock Brake System EPS Electrical Power Steering
A/C Air Conditioning, Air Conditioner EVAP Evaporative
ACL Air Cleaner EX Exhaust
A/F Air Fuel Ratio
ALR Automatic Locking Retractor F Front
ALT Alternator FIA Fuel Injection Air
AMP Ampere(s) FL Front Left
ANT Antenna FP Fuel Pump
API American Petroleum Institute FR Front Right
APPROX. Approximately FSR Fail Safe Relay
ASSY Assembly FWD Front Wheel Drive
A/T Automatic Transmission
ATDC After Top Dead Centre GAL Gallon
ATF Automatic Transmission Fluid GND Ground
ATT Attachment GPS Global Positioning System
ATTS Active Torque Transfer System
AUTO Automatic H/B Hatchback
AUX Auxiliary HC Hydrocarbons
HID High Intensity Discharge
BARO Barometric HO2S Heated Oxygen Sensor
BAT Battery
BDC Bottom Dead Centre IAB Intake Air Bypass
BTDC Before Top Dead Centre IAC Idle Air Control
IACV Idle Air Control Valve
CARB Carburettor IAR Intake Air Resonator
CAT Catalytic Converter IAT Intake Air Temperature
or CATA ICM Ignition Control Module
CHG Charge ID Identification
CKF Crankshaft Speed Fluctuation ID or I.D. Inside Diameter
CKP Crankshaft Position IG or IGN Ignition
CO Carbon Monoxide IMA Idle Mixture Adjustment
COMP Complete Integrated Motor Assist
CPB Clutch Pressure Back up IMMOBI. Immobilizer (Immobiliser)
CPC Clutch Pressure Control IN Intake
CPU Central Processing Unit INJ Injection
CVT Continuously Variable Transmission INT Intermittent
CYL Cylinder
CYP Cylinder Position KS Knock Sensor
Specifications
Design Specifications
Dimensions 2-18
Weight 2-18
Engine 2-18
Starter 2-19
Clutch 2-19
Manual Transmission 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
Alternator belt Deflection with 98 N (10 kgf, 22 lbs) applied Without A/C (with A/C, see Used belt: 8.5-11.0 mm (0.33-0.43 in.)
NOTE: Adjust a new belt midway between pulleys "Compressor belt" in the A/C table)
New belt: 6.5-8.5 mm (0.26-0.33 in.)
to the new belt spec., run
the engine for 5 minutes, Tension (measured with belt tension gauge) Without A/C (with A/C, see Used belt: 340-490 N (35-55 kgf, 77-110 lbs)
then readjust it to the "Compressor belt" in the A/C table)
used belt spec. New belt: 540-740 N (55-75 kgf, 120-170 lbs)
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Specifications - Standards and Service Limits
Engine Assembly
Item Measurement Qualification Standard or New Service Limit
Compression Pressure check at 250 rpm (min-1) with wide Minimum 930 kPa (9.5 kgf/cm2, 135 psi) -
open throttle. (See Design Specs for ratio.)
Maximum variation 200 kPa (2.0 kgf/cm2, 28 psi) -
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Specifications - Standards and Service Limits
Valve Springs Free length for D14Z6 engine Intake 58.70 mm (2.311 in.) -
Exhaust 58.70 mm (2.311 in.) -
Free length for D16V1, D16V3 engines VTEC intake 56.49 mm (2.224 in.) -
VTEC exhaust 58.70 mm (2.311 in.) -
Valve guides I.D. Intake 5.51-5.53 mm 5.55 mm (0.219 in.)
(0.217-0.218 in.)
Exhaust 18.65-19.15 mm -
(0.734-0.754 in.)
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Specifications - Standards and Service Limits
Crankshaft bearings Main bearing-to-journal oil clearance for D14Z6 No. 1 journal 0.018-0.036 mm (0.0007-0.0014 in.) 0.05 mm (0.002 in.)
engine No. 5 journal
No. 2 journal 0.020-0.038 mm (0.0008-0.0015 in.) 0.05 mm (0.002 in.)
No. 3 journal
No. 4 journal
Main bearing-to-journal oil clearance for D16V1, No. 1 journal 0.018-0.036 mm (0.0007-0.0014 in.) 0.05 mm (0.002 in.)
D16V3 engines No. 5 journal
No. 2 journal 0.024-0.042 mm (0.0009-0.0017 in.) 0.05 mm (0.002 in.)
No. 3 journal
No. 4 journal
Rod bearing clearance 0.024-0.042 mm (0.0009-0.0017 in.) 0.05 mm (0.002 in.)
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Specifications - Standards and Service Limits
Cooling
Item Measurement Qualification Standard or New Service Limit
Radiator Coolant capacity (Includes engine, heater, hoses M/T: engine overhaul 5.1 l (5.4 US qt, 4.5 Imp qt)
and reservoir)
M/T: coolant change 4.0 l (4.2 US qt, 3.5 Imp qt)
A/T: engine overhaul 5.0 l (5.3 US qt, 4.4 Imp qt)
A/T: coolant change 3.9 l (4.1 US qt, 3.4 Imp qt)
Reservoir Coolant capacity 0.4 l (0.4 US qt, 0.4 Imp qt)
Radiator cap Opening pressure 93-123 kPa (0.95-1.25 kgf/cm2, 14-18 psi)
Thermoswitch "OFF" temperature Subtract 3-8°C (5-15°F) from actual "ON" temperature
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Specifications - Standards and Service Limits
Engine idle Idle speed with headlights and radiator fan off M/T in neutral 700+50 rpm
A/T in or 700+50 rpm
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.) -
Clutch disc Rivet head depth 1.2-1.7 mm (0.047-0.067 in.) 0.2 mm (0.01 in.)
Thickness 8.3-9.0 mm (0.33-0.35 in.) 5.7 mm (0.22 in.)
Pressure plate Warpage 0.03 mm (0.001 in.) max. 0.15 mm (0.006 in.)
Height of diaphragm spring fingers Measure with feeler gauge and 0.6 mm (0.02 in.) max. 1.0 mm (0.04 in.)
special tool
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Specifications - Standards and Service Limits
Length A 51.97-52.03 mm -
(2.046-2.048 in.)
B 24.03-24.06 mm -
(0.946-0.947 in.)
Synchro ring Ring-to-gear clearance Ring pushed against gear 0.85-1.10 mm 0.4 mm
(0.033-0.043 in.) (0.016 in.)
Dual cone synchro Outer synchro ring-to-synchro cone clearance Ring pushed against gear 0.5-1.0 mm 0.3 mm
(0.02-0.04 in.) (0.01 in.)
Outer synchro ring-to-gear cone clearance Ring pushed against gear 0.95-1.68 mm 0.6 mm
(0.037-0.066 in.) (0.02 in.)
I.D. 18.042-18.066 mm -
(0.7103-0.7113 in.)
4th clutch pressure At 2,000 rpm (min-1) in 850-900 kPa 800 kPa
position (8.7-9.2 kgf/cm2, 120-130 psi) (8.2 kgf/cm2, 120 psi)
3rd clutch pressure At 2,000 rpm (min-1) in 850-900 kPa 800 kPa
position (8.7-9.2 kgf/cm2, 120-130 psi) (8.2 kgf/cm2, 120 psi)
2nd clutch pressure At 2,000 rpm (min-1) in 850-900 kPa 800 kPa
position (8.7-9.2 kgf/cm2, 120-130 psi) (8.2 kgf/cm2 120 psi)
1st clutch pressure At 2,000 rpm (min-1) in 880-930 kPa 830 kPa
position (9.0-9.5 kgf/cm2, 120-130 psi) (8.5 kgf/cm2, 120 psi)
1st-hold clutch pressure At 2,000 rpm (min-1) in 880-930 kPa 830 kPa
position (9.0-9.5 kgf/cm2, 120-130 psi) (8.5 kgf/cm2, 120 psi)
Torque converter Stall speed Check with vehicle on level ground D14Z6 engine 2,550 rpm (min-1) 2,400-2,700 rpm (min-1)
D16V1, D16V3 engines 2,800 rpm (min-1) 2,650-2,950 rpm (min-1)
Valve body Stator shaft needle bearing contact I.D. Torque converter side 27.000-27.021 mm (1.063-1.064 in.) When worn or damaged
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
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
1st-hold 0.5-0.8 mm
(0.020-0.031 in.)
Clutch return spring free length 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.)
Clutch disc thickness 1.94 mm (0.076 in.) -
Clutch plate thickness 1st, 1st-hold 1.6 mm (0.06 in.) When discoloured
2nd, 3rd and 4th 2.0 mm (0.079 in.) When discoloured
1st, 2nd, 3rd and 4th clutches end plate Mark 1 2.1 mm (0.083 in.) When discoloured
thickness
Mark 2 2.2 mm (0.087 in.) When discoloured
Mark 3 2.3 mm (0.091 in.) When discoloured
Mark 4 2.4 mm (0.094 in.) When discoloured
Mark 5 2.5 mm (0.098 in.) When discoloured
Mark 6 2.6 mm (0.102 in.) When discoloured
Mark 7 2.7 mm (0.106 in.) When discoloured
Mark 8 2.8 mm (0.110 in.) When discoloured
Mark 9 2.9 mm (0.114 in.) When discoloured
1st-hold clutch end plate thickness Mark 1 2.1 mm (0.083 in.) When discoloured
Mark 2 2.2 mm (0.087 in.) When discoloured
Mark 3 2.3 mm (0.091 in.) When discoloured
Mark 4 2.4 mm (0.094 in.) When discoloured
No Mark 2.5 mm (0.098 in.) When discoloured
Mark 6 2.6 mm (0.102 in.) When discoloured
Mark 7 2.7 mm (0.106 in.) When discoloured
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Specifications - Standards and Service Limits
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Specifications - Standards and Service Limits
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Specifications - Standards and Service Limits
Sub-shaft Diameter of needle bearing contact area at transmission housing 25.991-26.000 mm When worn or damaged
(1.023-1.024 in.)
1st-clutch feed pipe O.D. at 15 mm (0.6 in.) from end 7.97-7.98 mm 7.95 mm (0.313 in.)
(0.3138-0.3142 in.)
Regulator valve body Stator reaction spring 4.5 mm 35.4 mm 30.3 mm 1.9
springs, refer to the '01 (0.177 in.) (1.394 in.) (1.193 in.)
Civic Shop Manual on
this CD (see page 14- Regulator valve spring A 1.9 mm 14.7 mm 77.4 mm 15.2
186) (0.075 in.) (0.579 in.) (3.047 in.)
Servo body springs (see 1st accumulator spring 2.1 mm 16.0 mm 89.1 mm 16.2
page 14-94) (0.083 in.) (0.630 in.) (3.508 in.)
Lock-up valve body Lock-up shift valve spring 0.9 mm 7.6 mm 73.7 mm 32.0
springs, refer to the Civic (0.035 in.) (0.299 in.) (2.902 in.)
Shop Manual on this CD
(see page 14-189) Lock-up timing valve spring 0.9 mm 8.1 mm 80.7 mm 54.2
(0.035 in.) (0.319 in.) (3.177 in.)
I.D. 18.042-18.066 mm -
(0.7103-0.7113 in.)
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Specifications - Standards and Service Limits
Suspension
Item Measurement Qualification Standard or New Service Limit
Wheel alignment Camber Front 0°00'+45°
Rear -0°45'+45'
Caster Front 1°33'+1°
Total Toe Front 0+3 mm (0+0.12 in.)
Rear Adjust: IN 2+2-1 mm (0.08+0.08-0.04 in.)
Inspect: IN 2+3 mm (0.08+0.12 in.)
Front wheel turning angle Inside wheel 40°00'+2°
Outside wheel 31°00' (Reference)
Aluminium wheel Runout Axial 0-0.7 mm (0-0.03 in.) 2.0 mm (0.08 in.)
Radial 0-0.7 mm (0-0.03 in.) 1.5 mm (0.06 in.)
Steel wheel Runout Axial 0-1.0 mm (0-0.04 in.) 2.0 mm (0.08 in.)
Radial 0-1.0 mm (0-0.04 in.) 1.5 mm (0.06 in.)
Wheel bearings End play Front 0-0.05 mm (0-0.002 in.)
Rear 0-0.05 mm (0-0.002 in.)
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Specifications - Standards and Service Limits
Air Conditioning
Item Measurement Qualification Standard or New
Refrigerant Type HFC-134 a (R-134 a)
Compressor belt NOTE: Deflection with 98 N (10 kgf, 22 lbs) applied mid- Used belt: 8.5-11.0 mm (0.33-0.43 in.)
Adjust a new belt to the way between pulleys
new belt spec., run the New belt: 5.0-6.5 mm (0.20-0.26 in.)
engine for 5 minutes, Tension (measured with belt tension gauge) Used belt: 440-590 N (45-60 kgf, 100-130 lbs)
then readjust it to the
used belt spec. New belt: 930-1,125 N (95-115 kgf, 210-255 lbs)
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Specifications - Design Specifications
Design Specifications 2-
18
Item Measurement Qualification Specification
DIMENSIONS Overall length 4,285 mm (168.7 in.)
Overall width 1,695 mm (66.7 in.)
Overall height without roof antenna 1,495 mm (58.9 in.)
with roof antenna 1,585 mm (62.2 in.)
Wheelbase KE, KG, KR, KS models (MPW 2,685 mm (105.7 in.)
condition)
KY model 2,680 mm (105.5 in.)
Track Front KE, KG, KR, KS models 1,472 mm (58.0 in.)
(MPW condition)
Front KY model 1,470 mm (57.9 in.)
Rear KE, KG, KR, KS models 1,489 mm (58.6 in.)
(MPW condition)
Rear KY model 1,470 mm (57.9 in.)
Ground clearance 104 mm (4.10 in.)
Seating capacity Five (5)
WEIGHT Curb Weight (M/T) 1,130-1,195 kg (2,491-2,634 lbs)
(A/T) 1,164-1,1221 kg (2,566-2,692 lbs)
Max. permissible Weight European models 1,620-1,660 kg (3,570-3,660 lbs)
ENGINE Type D14Z6 engine Water-cooled, 4-stroke SOHC engine
D16V1, D16V3 engines Water-cooled, 4-stroke SOHC VTEC engine
Cylinder arrangement Inline 4-cylinder, transverse
Bore and stroke D14Z6 engine 75 x 79 mm (2.95 x 3.11 in.)
D16V1, D16V3 engines 75 x 90 mm (2.95 x 3.54 in.)
Displacement D14Z6 engine 1,396 cm3 (85 cu in.)
D16V1, D16V3 engines 1,590 cm3 (97 cu in.)
Compression ratio D14Z6 engine 10.4
D16V1 engine 9.4
D16V3 engine 10.4
Valve train D14Z6 engine Belt driven, SOHC 4 valves per cylinder
D16V1, D16V3 engines Belt driven, SOHC VTEC 4 valves per cylinder
Lubrication system Forced, wet sump, with trochoid pump
Oil pump displacement at 6,000 engine rpm (min-1) 36.4 l (38.5 US qt, 32.0 imp qt) per minute
Water pump displacement at 6,000 engine rpm (min-1) 130 l (137 US qt, 114 imp qt)/minute
Fuel required KE, KG, KR, KS models UNLEADED gasoline with 95 research octane number or higher
KY model LEADED gasoline with 91 research octane number or higher (RON of 91 UNLEADED gasoline may also
be used)
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Design Specification
Design Specification 2-
(cont'd)
19
Item Measurement Qualification Specification
STARTER Type Gear reduction
Normal output 0.8 kW, 1.0 kW
Hour rating 30 seconds
Direction of rotation Clockwise as viewed from gear end
CLUTCH Clutch M/T Single plate dry, diaphragm spring
A/T Torque converter
Clutch friction material surface area M/T 176 cm2 (102 sq in.)
MANUAL TRANSMISSION Type Synchronised, 5-speed forward, 1 reverse
Primary reduction Direct 1:1
Gear ratio 1st 3.461
2nd 1.869
3rd 1.241
4th 0.969
5th 0.805
Reverse 3.230
Final reduction Type Single helical gear
Gear ratio 4.411
AUTOMATIC Type Electronically controlled automatic, 4-speed forward, 1 reverse
TRANSMISSION
Primary reduction Direct 1:1
Gear ratio 1st 2.722
2nd 1.468
3rd 0.975
4th 0.673
Reverse 1.954
Final reduction Type Single helical gear
Gear ratio 4.357
STEERING Type 4-door Rack and pinion, with electrical power assistance
Overall ratio 14.49
Turns, lock-to-lock 2.83
Steering wheel diameter 380 mm (15.0 in.)
SUSPENSION Type Strut
Rear Double wishbone
Shock absorber Front and rear Telescopic, hydraulic, nitrogen gas-filled
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Specifications - Design Specifications
Design Specifications 2-
(cont'd)
20
Item Measurement Qualification Specification
WHEEL ALIGNMENT Camber Front 0°
Rear -0°45'
Caster Front 1°33'
Total toe Front 0 mm (0 in.)
Rear In 2 mm (1/16 in.)
BRAKE Type of service brake Front Power-assisted self-adjusting ventilated disc
Rear Power-assisted self-adjusting solid disc or drum
Type of parking brake Mechanical actuating, rear wheels
Pad friction surface area Front 35 cm2 x 2 (5.4 sq in. x 2)
Rear 67 cm2 x 2 (10.3 sq in. x 2)
Shoe friction surface area Rear 24 cm2 x 2 (4.2 sq in. x2)
TYRES Size of front, rear and Spare for KE model 1.4S, 1.4SE 185/70R14 88H
1.4SE Executive, 1.6S, 1.6SE, 195/60R15 88H
1.6SE Executive
Size of front and rear for KG, KR, KS model 1.4S, 1.4LS 185/70R 14 88H
1.6S, 1.6LS, 1.6ES 195/60R 15 88H
Size of spare for KG, KR, KS models T125/70D15 95M
Size of front, rear and spare for KY model 195/60R15 88H
AIR CONDITIONING Cooling capacity 3,870 kcal/h (15,400 BTU/h)
Compressor Type/manufacturer Scroll/SANDEN
Number of cylinders -
Capacity 85.7 ml/rev. (5.23 cu in./rev.)
Maximum speed 12,000 rpm
Lubricant capacity 130 ml (4 1/3 fl oz)
Lubricant type SP-10 (P/N 38897-P13-003, 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)
Temperature clutch Air-mix type
Compressor clutch Type Dry, single plate, poly-V belt drive
Electrical power consumption at 42 W maximum at 12 V
20°C (68°F)
Refrigerant Type HFC-134a (R-134a)
Quantity 500-550 g (17.5-19.5 oz)
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Specifications - Design Specifications
Design Specifications 2-
(cont'd)
21
Item Measurement Qualification Specification
ELECTRICAL RATINGS Battery 12 V-36 AH/5 hours
12 V - 45 AH/20 hours
Starter 12 V - 0.8 kW, 1.0 kW
Alternator 12 V - 70 A
Fuses Under-hood fuse/relay box 80 A, 40 A, 30 A, 20 A, 15 A, 7.5 A
Under-dash fuse/relay box 20 A, 15 A, 10 A, 7.5 A
Light bulbs Headlight high beam 12 V - 60 W
Headlight low beam 12 V - 55 W
Front turn signal/Front side marker 12 V - 21 W/5 W
lights
Front position lights 12 V - 5 W/3 CP (candlepower)
Side turn signal lights 12 V - 5 W
Rear turn signal lights 12 V - 21 W
Brake/Taillights/Rear side marker 12 V - 21W/5 W
light
Rear for light 12 V - 21 W
Taillights 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, 5 W
Luggage area light (5-door) 12 V - 5 W
Individual map light 12 V - 8 W
Spotlights 14 V - 8 W
Gauge light 14 V - 1.4 W
Indicator light 12 V - 1.12 W
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Body Specifications
Body Specifications 2-
22
Unit: mm (in.)
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Maintenance - Maintenance
Maintenance
Lubricants 3-2
and Fluids
Maintenance 3-4
Schedule for
Normal
Conditions
(KE, KG, KR,
KS Models)
Maintenance 3-6
Schedule for
Severe
Conditions
(KE, KG, KR,
KS Models)
Maintenance 3-8
Schedule for
Normal
Conditions
(KY Model)
Maintenance 3-10
Schedule for
Severe
Conditions
(KY Model)
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Maintenance - Lubricants and Fluids
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.
*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.
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Maintenance - Maintenance Schedule for Normal Conditions
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.
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Maintenance - Maintenance Schedule for Normal Conditions
● Check the brake pad and disc thickness. Check for damage or cracks. (see page 19-3)*1
● Check the wheel cylinder for leaks.
● Check the brake linings for cracking, glazing, wear or contamination.
● Check the callipers for damage, leaks and tightness.
Use only DOT 3 or DOT 4 brake fluid. (We recommend Genuine Honda Brake Fluid.) Check that Brake fluid level is between the (see page 19-7)*1
upper and lower marks on the reservoir.
Check the parking brake operation. (see page 19-6)*1
-
Check the position of the headlight. (see page 22-114)*1
Check for road stability, noise, vibrations and dashboard operation. -
● Check for correct installation and position, check for cracks, deterioration rust and leaks. -
● Check tightness of screws, nuts and joints. If necessary, retighten.
Check rack grease and steering linkage. Check the boot for damage and leaking grease. (see page 17-5)*1
*1: Refer to the Shop manual on this CD: '01 CIVIC MAINTENANCE, REPAIR and CONSTRUCTION Code No. 62S5A00
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Maintenance - Maintenance Schedule for Severe Conditions
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 l
Replace air cleaner element l l l l l l l l l l
Inspect valve clearance Every 40,000 km (24,000 miles)
Replace fuel filter l
Replace spark plugs Every 40, 000 km (24, 000 miles)
Replace timing belt and inspect water pump l
Inspect and adjust drive belts l l l l l
Inspect idle speed l
Replace engine coolant 200,000 km (120,000 miles) or 120 months, thereafter every 100,000 km (60,000 miles) or 60 months
Replace transmission fluid Manual Transmission Every 60,000 km (36,000 miles) or 48 months
Automatic Transmission 60,000 km (36,000 miles) or 48 months, thereafter every 40,000 km (24,000 miles) or 24 months
Inspect front and rear brakes Every 10,000 km (6,000 miles) or 6 months
Replace brake fluid Every 36 months
Check parking brake adjustment l 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 l
Test drive (noise, stability, dashboard operation) l 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 l
All fluid levels and condition of fluid
Exhaust system
Fuel line and connections
Tyre condition
Follow the Severe Conditions Maintenance Schedule if the customer's vehicle MAINLY under one or more of the following conditions:
● Driving less than 8 km (5 miles) per trip or in freezing temperatures, driving less hen 16 km (10 miles) per trip.
● Driving in extremely hot over 35°C (95°F) conditions.
● Extensive idling of long periods of stop-and-go-driving.
● Trailer towing, driving with a car-top carrier or driving in mountainous conditions.
● Driving on muddy, dusty or de-iced roads.
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Maintenance - Maintenance Schedule for Severe Conditions
● Check the brake pad and disc thickness. Check for damage or cracks. (see page 19-3)*1
● Check the wheel cylinder for leaks.
● Check the brake linings for cracking, glazing, wear or contamination.
● Check the calipers for damage, leaks and tightness.
Use only DOT 3 or DOT 4 brake fluid. (We recommend Genuine Honda Brake Fluid.) Check that Brake fluid level is between the (see page 19-7)*1
upper and lower marks on the reservoir.
Check the parking brake operation. (see page 19-6)*1
-
Check the position of the headlight. (see page 22-114)*1
Check for road stability, noise, vibrations and dashboard operation. -
● Check for correct installation and position, check for cracks, deterioration rust and leaks. -
● Check tightness of screws, nuts and joints. If necessary, retighten.
Check rack grease and steering linkage. Check the boot for damage and leaking grease. (see page 17-5)*1
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 the Shop manual on this CD: '01 CIVIC MAINTENANCE, REPAIR and CONSTRUCTION Code No. 62S5A00
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Maintenance - Maintenance Schedule for Normal Conditions
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
Replace engine oil Every 5,000 km (3,000 miles) or 6 months
Replace engine oil filter Every 10,000 km (6,000 miles) or 6 months
Clean or replace cleaner element Every 20,000 km (12,000 miles)
Inspect valve clearance Every 20,000 km (12,000 miles)
Replace fuel filter l l l l l
Replace spark plugs Every 20,000 km (12,000 miles)
Replace timing belt and inspect water pump l l
Inspect and adjust drive belts l l l l l
Inspect idle speed l l l
200,000 km (120,000 miles) or 120 months, thereafter every 100,000 km (60,000 miles)
Replace engine coolant
or 60 months
Replace transmission fluid Manual Transmission l l
Automatic Transmission l l
Inspect front and rear brakes Every 100,000 km (60,000 miles) or 6 months
Replace brake fluid Every 36 months
Check parking brake adjustment l l l l l l
Rotate tyre (Check tyre inflation and condition at least once per month) Every 100,000 km (60,000 miles)
Visually inspect the following items:
Tie rod ends, steering gearbox and boots Every 10,000 km (6,000 miles) or 6 months
Suspension components
Driveshaft boots
Brake hoses and lines (including ABS) 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
● Check the brake pad and disc thickness. Check for damage or cracks. (see page 19-3)*1
● Check the wheel cylinder for leaks.
● Check the brake linings for cracking, glazing, wear or contamination.
● Check the calipers for damage, leaks and tightness
Use only DOT 3 or DOT 4 brake fluid. (We recommend Genuine Honda Brake Fluid.) Check that Brake fluid level is between the (see page 19-7)*1
upper and lower marks on the reservoir.
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. (see page 17-5)*1
*1: Refer to the Shop manual on this CD: '01 CIVIC MAINTENANCE, REPAIR and CONSTRUCTION Code No. 62S5A00
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Maintenance - Maintenance Schedule for Severe Conditions
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)
Inspect valve clearance Every 20,000 km (12,000 miles)
Replace fuel filter l l l l l
Replace spark plugs Every 20,000 km (12,000 miles)
Replace timing belt and inspect water pump l l
Inspect and adjust drive belts l l l l l
Inspect idle speed l l l
200,000 km (120,000 miles) or 120 months, thereafter every 100,000 km (60,000 miles)
Replace engine coolant
or 60 months
Replace transmission fluid Manual Transmission l l l
Automatic Transmission l l l l
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
Rotate tyre (Check tyre inflation and condition at least once per month) Every 100,000 km (60,000 miles)
Visually inspect the following items:
Tie rod ends, steering gearbox and boots Every 10,000 km (6,000 miles) or 6 months
Suspension components
Driveshaft boots
Brake hoses and lines (including ABS) 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:
● Driving less than 8 km (5 miles) per trip or, in freezing temperatures, driving less than 16 km (10 miles) per trip.
● Driving in extremely hot over 35°C (95°F) conditions.
● Extensive idling of long periods of stop-and-go-driving.
● Trailer towing, driving with a car-top carrier, or driving in mountainous conditions.
● Driving on muddy, dusty, or de-iced roads.
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Maintenance - Maintenance Schedule for Severe Conditions
● Check the brake pad and disc thickness. Check for damage or cracks. (see page 19-3)*1
● Check the wheel cylinder for leaks.
● Check the brake linings for cracking, glazing, wear or contamination.
● Check the calipers for damage, leaks and tightness.
Use only DOT 3 or DOT 4 brake fluid. (We recommend Genuine Honda Brake Fluid.) Check that Brake fluid level is between the (see page 19-7)*1
upper and lower marks on the reservoir.
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. (see page 17-5)*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.
*1: Refer to the Shop Manual on this CD: '01 CIVIC MAINTENANCE, REPAIR and CONSTRUCTION Code No. 62S5A00
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Engine Electrical - Engine Electrical
Engine Electrical
Starting System
Component Location Index 4-2
Circuit Diagram 4-3
Starter Circuit Troubleshooting 4-4
Starter Solenoid Test 4-6
Starter Performance Test 4-7
Starter Replacement 4-8
Starter Overhaul 4-9
Ignition System
Component Location Index 4-19
Circuit Diagram 4-20
Ignition Timing Inspection 4-21
Spark Plug Inspection 4-22
NOTE: Refer to the '01 Civic Shop Manual, P/N 62S5A00 on this CD, for items not included in this section.
Outline of Model Change
D14Z6, D16V1 and D16V3 engines have been added.
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Engine Electrical - Engine Electrical
Engine Electrical 4-
Component Location Index
2
1. UNDER DASH FUSE/RELAY BOX
2. STARTER CUT RELAY (A/T)
Test, page 22-32
in the '01 Civic Shop Manual on this CD
3. STARTER
Starter Circuit Troubleshooting page 4-4
Solenoid Test, page 4-6
Performance Test, page 4-7
Replacement, page 4-8
Overhaul, page 4-9
4. TRANSMISSION RANGE SWITCH (A/T)
Test 4-door, page 14-160
in the '01 Civic Shop Manual on this CD
Replacement, page 14-161
in the '01 Civic Shop Manual on this CD
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Engine Electrical - Starting System
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Engine Electrical - Starting System
NOTE: 4. Check the battery condition. Check electrical connections at the battery and the
● Air temperature must be between 15o and 38oF (59o and 100oF) during this starter for looseness and corrosion. Then check the starter again.
Did the starter crank the engine?
procedure.
● After this test, or any subsequent repair, reset the Engine Control Module (ECM)/ YES - The starting system is OK.
Powertrain Control Module (PCM) to clear any Diagnostic Trouble Codes (DTCs) NO - Go to step 5.
for except KY model (see page 11-3) or KY model (see page 11-51).
5. Make sure the transmission is in neutral, then disconnect the BLK/WHT wire (A)
Recommended Procedure: from the starter solenoid (B). Connect a jumper wire from the battery positive
● Use a starter system tester. terminal to the solenoid terminal.
● Connect and operate the equipment in accordance with the manufacturer's Except D16V1 (KG, KR, KS models) engine with M/T
instructions.
Alternate Procedure
1. Hook up the following equipment:
● Ammeter, 0 - 400 A
2. Remove the No. 46 (15 A) fuse from the under-dash fuse/relay box.
3. With the shift lever in or (A/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 Did the starter crank the engine?
torque converter ring gear when you release the key, check for the following until YES - Go to step 6.
you find the cause.
NO - Remove the starter, and diagnose its internal problems.
● Solenoid plunger and switch malfunction
● Dirty drive gear or damaged overrunning clutch
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Engine Electrical - Starting System
6. Check the following items in the order listed until you find the open circuit.
● Check the BLK/WHT wire and connectors between the under-dash fuse/relay box
and the ignition switch and between the under-dash fuse/relay box and the starter.
● Check the ignition switch, refer to the '01 Civic Shop Manual on this CD (see page
22-83).
● Check the transmission range switch and connector (A/T).
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Engine Electrical - Starting System
1. Check the hold-in coil for continuity between the S terminal (A) and the armature
housing (ground).
There should be continuity.
● If there is continuity, go to step 2.
● If there is no continuity, replace the solenoid.
Except D16V1 (KG, KR, KS models) engine with M/T
2. Check the pull-in coil for continuity between the S terminal (A) and M terminal (B).
There should be continuity.
● If there is continuity, the solenoid is OK.
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Engine Electrical - Starting System
1. Disconnect the wires from the S terminal and the M terminal. 5. Disconnect the battery also 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.
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 Electric current Motor speed
DENSO 90 A or less 3,000 rpm (min-1) or more
(1.0 Kw)
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Engine Electrical - Starting System
1. Make sure you have the anti-theft code for the radio, then write down the D16V1 (KG, KR, KS models) engine with M/T
frequencies for the radio's preset buttons.
2. Disconnect the battery negative cable, then disconnect the positive cable and wait
at least 3 minutes.
3. Remove the resonator.
4. Disconnect the starter cable (A) from the B terminal on the solenoid, then
disconnect the BLK/WHT wire (B) from the S terminal.
Except D16V1 (KG, KR, KS models) engine with M/T
5. Remove the two bolts holding the starter, then remove the starter.
6. Install in the reverse order of removal. Make sure the crimped side of the ring
terminal (A) is facing out.
7. Connect the battery positive cable and negative cable to the battery.
8. Enter the anti-theft code for the radio, then enter the customer's radio station
presets.
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Engine Electrical - Starting System
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Engine Electrical - Starting System
Starting System 4-
Starter Overhaul (cont'd)
10
Disassembly/Reassembly - D16V1 (KY, KR, KS models) engine with A/T
1. STARTER SOLENOID
2. MOLYBDENUM DISULPHIDE
3. SOLENOID LEVER
4. GEAR HOUSING
5. OVERRUNNING CLUTCH
ASSEMBLY
6. ARMATURE
7. BRUSH HOLDER
8. END COVER
9. MOLYBDENUM DISULPHIDE
10. MOLYBDENUM DISULPHIDE
11. ARMATURE HOUSING
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Engine Electrical - Starting System
Starting System 4-
Starter Overhaul (cont'd)
11
Disassembly/Reassembly - D16V1 (KY, KR, KS models) engine with M/T
1. STARTER SOLENOID
2. OVERRUNNING CLUTCH
ASSEMBLY
3. MOLYBDENUM DISULPHIDE
4. SOLENOID LEVER
5. FRONT BEARING MOLYBDENUM
DISULPHIDE
6. GEAR HOUSING
7. SPRING CLIP
8. MOLYBDENUM DISULPHIDE
9. ARMATURE
10. BRUSH
11. INSULATOR
12. BRUSH SPRING
13. END COVER
14. ARMATURE HOUSING
15. GASKET
16. BRUSH HOLDER
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Engine Electrical - Starting System
Starting System 4-
Starter Overhaul (cont'd)
12
Armature Inspection and Test 5. Check the commutator diameter. If the diameter is below the service limit, replace
1. Remove the starter (see page 4-8). the armature (Except D16V1 (KG, KR, KS models) engine with M/T).
Commutator Diameter
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. Standard (New):27.9-28.0 mm (1.098-1.102 in.)
If there is wear or damage, replace the armature. Service Limit:27.0 mm (1.063 in.)
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) (Except D16V1 (KG, KR, KS models) engine with M/T).
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Engine Electrical - Starting System
Starting System 4-
Starter Overhaul (cont'd)
13
6. Measure the commutator (A) runout. 7. Check the mica depth (A). If the mica is too high (B), undercut the mica with a
● If the commutator runout is within the service limit, check the commutator for carbon hacksaw blade to the proper depth. Cut away all the mica (C) between the
dust or brass chips between the segments. commutator segments. The undercut should not be too shallow, too narrow, or V-
● If the commutator runout is not within the service limit, replace the armature. shaped (D).
Commutator Runout Commutator Mica Depth
D14Z6, D16V1 (KE model), D16V3 engines: Except D16V1 (KG, KR, KS models) engine with M/T:
Standard (New):0.05 mm (0.002 in.) max. Standard (New):0.50-0.75 mm (0.020-0.030 in.)
Service Limit:0.4 mm (0.02 in.) Service Limit:0.2 mm (0.008 in.)
D16V1 (KG, KR, KS models) engines with A/T: D16V1 (KG, KR, KS models) engine with M/T:
Standard (New):0.02 mm (0.001 in.) max. Standard (New):0.50-0.90 mm (0.020-0.035 in.)
Service Limit:0.05 mm (0.002 in.) Service Limit:0.2 mm (0.008 in.)
D16V1 (KG, KR, KS models) engine with M/T:
Standard (New):0.01 mm (0.0004 in.) max.
Service Limit:0.015 mm (0.0006 in.)
Except D16V1 (KG, KR, KS models) engine with M/T
8. Check for continuity between the segments of the commutator. If an open circuit
exists between any segments, replace the armature.
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Engine Electrical - Starting System
Starting System 4-
Starter Overhaul (cont'd)
14
9. Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the Starter Brush Inspection
armature core. If the blade is attracted to the core or vibrates while the core is 11. Measure the brush length. If it is not within the service limit, replace the armature
turned, the armature is shorted. Replace the armature. housing assembly.
Brush Length
D16Z6, D16V1 (KE model), D16V3 engines:
Standard (New):9.7 - 10.3 mm (0.38 - 0.41 in.)
Service Limit:6.0 mm (0.24 in.)
D16V1 (KG, KR, KS models) engines with A/T:
Standard (New):14.0 - 14.5 mm (0.55 - 0.57 in.)
Service Limit:9.0 mm (0.35 in.)
D16V1 (KG, KR, KS models) engine with M/T:
Standard (New):18 mm (0.7 in.)
Service Limit:5 mm (0.2 in.)
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-
Starter Overhaul (cont'd)
15
Starter Field Winding Test (Except D16V1 (KG, KR, KS Starter Brush Holder Test (D16V1 (KG, KR, KS models)
models) engine with M/T) engine with A/T):
12. Check for continuity between the brushes (A). If there is no continuity, replace the 14. Check that there is no continuity between the (+) brush holder (A) and (-) brush
armature housing (B). holder (B). If there is continuity, replace the brush holder assembly.
D14Z6, D16V1 (KE model), D16V3 engines:
13. Check for continuity between each brush (A) and the armature housing (B). If
there is continuity, replace the armature housing.
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Engine Electrical - Starting System
Starting System 4-
Starter Overhaul (cont'd)
16
Overrunning Clutch Inspection D16V1 (KG, KR, KS models) engine with M/T:
16. Slide the overrunning clutch along the shaft.
Replace it, if it does not slide smoothly.
17. 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.
D14Z6, D16V1 (KE model), D16V3 engines:
18. If the starter drive gear (B) is worn or damaged, replace the overrunning clutch
assembly; the gear is not available separately.
Check the condition of the flywheel or torque converter ring gear if the starter drive
gear teeth are damaged.
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Engine Electrical - Starting System
Starting System 4-
Starter Overhaul (cont'd)
17
Starter Reassembly (D14Z6, D16V1 (KE model), D16V3 Starter Reassembly (D16V1 (KG, KR, KS models) engine
engines) with A/T)
19. Install the armature in the housing and install the brush holder. Then install the 22. Pry back each brush spring with a screwdriver, then position the brush about
each brush in the holder. halfway out of its holder and release the spring to hold it there.
NOTE: To seat new brushes, slip a strip of #500 or #600 sandpaper, with the grit
side up, between the commutator and each brush and smoothly rotate will be
sanded to the same contour as the commutator.
20. Compress the spring and install it in the brush holder.
23. Install the armature in the housing and install the brush holder. Next, pry back
each brush spring again and push the brush down until it seats against the
commutator, then release the spring against the end of the brush.
NOTE: To seat new brushes, slip a strip of #500 or #600 sandpaper, with the grit
side up, between the commutator and each brush and smoothly rotate will be
sanded to the same contour as the commutator.
21. Install the brush holder insulator (A) and end cover (B).
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Engine Electrical - Starting System
Starting System 4-
Starter Overhaul (cont'd)
18
24. Install the starter end cover (A) to retain the brush holder (B). Starter Reassembly (D16V1 (KG, KR, KS models) engine
with M/T)
25. Install the armature in the housing and install the brush holder.
26. Pry back each brush spring with a screwdriver. Install the brush (A) and insulator
(B) in the holder, then release the spring against the insulator.
NOTE: To seat new brushes, slip a strip of #500 or #600 sandpaper, with the grit
side up, between the commutator and each brush and smoothly rotate will be
sanded to the same contour as the commutator.
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Engine Electrical - Ignition System
Ignition System 4-
Component Location Index
19
1. SPARK PLUG
Inspection, page 4-22
2. IGNITION COIL
Troubleshooting, page 4-23
in the '01 Civic Shop Manual on this CD
Removal/Installation, page 4-24
in the '01 Civic Shop Manual on this CD
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Engine Electrical - Ignition System
Ignition System 4-
Circuit Diagram
20
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Engine Electrical - Ignition System
Ignition System 4-
Ignition Timing Inspection
21
1. Start the engine. Hold the engine at 3,000 rpm (min-1) with no load Shift lever in 5. Point the light toward the pointers (A) on the timing belt cover. Check the ignition
Park or Neutral, until the radiator fan comes on, then let it idle. timing under a no load conditions: headlights, blower fan, rear window defogger and
2. Check the idle speed and adjust it if necessary: air conditioner are not operating. If the ignition timing differs from the specification
● 5-door(KE model), refer to the '01 Civic Shop Manual on this CD (see page 11- below, replace the ECM/PCM (see page 11-3).
425). Ignition Timing:
● 5-door(except KE model), refer to the '01 Civic Shop Manual on this CD (see M/T:8o + 2o BTDC (RED mark (B)) during idling in neutral
page 11-560).
A/T:8o + 2o BTDC (RED mark (B)) during idling in or
3. Short the SCS terminal to ground:
● Using the SCS short connector (Except KY model), refer to the '01 Civic Shop
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Engine Electrical - Ignition System
Ignition System 4-
Spark Plug Inspection
22
1. Inspect the electrodes and ceramic insulator. 3. Replace the plug at the specified interval, or if the centre electrode is rounded (A).
Burned or worn electrodes may be caused by: Use only the spark plugs listed below.
● Advanced ignition timing Spark Plugs:
● Loose spark plug Engine Type Spark Plug Type
● Plug heat range too hot
● Insufficient cooling
D14Z6, D16V1 ZFR5J-11 (NGK)
Fouled plug may be caused by: ZFR6J-11 (NGK)
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).
1. Cracked insulator
2. Damaged gasket
3. Worn or deformed electrodes
❍ Improper gap
❍ Oil-fouling
❍ Carbon deposits
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.)
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Engine Mechanical - Engine Mechanical
Engine Mechanical
Engine Assembly
Special Tools 5-2
Engine Removal 5-3
Engine Installation 5-12
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 62S5A00 on this CD, for items not included in this section.
Outline of Model Change
D14X6, D16V1 and D16V3 engines have been added.
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Engine Mechanical - Engine Assembly
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Engine Mechanical - Engine Assembly
7. Remove the intake air duct (A) and ground cable (B).
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Engine Mechanical - Engine Assembly
8. Remove the clutch slave cylinder (A) and clutch line bracket mounting bolt (B) (M/ 10. Relieve fuel pressure (see page 11-48).
T). 11. Remove the evaporative emission (EVAP) canister hose.
9. Remove the shift cable (A) and select cable (B) (M/T).
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Engine Mechanical - Engine Assembly
12. Remove the brake booster vacuum hose. 13. Remove the passenger's dashboard lower cover (A), refer to the '01 Civic Shop
RHD models: Manual on this CD (see page 20-220).
14. Disconnect the engine control module (ECM)/powertrain control module (PCM)
connectors (B) and main wire harness connector (C).
RHD models:
LHD models:
LHD models:
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Engine Mechanical - Engine Assembly
15. Remove the harness clamps (A) and grommet (B), then pull the engine wire 16. Remove the throttle cable (A) by loosening the locknut (B), then slipping the cable
harness through the bulkhead. end out of the accelerator linkage. Take care not to bend the cable when removing
RHD models: it. Always replace any kinked cable with a new one.
17. Remove the alternator, refer to the '01 Civic Shop Manual on this CD (see page 4-
31).
LHD models:
18. Remove the air conditioning (A/C) hose bracket.
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Engine Mechanical - Engine Assembly
19. Remove the alternator lower bracket (A), then remove the A/C compressor (B) 24. Loosen the drain plug in the radiator, drain the engine coolant, refer to the '01
without disconnecting the A/C hose. Civic Shop Manual on this CD (see page 10-8).
25. Drain the transmission fluid:
● Manual transmission, refer to the '01 Civic Shop Manual on this CD (see page
13-3).
● Automatic transmission, refer to the '01 Civic Shop Manual on this CD (see
page 14-122).
26. Drain the engine oil (see page 8-3).
27. Disconnect the primary heated oxygen sensor (primary HO2S) connector (A) and
the secondary heated oxygen sensor (secondary HO2S) connector (B) (Except
D16V3 engine).
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Engine Mechanical - Engine Assembly
29. Remove the shift cable covers (A), then remove the shift control cable (B) (A/T). 32. Lower the hoist.
33. Remove the ground cable (A), upper radiator hose (B), lower radiator hose (C)
and heater hose (D).
30. Disconnect the suspension lower arm joints and stabiliser, refer to the '01 Civic
Shop Manual on this CD (see page 18-18).
31. Remove the drivehafts, refer to the '01 Civic Shop Manual on this CD (see page
16-3). Coat all precision finished surface with clean engine oil. Tie plastic bags
over the driveshaft ends.
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Engine Mechanical - Engine Assembly
34. Remove the heater hose. 35. Remove the ATF cooler hoses, then plug the ATF cooler hoses and lines (A/T).
RHD models:
LHD models:
36. Attach the engine tilt hanger set (commercially available tool for EU models) to
the engine as shown.
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Engine Mechanical - Engine Assembly
Engine Assembly 5-
Engine Removal (cont'd)
10
37. Remove the front mount mounting bolt. 39. Remove the transmission mount bracket mounting bolt/nuts.
M/T:
A/T:
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Engine Mechanical - Engine Assembly
Engine Assembly 5-
Engine Removal (cont'd)
11
40. Make sure the hoist brackets are positioned properly. Raise the hoist to full height. 42. Use a marker to make alignment marks on the reference lines (A) that align with
41. Remove the rear mount mounting bolts. the centres of the rear sub-frame mounting bolts (B).
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Engine Mechanical - Engine Assembly
Engine Assembly 5-
Engine Installation
12
1. Install the accessory brackets and tighten their bolts and nuts to the specified torques.
1. REAR STIFFENER
(D14Z6, D16V1 engines M/T)
2. REAR STIFFENER
(D14Z6, D16V1 engines A/T)
3. ENGINE MOUNT BRACKET
4. A/C COMPRESSOR BRACKET
5. STIFFENER
(D16V3 engine)
6. FRONT STIFFENER
(Except D16V3 engine)
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Engine Mechanical - Engine Assembly
Engine Assembly 5-
Engine Installation (cont'd)
13
2. Position the engine under the vehicle. Attach the chain hoist to the engine, then lift 4. Tighten the rear mount mounting bolts.
the engine into position in the vehicle.
Reinstall the mounting bolts/support nuts in the sequence given. Failure to follow
this sequence may cause excessive noise and vibration and reduce bushing life.
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-
Engine Installation (cont'd)
14
7. Tighten the transmission mount bracket mounting bolt/nuts. 8. Tighten the front mount mounting bolt.
M/T:
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Engine Mechanical - Engine Assembly
Engine Assembly 5-
Engine Installation (cont'd)
15
14. Install exhaust pipe A (A); use new gaskets (B) and new self-locking nuts (C). 17. Install the font tyres/wheels.
18. Lower the hoist.
19. Install the ATF cooler hoses (A/T).
15. Connect the primary HO2S connector (D) and the secondary HO2S connector (E)
(Except D16V3 engine).
16. Install the splash shield.
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Engine Mechanical - Engine Assembly
Engine Assembly 5-
Engine Installation (cont'd)
16
20. Install the heater hose. 21. Install the upper radiator hose (A), lower radiator hose (B), heater hose (C) and
RHD models: ground cable (D).
LHD models:
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Engine Mechanical - Engine Assembly
Engine Assembly 5-
Engine Installation (cont'd)
17
22. Install the A/C compressor (A), then install the alternator lower bracket (B). 24. Loosely install the alternator.
25. Adjust the alternator belt, refer to the '01 Civic Shop Manual on this CD (see page
4-38).
26. Push the ECM/PCM connectors through the bulkhead, then install the grommet
(A).
RHD models:
LHD models:
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Engine Mechanical - Engine Assembly
Engine Assembly 5-
Engine Installation (cont'd)
18
28. Connect the ECM/PCM connectors (A) and main wire harness connector (B). 30. Install the throttle cable, then adjust the cable, refer to the '01 Civic Shop Manual
RHD models: on this CD (see page 11-149).
31. Install the brake booster vacuum hose.
RHD models:
29. Install the passenger's dashboard lower cover (C), refer to the '01 Civic Shop
Manual on this CD (se page 20-220).
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Engine Mechanical - Engine Assembly
Engine Assembly 5-
Engine Installation (cont'd)
19
32. Install the EVAP canister hose. 34. Install the clutch slave cylinder (A) and clutch line bracket mounting bolt (B) (M/T).
33. Install the shift cable (A) and shift cable (B) using the plastic washer (C), washer
(D) and new cotter pins (E) (M/T).
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Engine Mechanical - Engine Assembly
Engine Assembly 5-
Engine Installation (cont'd)
20
37. Install the battery cable (A) on the under-hood fuse/relay box, then install the 39. Clean the battery posts and cable terminals with sandpaper, then assemble them
harness clamps (B). and apply grease to prevent corrosion.
40. Move the shift lever to each gear and verify that the A/T gear position indicator,
follows the transmission range switch (A/T).
41. Check that the transmission shifts into gear smoothly (M/T).
42. 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 two or three times, then check for fuel leakage at any
point in the fuel line.
43. Refill the engine with engine oil (see page 8-3).
44. Refill the transmission with fluid:
● Manual transmission, refer to the '01 Civic Shop Manual on this CD (see page
13-3).
● Automatic transmission, refer to the '01 Civic Shop Manual on this CD (see page
14-122).
45. 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-
38. Install the intake resonator. 8).
46. Check the wheel alignment, refer to the '01 Civic Shop Manual on this CD (see
page 18-4).
47. 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
Cylinder Head Removal 6-8
Rocker Arms and Shafts Disassembly/Reassembly 6-13
Rocker Arms and Shafts Inspection 6-15
Camshaft Inspection 6-16
Valve Inspection 6-18
Cylinder Head Installation 6-18
NOTE: Refer to the '01 Civic Shop Manual, P/N 62S5A00 on this CD, for the items not included in this section.
Outline of Model Change
D14Z6, D16V1 and D16V3 engines have been added.
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Engine Mechanical - Cylinder Head
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Component Location Index
3
1. HEAD COVER GASKET
2. CYLINDER HEAD COVER
3. CAMSHAFT PULLEY
4. TDC SENSOR
5. RUBBER SEAL
6. UPPER COVER
7. LOWER COVER
8. CRANKSHAFT PULLEY BOLT
Replacement, page 6-16
in the '01 Civic Shop Manual in the CD
9. CRANKSHAFT PULLEY
Replacement, page 6-16
in the '01 Civic Shop Manual in the CD
10. TIMING BELT
Removal, page 6-18
in the '01 Civic Shop Manual in the CD
Inspection, page 6-18
in the '01 Civic Shop Manual in the CD
Installation, page 6-22
in the '01 Civic Shop Manual in the CD
11. AUTO-TENSIONER
12. TIMING BELT DRIVE PULLEY
13. Install with concave surface facing in.
14. CKP SENSOR
15. SIDE ENGINE MOUNT BRACKET
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Component Location Index (cont'd)
4
1. GASKET
2. WATER PASSAGE
3. CYLINDER HEAD BOLT
4. DOWEL PIN
5. O-RING
6. CYLINDER HEAD GASKET
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Engine Mechanical - Cylinder Head
D14Z6 engine:
1. ROCKER ARM ASSEMBLY
Overhaul, page 6-13
Inspection, 6-15
2. DOWEL PIN
3. CAMSHAFT
Inspection, page 6-16
4. VALVE SPRING
5. SEAL
6. CAMSHAFT PULLEY
7. INTAKE VALVE SEAL
Replacement, page 6-42
in the '01 Civic Shop Manual in
the CD
8. VALVE GUIDE
Replacement, page 6-44
in the '01 Civic Shop Manual in
the CD
9. BACK COVER
10. RUBBER SEAL
11. EXHAUST VALVE
Removal, page 6-42
in the '01 Civic Shop Manual in
the CD
Installation, page 6-48
in the '01 Civic Shop Manual in
the CD
12. INTAKE VALVE
13. CYLINDER HEAD
Removal, page 6-8
Inspection, page 6-34
in the '01 Civic Shop Manual in
the CD
Installation, page 6-18
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. O-RING
22. CYLINDER HEAD PLUG
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Engine Mechanical - Cylinder Head
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Engine Mechanical - Cylinder Head
Special Tools Required 8. Check that the air pressure on the shop air compressor gauge
● Air Stopper, 07LAJ-PR30201 indicates over 400 kPa (4 kgf/cm2, 57 psi).
● Valve Inspection Set, 07LAJ-PR30101 9. Inspect the valve clearance, refer to the '01 Civic Shop manual on this
D16V1, D16V3 engines: CD (see page 6-14).
1. Remove the resonator (see step 5 on page 6-9). 10. Cover the timing belt with a shop towel to protect the belt.
11. Plug the relief hole with the air stopper.
2. 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).
3. Remove the throttle cable clamps and harness holder from the cylinder
head cover (see step 21 on page 6-11).
4. Remove the cylinder head cover (see step 22 on page 6-12).
5. Set the No. 1 piston at TDC, refer to the '01 Civic Shop manual on this
CD (see step 3 on page 6-18).
6. Verify that the intake secondary rocker arm (A) moves independently
of the intake primary rocker arm (B).
● If the intake secondary rocker arm does not move, remove the
13. Loosen the valve on the regulator and apply the specified air pressure: NOTE:
Specified Air Pressure: ● Use fender covers to avoid damaging painted surfaces.
250 kPa (2.5 kgf/cm2, 36 psi) ● To avoid damage, unplug the wiring connectors carefully while holding the
NOTE: If the synchronising piston does not move after applying air pressure, move connector portion.
the primary or secondary rocker arm up and down manually by rotating the ● To avoid damaging the cylinder head, wait until the engine coolant temperature
crankshaft counter-clockwise. drops below 38oC (100oF) before loosening the cylinder head bolts.
14. Move the intake secondary rocker arm (A) for the No. 1 cylinder. The primary ● Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not
rocker arm (B) and secondary rocker arm should move together. contact other wiring or hoses, or interfere with other parts.
● If the intake primary rocker arm does not move, remove the primary and
1. Make sure you have the anti-theft code for the radio, then write down the
secondary rocker arms as an assembly and check that the piston in the frequencies for the radio's preset buttons.
secondary and primary rocker arms move smoothly. If any rocker arm needs 2. Disconnect the battery negative terminal.
replacing, replace the primary and secondary rocker arms as an assembly and 3. Drain the engine coolant, refer to the '01 Civic Shop manual on this CD (see page
retest. 10-8).
4. Remove the throttle cable (A) by loosening the locknut (B), then slipping the cable
end out of the accelerator linkage. Take care not to bend the cable when removing
it. Always replace any kinked cable with a new one.
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Engine Mechanical - Cylinder Head
5. Remove the intake resonator. 7. Remove the brake booster vacuum hose (A) and positive crankcase ventilation
(PCV) hose (B).
6. Disconnect the intake air temperature (IAT) sensor connector (A) and remove the
breather hose, then remove the air cleaner housing (B).
8. Relieve fuel pressure (see page 11-48).
9. Remove the evaporative emission (EVAP) canister hose.
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Cylinder Head Removal (cont'd)
10
10. Remove the ground cable (A), upper radiator hose (B), lower radiator hose (C), 13. Remove the alternator, refer to the '01 Civic Shop manual on this CD (see page 4-
heater hose (D) and water bypass hose (E). 31).
14. Remove the air conditioning (A/C) hose bracket (A) and P/S hose bracket (B).
11. Remove the two bolts securing the connecting pipe, then remove the connecting 15. Remove the engine wire harness connectors and wire harness clamps from the
pipe (B) from the water passage. intake manifold.
● Idle air control (IAC) valve connector
engines)
● Engine coolant temperature (ECT) sensor connector
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Cylinder Head Removal (cont'd)
11
16. Support the engine with a jack and wood block under the oil pan. 19. Remove the intake manifold.
17. Remove the upper bracket.
18. Remove the cover (A), then remove the exhaust manifold (B).
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Cylinder Head Removal (cont'd)
12
22. Remove the cylinder head cover. 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:
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).
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Rocker Arms and Shafts Disassembly/
Reassembly
13
NOTE:
● Identify parts as they are removed to ensure reinstallation in original location.
● Inspect the rocker shafts and rocker arms (see page 6-15).
● 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.
D14Z6 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" in stamped on the rocker
arm
13. SPRING
14. EXHAUST ROCKER ARM A
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-
Rocker Arms and Shafts Disassembly/
Reassembly (cont'd)
14
NOTE:
● Identify parts as they are removed to ensure reinstallation in original location.
● Inspect the rocker shafts and rocker arms (see page 6-15).
● 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.
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Rocker Arms and Shafts Inspection
15
1. Measure the diameter of the shaft at the first rocker location. 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.)
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 set).
5. Inspect the synchronising piston (A). Push it manually. If it does not move smoothly,
replace the rocker arm assembly(D16V1, D16V3 engines).
NOTE:
● When reassembling the primary rocker arm (B), carefully apply air pressure to its
oil passage.
● Apply oil to the pistons when reassembling.
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Camshaft Inspection
16
NOTE: 4. Unscrew the camshaft holder bolts 2 turns at a time, in a criss-cross pattern. Then
● Do not rotate the camshaft during inspection. remove the camshaft holders from the cylinder head.
● Remove the rocker arms and rocker shafts. 5. Lift the camshaft out of the cylinder head, wipe them clean, then inspect the lift
1. Put the camshaft and the camshaft holders on the cylinder head, then tighten the ramps. Replace the camshaft if any lobes are pitted, scored, or excessively worn.
bolts to the specified torque. 6. Clean the camshaft journal surfaces in the cylinder head, then set the camshaft
Specified torque: back in place. Place a plastigage strip across each journal.
7. Install the camshaft holders, then tighten the bolts to the specified torque as shown
8 mm bolts:20 Nm (2.0 kgf/m, 14 lbf/ft)
in step 1.
Apply engine oil to the bolt threads. 8. Remove the camshaft holders. Measure the widest portion of plastigage on each
6 mm bolts:12 Nm (1.2 kgf/m, 8.7 lbf/ft) journal.
Apply engine oil to the bolt threads. ● 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
6 mm bolts:(11), (12), (13), (14)
has been replaced, replace the cylinder head.
● If the camshaft-to-holder clearance is beyond the service limit and the camshaft
2. Seat the camshaft by pushing it away from the camshaft pulley end of the cylinder
head.
3. Zero the dial indicator against the end of the camshaft, then push the camshaft
back and forth and read the end play.
Camshaft End Play:
Standard (New):0.05 - 0.15 mm
(0.002 - 0.006 in.)
Service Limit:0.5 mm (0.02 in.)
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Camshaft Inspection (cont'd)
17
9. Check the total runout with the camshaft supported on V-blocks. 10. Measure cam lobe height.
● If the total runout of the camshaft is within the service limit, replace the cylinder Cam Lobe Height Standard (New):
head.
INTAKE EXHAUST
● If the total runout is beyond the service limit, replace the camshaft and recheck
the camshaft-to-holder oil clearance. If the oil clearance is still out of tolerance, D14Z6 engine 34.158 mm 36.488 mm
replace the cylinder head. (1.3448 in.) (1.4365 in.)
Camshaft Total Runout: D16V1, D16V3 engines PRI 38.427 mm 38.784 mm
Standard (New):0.03 mm (0.001 in.) max. (1.5129 in.) (1.5269 in.)
Service Limit:0.04 mm (0.002 in.) SEC 32.848 mm
(1.2932 in.)
PRI: PrimarySEC: Secondary
IN: IntakeEX: ExhaustT/B: Timing Belt
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Engine Mechanical - Cylinder Head
Measure the valve in these areas. Install the cylinder head in the reverse order of removal:
D14Z6, D16V1 engines: 1. Clean the cylinder head and block surface.
Intake Valve Dimensions 2. Install the cylinder head gasket (A) and dowel pins (B) on
the cylinder block. Always use a new cylinder head gasket.
A Standard (New):29.90 - 30.10 mm
(1.177 - 1.185 in.)
B Standard (New):118.17 - 118.97 mm
(4.652 - 4.684 in.)
C Standard (New):5.480 - 5.490 mm
(0.2157 - 0.2161 in.)
C Service Limit:5.45 mm (0.215 in.)
Exhaust Valve Dimensions
A Standard (New):25.60 - 26.10 mm
(1.020 - 1.028 in.)
B Standard (New):115.55 - 116.35 mm
(4.549 - 4.581 in.)
C Standard (New):5.450 - 5.460 mm
(0.2146 - 0.2150 in.)
C Service Limit:5.42 mm (0.213 in.)
D16V3 engine:
3. Set the crankshaft to TDC. Align the TDC mark (A) on the
Intake Valve Dimensions timing belt drive pulley with the pointer (B) on the oil pump.
A Standard (New):29.90 - 30.10 mm
(1.177 - 1.185 in.)
B Standard (New):118.27 - 118.87 mm
(4.656 - 4.680 in.)
C Standard (New):5.480 - 5.490 mm
(0.2157 - 0.2161 in.)
C Service Limit:5.45 mm (0.215 in.)
Exhaust Valve Dimensions
A Standard (New):25.90 - 26.10 mm
(1.020 - 1.028 in.)
B Standard (New):115.65 - 116.25 mm
(4.553 - 4.577 in.)
C Standard (New):5.450 - 5.460 mm
(0.2146 - 0.2150 in.)
C Service Limit:5.42 mm (0.213 in.)
Cylinder Head 6-
Cylinder Head Installation (cont'd)
19
4. Clean the camshaft pulley and set it to TDC. 6. Apply engine oil to the bolt threads and under the bolt heads of all the cylinder head
1. The ''UP'' mark (A) on the camshaft pulley should be at the top. bolts.
2. Align the TDC marks (B) on the camshaft pulley with the top edge of the head. 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:
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Cylinder Head Installation (cont'd)
20
8. Install the timing belt, refer to the '01 Civic Shop Manual on this CD (see page 6-22). 13. Install the new exhaust manifold gasket (A) and exhaust manifold (B). Loosely
9. Adjust the valve clearance, refer to the '01 Civic Shop Manual on this CD (see page install the new nuts, then install the cover (C) and loosely install the new bolts.
6-14).
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 crisscross pattern in 2
or 3 steps, beginning with the inner nut. Always use a new intake manifold gasket
(B).
12. Tighten the three bolts (C) securing the intake manifold and brackets.
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Cylinder Head Installation (cont'd)
21
17. Loosely install the alternator. 21. Install the ground cable (A), upper radiator hose (B), lower radiator hose (C),
18. Adjust the alternator belt tension, refer to the '01 Civic Shop Manual on this CD heater hose (D) and water bypass hose (E).
(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. Install the connecting pipe (A) with new O-ring (B).
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Engine Mechanical - Cylinder Head
Cylinder Head 6-
Cylinder Head Installation (cont'd)
22
23. Install the brake booster vacuum hose (A) and PCV hose (B). 25. Install the intake resonator.
24. Install the air cleaner housing (A), then connect the IAT sensor connector (B) and
breather hose. 26. Install the cruise control cable, then adjust the cable, refer to the '01 Civic Shop
Manual on this CD (see page 11-449).
27. After installation, check that all tubes, hoses and connectors are installed correctly.
28. Clean the battery posts and cable terminals with sandpaper, then assemble them
and apply grease to prevent corrosion.
29. 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.
30. 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).
31. 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
D14Z6, D16V1 and D16V3 engines have been added.
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Engine Mechanical - Engine Block
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Engine Mechanical - Engine Block
Engine Block 7-
Component Location Index
3
1. DRAIN BOLT
2. WASHER
3. OIL PAN
Installation for Aluminium Oil Pan Type, page 7-24 in
the '01 Civic Shop Manual on this CD
4. FLYWHEEL (M/T)
5. THRUST WASHERS
6. CRANKSHAFT OIL SEAL, TRANSMISSION END
Installation, page 7-11
7. ENGINE BLOCK END COVER
8. DOWEL PIN
9. 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, page7-11
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 Oil Pan Type, page 7-25 in the '01
Civic Shop Manual on this CD
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Engine Mechanical - Engine Block
Engine Block 7-
Component Location Index (cont'd)
4
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 BEARINGS
Oil Clearance, page 7-7
Selection, page 7-7
6. CONNECTING ROD BEARING CAP
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
Main Bearing Clearance Inspection 5. Remove the cap and bearing half, and measure the widest part of the plastigage.
1. To check main bearing-to-journal oil clearance, remove the main caps and bearing Main Bearing-to-Journal Oil Clearance:
halves. D14Z6 engine
2. Clean each main journal and bearing half with a clean shop towel. Standard (New):
3. Place one strip of plastigauge across each main journal. No. 1, 5:0.018-0.036 mm
NOTE: If the engine is still in the car when you bolt the main cap down to check the
(0.0007-0.0014 in.)
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 No. 2, 3, 4:0.020-0.038 mm
an accurate reading, support the crank with a jack under the counterweights, and (0.0009-0.0017 in.)
check only one bearing at a time. Service Limit:0.05 mm
4. Reinstall the bearings and caps, then torque the bolts. Do not rotate the crankshaft. (0.002 in.)
Tightening torque: D16V1, D16V3 engines
D14Z6 engine:44Nm (4.5 kgf/m, 33 lbf/ft) Standard (New):
D16V1, D16V3 engines:51 Nm (5.2 kgf/m, 38 lbf/ft) 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:0.05mm
(0.002 in.)
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
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Engine Mechanical - Engine Block
Rod Bearing Clearance Inspection 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
1. Remove the connecting rod cap and bearing half.
the clearance. Do not file, shim, or scrape the bearings or the caps to adjust
2. Clean the crankshaft rod journal and bearing half with a clean shop towel.
clearance.
3. Place a strip of plastigauge across the rod journal.
7. If the plastigauge shows the clearance is still incorrect, try the next larger or
4. Reinstall the bearing half and cap, and torque the bolts to 32 Nm (3.3 kgf/m, 24 lbf/
smaller bearing (the colour listed above or below that one) and check clearance
ft). Do not rotate the crankshaft.
again. If the proper clearance cannot be obtained by using the appropriate larger or
5. Remove the rod cap and bearing half and measure the widest part of the
smaller bearings, replace the crankshaft and start over.
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.)
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Engine Mechanical - Engine Block
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
1. Using a ring expander (A), remove the old piston rings (B). 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. 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 2.0 mm (0.08 in.) wide (D14Z6, D16V1 4. Measure the piston ring end-gap (B) with a feeler gauge:
engines), 2.8 mm (0.11 in.) wide (D16V1 engine). ● 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
File down a blade if necessary.
limits, refer to the '01 Civic Shop Manual on this CD (see page 7-14).
Do not use a wire brush to clean the ring grooves, or cut the ring grooves deeper If the bore is over the service limit, the cylinder block must be rebored.
with cleaning tools.
Piston Ring End-Gap:
NOTE: If the piston is to be separated from the connecting rod, do not install new
Top Ring
rings yet.
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
D14Z6, D16V1 engines:
Standard (New):0.20 - 0.80 mm
(0.008 - 0.031 in.)
Service Limit:0.80 mm (0.031 in.)
D16V3 engine:
Standard (New):0.20 - 0.80 mm
(0.008 - 0.031 in.)
Service Limit:0.90 mm (0.035 in.)
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Engine Mechanical - Engine Block
Engine Block 7-
Piston Ring Replacement (cont'd)
10
5. Install the top ring (A) and second ring (B) as shown. The manufacturing marks (C) 6. Rotate the rings in their grooves to make sure they do not bind.
must be facing upward. 7. Position the ring end gaps as shown:
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Engine Mechanical - Engine Block
Engine Block 7-
Crankshaft Installation
11
Special Tools Required 10. Check the main bearing clearance with plastigauge (see page 7-5).
● Handle Driver, 07749-0010000 11. Install the bearing cap bridge. Coat the bolt threads with engine oil.
● Driver Attachment, 96 mm, 07948-SB00101 12. Torque the cylinder head bolts sequentially in 2 steps.
1. Apply engine oil to the main bearings and rod bearings. 1st step torque:25 Nm (2.5 kgf/m, 18 lbf/ft)
2. Install the bearing halves in the cylinder block and connecting rods. 2nd step torque:
3. Hold the crankshaft so rod journal No. 2 and rod journal No. 3 are straight up and D14Z6 engine:44 Nm (4.5 kgf/m, 33 lbf/ft)
lower the crankshaft into the block.
D16V1, D16V3 engines:
4. Install the thrust washers (A) on both edges of the No. 4 main bearing recess.
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:
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Engine Mechanical - Engine Block
Engine Block 7-
Crankshaft Installation (cont'd)
12
13. The seal mating surface on the engine block end cover should be dry. Apply a light 16. Clean and dry the engine block end cover mating surfaces.
coat of grease to the crankshaft and to the lip of the seal. 17. Apply liquid gasket, part No. 08C70-K0234M, 08C70-K0334M or 08C70-X0331S,
14. Drive the crankshaft oil seal squarely into the engine block end cover. 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.)
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-
Crankshaft Installation (cont'd)
13
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. 08C70-K0234M, 08C70-K0334M or 08C70-
X0331S, 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.
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 included in this section.
Outline of Model Change
D14Z6, D16V1 and D16V3 engines have been added.
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Engine Mechanical - Engine Lubrication
Engine Lubrication 8-
Component Location Index
2
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, page 7-24
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
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Engine Mechanical - Engine Lubrication
1. Warm up the engine. 4. Refill with the recommended oil (see page 3-2).
2. Remove the drain bolt (A) and drain the engine oil. Capacity
D14Z6, D16V1 engines: D14Z6, D16V1 engines:
3.3 l (3.5 US qt, 2.9 Imp qt) at oil change.
3.5 l (3.7 US qt, 3.1 Imp qt) at oil change.
including filter
4.2 l (4.4 US qt, 3.7 Imp qt) after engine overhaul.
D16V3 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.
5. Run the engine for more than 3 minutes then check for oil leakage.
D16V3 engine:
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Engine Mechanical - Engine Mechanical
Engine Mechanical
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
D14Z6, D16V1 and D16V3 engines have been added
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Engine Mechanical - Intake Manifold and Exhaust System
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Engine Mechanical - Intake Manifold and Exhaust System
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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: D16W7, D16V1 engines
*2: A/T
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
*1: A/T
*2: D16V1, D16W7 engines
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Fuel and Emissions - Fuel and Emissions Systems
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
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Fuel and Emissions - Fuel and Emissions Systems
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
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Fuel and Emissions - Fuel and Emissions Systems
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
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Fuel and Emissions - Fuel and Emissions Systems
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
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
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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 under-dash fuse/relay box. Wire side of female terminals
● A loose No. 20 IG (40A) fuse in the under-hood fuse/relay box.
8. Turn the ignition switch ON (II).
● A loose No. 6 ECU (ECM/PCM) (15A) fuse in the under-hood fuse/relay box.
Does the MIL come on for 2 seconds after the ignition switch is
● A loose No. 17 FUEL PUMP (15A) fuse in the under-dash fuse/relay box.
turned ON (II)?
● A poor connection at ECM/PCM terminal E31.
● An intermittent open in the GRN/ORN wire between the ECM/PCM (E31) and the
YES - Replace the inertia switch.
gauge assembly. NO - Go to step 9.
● An intermittent short in the wire between the ECM/PCM (A21) and the manifold 9. Turn the ignition switch OFF.
absolute pressure (MAP) sensor. 10. Turn the ignition switch ON (II).
● An intermittent short in the wire between the ECM/PCM (A20) and the throttle Is the low oil pressure light on?
position (TP) sensor, knock sensor, exhaust gas recirculation (EGR) valve
YES - Go to step 13.
position sensor.
● An intermittent short in the wire between the ECM/PCM (A8) and the knock
NO - Go to step 11.
sensor. 11. Inspect the No. 10 METER (7.5 A) fuse in the under-dash fuse/relay box.
2. Turn the ignition switch OFF. Is the fuse OK?
3. Press the inertia switch button. YES - Go to step 12.
4. Turn the ignition switch ON (II). NO - Repair short in the wire between No. 10 METER (7.5A) fuse and the gauge
Does the MIL come on for 2 seconds after the ignition switch is assembly. Also replace the No. 10 METER (7.5A) fuse.
turned ON (II)?
YES - Intermittent failure system is OK at this time.
NO - Go to step 5.
5. Turn the ignition switch OFF.
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Fuel and Emissions - PGM-FI System
21. Check for continuity between body ground and the PGM-FI main relay 14P
connector terminals No. 2 and No. 4 individually.
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Fuel and Emissions - PGM-FI System
● Injectors
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
● Knock sensor
NO - Substitute a known-good ECM/PCM and recheck, refer to the '01 Civic Shop
Manual on this CD (see page 11-313). If symptom/indication goes away, replace the
original ECM/PCM.
63. Measure voltage between body ground and ECM/PCM connector terminal A20. Wire side of female terminals
ECM/PCM CONNECTOR A (31P) Is there about 5 V?
YES - Replace the sensor that restored about 5 V when disconnected.
NO - Go to step 66.
66. Turn the ignition switch OFF.
67. Disconnect the 3P connectors from the following sensors.
● Exhaust gas recirculation (EGR) valve position sensor
● Knock sensor
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
3. Start the engine. Hold the engine at 3,000 rpm (min-1) with no load (in Park or
neutral) until the radiator fan comes on, then let it idle.
4. Turn the ignition switch OFF.
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Fuel and Emissions - Fuel Supply System
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Fuel and Emissions - Fuel Supply System
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Fuel and Emissions - Fuel Supply System
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Fuel and Emissions - Fuel Supply System
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Fuel and Emissions - Fuel Supply System
11. Disconnect the quick-connect fitting (A): Hold the connector (B) with one hand and
squeeze the retainer tabs (C) with the other hand to release them from the locking
pawls (D). Pull the connector off.
NOTE:
● Prevent the remaining fuel in the fuel feed pipe or hose from flowing out with a
rag or shop towel.
● Be careful not to damage the pipe (E) or other parts.
Do not use tools.
4. Start the engine and let it idle until it stalls.
●
If the connector does not move, keep the retainer tabs pressed down and
NOTE: The DTCs or Temporary DTCs P0301, P0302, P0303, P0304 may come on
●
alternately pull and push the connector until it comes off easily.
during this procedure. If any DTCs are stored, ignore them.
● Do not remove the retainer from the pipe; once removed, the retainer must be
5. Turn the ignition switch OFF. replaced with a new one.
6. Remove the fuel fill cap and relieve fuel pressure in the fuel tank.
7. Disconnect the negative cable from the battery.
8. Remove the quick-connect fitting cover (A).
12. After disconnecting the quick-connect fitting, check it for dirt or damage, refer to the
'01 Civic Shop Manual on this CD (see step 4 on page 11-435).
9. Check the fuel quick-connect fitting for dirt and clean if necessary.
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KY model
KY model
PGM-FI System
Component Location Index 11-72
DTC Troubleshooting 11-75
MIL Circuit Troubleshooting 11-77
Refer to the 2001 Civic Shop Manual, P/N 62S5A00 on this CD, for items not shown in this section.
Outline of Model Change
KY model has been added.
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Fuel and Emissions - Fuel and Emissions Systems
3. Check the Diagnostic Trouble Code (DTC) and note it. Refer to the DTC
Troubleshooting Index and begin the appropriate troubleshooting procedure.
If the MIL did not come on
If the MIL did not come on but there is a driveability problem, refer to the Symptom
Troubleshooting Index in this section.
If you cannot duplicate the DTC
Some of the troubleshooting in this section requires you to reset the Engine Control
Module (ECM)/Powertrain Control Module (PCM) and try to duplicate the DTC. If the
problem is intermittent and you cannot duplicate the code, do not continue through the
procedure. To do so will only result in confusion and possibly, a needlessly replaced
ECM/PCM.
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
2. If you cannot get to the wire side of the connector or the wire side is sealed (A),
disconnect the connector and probe the terminals (B) from the terminal side. Do not
force the probe into the connector.
Do not puncture the insulation on a wire. Punctures can cause poor or intermittent
electrical connections.
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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Fuel and Emissions - Fuel and Emissions Systems
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
*1: A/T
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Fuel and Emissions - Fuel and Emissions Systems
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
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Fuel and Emissions - Fuel and Emissions Systems
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
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Fuel and Emissions - Fuel and Emissions Systems
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
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Fuel and Emissions - Fuel and Emissions Systems
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
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
● Injectors
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
● Knock sensor
● Knock sensor
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - PGM-FI System
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Fuel and Emissions - Fuel Supply System
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Fuel and Emissions - Fuel Supply System
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Fuel and Emissions - Fuel Supply System
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Fuel and Emissions - Fuel Supply System
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Fuel and Emissions - Fuel and Emissions
Transaxle
Automatic 14-1
Transmission
Driveline/Axle 16-1
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Automatic Transmission - Automatic Transmission
Automatic Transmission
Automatic Transmission
Symptom Troubleshooting Index 14-2
System Description 14-16
Interlock System
Shift Lock System Circuit Troubleshooting 14-66
Reverse Lock System Circuit Troubleshooting 14-72
Road Test 14-75
Stall Speed Test 14-77
D3 Switch Replacement 14-78
Shift Lever Removal 14-79
Shift Lever Installation 14-80
Shift Lever Disassembly/Reassembly 14-82
Shift Cable Replacement 14-83
Shift Cable Adjustment 14-86
Valve Body
Servo Body
Disassembly, Inspection and Reassembly 14-94
Refer to the '01 Civic Shop Manual (P/N 62S5A00A on this CD) for the 7-position transmission on the 5-door model service procedures and information not included in this
supplement.
Outline of Model Change
Civic 5-door model of made-in-England (Honda of U.K. Manufacturing) has been added; equipped with the 7-position transmission.
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Automatic Transmission - Automatic Transmission
These symptoms DO NOT trigger Diagnostic Trouble Codes (DTCs) or cause the indicator light to blink. If the Malfunction Indicator Lamp (MIL) was reported ON or the
indicator light has been blinking, check for DTCs. But if the vehicle has one of the symptoms in the following chart, check the probable cause(s) for it, in the sequence listed, until you
find the problem.
Symptom Probable cause(s) Notes
When you turn the ignition switch 1. Communication line between multiplex Check that the MIL indicates code for communication line between the
ON (II), the indicator light control unit and gauge assembly multiplex control unit and the gauge assembly, refer to the'01 Civic Shop
comes on and stays on or never defective Manual on this CD (see page 22-273). If the MIL does not indicate code,
comes on at all 2. Blown indicator light bulb replace the indicator light bulb, refer to the'01 Civic Shop Manual on this
CD (see page 22-87).
, or indicator
light does not indicate while the
shift lever is in that position
Shift lever cannot be moved from A problem in the shift lock system (interlock system) Check the interlock system-shift lock system circuit:
position while you are KE, KG, KE and KY models, refer to the'01 Civic Shop Manual on this CD
pushing on the brake pedal (see page 14-101).
KS model (see page 14-72).
Ignition key cannot be moved A problem in the key interlock system (interlock Check the interlock system-key interlock system circuit, refer to the'01
from ACC (I) position to LOCK system) Civic Shop Manual on this CD (see page 14-105).
(0) position when you are
pushing it with the shift lever in
position
Shift lever cannot pass through A problem in the reverse lock system of interlock Check the interlock system-reverse lock system circuit
position from system KE, KG, KR and KY models, refer to the'01 Civic Shop Manual on this CD
position (see page 14-107).
KS model (see page 14-66).
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
Engine idle vibration 1. Low ATF level ● Set idle rpm in gear to the specified idle speed. If still no good, adjust the
2. Shift solenoid valve A defective engine mounts as outlined in the engine section of the '01 shop manual on
3. A/T clutch pressure control solenoid valve A this CD.
defective ● Check ATF level and check ATF cooler lines for leakage and loose
4. Drive plate defective or transmission connections. If necessary, flush ATF cooler lines.
misassembled ● Check the indicator light indication and check for loose connectors.
5. Engine output low, low idle speed Inspect the shift solenoid valve filter/gasket and the shift solenoid valve A for
6. Lock-up clutch piston defective seizure.
7. ATF pump worn or binding ● Inspect the A/T clutch pressure control solenoid valve filter/gasket for wear
8. Lock-up shift valve defective and damage. If the A/T clutch pressure control solenoid valve A is stuck,
9. Restricted ATF cooler inspect the CPC valve.
10. Misadjusted engine mounts ● Check ATF cooling system for restriction.
Vehicle moves in position 1. Excessive ATF ● Check ATF level and drain ATF.
2. 1st clutch defective ● Inspect the clutch piston, clutch piston check valve and O-rings. Check the
3. 2nd clutch defective spring retainer for wear and damage. Inspect the clutch end-plate-to-top-disc
4. 3rd clutch defective clearance. If the clearance is out of tolerance, inspect the clutch discs and
5. 4th clutch defective plates for wear and damage. If the discs and plates are worn or damaged,
6. Foreign material in main orifice replace them as a set. If they are OK, adjust the clearance with the clutch end
7. Clutch clearance incorrect plate.
8. Needle bearing seized up, worn or damaged ● Check for clutch pressure in neutral.
9. Thrust washer seized up, worn or damaged
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Automatic Transmission - Automatic Transmission
Erratic shifting gears: 1. 2-3 shift valve defective Check the indicator light indication and check for loose connectors. Inspect
2. 3-4 shift valve defective the shift solenoid valve filter/gasket and the shift solenoid valve A for seizure.
Fails to shift in and
3. Shift solenoid valve A defective
positions; shifts from 1st to 4th gear
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Automatic Transmission - Automatic Transmission
Erratic upshift: 1. 1-2 shift valve defective Check the indicator light indication and check for loose connectors. Inspect the shift
1st to 2nd gear 2. Shift solenoid valve A defective solenoid valve filter/gasket and the shift solenoid valve A for seizure.
Erratic upshift: 1. 2-3 shift valve defective Check the indicator light indication and check for loose connectors. Inspect the shift
2nd to 3rd gear 2. Shift solenoid valve B defective solenoid valve filter/gasket and the shift solenoid valve B for seizure.
Erratic upshift: 1. 3-4 shift valve defective Check the indicator light indication and check for loose connectors. Inspect the shift
3rd to 4th gear 2. Shift solenoid valve A defective solenoid valve filter/gasket and the shift solenoid valve A for seizure.
Harsh upshift: 1. 2nd clutch defective ● Inspect the clutch piston, clutch piston check valve and O-rings. Check the
1st to 2nd gear 2. A/T clutch pressure control solenoid valve A spring retainer for wear and damage. Inspect the clutch end plate-to-top disc
defective clearance. If the clearance is out of tolerance, inspect the clutch discs and
3. A/T clutch pressure control solenoid valve B plates for wear and damage. If the discs and plates are worn or damaged,
defective replace them as a set. If they are OK, adjust the clearance with the clutch end
4. CPC valve defective plate.
5. Foreign material in main orifice ● Check the 2nd clutch pressure.
6. Torque converter clutch solenoid valve defective ● Check the indicator light indication and check for loose connectors.
7. Mainshaft speed sensor defective Inspect the A/T clutch pressure control solenoid valve filter/gasket for wear
8. Countershaft speed sensor defective and damage. If the A/T clutch pressure control solenoid valve is stuck,
inspect the CPC valve.
● Check the indicator light indication and check for loose connectors.
Inspect the O-rings and check the torque converter clutch solenoid valve for
seizure.
● Check the mainshaft speed sensor installation.
● Check the countershaft speed sensor installation.
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
Harsh downshift: 1. 2nd clutch defective ● Inspect the clutch piston, clutch piston check valve and O-rings. Check the
3rd to 2nd gear 2. A/T clutch pressure control solenoid valve A spring retainer for wear and damage. Inspect the clutch end plate-to-top disc
defective clearance. If the clearance is out of tolerance, inspect the clutch discs and
3. CPC valve defective plates for wear and damage. If the discs and plates are worn or damaged,
4. 3rd accumulator defective replace them as a set. If they are OK, adjust the clearance with the clutch
5. Foreign material in separator plate orifice end plate.
6. CPB valve defective ● Check the 2nd clutch pressure.
7. Foreign material in 3rd exhaust orifice ● Check the indicator light indication and check for loose connectors.
8. Mainshaft speed sensor defective Inspect the A/T clutch pressure control solenoid valve filter/gasket for wear
9. Countershaft speed sensor defective and damage. If the A/T clutch pressure control solenoid valve is stuck,
10. 3rd sub accumulator defective inspect the CPC valve.
● Check the mainshaft speed sensor installation.
● Check the countershaft speed sensor installation.
Harsh downshift: 1. 3rd clutch defective ● Inspect the clutch piston, clutch piston check valve and O-rings. Check the
4th to 3rd gear 2. A/T clutch pressure control solenoid valve A spring retainer for wear and damage. Inspect the clutch end plate-to-top disc
defective clearance. If the clearance is out of tolerance, inspect the clutch discs and
3. CPC valve defective plates for wear and damage. If the discs and plates are worn or damaged,
4. 4th accumulator defective replace them as a set. If they are OK, adjust the clearance with the clutch
5. Foreign material in separator plate orifice end plate.
6. CPB valve defective ● Check the 3rd clutch pressure.
7. Foreign material in 4th exhaust orifice ● Check the indicator light indication and check for loose connectors.
8. Mainshaft speed sensor defective Inspect the A/T clutch pressure control solenoid valve filter/gasket for wear
9. Countershaft speed sensor defective and damage. If the A/T clutch pressure control solenoid valve is stuck,
inspect the CPC valve.
● Check the mainshaft speed sensor installation.
● Check the countershaft speed sensor installation.
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
Fails to shift: 1. A/T clutch pressure control solenoid valve A ● Check the indicator light indication and check for loose connectors.
stuck in 4th gear defective Inspect the A/T clutch pressure control solenoid valve filter/gasket for wear
2. Shift solenoid valve A defective and damage. If the A/T clutch pressure control solenoid valve is stuck,
3. Shift solenoid valve B defective inspect the CPC valve.
● Check the indicator light indication and check for loose connectors.
Inspect the shift solenoid valve filter/gasket and the shift solenoid valves A
and B for seizure.
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Automatic Transmission - Automatic Transmission
No engine braking in position 1st-hold clutch defective ● Check 1st-hold clutch pressure.
● Inspect the clutch piston and O-rings. Check the spring retainer for wear and
damage. Inspect the clutch end plate-to-top disc clearance. If the clearance is
out of tolerance, inspect the clutch discs and plates for wear and damage. If
the discs and plates are worn or damaged, replace them as a set. If they are
OK, adjust the clearance with the clutch end plate.
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Automatic Transmission - Automatic Transmission
Look-up clutch does not engage 1. Torque converter check valve defective ● Check the indicator light indication and check for loose connectors.
2. Lock-up timing valve defective Inspect the A/T clutch pressure control solenoid valve filter/gasket for wear
3. Lock-up shift valve defective and damage. If the A/T clutch pressure control solenoid valve is stuck,
4. Lock-up control valve defective inspect the CPC valve.
5. Lock-up clutch piston defective
6. Torque converter clutch solenoid valve defective ● Check the indicator light indication and check for loose connectors.
7. A/T clutch pressure control solenoid valve B Inspect the O-rings and check the torque converter clutch solenoid valve for
defective seizure.
8. Mainshaft speed sensor defective ● Check the mainshaft speed sensor installation.
9. Countershaft speed sensor defective ● Check the countershaft speed sensor installation.
A/T gear position indicator does not 1. Shift cable broken or out of adjustment ● Check for a loose shift cable on the shift lever and the transmission control
indicate shift lever positions 2. Joint in shift cable and transmission or body worn shaft.
3. Transmission range switch defective or out of ● Check the indicator light indication and check for loose connectors.
adjustment Inspect the transmission range switch. If the transmission range switch is
faulty, replace it. If the transmission range switch is out of adjustment, adjust
it and the shift cable.
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Automatic Transmission - Automatic Transmission
In position (3rd and 4th) and position (3rd), pressurised fluid is drained from the back of the torque converter through a fluid passage, causing the lock-up piston to be held
against the torque converter cover. As this takes place, the mainshaft rotates at the same speed as the engine crankshaft. Together with hydraulic control, the PCM optimises the
timing of the lock-up mechanism. When the torque converter clutch solenoid valve activates, modulator pressure changes to switch lock-up on and off. The lock-up control valve and
the lock-up timing valve control the range of the lock-up according to A/T clutch pressure control solenoid valve B. The torque converter clutch solenoid valve is mounted on the torque
converter housing and A/T clutch pressure control solenoid valve B is mounted on the transmission housing with solenoid valve A as an assembly. They are all controlled by the PCM.
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Automatic Transmission - Automatic Transmission
The shift lever has 7 positions: PARK, REVERSE, NEUTRAL, DRIVE 1st through 4th gear ranges, DRIVE 1st through 3rd gear ranges, SECOND
and FIRST.
Position Description
PARK Front wheels locked; park pawl engaged with the park gear on the countershaft. All clutches released.
REVERSE Reverse; reverse selector engaged with countershaft reverse gear and 4th clutch engaged.
DRIVE General driving; starts off in 1st, shifts automatically to 2nd, 3rd, then 4th, depending on vehicle speed and throttle position. Downshift
through 3rd, 2nd and 1st on deceleration to stop. The lock-up mechanism operates in 3rd and 4th gears.
(1st through 4th)
DRIVE For rapid acceleration at highway speeds and general driving; up-hill and down-hill driving; starts off in 1st, shifts automatically to 2nd,
then 3rd, depending on vehicle speed and throttle position. Downshifts through 2nd to 1st on deceleration to stop. The lock-up
(1st through 3rd) mechanism operates in 3rd gear.
SECOND Driving in 2nd gear; stays in 2nd gear, does not shift up and down. For engine braking or better traction starting off on loose or slippery
surface.
FIRST Driving in 1st gear; stays in 1st gear, does not shift up. For engine braking.
Starting is possible only in and positions through the use of a slide-type, neutral-safety switch.
Automatic Transaxle (A/T) Gear Position Indicator
The A/T gear position indicator in the instrument panel shows what gear has been selected without looking down at the console.
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Automatic Transmission - Automatic Transmission
The 1st-hold clutch engages/disengages 1st-hold or position and is located at the middle of the sub-shaft. The 1st-hold clutch is supplied hydraulic pressure by its ATF feed pipe
within the sub-shaft.
One-way Clutch
The one-way clutch is positioned between the countershaft 1st gear and the park gear. The park gear is splined with the countershaft and rotates with the countershaft. The
countershaft 1st gear provides the outer race surface of the one-way clutch and the park gear provides the inner race surface.
The one-way clutch locks up when power is transmitted from the mainshaft 1st gear to the countershaft 1st gear. The 1st clutch and gear remain engaged in the 1st, 2nd, 3rd and 4th
gear ranges in the , , or position. However, the one-way clutch disengages when the 2nd, 3rd and 4th clutches and gears are applied in the , or
position. This is because the increased rotational speed of the gears on the countershaft overrides the locking ''speed range'' of the one-way clutch. The one-way clutch free-wheels
when the 1st clutch is engaged.
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
O X X X X X X X O
O X X X X X O O X
O X X X X X X X X
1st O X O*2 X X X X X X
and 2nd O X O*1 O X X X X X
3rd O X O*1 X O X X X X
4th O X O*1 X X O O X X
O X O*1 O X X X X X
O O O*2 X X X X X X
O : Operates
x : Does not operate
*1: Although the 1st clutch engages, driving power is not transmitted as the one-way clutch slips.
*2: The one-way clutch engages when accelerating and slips when decelerating.
Gear Operation
Gears on the mainshaft
● The 1st gear engages/disengages with the mainshaft by the 1st clutch.
● The 2nd gear engages/disengages with the mainshaft by the 2nd clutch.
● The 3rd gear is integral with the mainshaft.
● The 4th gear engages/disengages with the mainshaft by the 4th clutch.
● The reverse gear engages/disengages with the mainshaft by the 4th clutch.
● The 4th gear and reverse gear rotate freely from the countershaft. The reverse selector engages the 4th gear or the reverse gear with the reverse selector hub. The reverse
selector hub is splined with the countershaft so that the 4th gear or reverse gear engage with the countershaft.
Gears on the sub-shaft
● The 1st gear is splined with the sub-shaft and rotate with the sub-shaft.
● The 4th gear engages/disengages with the sub-shaft by the 1st-hold clutch.
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Automatic Transmission - Automatic Transmission
Position
Engine power transmitted from the torque converter drives the mainshaft, but hydraulic pressure is not applied to the clutches. Power is not transmitted to the countershaft. The
countershaft 4th gear is engaged with the reverse selector hub and the countershaft by the reverse selector when the shift lever is shifted in position from position. The
countershaft reverse gear is engaged when shifted from position.
1. TORQUE CONVERTER
2. 2ND CLUTCH
3. 4TH CLUTCH
4. 1ST-HOLD CLUTCH
5. SUB-SHAFT
6. 1ST CLUTCH
7. MAINSHAFT
8. COUNTERSHAFT
9. PARK GEAR
10. ONE-WAY CLUTCH
11. SERVO VALVE
12. 3RD CLUTCH
13. FINAL DRIVEN GEAR
14. FINAL DRIVE GEAR
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Automatic Transmission - Automatic Transmission
In position, hydraulic pressure is applied to the 1st clutch and the 1st-hold clutch.
The power flow when accelerating is as follows:
● Hydraulic pressure is applied to the 1st clutch, then the 1st clutch engages the mainshaft 1st gear with the mainshaft.
● The mainshaft 1st gear drives the countershaft 1st gear and the countershaft.
● Power is transmitted to the final drive gear, which in turn drives the final driven gear.
1. TORQUE CONVERTER
2. 1ST-HOLD CLUTCH
3. SUB-SHAFT 1ST GEAR
4. SUB-SHAFT
5. MAINSHAFT 1ST GEAR
6. 1ST CLUTCH
7. MAINSHAFT
8. COUNTERSHAFT
9. ONE-WAY CLUTCH
10. PARK GEAR
11. COUNTERSHAFT 1ST GEAR
12. FINAL DRIVEN GEAR
13. FINAL DRIVE GEAR
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
NOTE: Hydraulic pressure is applied to the 1st clutch, but since the rotation speed of 2nd gear exceeds that of 1st gear, power from 1st gear is cut off at the one-way clutch.
1. TORQUE CONVERTER
2. MAINSHAFT 2ND GEAR
3. 2ND CLUTCH
4. SUB-SHAFT
5. MAINSHAFT
6. COUNTERSHAFT
7. COUNTERSHAFT 2ND GEAR
8. FINAL DRIVEN GEAR
9. FINAL DRIVE GEAR
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Automatic Transmission - Automatic Transmission
NOTE: Hydraulic pressure is applied to the 1st clutch, but since the rotation speed of 3rd gear exceeds that of 1st gear, power from 1st gear is cut off at the one-way clutch.
1. TORQUE CONVERTER
2. MAINSHAFT 3RD GEAR
3. SUB-SHAFT
4. MAINSHAFT
5. COUNTERSHAFT
6. COUNTERSHAFT 3RD GEAR
7. 3RD CLUTCH
8. FINAL DRIVEN GEAR
9. FINAL DRIVE GEAR
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Automatic Transmission - Automatic Transmission
● Hydraulic pressure is applied to the servo valve to engage the reverse selector with the countershaft 4th gear while the shift lever is in the forward range ( , , and
positions).
● Hydraulic pressure is also applied to the 4th clutch, then the 4th clutch engages the mainshaft 4th gear with the mainshaft.
● The mainshaft 4th gear drives the countershaft 4th gear, which drives the reverse selector hub and the countershaft.
● Power is transmitted to the final drive gear, which in turn drives the final driven gear.
NOTE: Hydraulic pressure is applied to the 1st clutch, but since the rotation speed of 4th gear exceeds that of 1st gear, power from 1st gear is cut off at the one-way clutch.
1. TORQUE CONVERTER
2. 4TH CLUTCH
3. MAINSHAFT 4TH GEAR
4. SUB-SHAFT
5. MAINSHAFT
6. COUNTERSHAFT
7. REVERSE SELECTOR HUB
8. REVERSE SELECTOR
9. COUNTERSHAFT 4TH GEAR
10. FINAL DRIVEN GEAR
11. FINAL DRIVE GEAR
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Automatic Transmission - Automatic Transmission
● Hydraulic pressure is applied to the servo valve to engage the reverse selector with the countershaft reverse gear while the shift lever is in the position.
● Hydraulic pressure is also applied to the 4th clutch, then the 4th clutch engages the mainshaft reverse gear with the mainshaft.
● The mainshaft reverse gear drives the countershaft reverse gear via the reverse idler gear. The countershaft reverse gear drives the reverse selector, reverse selector hub and the
countershaft.
● The rotation direction of the countershaft reverse gear is changed via the reverse idler gear.
● Power is transmitted to the final drive gear, which in turn drives the final driven gear.
1. TORQUE CONVERTER
2. 4TH CLUTCH
3. SUB-SHAFT
4. MAINSHAFT REVERSE GEAR
5. MAINSHAFT
6. COUNTERSHAFT
7. REVERSE SELECTOR
8. COUNTERSHAFT REVERSE GEAR
9. REVERSE SELECTOR HUB
10. SERVO VALVE
11. FINAL DRIVEN GEAR
12. FINAL DRIVE GEAR
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
Also, a Grade Logic Control System has been adopted to control shifting in and positions. The PCM compares actual driving conditions with memorised driving conditions,
based on the input from the throttle position sensor, the engine coolant temperature sensor, the barometric pressure sensor, the brake pedal position switch signal, cruise control
signal and the shift lever position signal, to control shifting while vehicle is ascending or descending a slope, or reducing speed.
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Automatic Transmission - Automatic Transmission
2nd ON ON
1st OFF ON
Reverse ON OFF
Reverse inhibit OFF ON
- OFF OFF
- OFF OFF
NOTE: For a description of the reverse inhibit mode, refer to page 14-53.
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Automatic Transmission - Automatic Transmission
When the PCM determines that the vehicle is climbing a hill in and positions, the system extends the engagement area of 2nd and 3rd gear to prevent the transmission
from frequently shifting between 2nd and 3rd gears and between 3rd and 4th gears, so the vehicle can run smooth and have more power when needed.
Shift schedules stored in the PCM between 2nd and 3rd gears and between 3rd and 4th gears, enable it to automatically select most suitable gear according to the magnitude of a
gradient.
Descending Control
When the PCM determines that the vehicle is going down a hill in and positions, the shift-up speed from 3rd to 4th gear and from 2nd to 3rd (when the throttle is closed)
becomes faster than the set speed for flat road driving to widen the 3rd gear and 2nd gear driving areas. This, in combination with engine braking from the deceleration lock-up,
achieves smooth driving when the vehicle is descending. There are two descending modes with different 3rd gear driving areas and 2nd gear driving areas to suit the magnitude of the
gradients stored in the PCM. When the vehicle is in 4th gear and you are decelerating when you are applying the brakes on a steep hill, the transmission will downshift to 3rd gear.
When you accelerate, the transmission will then return to higher gear.
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
A3 YEL/BLK IGP1 Power supply circuit from main relay With ignition switch ON (II): Battery voltage
With ignition switch OFF: 0 V
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Automatic Transmission - Automatic Transmission
0 V in these positions:
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Automatic Transmission - Automatic Transmission
E13 WHT/BLU ILU Interlock control With ignition switch ON (II), brake pedal pressed and accelerator
pedal released: Battery voltage
E22 WHT/BLK BK SW Brake pedal position switch signal output Brake pedal pressed: Battery voltage
Brake pedal released: 0 V
E23 LT BLU K-LINE Communication line between PCM and scan With ignition switch ON (II): Battery voltage
tool
E29 BRN SCS Timing and adjustment service check signal With ignition switch ON (II) and service check connector open: 5
V
With ignition switch ON (II) and service check connector
connected with special tool: 0 V
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
Increases in hydraulic pressure according to torque are performed by the regulator valve using stator torque reaction. The stator shaft is splined with the stator in the torque converter
and its arm end contacts the regulator spring cap. When the vehicle is accelerating or climbing (Torque Converter Range), stator torque reaction acts on the stator shaft and the stator
arm pushes the regulator spring cap in the direction of the arrow in proportion to the reaction. The stator reaction spring compresses and the regulator valve moves to increase the line
pressure which is regulated by the regulator valve. The line pressure reaches its maximum when the stator torque reaction reaches its maximum.
1. TORQUE CONVERTER
2. STATOR
3. REGULATOR VALVE BODY
4. REGULATOR VALVE
5. REGULATOR SPRING CAP
6. STATOR SHAFT ARM
7. STATOR SHAFT
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
Key to abbreviations:
● CPC: Clutch pressure control
● SH A: Shift solenoid valve A
● SH B: Shift solenoid valve B
● LC A: Torque converter clutch solenoid valve
● LINEAR SOL A: A/T clutch pressure control solenoid valve A
● LINEAR SOL B: A/T clutch pressure control solenoid valve B
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
When shifting to or position from , the manual valve uncovers the port leading line pressure (4) to the 1st clutch and the PCM turns the shift solenoid valve B ON, but
shift solenoid valve A remains OFF. Modulator (SH B) pressure (6B) in the right side of the 1-2 shift valve and in the left side of the 2-3 shift valve is released, then 1-2 shift valve is
moved to the right side and 2-3 shift valve is moved to the left side. The 1-2 shift valve creates 1st clutch circuit bypass to reduce engaging shock of the 1st clutch. The 1st clutch
pressure (10) is applied to the 1st clutch and the 1st clutch is engaged.
NOTE: When used, ''left'' or ''right'' indicates direction on the hydraulic circuit.
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
When the position is selected while the vehicle is moving forward at speed over 6 mph (10 km/h), the PCM outputs the 1st speed signal to shift solenoid valves A and B; shift
solenoid valve A is OFF and shift solenoid valve B is turned ON. The 1-2 shift valve is moved to the right side and covers the port to stop line pressure (3') to the servo valve. Line
pressure (3') is not applied to the servo valve and the 4th clutch pressure (40) is not applied to the 4th clutch. Power is not transmitted to the reverse direction.
NOTE: When used, ''left'' or ''right'' indicates direction on the hydraulic circuit.
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
The shift lever has 7 positions: , , , , , and and shifts between positions along the gate in the A/T gear position indicator panel. The shift lever
can shift out of position and into position from without pressing or pulling the shift lever. The shift lock/reverse lock mechanism is an additional shift lever lockout
mechanism. The shift lever sifts the transmission into , , , , and positions using the shift cable connected between the shift lever and the transmission
control shaft. When the shift lever shifts into position, the shift lever is moved to the next position from and it pushes the D3 switch to turn ON. Then the transmission shifts
into D3 position mode, but the shifting position in the transmission is held in position.
1. SHIFT LOCK RELEASE
2. A/T GEAR POSITION INDICATOR
PANEL
3. SHIFT LOCK STOP
4. SHIFT LOCK RELEASE
5. SHIFT LOCK SOLENOID
6. D3 SWITCH
7. SHIFT LEVER BRACKET BASE
8. REVERSE LOCK STOP
9. SHIFT LEVER
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
Downshift
Throttle Opening Unit of Speed Lock-up OFF 4th3rd 3rd2nd 2nd1st
Throttle position sensor voltage: 0.5 V mph 13-17 17-20 6-10 (3rd1st)
km/h 21-26 27-32 10-15 (3rd1st)
Fully-opened throttle, Throttle position sensor mph 93-104 85-95 54-61 23-29
voltage: 4.5 V
km/h 150-166 136-152 87-98 37-45
7. Accelerate to about 35 mph (57 km/h) so the transmission is in 4th, then shift from position to position. The vehicle should immediately begin slowing down from engine
braking.
8. Check for abnormal noise and clutch slippage in the following positions.
(1st Gear) Position
● Accelerate from a stop at full throttle. Check that there is no abnormal noise or clutch slippage.
● Upshifts should not occur with the shift lever in this position.
(2nd Gear) Position
● Accelerate from a stop at full throttle. Check that there is no abnormal noise or clutch slippage.
● Upshifts and downshifts should not occur with the shift lever in this position.
(Reverse) Position
Accelerate from a stop at full throttle and check for abnormal noise and clutch slippage.
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
5. Remove the shift cable lock (C) holding its middle (D) with needle-nose pliers (E)
from the shift cable end and shift cable end holder.
NOTE: Do not pry the shift cable lock with a screwdriver, it may damage the shift 8. Disconnect the D3 switch/shift lock solenoid connector (6P) (B).
cable end holder. 9. Cover around the opening of the console with tape to prevent damage to the console.
6. Rotate the socket holder (A) on the shift cable (B) counterclockwise a quarter turn; 10. Remove the 4 bolts (C), then remove the shift lever assembly (D); lift it up slightly,
the projection (C) on the socket holder faces direction to remove. Then slide the clear the harness, rotate counterclockwise a quarter turn, then lift up and remove.
holder to remove the shift cable from the shift cable bracket (D).
NOTE: Do not remove the shift cable by twisting the shift cable guide (E) and
damper (F).
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
13. Remove the 6.0 mm (0.24 in.) pin that was installed to hold the shift lever.
14. Move the shift lever to each gear and verify that the A/T gear position indicator
follows the transmission range switch.
10. Verify that the shift cable end is properly installed into the shift cable end holder. If
15. Push the shift lock release and verify that the shift lever releases.
improperly installed, remove the shift cable from the shift lever bracket base and
16. Reinstall the console panel and related parts.
reinstall the shift cable end and shift cable. Do not install the shift cable end into the
shift cable end holder while the shift cable is on the shift lever bracket base.
11. Rotate the holder clockwise a quarter turn to secure the shift cable.
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Automatic Transmission - Automatic Transmission
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Automatic Transmission - Automatic Transmission
8. Remove the shift cable guide bracket (A) and grommet (B), then remove the guide
bracket from the cable.
6. Rotate the shift cable lock (C) holding its middle (D) with needle-nose pliers (E) from
the shift cable end and shift cable holder.
NOTE: Do not pry the shift cable lock with a screwdriver, it may damage the shift
cable end holder.
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Automatic Transmission - Automatic Transmission
10. Remove the lock bolt securing the control lever (C), then remove the shift cable (D)
with the control lever from the control shaft (E). 20. Turn the ignition switch OFF.
11. Insert the new shift cable through the grommet hole. 21. Insert a 6.0 mm (0.24 in.) pin (A) into the positioning hole on the shift lever bracket
12. Install the shift cable guide bracket on the shift cable, then install the shift cable base through the positioning hole on the shift lever assembly. The shift lever is
guide bracket to the body.
secured in position.
13. Verify that the transmission is in position on the control shaft.
14. Install the control lever with the shift cable on the control shaft. Do not bend the
shift cable excessively.
15. Secure the shift cable holder with the bolts on the transmission.
16. Install the lock bolt with a new lock washer (F), then bend the lock washer tab
against the bolt head.
17. Install the shift cable covers.
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Automatic Transmission - Automatic Transmission
26. Remove the 6.0 mm (0.24 in.) pin that was installed to hold the shift lever.
27. Move the shift lever to each position and verify that the A/T gear position indicator
follows the transmission range switch.
23. Verify that the shift cable end is properly installed into the shift cable end holder. If 28. Allow the wheels to rotate freely.
improperly installed, remove the shift cable from the shift lever bracket base and 29. Start the engine and check the shift lever operation in all gears.
reinstall the shift cable end and shift cable. Do not install the shift cable end holder 30. Reinstall the console panel and related parts.
while the shift cable is on the shift lever bracket base.
24. Rotate the holder clockwise a quarter turn to secure the shift cable.
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Automatic Transmission - Automatic Transmission
5. Remove the shift cable lock (C) holding its middle (D) with needle-nose pliers (E)
from the shift cable end and shift cable end holder.
NOTE: Do not pry the shift lock with a screwdriver, it may damage the shift cable
end holder.
6. Rotate the socket holder (A) on the shift cable (B) counterclockwise a quarter turn; 8. Turn the ignition switch ON (II) and verify that the position indicator light comes
the projection (C) on the socket holder faces direction to remove. Then slide the on.
holder to remove the shift cable from the shift cable bracket base (D). 9. Turn the ignition switch OFF.
NOTE: Do not remove the shift cable by twisting the shift cable guide (E) and 10. Insert a 6.0 mm (0.24 in.) pin (A) in to the positioning hole on the shift lever bracket
damper (F). base through the positioning hole on the shift lever assembly. The shift lever is
secured in position.
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Automatic Transmission - Automatic Transmission
15. Remove the 6.0 mm (0.24 in.) pin that was installed to hold the shift lever.
16. Move the shift lever to each gear and verify that the A/T gear position indicator
follows the transmission range switch.
17. Push the shift lock release and verify that the shift lever releases.
12. Verify that the shift cable end is properly installed into the shift cable end holder. If 18. Reinstall the console panel and related parts.
improperly installed, remove the shift cable from the shift lever bracket base and
reinstall the shift cable end into the shift cable end holder while the shift cable is on
the shift lever bracket base.
13. Rotate the holder clockwise a quarter turn to secure the shift cable.
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A/T Gear Position Indicator
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Automatic Transmission - A/T Interlock System
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Automatic Transmission - A/T Interlock System
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Automatic Transmission - A/T Interlock System
● If there is no voltage, check for a blown No. 8 (7.5 A) fuse in the under-dash fuse/ (G401).
relay box or an open or short in the wire.
INTERLOCK CONTROL UNIT CONNECTOR
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Automatic Transmission - A/T Interlock System
3. Connect the No. 1 terminal of the D3 switch/shift lock solenoid connector (6P) to the
battery positive terminal and connect the No. 3 terminal to the battery negative
terminal.
4. Check that the shift lever can be moved from the position. Release the battery
terminals from the D3 switch/shift lock solenoid connector. Move the shift lever back
to the position and make sure it locks.
NOTE: Do not connect power the No. 3 terminal (reverse polarity) or you will
damage the diode inside the solenoid.
5. If the shift lock solenoid does not work, remove the shift lever assembly (see page
14-79). Go to step 10, when the shift lock solenoid works properly.
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Automatic Transmission - A/T Interlock System
5. Install the shift lock solenoid plunger (C) and plunger spring (D) in the new shift lock
solenoid.
6. Apply silicone grease the inside of the slot on the shift lock solenoid plunger and tip
of the shift lock/reverse lock stop.
7. Install the shift lock solenoid by aligning the joint of the shift lock solenoid plunger
with the tip (E) of the shift lock/reverse lock stop.
8. Connect the shift lock solenoid connector (2P) and install it to the shift lever bracket
base.
9. Hook the D3 switch wire on its hook.
10. Install the shift lever assembly (see page 14-80).
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Valve Body
SPRING SPECIFICATIONS
No. Spring Standard (New)-Unit: mm (in.)
Wire Dia. O.D. Free Length No. of Coils
(1) 1st accumulator spring 2.1 (0.083) 16.0 (0.630) 89.1 (3.508) 16.2
(2) 4th accumulator spring A 2.6 (0.102) 17.0 (0.669) 88.4 (3.480) 14.2
(3) 4th accumulator spring B 2.3 (0.091) 10.2 (0.402) 51.6 (2.031) 13.8
(4) 3rd accumulator spring A 2.8 (0.110) 17.5 (0.689) 94.3 (3.713) 15.9
(5) 3rd accumulator spring B 2.1 (0.083) 31.0 (1.220) 38.2 (1.504) 2.6
(6) 2nd accumulator spring C 2.2 (0.087) 14.5 (0.571) 68.0 (2.677) 13.9
(7) 2nd accumulator spring A 2.4 (0.094) 29.0 (1.142) 39.0 (1.535) 2.9
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Transaxle - Transaxle
Transaxle
Driveline/Axle
Driveshaft Reassembly 16-2
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Transaxle - Driveline/Axle
Driveline/Axle 16-2
Driveshaft Reassembly
Exploded View
1. INBOARD JOINT
2. CIRCLIP
3. (Right driveshaft)
4. ROLLER
5. DOUBLE LOOP BAND
Replace.
(Replacement parts only)
6. INBOARD BOOT
Pack cavity with grease.
7. EAR CLAMP BAND
Replace.
8. LOW PROFILE BAND
Replace.
9. EAR CLAMP BAND
Replace.
10. DRIVESHAFT
11. STOP RING
Replace.
12. EAR CLAMPS BANDS
Replace.
13. OUTBOARD JOINT
14. Pack cavity with grease.
15. OUTBOARD BOOT
16. Right driveshaft
17. DYNAMIC DAMPER
(Undirectional)
18. Left driveshaft
19. SPIDER
20. Pack cavity with grease.
21. SET RING
Replace.
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Transaxle - Driveline/Axle
Driveline/Axle 16-3
Driveshaft Reassembly (cont'd)
Special Tools Required 3. Install the spider (A) onto the driveshaft by aligning the marks (B) on the spider and
● Boot band tool, KD-3191 or equivalent commercially available the end of the driveshaft.
● Boot band pincers, KENT-MOORE J-35910 or equivalent commercially available
4. Fit the circlip (C) into the driveshaft groove. Always rotate the circlip in its groove to
make sure it is fully seated.
5. Fit the rollers (A) onto the spider (B) with their high shoulders facing outward and
note the following items:
● Reinstall the rollers in their original positions on the spider by aligning the marks
(C).
2. Install the dynamic damper, inboard boot and the ear clamp bands (B) onto the ● Hold the driveshaft pointed upward to prevent the rollers from falling off.
driveshaft, then remove the vinyl tape. Take care not to damage the inboard boot
and dynamic damper.
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Transaxle - Driveline/Axle
Driveline/Axle 16-4
Driveshaft Reassembly (cont'd)
6. Pack the inboard joint with the joint grease included in the new driveshaft set. 8. Adjust the length of the driveshafts to the figure below, then adjust the boots to
Grease quantity halfway between full compression and full extension. Make sure the ends of the
Inboard joint: boots seat in the grooves of the driveshaft and joint.
D14Z6 engine models: Left driveshaft:
Right driveshaft: D14Z6 engine models:
108-126 g (3.8-4.4 oz) M/T: 787.7 – 792.7 mm (31.0 – 31.2 in.)
Left driveshaft: A/T: 791.2 – 796.2 mm (31.1 – 31.3 in.)
103.5-121.5 g (3.7-4.3 oz) D16V1 engine models:
D16V1 engine models: M/T: 784 – 789 mm (30.9 – 31.1 in.)
100-110 g (3.5-3.9 oz) A/T: 787 – 792 mm (31.0 – 31.2 in.)
Right driveshaft:
D14Z6 engine models:
498.7 – 503.7 mm (19.6 – 19.8 in.)
D16V1 engine models:
498 – 503 mm (19.6 – 19.8 in.)
7. Fit the inboard joint onto the driveshaft and note these items:
● Reinstall the inboard joint onto the driveshaft by aligning the marks (A) on the
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Transaxle - Driveline/Axle
Driveline/Axle 16-5
Driveshaft Reassembly (cont'd)
11. Install the new low profile band (A) onto the boot (B) and dynamic damper, then 13. Fit the boot ends onto the driveshaft and the inboard joint, then install the band (A)
hook the tab (C) on the band. onto the boot.
12. Close the hook portion of the band with a commercially available boot band pincers
(A), then hook the tabs (B) on the band.
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Transaxle - Driveline/Axle
Driveline/Axle 16-6
Driveshaft Reassembly (cont'd)
16. Thread the free end of the band through the nose section of the commercially 19. Unwind the boot band tool and cut off the excess free end of the band to leave a 5
available boot band tool KD-3191 or equivalent (A) and into the slot on the winding – 10 mm (0.2 – 0.4 in.) tail protruding from the clip.
mandrel (B).
20. Bend the band end (A) by tapping it down with a hammer.
NOTE:
● Make sure the band and clip do not interfere with anything and the band does not
move.
● Remove any grease remaining on the surrounding surfaces.
17. Place a wrench on the winding mandrel of the boot band tool and tighten the band
until the marked spot (C) on the band meets the edge of the clip.
18. Lift up the boot band tool to bend the free end of the band 90 degrees to the clip.
Centre punch the clip, then fold over the remaining tail onto the clip.
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Transaxle - Driveline/Axle
Driveline/Axle 16-7
Driveshaft Reassembly (cont'd)
21. Close the ear portion (A) of the band with a commercially available boot band 23. Install the new set ring.
pincer (B).
22. Check the clearance between the closed ear portion of the band. If the clearance is
not within the standard, close the ear portion of the band further.
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Transaxle - Driveline/Axle
Driveline/Axle 16-8
Driveshaft Reassembly (cont'd)
Outboard Joint Side: 4. Insert the driveshaft (A) into the outboard joint (B) until the stop ring (C) is close to
1. Wrap the splines with vinyl tape (A) to prevent damage to the outboard boot. the joint.
2. Install the new ear clamp bands (B) and outboard boot onto the driveshaft, then
remove the vinyl tape. Take care not to damage the outboard boot.
3. Install the new stop ring into the driveshaft groove (A).
5. To completely seat the outboard joint, pick up the driveshaft and joint and drop them
from about 10 cm (4 in.) onto a hard surface. Do not use a hammer as excessive
force may damage the driveshaft.
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Transaxle - Driveline/Axle
Driveline/Axle 16-9
Driveshaft Reassembly (cont'd)
6. Check the alignment of the paint mark (A) with the outboard joint end (B). 8. Fit the boot (A) ends onto the driveshaft (B) and outboard joint (C).
7. Pack the outboard joint with the joint grease included in the new joint boot set.
Grease quantity
Outboard joint:
D14Z6 engine models:
9. Close the ear portion (A) of the band with a commercially available boot band pincer
80 – 100 g (2.8 – 3.5 oz)
(B).
D16V1 engine models:
95 – 105 g (3.4 – 3.7 oz)
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Transaxle - Driveline/Axle
Driveline/Axle 16-
Driveshaft Reassembly (cont'd)
10
10. Check the clearance between the closed ear portion of the bands. If the clearance
is not within the standard, close the ear portion of the bands further.
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Body - Body
Body
Doors
Component Location Index - Front Door 20-2
Front Door Panel Removal/Installation - Manual Window 20-3
Mirrors
Mirror Holder Replacement 20-5
Interior Trim
*Carpet Replacement 20-6
Bumpers
Front Bumper Removal/Installation 20-8
Tailgate
Tailgate Support Strut Replacement 20-9
Exterior Trim
Emblem Replacement 20-10
Openers
Hood Opener Cable Replacement 20-11
Fuel Fill Door Opener Cable Replacement 20-12
NOTE: Refer to the '01 Civic Shop Manual, P/N 62S5A00 on this CD, for the items not shown in this manual.
Outline of 5-door Model Changes
● The U.K. Manufacturing produced vehicles have been added. The LHD models have been added; the LHD models are symmetrical and same manner
against the RHD models.
● On the front door for some models, the manual windows have been added.
● For some models, the manual door mirror has been added; the mirror holder removal/installation procedures are different.
● For some models the headlight washer has been equipped to the front bumper.
● Some emblems have been added and the attachment points are different.
● For the LHD models, the hood and fuel fill door opener cables replacement procedures have been added.
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 and some models include side airbags in the front seat-backs. Information necessary to safely service the SRS is included in the 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.
WARNING
● To avoid rendering the SRS inoperative, which could lead to personal injury or death in the
event of a severe frontal collision, all SRS service work must be performed by an authorised
Honda dealer.
● Improper service procedures, including incorrect removal and installation of the SRS, could lead
to personal injury caused by unintentional deployment of the airbags.
● 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 and in the
dashboard above the glove box. Do not use electrical test equipment on these circuits.
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Body - Body
Body
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 and some models include side airbags in the front seat-backs. Information necessary to safely service the SRS is included in the 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.
WARNING
● To avoid rendering the SRS inoperative, which could lead to personal injury or death in the
event of a severe frontal collision, all SRS service work must be performed by an authorised
Honda dealer.
● Improper service procedures, including incorrect removal and installation of the SRS, could lead
to personal injury caused by unintentional deployment of the airbags.
● 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 and in the
dashboard above the glove box. Do not use electrical test equipment on these circuits.
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Body - Doors
Doors 20-
Component Location Index - Front Door
2
1. DOOR UPPER OUTER CHANNEL TAPE
2. DOOR CENTRE OUTER CHANNEL TAPE
3. DOOR GLASS OUTER WEATHERSTRIP
4. HINGE
5. DETENT ROD
6. HINGE
7. DOOR
8. DOOR GLASS INNER WEATHERSTRIP
9. DOOR PANEL
(Power window)
10. Passenger's:
11. SWITCH PANEL
12. POWER WINDOW SWITCH
13. GRIP BASE
14. DOOR PANEL
(Manual window)
Removal/Installation, page 20-3
15. GRIP COVER
16. POWER WINDOW SWITCH
17. POWER WINDOW SWITCH
18. SWITCH PANEL
19. Rear manual window:
20. PANEL
21. Front and rear manual window:
22. SWITCH PANEL
23. LOCK KNOB TRIM
24. SPEAKER
25. DOOR WEATHERSTRIP
26. PLASTIC COVER
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Body - Doors
Doors 20-3
Front Door Panel Removal/Installation - Manual
Window
3. 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 out the inner handle forward and out half-way to release the hook (E).
4. Disconnect the inner handle rod (F).
Fastener Locations
: Screw, 2
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Body - Doors
Doors 20-4
Front Door Panel Removal/Installation - Manual
Window (cont'd)
5. Remove the screws from the grip base (A) and door panel (B). 6. Release the clips that hold the door panel (A) with a commercially available trim pad
Fastener Locations 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.
: Screw, 3
Fastener Locations
: Clip, 7
7. Install the door panel in the reverse order of removal and note these items:
● Replace any damaged clips.
● Install the regulator handle so it points forward with the glass fully closed.
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Body - Mirrors
Mirrors 20-5
Mirror Holder Replacement
1. Carefully pull out the bottom edge of the mirror holder (A) by hand. Take care not to
scratch the mirror.
2. Separate the mirror holder from the actuator (B) by slowly pulling them apart while
detaching the clips (C). If equipped, disconnect the mirror defogger connectors (D)
from the heater pad terminals.
3. If equipped, reconnect the mirror defogger connector.
4. Reattach the clips of the mirror holder to the actuator, then position the mirror holder
on the actuator. Carefully push on the clip portions of the mirror holder until the
mirror holder locks into place.
5. Check the operation of the actuator.
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Body - Mirrors
Mirrors 20-6
Carpet Replacement
LHD 3. Using a utility knife, cut the carpet (A) under the heater area (B) on the driver's side,
SRS components are located in this area. Review the SRS component locations (see then pull back the carpet.
page 23-24) and the precautions and procedures (see page 23-25) in the SRS section
before performing repairs or service. Refer to the '01 Civic Shop Manual, P/N 62S5A00
on this CD.
NOTE:
● Put on gloves to protect your hands.
● Take care not to damage, wrinkle or twist the carpet.
● Be careful not to damage the dashboard or other interior trim pieces.
1. Remove these items, refer to the '01 Civic Shop Manual, P/N 62S5A00 on this CD:
● Front seats, both sides (see page 20-229)
2. Remove the nut (A) and using a hex wrench, release the clip (B), then remove the A : Clip, 3
footrest (C).
Fastener Locations
A : Nut, 1B : Clip, 1
5. Remove the rear floor carpet, refer to the '01 Civic Shop Manual, P/N 62S5A00 on
this CD (see step 6 on page 20-214)
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Interior Trim
6. Install the carpet in the reverse order of removal and note these items:
● Take care not to damage, wrinkle or twist the carpet.
● Reattach the cut areas under the heater with a wire tie.
● When installing a new carpet, cut the carpet (A) under the heater area (B). After
installing new carpet, slip the carpet from the driver's and passenger's side
through the space between the heater unit and body.
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Bumpers
Bumpers 20-8
Front Bumper Removal/Installation
NOTE:
● Have an assistant help you when removing and installing the front bumper.
● Take care not to scratch the front bumper and body.
● Put on gloves to protect your hands.
Fastener Locations
A : Screw, 2 B : Screw, 2 C : Bolt, 4 D : Clip, 7 E : Clip, 2
1. HOOKS
2. HOOKS
3. SIDE SPACER
4. UPPER BEAM
5. FRONT INNER FENDER
6. FRONT BUMPER
7. HEADLIGHT WASHER TUBE
(For some models)
8. FRONT AIR SPOILER
9. 6 x 1.0 mm
9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
10. AIR SPOILER PLATE
11. PLATE
12. SPOILER
13. BUMPER
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Tailgate
Tailgate 20-9
Tailgate Support Strut Replacement
1. With the help of an assistant, use a flat-tip screwdriver (A) to pry the support strut
clips (B) from each end of the support strut (C) at the tailgate and body, then release
the support strut from the pivot bolts (D). Do not remove the clips from the support
strut
2. Set the clips (A) to the original position, then reattach the support strut (B) on the
pivot bolts (C) by pushing on the support strut.
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Exterior Trim
Unit: mm (in)
Openers 20-
Hood Opener Cable Replacement
11
LHD
NOTE:
● Put on gloves to protect your hands.
● Take care not to scratch the body and related parts.
1. Remove these items:
● Front bumper (see page 20-8)
● Front inner fender, left side, refer to the '01 Civic Shop Manual, P/N 62S5A00 on this CD (see page 20-259)
● Kick panel, left side, refer to the '01 Civic Shop Manual, P/N 62S5A00 on this CD (see page 20-206)
2. Disconnect the hood opener cable (A) from the hood latch (B), refer to the '01 Civic Shop Manual, P/N 62S5A00 on this CD (see page 20-226) and remove the bolts (C), then
remove the hood release handle (D) from the body.
Fastener Locations
C : Bolt, 2 E : Clip, 3
3. Using a clip remover, detach the clips (E) and remove the grommet (F) from the body, then remove the hood opener cable from the vehicle. Take care not to bend the cable.
4. Install the cable in the reverse order of removal and replace any damaged clips.
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Body - Openers
Openers 20-
Fuel Fill Door Opener Cable Replacement
12
LHD
SRS components are located in this area. Review the SRS component locations (see page 23-24) and the precautions and procedures (see page 23-25) in the SRS section before
performing repairs or service. Refer to the '01 Civic Shop Manual, P/N 62S5A00 on this CD.
NOTE:
● Put on gloves to protect your hands.
● Take care not to scratch the body and related parts.
1. Remove these items from left side of the vehicle, refer to the '01 Civic Shop Manual, P/N 62S5A00 on this CD:
● Front door sill trim, right side (see page 20-206)
2. Pull the carpet and rear floor carpet back as necessary, refer to the '01 Civic Shop Manual, P/N 62S5A00 on this CD (see page 20-212).
3. Disconnect the fuel fill door opener cable (A) from the opener (B), refer to the '01 Civic Shop Manual, P/N 62S5A00 on this CD (see step 3 on page 20-267).
Fastener Locations
C : Clip, 1 D : Cushion E : Clip, 1
tape, 5
4. Remove the opener cable from the clip (C). Remove the cushion tape (D) and detach the clip (E) by using a clip remover.
5. Remove the fuel fill door latch (F) from the body by turning it 90°.
6. Remove the fuel fill door opener cable from the vehicle. Take care not to bend the cable.
7. Install the opener cable in the reverse order of removal and replace the cushion tape and replace the clip if it damaged.
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Body Electrical - Body Electrical
Body Electrical
Power Distribution
Fuse to Components Index 22-4
Ground Distribution
Circuit Identification 22-6
Power Relays
Power Relay Test 22-8
WARNING
● To avoid rendering the SRS inoperative, which could lead to personal injury or death in the
event of a severe frontal collision, all SRS service work must be performed by an authorised
Honda dealer.
● Improper service procedures, including incorrect removal and installation of the SRS, could lead
to personal injury caused by unintentional deployment of the airbags.
● 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 and in the
dashboard above the glove box. Do not use electrical test equipment on these circuits.
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Body Electrical - Body Electrical
Body Electrical
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 and some models include side airbags in the front seat-backs. Information necessary to safely service the SRS is included in the 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.
WARNING
● To avoid rendering the SRS inoperative, which could lead to personal injury or death in the
event of a severe frontal collision, all SRS service work must be performed by an authorised
Honda dealer.
Improper service procedures, including incorrect removal and installation of the SRS, could lead
to personal injury caused by unintentional deployment of the airbags.
● 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 and in the
dashboard above the glove box. Do not use electrical test equipment on these circuits.
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Body Electrical - Relay and Control Unit Locations
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Body Electrical - Relay and Control Unit Locations
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Body Electrical - Power Distribution
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Body Electrical - Power Distribution
*: Not used
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Body Electrical - Ground Distribution
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Body Electrical - Ground Distribution
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Relays
Relays 22-8
Power Relay Test
Use this chart to identify the type of relay, then do the test listed for it.
Relay Test
SHIFT LOCK RELAY
KEY INTERLOCK RELAY 5 terminal type
(KG model: daytime running lights)
5-terminal type
Check for continuity between the terminals.
● There should be continuity between the No. 1 and No. 2 terminals when power and
ground are connected to the No. 3 and No. 5 terminals.
● There should be no continuity between the No. 1 and No. 4 terminals when power is
disconnected.
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