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1995 Honda Civic Hatchback Maintenance Manual EDM

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1. WHT RED LT GRN RED INTEGRATED CONTROL UNIT LT GRN RED UNDER DASH FUSE RELAY BOX CEILING LIGHT 5 8W GRN BLU LT GRN RED DRIVER S DOOR SWITCH FRONT PASSENGER S DOOR SWITCH Sedan LT GRN RED LT GRN RED LEFT RIGHT REAR REAR SWITCH SWITCH Horn Circuit Diagram With SRS Type III Without SRS Type lll UNDER HOOD UNDER HOOD FUSE RELAY BOX FUSE RELAY BOX BATTERY BATTERY No 42 20A O O No 42 20A oe WHT GRN WHT GRN WHT GRN WHT GRN WHT GRN WHT GRN WHT GRN BRAKE LIGHT CIRCUIT BRAKE LIGHT CIRCUIT INTERLOCK SYSTEM INTERLOCK SYSTEM HORN BLU GRN BLU RED BLU RED BLU GRN lor GRY CABLE 1 SLIP RING REEL or 2 CONTACT RING poc EEUU BERES 1 JOINT CONNECTOR Without cruise control HORN BLU RED HORN SWITCH 1 1 SET HORN RESUME 1 SWITCH 1 SWITCH 1 1 SWITCH CIRCUIT With cruise control 1 With SRS Type G301 6461 RHD 2 Without SRS 23 39 Cruise Control KM Circuit Diagram IGNITION UNDER HOOD FUSE RELAY BOX SWITCH BATTERY No 41 80A 39 50 NO NO WHT BLK eWHT EO Ose BLK YEL UNDER DASH FUSE RELAY PDS SES BLOCK WHT GRN BOSE ue WHT GRN WHT GRN WHT GRN aren VEL BLK YEL RED 8LK KEY INTERLOCK SOLENOID INDICATO
2. e Downshift 4th 3rd 3rd gt 2nd Full closed throttle Km h 28 5 32 5 8 8 12 8 mph 17 7 20 2 5 5 8 0 Full opened throttle 120 1 130 6 82 8 90 3 40 0 44 5 74 6 81 2 51 4 56 1 24 9 27 7 14 4 Lock up Throttle Opening Unit of speed Da Position D3 Position Lock up ON Lock up OFF Lock up ON Lock up OFF Full closed throttle Km h 24 27 23 26 97 103 92 98 mph 15 17 14 16 60 64 57 61 6 16 throttle Km h 107 113 87 93 107 113 92 98 mph 66 70 54 58 66 70 57 61 Full opened throttle Km h 141 147 136 142 132 138 126 132 88 91 85 88 82 86 78 82 01626 01627 and D16Y1 engines D or D Position e Upshift Throttle Opening Unit of speed 1st gt 2nd 2nd gt 3rd 3rd 4th Full closed throttle Km h 15 0 19 0 36 4 40 4 49 3 53 3 mph 9 3 11 8 22 6 25 1 30 6 33 1 3 16 throttle Km h 21 8 25 8 52 0 56 0 67 3 73 3 mph 13 5 16 0 32 3 34 8 41 8 45 5 6 16 throttle Km h 27 3 35 3 65 2 77 2 85 7 97 7 mph 17 0 21 9 40 5 48 0 53 3 60 7 Full opened throttle Km h 55 4 59 9 104 0 111 5 151 2 161 7 mph 34 4 37 2 64 6 69 3 94 0 100 5 e Downshift Throttle Opening Unit of speed Full closed thrott
3. 1 30A WHT Sunroof motor 2 20A WHT BLK Seat heater Some model versions of KG and KS 3 7 WHT RED Ceiling light Data link connector Trunk cargo area light 4 20A YEL BLK Right rear power window motor 5 20A WHT YEL Driver s power window motor Power window master switch 6 20A WHT GRN Power door lock control unit 7 20A GRN BLK Left rear power window motor 8 20A BLU BLK Front passenger s power window motor 9 10A RED BLU Right headlight HIGH Integrated control unit KE KS 10 10A RED GRN Left headlight HIGH High beam indicator light 11 20A WHT BLK Headlight washer control unit Some model versions of KG and KS 12 15A BLK YEL Alternator Without SRS 13 7 5A BLK YEL Rear window defogger relay ABS relays 14 20A GRN BLK Windshield wiper motor Sunroof relays 15 10A YEL Gauge and indicator lights Clock 16 7 5A YEL BLK Integrated control unit KS 17 10A RED BLU e Left taillight Option KG e Taillights Front parking light KS RED BLK Integrated control unit KE WHT YEL KE Option General exports 18 7 5A BLU WHT PGM FI ECU PGM FI main relay 19 10A RED BLK Dash lights Taillights Front parking lights Except KS 20 7 5A RED WHT Rear fog light European models 21 10A RED WHT Right headlight LOW 22 100 RED YEL Left headlight LOW 23 15A YEL RED Radio cassette player 24 15A BLK YEL Alternator SRS indicator light RED or
4. Bur mg HIJKLMN 23 34 Bulb Check System Bulb Check System brake system light KB KQ Wire Terminal Test condition Under all conditions View from wire side Test desired result Check for continuity to ground There should be continuity N BLU WHT Possible cause if result is not obtained Poor ground G401 Anopen in the wire BLU WHT Ignition switch at START Check for voltage to ground There should be battery voltage Blown No 18 15 A fuse in the under dash fuse relay box Faulty neutral safety switch A T open in the wire GRN RED full and parking brake lever down Except KB and No Terminal Test condition Under all conditions Ignition switch to ON brake fluid reservoir Connect to ground Brake system light should come on Test desired result Check for continuity to ground There should be continuity Blown No 15 10 A fuse in the under dash fuse relay box Blown brake system light An open in the wire Possible cause if result is not obtained Poor ground G401 in the wire Ignition switch at START Check for voltage to ground There should be battery voltage Blown No 18 15 A fuse in the under dash fuse relay box Faulty neutral safety switch A T in the wire
5. Belt tension conditions Alternator Power steering compressor Timing belt R R Water pump 1 1 Cooling system hoses and connections Engine coolant R R R R Spark plug For Pt tipped type Brazil type only Except for For cars with catalytic converter R R R R Pt tipped type For KS model replace every 48 000 For cars without catalytic converter R R R R R R Ignition timing and For European models control system For carburetor types For Other than European models Air cleaner element For cars with catalytic converter R R R For cars without catalytic converter R R Tank fuel lines and connections Fuel filter Positive crankcase ventilation valve 1 2 4 5 4 4 Throttle control system For European models choke opener operation For carburetor types For Other than European models Day to day care engine oil ATF and coolant level should be done practically according to the owner s manual by the customer Forcars with Power steering system Forcars with Air conditioning system Replace every 6 years or 100 000 km 60 000 miles whichever comes first For KS models recommended by manufacturer only except for KS models it is required For K
6. 520 21 2000001 21 3000001 Automatic Transmission Number S24A 4000001 Transmission Type Serial Number 1 2 European Model 4 door Sedan Vehicle Identification Number JHMEG8 54005300001 Manufacturer Make and Type of Vehicle JHM HONDA MOTOR CO LTD JAPAN HONDA Passenger car Line Body and Engine Type 8 CIVIC 4 door D15B2 01571 9 CIVIC 4 door B16A2 CIVIC 4 door AWD D16Z7 9 CIVIC 4 door D16A7 01626 01677 Body and Transmission 5 4 door Sedan 5 speed Manual 6 4 door Sedan 4 speed Automatic Vehicle Grade Series 4 DXi EG8 KG KS EX EH9 KR 5 LSi EG8 KG KF KS KE KW 6 EG8 KG KF KS KE 8 KG KZ KF KS KE KW RTSi EH1 KG 9 VTi EG9 KG KF KS KE KW Fixed Code Auxiliary Number Factory Code 5 Suzuka Factory in Japan Model Year 3 1995 Serial Number B16A2 D15B2 D15Z1 01626 01627 Transmission 520 Except B16A2 engine 4WD model 21 21 For B16A2 engine 22 For 4WD model Serial Number 520 21 522 2000001 21 3000001 Engine Number Engine Type D16A7 Serial Number B16A2 1300001 D15B2 7000001 01571 D16Z6 4700001 D16A7 5300001 01627 for Germany 1600001 D16Z7 for 4WD 1700001 Manual Transmi
7. sn sun Do Isa a 2 J f A T X i NEUTRAL SAFETY SWITCH In shift i BLK WHT position switch i BLK RED BLK WHT Starter solenoid i BLK RED 4 UNDER DASH FUSE RELAY BOX No 18 7 5A Internal connection Integrated control unit Te ee rt re 1 BLU WHT FI ECU 1 COMBINATION LIGHT SWITCH SE doy TES TA ee IKr KG I No 17 10A Internal connection RED GRN Option 1 RED BLU Left outer taillight en ee L e anal dee d wn e en J mc era ie ene hw ee as ES 1 i INTEGRATED CONTROL UNIT I EE s No 17 10A Internal connection RED 8LK Option Right Left RED BLK D ue RED BLU front parking light Left outer taillight RED BLK Right outer taillight Right Left Right Left inner taillight license plate light NE em b Option i S usa WHT BLU WHT BLU TP Radio cassette player Clock 23 9 Ground Distribution Circuit Identification NOTE This page corresponds to page 23 34 of the Shop Manual 62SR320 and reflects the model changes Radio cassette player BLK 6501 BLK C
8. 3 30 QOO Ee m CONN WON OOOO a0 D DO D A to to O to gt to gt gt to 00 00 NI 00 to 00 O to 00 O 2 Q 00 0o O D Free Length No of Coils 14 7 0 58 87 8 3 46 16 5 9 6 0 38 44 0 1 73 7 5 26 40 1 039 30 3 1 19 2 1 8 4 0 33 36 4 1 43 12 8 4 0 33 52 0 2 05 23 0 6 6 0 26 38 5 1 52 6 1 0 24 36 9 1 41 8 5 0 33 41 3 1 63 6 2 0 24 30 0 1 18 8 6 0 34 40 4 1 59 8 6 0 34 35 8 1 41 7 6 0 30 59 7 2 35 13 7 0 54 71 3 2 81 24 3 0 96 59 5 2 34 18 6 0 73 81 0 3 19 16 1 0 63 88 4 3 48 15 5 0 61 78 7 3 10 6 6 0 26 47 9 1 89 5 6 0 22 43 6 1 72 9 4 0 37 32 0 1 30 8 1 0 32 51 0 2 01 6 4 0 25 42 7 1 68 8 4 0 33 36 4 1 43 8 6 0 34 1 2 0 72 8 1 0 32 42 0 1 65 6 6 0 26 37 0 1 46 6 4 0 25 42 7 1 68 Inside Diameter Differential 2WD S20 Section 15 MEASUREMENT STANDARD NEW Unit of length mm in SERVICE LIMIT Final driven gear Backlash 0 070 0 130 0 0028 0 0051 0 180 0 0071 Differential carrier Pinion shaft bore diameter Carrier to pinion shaft clearance Driveshaft bore diameter Carrier to driveshaft clearance 18 000 18 018 0 7087 0 7094 0 013 0 047 0 0005 0 0019 26 025 26 045 1 0246 1 0254 28 025 28 045 1 1033 1 1041 0 045 0 086 0 0018 0 0034
9. 01584 20 2 Red BTDC Others 16 2 Red BTDC Alternator beit Deflection with 100 N 10 kg 22 Ibs between pulleys Except B16A2 B16A3 B16A2 B16A3 7 0 10 5 0 28 0 41 with used belt 5 5 8 0 0 22 0 31 with new belt 5 0 7 0 0 20 0 28 with new belt Tension measured with belt tension gauge kg Ibs Except B16A2 B16A3 B16A2 B16A3 350 500 35 50 77 110 with used belt 550 750 55 75 121 165 with new belt 700 900 70 90 154 198 with new belt Alternator Output 13 5 V athot A 70 NIPPONDENSO Coil resistance rotor Q 2 3 Slip ring O D 14 40 0 567 14 00 0 551 Brush length 10 5 0 41 1 5 0 06 Brush spring tension g oz 330 11 7 Alternator Output 13 5 V athot 70 MITSUBISHI Coil resistance rotor 0 3 4 3 8 Slip ring O D 22 7 0 89 22 2 0 87 Brush length 20 0 0 79 5 0 0 20 Brush spring tension g oz 300 450 10 6 15 9 Alternator Output 13 5 athot A 80 NIPPONDENSO Coil resistance rotor Q 2 9 Slip ring O D 14 40 0 567 14 00 0 551 Brush length 10 5 0 41 1 5 0 06 Brush spring tension g oz 300 360 10 6 12 7 Se Starter motor Type Direct drive HITACHI 0 8 kW Mica depth 0 5 0 8 0 02 0 03 0 20 0 008 Commutator runout 0 0 10 0 0 004 0 40 0 016 Commutator O D 40 00 1 575 39 00 1 535 Brush length 14 5 15 5 0 57 0 61 11 0 0 43
10. full and parking brake lever down Ignition switch to ON brake fluid reservoir Connect to ground Brake system light should come on Blown No 15 10 A fuse in the under dash fuse relay box Blown brake system light An open in the wire 23 35 Integrated Control Unit Control Unit Input Test Seat Belt Reminder System Key in Beeper System Lights on Beeper System KB KM D15B7 D16Z6 engine KY A B C LT GRN RED BLU WHT rrt J RED BLU GRN BLU View from wire side KG KM B16A3 engine A E F GRN BLU Wire Terminal Test condition Under all conditions Combination light switch ON amp amp or View from Test desired result Check for continuity to ground There should be continuity erc TER LT GRN RED wire side Possible cause if result is not obtained Poor ground G401 Anopen in the wire Check for voltage to ground There should be battery voltage Faulty combination light switch Blown 19 10A fuse in the under dash fuse relay box An open in the wire Under all conditions Check for voltage to ground There should be battery voltage Blown No 3 7 5A fuse under dash fuse relay box An open in the wire in the Ignition switch to ON Check for voltage to ground There should be battery voltag
11. 23 34 Circuit Diagram 23 12 Ceiling Trunk Cargo Area Lights Ignition System Circuit Diagram 23 38 Ignition Timing Inspection and Horn Setting KM 23 14 Circuit Diagram 23 39 Idle Speed Inspection KM 23 15 Cruise Control KB KM Ignition Timing Inspection and Circuit Diagram 23 40 Setting 01382 engine 23 15 Control Unit Input Test 23 42 Spark Plug Inspection KM 23 16 Spark Plug Inspection Read the SRS precautions in the Shop Manuals Except KM nn ige 23 17 62SR300 and 62SR321 then install the short connector s on the airbag s before working these areas Outline of Model Changes Starting System A clutch interlock switch has been added Ignition System spark plug and service check connector specifications have been changed and the KM model has been added Interlock System The wire colors have been changed and a parking pin switch has been adopted for the KB and KM models Shift Lever Position Indicator The circuit diagrams have been changed Integrated Control Unit The wire colors have been changed and the KM model has been added Ceiling Trunk Cargo Area Lights The wire colors have been changed Horn The circuit diagrams have been changed Cruise Control The cruise control system
12. Manufacturer Make and Engine Type Type of Vehicle D15B7 1500 SOHC 16 valves Sequential 2HG HONDA OF CANADA Multiport Fuel injected Engine MFG INC with CATA HONDA Passenger car 01626 1600 SOHC 16 valves Sequential JHM HONDA MOTOR CO LTD Multiport Fuel injected VTEC JAPAN Engine with CATA HONDA Passenger car B16A3 1600 DOHC 16 valves Sequential Line Body and Engine Type Multiport Fuel injected VTEC EH2 CIVIC 3 door D15B7 Engine with CATA CIVIC 3 door D16Z6 Serial Number EG6 CIVIC 3 door B16A3 D15B7 4500001 Body Type and Transmission Type 016276 4600001 3 2 door Hatchback 5 speed Manual B16A3 3300001 4 3 door Hatchback 4 speed Automatic Vehicle Grade Series 6 DX 8 Si Manual Transmission Number 9 VTi Check Digit or Fixed Code 520 2000001 Check Digit 0 Fixed Code Transmission Type Production Year 20 Except B16A3 engine R 1994 21 Y21 For B16A3 engine S 1995 Serial Number Factory Code 520 21 2000001 S Suzuka Factory in Japan 21 3000001 H Ontario Factory in Canada Serial Number JAPAN 300001 JP CANADA 650001 Automatic Transmission Number 524 4000001 Transmission Serial Number 1 6 Except European Model 4 door Sedan KM Vehicle Identification Number 1HGEH4 5 4 SL 700001 Manufacturer Make and Type of Vehicle 1HG HONDA OF A
13. SERVICE LIMIT Engine oil Capacity 0 US qt Imp qt 4 8 5 1 4 2 for engine overhaul 4 0 4 2 3 5 for oil change including ail filter 3 7 3 9 3 3 for oil change without filter Inner to outer rotor radial clearance Housing to rotor radial clearance Housing to rotor axial clearance Oil pump 0 04 0 16 0 002 0 006 0 10 0 19 0 004 0 007 0 02 0 07 0 001 0 003 Relief valve Pressure setting 80 C 176 F kPa kg cm psi at idle at 3 000 min rpm 3 8 70 0 7 10 min 350 3 5 50 min Cooling Section 10 MEASUREMENT Unit of length mm in STANDARD NEW Radiator Coolant capacity 2 US at Imp qt M T including engine heater cooling line and reservoir Reservoir capacity 0 4 2 0 42 US qt 0 35 Imp qt B16A2 4 8 5 1 4 2 for overhaul 3 9 4 1 3 4 for coolant change Except B16A2 D15Z1 4 5 4 8 4 0 for overhaul 3 6 3 8 3 2 for coolant change 01521 4 4 4 6 3 9 for overhaul 3 5 3 7 3 1 for coolant change D12B1 D15B2 D15B3 D15B7 4 4 4 6 3 9 for overhaul 3 5 3 7 3 1 for coolant change D16A9 01626 01677 D16Y1 4 7 5 0 4 1 for overhaul 3 8 4 0 3 3 for coolant change Radiator cap Opening pressure kPa kg cm psi Thermostat Start to opening C F 01571 01571 Fully open C F 01571 Except 01521 Valve lift at fully open 95 125 0 95 1 25 13 5
14. Cooler relief valve spring Relief valve spring 1 10 0 043 1 00 0 039 8 40 0 331 36 40 1 433 12 0 8 40 0 331 52 00 2 047 23 0 2 3 shift valve spring 0 80 0 031 7 60 0 299 42 00 1 654 22 7 1 2 shift valve spring 2 3 shift valve ball spring 0 45 0 018 0 45 0 018 4 50 0 177 4 40 0 173 13 30 0 524 48 00 1 890 1 2 shift valve ball spring 0 45 0 018 4 50 0 177 10 70 0 421 12 7 Regulator valve spring A D12B1 D15B3 D16A9 1 80 0 071 1 80 0 071 14 70 0 579 14 70 0 579 3 85 40 3 362 87 80 3 457 16 5 16 5 Regulator valve spring Stator reaction spring 1 80 0 071 5 50 0 217 9 60 0 378 26 40 1 039 44 00 1 732 30 30 1 193 Lock up control D12B1 D15B3 0 70 0 028 6 60 0 260 32 50 1 280 14 0 valve spring D16A9 0 60 0 024 6 60 0 260 32 80 1 291 15 8 D Torque converter check valve spring 1 10 0 043 8 40 0 331 36 40 1 433 12 0 Modulator valve D12B1 D15B3 1 20 0 047 7 00 0 276 26 30 1 035 8 0 spring 1 20 0 047 7 00 0 276 27 20 1 071 8 0 D16A9 20 0 047 7 00 0 276 26 30 1 035 8 0 20 0 047 7 00 0 276 26 40 1 039 8 0 Throttle valve A D12B1 D15B3 1 10 0 043 8 50 0 335 22 30 0 878 8 1 spring
15. 23 17 Interlock System Component Location Index CAUTION All SRS wire harnesses are covered with yellow insulation Replace the entire affected SRS harness assembly if it has an open circuit or damaged wiring Before disconnecting the SRS wire harness disconnect the positive cable and wait at least three minutes SRS Ill only Whenever the ignition switch is ON Il or has been turned OFF f the SRS unit the airbags could accidentally deploy and cause damage or injuries Before you disconnect any part of an SRS wire harness connect the short connectors RED to the airbags Refer to the additional precautions in the SRS sub section section 23 SRS Type Il SRS Type Ill SRS UNIT With built in sensors SRS MAIN HARNESS Covered with yellow insulation SRS MAIN HARNESS SRS UNIT Covered with yellow insulation With built in sensors NOTE LHD type is shown RHD type is symmetrical KEY INTERLOCK SOLENOID and KEY INTERLOCK SWITCH INTERLOCK CONTROL UNIT Input Test page 23 24 V ouem S SS DD 7 SHIFT LOCK SOLENOID PARKING PIN SWITCH KB KM Test page 23 23 Replacement page 23 23 23 18 turn the ignition switch OFF disconnect the battery negative cable then or less than three minutes be careful not to bump Description KB KM The car is equipped with the following devices to prevent inadvertent shifting Key cylinder with interlocked ignition key K
16. 1 I I 1 I o 5 Q lt 1 1 E Exo With deshlight Without dashlight brightness controller brightness controiler 23 27 Shift Lever Position Indicator Circuit Diagram 4WD IGNITION UNDER DASH UNDER HOOD FUSE RELAY BOX SWITCH FUSE RELAY BOX BATTERY No 41 80A No 39 50 O WHT BLK WHT O BLK YEL ONO No 19 10A NT CONTROL EA FI ECU YEL RED BLK Y 2s es In the gauge assembly C14 C13 A T CONTROL UNIT GRN SHIFT LEVER POSITION INDICATOR DIMMING CIRCUIT T n m RED YEL 6 6 9 9 9 1 4Wx8 d LOW SE c2 C4 C5 11 C7 eee A T CONTROL UNIT GRN WHT GRN GRN BLU BLK PED NER MERI GRN RED GRN BLK GRN RED GRN BLK GRN BLU GRN YEL No 19 10A FUSE RED BLK SHIFT POSITION CONSOLE PGM Fi ECU LIGHT 1 4W Y GRN BLU GRN BLK SHIFT POSITION CONSOLE SWITCH RED BLK 23 28 Indicator Input Test CAUTION All SRS wire harnesses are covered with yellow insulation Replace the entire affected SRS harness assembly if it has an open circuit or damaged wiring Before disconnecting the SRS wire harness turn the ignition switch OFF disconnect the battery negative cable then disconnect the positive cable and wait at least three minutes S
17. 4 Turn the ignition switch OFF Restart the engine and hold engine at idle for two minutes And hold engine at 3 000 3 500 rpm min for one minute Check specification for idle CO with headlights heater blower rear window defogger cooling fan and air conditioner off Specified CO below 0 2 96 f idle CO is as specified go to step 5 If not refer to base Shop Manual P N 62SR300A 11 107 adjust the idle CO 11 2 Fuel and Emissions Fuel Injected Engine Component Locations Index B16A3 11 4 System Description Vacuum Connections B16A3 11 5 Electrical Connections B16A3 engine 11 6 Troubleshooting Self diagnostic Procedures B16A3 engine 11 8 PGM FI System Knock Sensor 16 11 9 Idle Control System Idle Speed Setting KM model eerte 11 11 Fuel Supply System FUEL EINS a ee een nen ge 11 12 Fuel Tube Quick Connect Fittings except D15B7 D16Z6 engines of KM KH models 11 13 SR 11 16 Emission Control System System Description KM modell 11 16 Tailpipe Emission KM model 11 16 Outline of Model Changes B16A3 engine has been added refer to base Shop Manuals B16A2 engine P N 62SR300A 62SR32
18. Outer handle see page 20 2 2 Disconnect and detach the connector from the door Detach the inner handle rod and lock rod 3D from the door Remove the screws then remove the latch through the hole in the door NOTE Take care not to bend the outer handle rod cylinder rod inner handle rod and lock rod 4D LOCK KNOB Align the lock knob with the marks gt mn the door LOCK ROD CYLINDER OUTER ROD HANDLE ROD INNER SCREWS 6 x 1 0 mm LATCH 6 N m 0 6 kg m 4 3 Ib ft 3D CYLINDER OUTER ROD HANDLE ROD SCREWS 6 x 1 0 mm 6 N m 0 6 kg m 4 3 Ib ft 3 Installation is the reverse of the removal procedure NOTE Make sure the door locks and opens properly 20 3 Doors Door Channel Tape Replacement Japan produced cars The following tools are required to replace the door channel tape PLASTIC SQUEEGEE Plastic squeegee Alcohol e Sponge or Shop towel Hair dryer Pin SS Ke FELT NOTE Keep dust away from the working area When working at lower temperatures heat the door channel and door channel tape with a hair dryer Door channel 59 F 15 C min Door channel tape about 95 F 35 C When heating the door channel tape heat it evenly and gradually to prevent deformation When pressing the door channel tape slowly press it from the corner to prevent air bubbles and wrinkles e The symbol ge in the replacement illustrations means to
19. 0 0406 05 0 041 1 220 1 230 0 0480 0 0484 25 0 049 1 220 1 230 0 0480 0 0484 25 0 049 1 520 1 530 0 0598 0 0602 55 0 061 2 805 2 820 0 1104 0 1110 85 0 112 2 805 2 825 0 1104 0 1112 85 0 112 4 005 4 025 0 1577 0 1585 05 0 159 01521 01521 Piston ring Ring to groove Top clearance Second 01521 0 035 0 060 0 0014 0 0024 0 030 0 055 0 0012 0 0022 0 030 0 060 0 0012 0 0024 3 0 035 0 060 0 0014 0 0024 1 1 1 1 2 2 4 0 0 0 0 0 030 0 055 0 0012 0 0022 0 0 0 0 0 0 0 0 0 0 Pin to piston clearance 0 005 Except 01541 0 030 0 055 0 0012 0 0022 0 005 Ring end Top 0 15 0 30 0 006 0 012 60 0 024 Second 0 30 0 45 0 012 0 018 70 0 028 Oil 01571 0 20 0 50 0 008 0 020 70 0 028 0 20 0 70 0 008 0 028 80 0 031 01626 D16Y1 0 20 0 50 0 008 0 020 70 0 028 0 20 0 80 0 008 0 031 90 0 035 01627 0 20 0 50 0 008 0 020 70 0 028 Except 01541 01676 01677 D16Y1 0 20 0 80 0 008 0 031 90 0 035 Piston pin OD 18 994 19 000 0 7478 0 7480 0 010 0 022 0 0004 0 0009 Pin to rod interference Small end bore diameter Large end bore diameter Nominal D12B1 D13B2 01383 01582 01583 01587 01571 01572 D16A7 D16A9
20. 0 059 2 43 2 50 0 096 0 098 Wear or damage Wear or damage Countershaft 3rd gear thrust washer thickness 2 87 2 90 0 113 0 114 2 92 2 95 0 115 0 116 2 97 3 00 0 117 0 118 3 02 3 05 0 119 0 120 3 07 3 10 0 121 0 122 3 12 3 15 0 123 0 124 3 17 3 20 0 125 0 126 3 22 3 25 0 127 0 128 3 27 3 30 0 129 0 130 3 32 3 35 0 131 0 132 3 37 3 40 0 133 0 134 Wear or damage Wear or damage Mainshaft 4th gear thrust washer thickness One way clutch contact area l D Countershaft 1st gear Parking gear Mainshaft feed pipe A O D Mainshaft feed pipe B O D Countershaft feed pipe O D Sub shaft feed pipe O D Mainshaft sealing ring thickness Mainshaft bushing 1 D Mainshaft bushing l D Countershaft bushing D Sub shaft bushing D Mainshaft sealing ring groove width 2 93 3 00 0 115 0 118 83 339 83 365 3 2811 3 2821 66 685 66 698 2 6254 2 6259 8 97 8 98 0 353 0 354 5 970 5 980 0 2350 0 2354 7 970 7 980 0 3138 0 3142 5 970 5 980 0 2350 0 2354 1 980 1 995 0 0780 0 0785 6 018 6 030 0 2369 0 2374 9 000 9 015 0 3543 0 3549 8 000 8 015 0 3150 0 3156 6 018 6 030 0 2369 0 2374 2 025 2 060 0 0797 0 0811 Wear or damage Wear or damage 8 95 0 352 5 95 0 234 7 95 0 313 5 9
21. 18 80 84 176 183 76 80 169 176 95 203 90 194 8 0 0 31 min Radiator fan Thermoswitch ON temperature C F Thermoswitch temperature C F 91 0 95 0 196 203 Subtract 3 8 37 46 from actual ON temperature 3 9 Standards and Service Limits Fuel and Emissions Carbureted Engine Section 11 MEASUREMENT STANDARD NEW Fuel pump Displacement 60 seconds cm fl oz Imp oz 833 3 28 18 29 33 min Relief valve opening pressure kPa kg cm psi 7 23 0 07 0 23 1 0 3 3 min Fuel tank Capacity 0 US gal Imp gal 45 11 9 9 9 Engine speed with headlight and cooling fan off M T Neutral A T N or P position min rpm 01281 D15B3 800 50 1 000 50 D13B2 D15Z2 800 50 D13B3 900 50 Idle CO 96 With CATA 0 5 max Without 1 0 max Fuel and Emissions Engine Section 11 MEASUREMENT STANDARD NEW Fuel pump Displacement 10 seconds cm fl oz Imp oz 120 4 1 4 2 min Relief valve opening pressure kPa kg cm psi 450 600 4 5 6 0 64 85 min Pressure Pressure with regulator vacuum D15B2 245 285 2 45 2 85 35 41 regulator hose disconnected kPa kg cm psi Except D15B2 280 330 2 8 3 3 40 47 Fuel tank Capacity 2 US gal Imp gal 45 11 9 9 9 T Ie Engine Idle speed with headlight a
22. 18 2 Lock up shift valve spring D12B1 D15B3 D16A9 0 70 0 028 1 10 0 043 8 10 0 319 8 10 0 319 39 00 1 535 51 80 2 039 15 4 22 3 Lock up timing valve spring 1 00 0 039 6 60 0 260 52 30 2 059 30 1 Governor spring A 1 00 0 039 18 80 0 740 20 40 0 803 4 0 Governor spring B 0 80 0 031 0 80 0 031 11 80 0 465 11 80 0 465 30 90 1 217 26 70 1 051 6 0 6 0 Kick down valve spring 1 30 0 051 10 10 0 398 33 20 1 307 10 3 Orifice control D12B1 D15B3 0 80 0 031 6 10 0 240 36 20 1 425 14 6 valve spring D16A9 0 90 0 035 6 10 0 240 36 00 1 417 19 8 Shift timing valve spring 0 90 0 035 8 60 0 339 42 90 1 689 4th exhaust valve spring 0 90 0 035 6 10 0 240 43 70 1 720 Accumulator control valve spring u 1 20 0 047 8 60 0 339 45 60 1 795 14 7 Lock up cut valve spring 0 70 0 028 7 60 0 299 29 00 1 142 Reverse control valve spring 0 70 0 028 7 60 0 299 37 20 1 465 15 3 valve spring CPC Clutch Pressure Control 1st accumulator spring 0 90 0 035 2 90 0 114 8 60 0 339 21 50 0 846 18 20 0 717 5 54 58 80 2 315 1st accumulator spring 2 30 0 091 7
23. On stator shaft stator side On reverse idler gear shaft holder End play Mainshaft 1st gear Mainshaft 2nd gear Mainshaft 4th gear Countershaft 1st gear Countershaft 3rd gear Countershaft 4th gear Sub shaft 4th gear Reverse idler gear Countershaft reverse gear Selector hub O D Mainshaft 4th gear collar length Mainshaft 1st gear collar length Mainshaft 1st gear collar flange thickness SERVICE LIMIT fovea NEW 38 000 38 016 1 4961 1 4967 33 000 33 016 1 2992 1 2998 38 000 38 016 1 4961 1 4967 32 000 32 016 1 2598 1 2605 18 007 18 020 0 7089 0 7094 29 000 29 013 1 1417 1 1422 27 000 27 021 1 0630 1 0638 14 416 14 434 0 5676 0 5683 0 08 0 24 0 003 0 009 0 05 0 130 0 002 0 0051 0 05 0 135 0 002 0 0053 0 10 0 50 0 004 0 020 0 05 0 130 0 002 0 0051 0 05 0 130 0 002 0 0051 0 05 0 17 0 002 0 007 0 05 0 18 0 002 0 007 0 10 0 25 0 004 0 010 51 87 51 90 2 042 2 043 45 00 45 03 1 772 1 773 27 00 27 15 1 063 1 069 2 50 2 60 0 098 0 102 Wear or damage Wear or damage Wear or damage Wear or damage Countershaft distance collar length 28 mm 38 97 39 00 1 534 1 535 39 02 39 05 1 536 1 537 39 07 39 10 1 538 1 539 39 12 39 15 1 540 1 541 39 17 39 20 1
24. 01676 01627 D16Y1 End play installed on crankshaft Connecting rod 0 014 0 040 0 0006 0 0016 18 96 18 98 0 746 0 747 43 0 1 69 45 0 1 77 48 0 1 89 0 15 0 30 0 006 0 012 0 40 0 016 Crankshaft Main journal diameter D12B1 D13B2 D13B3 D15B2 D15B3 01587 1521 015 2 D16A7 D16A9 01676 01627 D16Y1 Rod journal diameter 01281 01382 01383 01582 01583 01587 01571 01572 0167 D16A9 01676 01677 D16Y1 Out of round End play Total runout 44 976 45 000 1 7707 1 7717 54 976 55 000 2 1644 2 1654 39 976 40 000 1 5739 1 5748 41 976 42 000 1 6526 1 6535 44 976 45 000 1 7707 1 7717 0 0025 0 00010 max 0 005 0 0002 0 0025 0 00010 max 0 005 0 0002 0 10 0 35 0 004 0 014 0 4 0 03 0 001 max 0 0 Main bearing to journal oil clearance No 1 and 5 journals No 2 3and 4 journals Rod bearing to journal oil clearance Bearings 1 TEIKOKU PISTON RING manufactured piston ring 2 RIKEN manufactured piston ring 3 6 0 018 0 036 0 0007 0 0014 0 024 0 042 0 0009 0 0017 0 020 0 038 0 0008 0 0015 8 ALLIED RING CORP manufactured piston ring Unit of length mm Engine Block Section 7 B16A2 Engine MEASUREMENT STANDARD NEW SERVICE LIMIT Cylinder block Warpage of deck
25. 1 2209 37 989 38 000 1 4956 1 4961 56 450 56 550 2 2224 2 2264 26 03 26 08 1 025 1 027 Ath 5th gear side 31 06 1 223 37 94 1 494 2WD Manual Transmission 21 S21 Section 13 MEASUREMENT STANDARD NEW Unit of length mm SERVICE LIMIT Reverse idler gear 1 D Gear to reverse gear shaft clearance Synchro ring Ring to gear clearance Ring pushed against gear 20 016 20 043 0 7880 0 7891 0 036 0 084 0 0014 0 0033 0 85 1 10 0 033 0 043 20 090 0 7909 0 16 0 006 0 40 0 016 Double cone synchro ring Clearance Ring pushed against gear Outer synchro ring to gear Synchro cone to gear Outer synchro ring to synchro cone 68 0 037 0 066 1 0 0 02 0 04 1 0 0 02 0 04 Shift fork Fork finger thickness Fork to synchro sleeve clearance 7 60 0 291 0 299 0 65 0 014 0 026 1 0 0 04 Reverse shift fork Fork paw groove width Fork to reverse idler gear clearance L groove width At bth gear side At reverse side Fork to 5th reverse shift piece pin clearance At 5th gear side At reverse side EE 0 524 1 1 0 02 0 04 7 7 0 29 0 30 5 7 25 0 278 0 285 0 9 0 02 0 04 1 8 0 07 Shift piece Shift piece to shift arm clearance Groove width of shift arm contact area Shift piece to shift fork shaft clearance Wi
26. 25 000 0 9837 0 9843 27 987 28 000 1 1018 1 0 02 0 001 max 7 977 27 990 1 1015 1 1020 27 920 1 0992 34 930 1 3752 24 930 0 9815 1024 27 930 1 0996 0 05 0 002 I D End play Thickness 40 009 40 025 1 5752 1 5758 0 06 0 21 0 002 0 008 32 42 32 47 1 276 1 278 40 07 1 578 0 30 0 012 32 30 1 272 Mainshaft 4th gear I D End play Thickness 40 009 40 025 1 5752 1 5758 0 06 0 21 0 002 0 008 30 92 30 97 1 217 1 219 40 07 1 578 0 30 0 012 30 80 1 213 Mainshaft 5th gear I D End play Thickness 40 009 40 025 1 5752 1 0 06 0 21 0 002 0 008 30 42 30 47 1 198 1 200 40 07 1 578 0 30 0 012 30 30 1 193 5758 Countershaft Diameter of needle bearing contact area A Diameter of super low 3rd gear contact area B Diameter of ball bearing contact area C Runout 29 000 29 015 1 1417 1 36 464 36 480 1 4356 1 24 987 25 000 0 9837 O 0 02 0 001 max 1423 28 940 1 1394 4362 36 41 1 433 9843 24 930 0 9815 0 05 0 002 Countershaft 1st gear I D End play When tightened by the specified torque Thickness Countershaft 2nd gear 1 D End play When tightened by the specified torque Thickness
27. 5 BRAKE PARKING FRONT DRIVER S IGNITION DRIVER S FLUID BRAKE PASSENGER S DOOR KEY SEAT BELT LEVEL SWITCH DOOR SWITCH SWITCH SWITCH SWITCH SWITCH i X G301 LHD G401 G551 G401 G201 RHD G552 23 31 Integrated Control Unit Circuit Diagram UNDER HOOD FUSE RELAY BOX 41 80 39 50A ONO ONO IGNITION SWITCH BATTERY UNDER DASH FUSE RELAY BOX No 36 50A No 3 7 5A gt WHT RED SEAT BELT REMINDER LIGHT 1 4W INT internal connection Internal connection internal connection RED BLU wo INTEGRATED CONTROL UNIT BEEPER SEAT BELT REMINDER KEY IN BEEPER CIRCUIT KY WIPER RELAY CIRCUIT 4 I CEILING LIGHT 1 LTGRN RED GRN BLU BLU WHT RED BLU BLU WHT I LT GRN RED I LT GRN RED RED BLU WINDSHIELD WIPER MOTOR FRONT DRIVER S IGNITION T priver s PASSENGER S DOOR KEY SEAT BELT DOOR SWITCH switch SWITCH SWITCH BLK BLK BLK BLK BLK 6401 Geer Gan 6552 23 32 15 10 O O 14 20 ONO YEL BLU BLU GRN INTERMITTENT a WINDSHIELD WIPER WASHER SWITCH OFF INT WHT BLK e WHT BLK YEL WINDSHIELD WIPER WASHER SWITCH OFF 1 BLU GRN A10 WINDSHIELD WIPER MOTOR As Circuit Diagram UNDER HOOD FUSE RELAY BOX IGNITION SWITCH
28. 50 009 50 025 1 9689 1 0 03 0 08 0 001 0 003 32 95 33 00 1 297 1 299 9695 50 07 1 971 0 180 0 0071 32 83 1 293 50 009 50 025 1 9689 1 0 03 0 08 0 001 0 003 32 92 32 97 1 296 1 298 9695 50 07 1 971 0 180 0 0071 32 8 1 29 Reverse idler gear Super low 1st shaft 1 D Gear to shaft clearance Mainshaft 4th I D 28 002 28 012 1 1024 1 1028 28 06 1 105 and 5th gear O D 34 989 35 000 1 3775 1 3780 34 93 1 375 distance collar Length 26 03 26 08 1 025 1 027 26 01 1 024 Countershaft I D 36 48 36 49 1 436 1 437 36 54 1 439 2nd gear O D 43 989 44 000 1 7318 1 7323 43 93 1 730 distance collar Length 28 95 29 05 1 140 1 144 Adjust 20 016 20 043 0 7880 0 7891 0 036 0 084 0 0014 0 0033 20 08 0 791 0 14 0 006 Distance of needle bearing contact area 23 984 23 993 0 9443 0 9446 23 93 0 942 Super low 3rd gear 3 14 Diameter of needle bearing contact area Width of needle bearing contact area 43 984 44 000 1 7317 1 31 03 31 08 1 222 1 224 7323 43 93 1 730 31 01 1 221 AWD Manual Transmission S22 Section 13 Transfer shaft MEASUREMENT Diameter of needle bearing contact area Diameter of taper bear
29. Brush spring tension new N kg Ibs 13 1 3 2 9 Starter motor Type Gear reduction MITSUBA Mica depth 0 40 0 50 0 016 0 020 0 15 0 006 1 0 kW 1 2 kW Commutator runout 0 0 02 0 0 001 0 05 0 002 1 4 kW Commutator D 28 00 28 10 1 102 1 106 27 50 1 083 Brush length 1 0kW 1 2KW 14 3 14 7 0 56 0 58 9 5 0 37 1 4kW 15 8 16 2 0 62 0 64 11 0 0 43 Brush spring tension new 1 0kW 1 2kW 18 5 23 5 1 85 2 35 4 08 5 18 N kg Ibs 1 4kW 16 18 1 6 1 8 3 5 4 0 RT Starter motor Type Gear reduction 5 Mica depth 0 5 0 8 0 02 0 03 0 20 0 008 1 0 kW 1 2 kW Commutator runout 0 0 02 0 0 001 0 05 0 002 Commutator D 29 90 30 00 1 177 1 181 29 0 1 14 Brush length 1 0kW 13 0 13 5 0 51 0 53 8 5 0 33 1 2kW 15 0 15 5 0 59 0 61 10 0 0 39 Brush spring tension new 1 0kW 18 24 1 8 2 4 4 0 5 3 N kg Ibs 1 2kW 13 21 1 3 2 1 2 9 4 6 1 D12B1 D13B2 01383 01583 01522 engines 2 D15B2 D15B7 01521 D16A7 D16A9 01676 01677 D16Y1 B16A2 B16A3 engines 3 When using a new belt adjust deflection or tension to new belt values Run the engine for 5 minutes then turn it off Readjust deflection or tension to used belt values 3 37 Design Specifications METRIC ENGLISH NOTES DIMENSIONS 2 door Hatchback Overall length Overall width Overall height Wheelba
30. Countershaft reverse gear collar flange thickness Countershaft 1st gear collar length Countershaft 1st gear collar flange thickness 38 97 39 00 1 534 1 535 39 02 39 05 1 536 1 537 39 07 39 10 1 538 1 539 39 12 39 15 1 540 1 541 39 17 39 20 1 542 1 543 39 22 39 25 1 544 1 545 39 27 39 30 1 546 1 547 38 87 38 90 1 530 1 531 38 92 38 95 1 532 1 533 14 50 14 55 0 571 0 573 2 45 2 55 0 096 0 100 14 50 14 55 0 571 0 573 2 45 2 55 0 096 0 100 Wear or damage Wear or damage 2WD Automatic Transmission M48A Section 14 Transmission cont d MEASUREMENT Unit of length mm in Mainshaft 2nd gear thrust washer thickness STANDARD NEW SERVICE LIMIT 3 47 3 50 0 137 0 138 Wear or damage 3 52 3 55 0 139 0 140 3 57 3 60 0 141 0 142 3 62 3 65 0 143 0 144 3 67 3 70 0 144 0 146 3 72 3 75 0 146 0 148 3 77 3 80 0 148 0 150 3 82 3 85 0 150 0 152 3 87 3 90 0 152 0 154 Wear or damage Thrust washer thickness Mainshaft 4th gear Mainshaft ball bearing L side Mainshaft 1st gear L side Mainshaft 1st gear R side 4 45 4 55 0 175 0 179 2 95 3 05 0 116 0 120 1 45 1 50 0 057 0 059 2 43 2 50 0 096 0 098 Wear or damage Wear or damage Countershaft 3rd gear splin
31. Front Door NOTE j DIAGONAL Raise the glass fully CUTTERS 1 Remove Door panel N Plastic cover 2 Remove the mounting bolts JOINT NOTE Take care not to drop the mounting bolts inside the door OUTER HANDLE BUSHING CAUTION ROD Replace Use protective tape around the outer handle to OUTER prevent damage HANDLE OUTER PROTECTIVE HANDLE TAPE LOCK JOINT OUTER s HANDLE CYLINDER gt CYLINDER ROD 4 Pull out the retainer clip then remove the lock cylinder and cylinder protector OUTER HANDLE MOUNTING BOLTS 6 x 1 0 mm 10 N m 1 0 kg m 7 2 Ib ft LOCK CYLINDER 3 Pull out the outer handle Pry the outer handle rod out of its joint using diagonal cutters and disconnect the cylinder rod by turning the outer handle NOTE To ease reassembly note location of the outer RETAINER CLIP handle rod on the joint before disconnecting it Take care not to bend the outer handle rod 5 Installation is the reverse of the removal procedure Take care not to damage the joint of the lock cylinder NOTE Make sure the outer handle rod and cylinder rod are connected securely Make sure the door locks and opens properly 20 2 Latch Replacement Front Door NOTE Raise the glass fully 1 Remove Door panel Plastic cover Center channel
32. Front position Lights 12V 5W Side Turn Signal Lights 12V 5W Rear Turn Signal Lights 12V 21W Brake Taillights 12 V 21 5 W High Mount Brake Light 3 door 12 V 21 CP KQ and KY models 4 door 12 V 32 CP KB mode 12V 21W KO and KY models Back up Lights 12 21 License Plate Lights 12 V 5W 12 V 8W KB model Ceiling Lights 12 V 5W Trunk Luggage Area Lights 12 V 3 4 W Gauge Lights 12V 3 0W Indicator Lights 12V 1 2W 1 4 W 0 84 W and Pilot Lights 12 1 4 1 12 0 84 W 12 V 0 91 W 0 56 W LED Heater Illumination Lights 12V 1 4W Rear Fog Light 12V 21W European KB and KP models 3 47 Body Specifications INS AM DN 3d62X3 AM cx zy AUO puequiy Unit mm in 7 091 670 0091 0 0 107191 060 9 091 080 100 0292 enlEES SSE L s IL ES 04271 0 S Sve L s 6 99 00 71 4 99 46971 2 door Hatchback 3 48 Maintenance Lubrication Points For the details of lubrication points and types of lubricants to be applied refer to the Illustrated Index and various work procedures such as Assembly Reassembly Replacement Overhaul Installation etc contained in each section No LUBRICATION POINTS LUBRICANT 1 Engine API Service Grade SF SG or SH fuel efficient oil SAE Viscosity See chart below 1 2 Tran
33. KU EX EG8 KP KT KY 4 GLi EG8 7 VEi EG8 KQ Si EH9 KP KT KY 9 VTi EH9 KO Auxiliary Number 0001 Factory Code S Suzuka Factory in Japan Model Year 3 1995 Serial Number Engine Type D12B1 D13B3 D15B3 D15B7 01571 01649 D16Y1 Serial Number D12B1 D15B7 D16Y1 Manual Transmission Number S20 2000001 Transmission Type Serial Number Engine Number D12B1 2300001 1200 SOHC 16 valves 1 carbureded Engine without CATA 1300 SOHC 16 valves 1 carbureded Engine without CATA 1500 SOHC 16 valves 1 carbureded Engine without CATA 1500 SOHC 16 valves Sequential Multiport Fuel injected Engine with CATA 1500 SOHC 16 valves Sequential Multiport Fuel injected Engine with CATA 1600 DOHC 16 valves Sequential Multiport Fuel injected Engine without CATA 1600 SOHC 16 valves Sequential Multiport Fuel injected VTEC Engine with CATA D13B3 01583 D16A9 2300001 01521 4700001 1100001 Automatic Transmission Number Transmission Type S24A S48A Serial Number S24A 4000001 Except D12B1 D15B3 D16A9 engines D12B1 D15B3 D16A9 engines 1 5 Chassis Engine Numbers Except European Model 2 door Hatchback KM Vehicle Identification Number Engine Number 2 2 3 4 S H 650001 D15B7 4500001
34. No of Cylinder Capacity 150 cm rev 9 15 cu in rev Max Speed 8 000 min rpm Lubricant Type GU10 Lubricant Capacity 140 m2 4 2 3 fl oz 4 9 Imp oz Compressor Type Make Swash plate NIPPONDENSO B16A2 B16A3 No of Cylinder 10 Capacity 155 3 cm rev 9 47 cu in rev Max Speed 7 600 min rpm Lubricant Type ND OIL8 Lubricant Capacity 120 m 4 fl oz 4 2 Imp oz Condenser Type Corrugated fin Evaporator Type Corrugated fin Blower Type Sirocco fan Motor Input 200 W 12 V max Speed Control 4 speed Max Capacity 430 m3 h 15 188 cu ft h 3 45 Design Specifications AIR CONDITIONING Temp Control Type METRIC ENGLISH Air mix Compressor Clutch Type Power Consumption Dry single plate poly V belt drive 42 W 12 V 40 W max 12 V HADSYS Except HADSYS Refrigerant Type Quantity HFC 134a R 134a 550 g 19 4 2 02 STEERING SYSTEM P S M S P S P S M S P S P S M S Except VTi and VTi VEi VTi Type VTi Except VTi Overall Ratio Turns Lock to lock VTi Except VTi Steering Wheel Diameter Power assisted rack and pinion Rack and pinion LHD 17 5 RHD 16 5 LHD 17 5 RHD 17 0 LHD 19 0 RHD 19 0 LHD 3 3 RHD 3 1 LHD 3 6 RHD 3 5 LHD 3 9 RHD 3 9 375 mm 14 8 in 380 mm 15 0 in 377 mm 14 8 in SUSPENSION Front and Rear Front and Rear Type Shock Absorber Independent double wishbone coil spring Telescop
35. Wear or damage Wear or damage 8 95 0 352 5 95 0 234 7 95 0 313 7 95 0 313 1 80 0 071 6 045 0 2380 9 030 0 3555 8 030 0 3161 8 030 0 3161 2 080 0 0819 Regulator valve body Sealing ring contact 1 D 35 000 35 025 1 3780 1 3789 35 050 1 3799 Shifting device and parking brake control Reverse shift fork finger thickness Parking brake ratchet pawl Parking brake gear Throttle cam stopper height 5 90 6 00 0 232 0 236 27 00 27 10 1 063 1 067 5 40 0 213 Wear or other defect Servo body Shift fork shaft bore I D 14 000 14 010 0 5512 0 5516 Shift fork shaft valve 1 D 37 000 37 039 1 4567 1 4582 37 045 1 4585 Oil pump Oil pump gear side clearance Drive Driven Oil pump gear to body clearance Drive Driven Oil pump driven gear I D Oil pump shaft O D 0 030 0 050 0 0012 0 0020 0 040 0 060 0 0016 0 0024 0 210 0 265 0 0083 0 0104 0 070 0 125 0 0028 0 0049 14 016 14 034 0 5518 0 5525 13 980 13 990 0 5504 0 5508 0 07 0 003 0 07 0 003 Wear or damage Wear or damage cont d 3 25 Standards and Service Limits 2WD Automatic Transmission 24 cont d Section 14 STANDARD NEV 3 26 Inside Diameter MEASUREMENT Wire Dia O D Free Length of Coils
36. system HADSYS Engine type D15B7 01571 01626 01627 D16Y1 Lubricant type SP 10 P N 38899 P13 003 For Refrigerant HFC 134a R 134a Lubricant capacity Condenser m2 fl oz Imp oz Evaporator Line or hose Receiver 20 2 3 0 7 45 1 1 2 1 6 10 1 3 0 4 10 1 3 0 4 MATSUSHITA Engine type D12B1 D13B2 01383 D15B2 D15B3 D15Y2 Lubricant type GU10 P N 38899 P08 003 For Refrigerant HFC 134a R 134a Lubricant capacity Condenser m fl oz Imp oz Evaporator Line or hose Receiver 15 1 2 0 5 35 1 1 6 1 2 10 1 3 0 4 10 1 3 0 4 NIPPONDENSO Engine type B16A2 B16A3 Lubricant type ND OIL8 P N 38899 PR7 003 F Lubricant capacity Condenser m 0 fl oz Imp oz Evaporator Line or hose Receiver Refrigerant HFC 134a 134 25 5 6 0 9 60 2 0 2 1 10 1 3 0 4 10 1 3 0 4 Compressor HADSYS Engine type D15B7 01521 01626 01627 D16Y1 Lubricant type SP 10 P N 38899 P13 003 For Refrigerant HFC 134a R 134a Lubricant capacity m2 fl oz Imp oz Field coil resistance at 20 C 68 0 Pulley to pressure plate clearance 120 4 1 4 2 2 65 2 95 0 5 0 15 0 02 0 006 MATSUSHITA Engine type D12B1 D13B2 D13B3 D15B2 D15B3 D15Y2 Lubricant type GU10 P N 38899 8 003 For Refrigerant HFC 134a R 1
37. the Shop Manual 62SR300 23 15 Ignition System Spark Plug Inspection KM 1 Inspect the electrodes and ceramic insulator for Worn or deformed electrodes E I t Cracked center Damaged gasket Cracked insulator Improper gap Oil fouling Carbon deposits electrode insulator Burned or worn electrodes may be caused by Advanced ignition timing Loose spark plug Plug heat range too low Insufficient cooling Fouled plug may be caused by e 2 D15B7 D16Z6 engine Adjust the gap with a suitable gapping tool and replace the plug if the center electrode rounded as shown below Electrode Gap Retarded ignition timing Oil in combustion chamber Incorrect spark plug gap Plug heat range too high Excessive idling low speed running Clogged air cleaner element Deteriorated ignition coil or ignition wires Standard 1 1 9 0 1 mm 0 043 D 0 004 1 1 mm 0 043 23 16 ROUNDED ELECTRODE 3 B16A3 engine Do not adjust the gap of a platinum tip plug replace the spark plug if the center electrode is rounded or the gap is not within the specification Electrode Gap Standard 13 mm 0 051 _ in 9 PLATINUM TIP NOTE Use only the spark plugs listed below Spark Plug D15B7 engine ZFR5F 11 NGK KJ16CR L11 Nippondenso
38. 0 5 6 0 22 33 0 1 30 21 7 4th exhaust valve spring 0 9 0 6 6 0 26 43 3 1 70 22 4WD Automatic Transmission M25A Section 14 Transmission fluid MEASUREMENT STANDARD NEW Unit of length mm in SERVICE LIMIT Capacity 2 US qt Imp qt 6 4 6 8 5 6 for overhaul 3 2 3 4 2 8 for fluid change Hydraulic pressure kPa kg cm psi Line pressure at 2 000 min rpm or P position 850 900 8 5 9 0 121 128 800 8 0 114 2nd clutch pressure at 2 000 rpm D position 3rd clutch pressure at 2 000 min rpm D position 4th clutch pressure at 2 000 min rpm 500 5 0 71 throttle fully closed 850 900 8 5 9 0 121 128 450 4 5 64 throttle fully closed 800 8 0 114 throttle more than 1 position D4 position throttle more than 3 8 opened 3 8 opened 2nd clutch pressure at 2 000 rpm 850 900 8 5 9 0 121 128 800 8 0 114 2 position 1st clutch pressure at 2 000 min rpm 850 900 8 5 9 0 121 128 800 8 0 114 1st hold clutch pressure at 2 000 min rpm 1 position 850 900 8 5 9 0 121 128 800 8 0 114 Throttle B pressure Throttle fully closed Throttle fully open 0 850 900 8 5 9 0 121 128 800 8 0 114 Stall speed mim rpm check with car on level ground 2 600 2 300 2 900 Clutch Clutch initial clearanc
39. 0 106 0 110 MARK6 2 80 2 90 0 110 0 114 MARK7 2 90 3 00 0 114 0 118 MARK8 3 00 3 10 0 118 0 122 9 3 10 3 20 0 122 0 126 MARK10 3 20 3 30 0 126 0 130 MARK11 2 00 2 10 0 079 0 083 MARK12 2 10 2 20 0 083 0 087 Y MARK13 2 20 2 30 0 087 0 091 Discoloration cont d 3 17 Standards and Service Limits 2WD Automatic Transmission M48A cont d Section 14 MEASUREMENT STANDARD NEW SERVICE LIMIT Transmission Diameter of needle bearing contact area On mainshaft and stator shaft On mainshaft 2nd gear On mainshaft 4th gear collar On mainshaft 1st gear collar On countershaft L side On countershaft 3rd gear distance collar On countershaft 4th gear On countershaft reverse gear collar On countershaft 1st gear collar On reverse idler gear shaft On mainshaft 1st gear Inside diameter of needle bearing contact area On mainshaft 2nd gear On mainshaft 4th gear On countershaft 1st gear On countershaft 3rd gear On countershaft 4th gear On countershaft reverse gear On reverse idler gear On stator shaft R side On stator shaft stator side On reverse idler shaft holder End play Mainshaft 1st gear Mainshaft 2nd gear Mainshaft 4th gear Countershaft 1st gear Countershaft 3rd gear Countershaft 4th gear Reverse idler gear Countershaft reverse gear Selector hub O D Mainshaft 4th gear collar length Mainshaft 1st gear col
40. 0 45 R Front Stopper 5 3 i Locate Hole POINT d POINT n 917 0 56 Rear Beam Point 011 5 0 45 L Front Stopper Front Oamper Lower Bush 20 12 POINT u POINT t POINT v POINT w ES POINT PS 13 11 4 mc CN 920 0 8 ez CH PALA POINT p SE ES EEN es H LE Zz aja a 5 5 SIS BEE bos u _8 E Nas aj eig 8 1 FL L 1 xs as K ds Ee lee LEN r B cM Ween POINT z JI st m EU E POINT s 312 9 138 j Mel S 5 4 2 911 5 0 45 187 7 361167 2 6 gc epe M a SEN 382 15 0 36 1 41 980 ED E POINT w POINT v Rear Damper SECTION EE 912 0 47 Upper Arm Point N Center POINT u Upper Arm Point POINT t 912 0 47 Upper Arm Point POINT 5 5 l 914 0 55 Trailing Arm Pont Le POINT x AS 5 925 1 0 Locate Hole P 2 55 2 POINT q 14 N yr 3 Compensator Arm Center F gt SA S 9 Pty 9 5 K v Gel SIE I 1 CL SE SS T POINT p 925 1 0 Locate Hole S POINT x Lower Arm Center 28 1 11 POINT 2 920 0 8 Locate Hole POINT y 20 0 8 Locate Hole 20 13 Frame Repair Chart cont d 4WD N
41. 2 door Hatchback Vehicle Identification Number Engine Number JHMEG3 32005300001 B16A2 1300001 Manufacturer Make and Engine Type Type of Vehicle B16A2 1600 DOHC 16 valves Sequential JHM HONDA MOTOR CO LTD Multiport Fuel injected VTEC JAPAN Engine with CATA HONDA Passenger car D13B2 1300 SOHC 16 valves 1 carbureded Line Body and Engine Type Engine with CATA EG3 CIVIC 3 door D13B2 D15B2 1500 SOHC 16 valves Dual point EG4 CIVIC 3 door D15B2 01571 Fuel injected Engine with CATA CIVIC 3 door D16Z6 01541 1500 SOHC 16 valves Sequential EG6 CIVIC 3 door B16A2 Multiport Fuel injected VTEC E Body Type and Transmission Type Engine with CATA 3 2 door Hatchback 5 speed Manual 01626 1600 SOHC 16 valves Sequential 4 2 door Hatchback 4 speed Automatic Multiport Fuel injected VTEC Vehicle Grade Series Engine with CATA 2 DX EG3 KG KZ KF KS KE Serial Number 3 EX EG3 KG KZ KF B16A2 1300001 4 DXi EG4 KG KZ KS D13B2 2300001 5 LSi EG4 KG KZ KF KS KE KW D15B2 7000001 6 VEi EG4 KG KF KS KE DX EH2 KM 01521 01626 4700001 8 ESi EG5 KG KF KS KE KW Si EH3 KM 9 VTi EG6 KG KF KS KE KW zc Fixed Code Manual Transmission Number Auxiliary Number Factory Code 20 2000001 S Suzuka Factory in Japan Model Year Transmission Type 3 1995 520 Except B16A2 engine Serial Number nn 521 21 For B16A2 engine Serial Number
42. 2201 36 004 36 017 1 4175 1 4180 31 975 31 991 1 2589 1 2595 27 980 27 993 1 1016 1 1021 29 980 29 993 1 1803 1 1808 31 975 31 991 1 2589 1 2595 27 991 28 000 1 1020 1 1024 29 980 29 993 1 1803 1 1808 13 990 14 000 0 5508 0 5512 36 000 36 016 1 4173 1 4179 41 000 41 016 1 6142 1 6148 38 000 38 016 1 4961 1 4967 38 000 38 016 1 4961 1 4967 38 000 38 016 1 4961 1 4967 33 000 33 016 1 2992 1 2998 36 000 36 016 1 4173 1 4179 35 000 35 016 1 3780 1 3786 18 007 18 020 0 7089 0 7094 26 000 26 013 1 0236 1 0241 24 000 24 021 0 9449 0 9457 14 416 14 434 0 5676 0 5683 0 08 0 24 0 003 0 009 0 07 0 15 0 003 0 006 0 0 08 0 0 0 003 0 10 0 45 0 004 0 018 0 07 0 15 0 003 0 006 0 07 0 15 0 003 0 006 0 05 0 18 0 002 0 007 0 10 0 45 0 004 0 018 51 87 51 90 2 042 2 043 46 500 46 530 1 8307 1 8319 24 500 24 550 0 9646 0 9665 2 50 2 60 0 098 0 102 Wear or damage Wear or damage Wear Wear damage Wear or damage Wear or damage 38 97 39 00 1 534 1 535 39 02 39 05 1 536 1 537 39 07 39 10 1 538 1 539 39 12 39 15 1 540 1 541 39 17 39 20 1 542 1 543 39
43. 262 SERVICE LIMIT Cylinder Head Valve Train Section 6 B16A2 B16A3 Engines MEASUREMENT Unit of length mm in STANDARD NEW SERVICE LIMIT Compression wide open throttle kPa kg cm psi 250 min rpm Nominal Minimum Maximum variation 1 550 15 5 220 950 9 5 135 200 2 0 28 Cylinder head Warpage 0 05 0 002 Height 141 95 142 05 5 589 5 593 Camshaft End play 0 05 0 15 0 002 0 006 0 5 0 02 Camshaft to holder oil clearance 0 050 0 089 0 0020 0 0035 0 15 0 006 Total runout 0 03 0 001 max 0 04 0 002 Cam lobe height IN Primary Mid Secondary EX Primary Mid Secondary 33 088 1 3027 36 267 1 4278 34 978 1 3771 32 785 1 2907 35 720 1 4063 34 691 1 3658 Valve clearance Valve stem O D Stem to guide clearance 0 15 0 19 0 006 0 007 0 17 0 21 0 007 0 008 5 475 5 485 0 2156 0 2159 5 450 5 460 0 2146 0 2150 0 025 0 055 0 0010 0 0022 0 050 0 080 0 0020 0 0031 5 445 0 2144 5 420 0 2134 0 08 0 003 0 11 0 004 Valve seat Width Stem installed height 1 25 1 55 0 049 0 061 1 25 1 55 0 049 0 061 37 465 37 935 1 4750 1 4935 37 165 37 635 1 4632 1 4817 2 00 0 079 2 00 0 079 38 185 1 5033 37 885 1 4915 Valve sp
44. 3 3 Q 09 8 9 99 9 D 98 89 8 TORQUE SPECIFICATIONS Torque Value Bolt Size Remarks 6 x 1 0 mm 12 N m 1 2 kg m 9 Ib ft 14 7 Sub shaft Disassembly Reassembly Remove the oil guide cap by pushing the sub shaft inside the transmission housing Remove the 1st hold clutch assembly by pulling the sub shaft then remove the sub shaft Instail new O rings on the sub shaft NOTE Wrap the shaft splines with tape to prevent damaging the O rings Place the sub shaft in the transmission housing and install the 1st hold clutch assembly Install new oil guide cap using the special tools as shown DRIVER OIL GUIDE 07749 0010100 0 0 5 mm 0 0 02 in ATTACHMENT 32 x 35 mm 07746 0010100 1ST HOLD CLUTCH ASSEMBLY 14 8 Clutch Illustrated Index 1ST HOLD CLUTCH SNAP RING CLUTCH END PLATE CLUTCH DISCS Standard thickness 1 94 mm 0 076 in SNAP RING SPRING RETAINER RETURN SPRING DISC SPRING CLUTCH PISTON O RINGS Replace CLUTCH PLATES Standard thickness 2 00 mm 0 079 in CLUTCH DRUM 14 9 Gearshift Selector KB and KM models Disassembly Reassembly CAUTION All SRS wire harnesses are covered with yellow insulation e Whenever the ignition switch is ON or has been turned OFF for less than three minutes be careful not to bump the SRS unit the airb
45. 490 0 2157 0 2161 5 450 0 2146 EX 5 450 5 460 0 2146 0 2150 5 420 0 2134 Stem to guide clearance IN 0 02 0 05 0 001 0 002 0 08 0 003 EX 0 05 0 08 0 002 0 003 0 11 0 004 Valve seat Width IN 0 85 1 15 0 033 0 045 1 60 0 063 EX 1 25 1 55 0 049 0 061 2 00 0 079 Stem installed height IN 46 985 47 455 1 8498 1 8683 47 705 1 8781 49 685 1 9561 5 55 0 219 5 55 0 219 Rocker arm 1 NIHON HATSUJO manufactured valve spring 3 2 Arm to shaft clearance 0 017 0 050 0 0007 0 0020 0 018 0 054 0 0007 0 0021 0 08 0 003 0 08 0 003 2 CHUO HATSUJO manufactured valve spring Cylinder Head Valve Train Section 6 01521 01627 D16Y1 Engines Unit of length mm in MEASUREMENT STANDARD NEW SERVICE LIMIT Compression 250 min rpm Nominal 1 300 13 0 185 wide open throttle Minimum 1 150 11 5 164 kPa kg cm psi Maximum variation 200 2 0 28 Cylinder head Warpage a 0 05 0 002 Height 92 95 93 05 3 659 3 663 2 7 Camshaft End play 0 05 0 15 0 002 0 006 0 5 0 02 Camshaft to holder oil clearance 0 050 0 089 0 0020 0 0035 0 15 0 006 Total runout 0 03 0 001 max 0 04 0 002 Cam 01521 IN Primary 38 427 1 5129 lobe Secondary 32 292 1 2713 height EX 37 997 1 4959 Except D15Z1 IN Primary 35 900
46. 5 kg m 33 Ib ft WASHER Replace WASHER SET SCREW Replace 22 N m 2 2 kg m 16 SUPER LOW SHIFT LEVER BOLT 40 N m 4 0 kg m 29 Ib ft 13 6 SUPPLEMENTAL RESTRAINT SYSTEM SRS If automatic transmission maintenance is required The Civic SRS includes a driver s airbag located in the steering wheel hub addition some models have also a front passenger s airbag located in the dashboard above the glove box There are two types SRS Type Il SRS unit is part of the airbag assembly which is used for models without front passenger s airbag and Type SRS unit is not part of the airbag assembly and has built in sensors which is used for models with front passenger s airbag Information necessary to safely service the SRS is included in this Shop Manual Items marked with an asterisk on the contents page include or are located near SRS components Servicing disassembling or replacing these items will require special precautions and tools and should therefore be done by an authorized Honda dealer AW ARNING 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 authorized Honda dealer Improper service procedures including incorrect removal and installation of the SRS could lead to personal injury caused by unintentional activation of the airbag s Do not bump the SRS unit O
47. 50 1 5 1 16 13 64 Master cylinder Piston to pushrod clearance 0 0 40 0 0 0 016 Disc brake Disc thickness Front 21 0 0 83 19 0 0 75 D13B2 D13B3 3D 17 0 0 67 15 0 0 59 Rear 9 0 0 35 8 0 0 31 Disc runout 0 10 0 004 Rear 0 10 0 004 Disc parallelism Front and Rear 0 015 0 0006 Front D13B2 D13B3 3D 9 5 0 37 1 60 0 063 B16A2 B16A3 10 0 0 39 1 60 0 063 01627 4WD Others 9 0 0 35 1 60 0 063 Rear 7 5 0 30 1 60 0 063 Rear brake drum l 2WD 180 0 7 09 181 0 7 13 4WD 200 0 7 87 201 0 7 91 Lining thickness 2WD 4 5 0 18 2 0 0 08 4wD 4 0 0 16 2 0 0 08 Brake booster Characteristics at 200 N 20 kg 44 Ibs pedal force Vacuum mmHg Line pressure kPa inHg kg cm psi 01627 4WD 0 0 0 1 310 13 1 186 without ABS 300 11 8 5 460 54 6 776 500 19 7 8 300 83 0 1 180 B16A2 B16A3 0 0 0 1 310 13 1 186 without ABS 300 11 8 5 460 54 6 776 500 19 7 7 650 76 5 1 088 D16Z7 4WD 0 0 0 920 9 2 131 B16A2 B16A3 300 11 8 5 570 55 7 792 with ABS 500 19 7 8 740 87 4 1 243 D13B2 D13B3 3D 0 0 0 1 520 15 2 216 300 11 8 5 310 53 1 755 500 19 7 7 880 78 8 1 121 Others 0 0 0 1 520 15 2 216 300 11 8 6 380 63 8 907 500 19 7 8 870 88 7 1 261 3 35 Standards and Service Limits Air Conditioning Section 22 MEASUREMENT STANDARD NEW Air conditioning
48. B spring 1 4 0 06 8 5 0 33 41 5 1 63 10 5 Throttle valve B spring 1 4 0 06 8 5 0 33 41 5 1 63 11 2 Throttle valve B spring 1 4 0 06 8 5 0 33 41 6 1 64 12 4 1 2 shift valve spring 0 45 0 018 5 1 0 20 52 8 2 08 29 1 2 shift valve ball spring 0 45 0 018 4 5 0 18 10 7 0 42 12 7 2 3 shift valve spring 0 9 0 04 7 1 0 28 65 3 2 57 32 1 2 3 shift valve ball spring 0 45 0 018 4 5 0 18 13 3 0 52 8 0 3 4 shift valve spring 0 9 0 04 9 6 0 38 32 5 1 28 10 3 3 4 shift valve ball spring 0 5 0 02 4 5 0 18 11 3 0 44 7 4 1st hold accumulator spring 4 0 0 16 21 5 0 85 71 7 2 82 8 3 1st accumulator spring A 2 6 0 10 24 3 0 96 101 9 4 01 11 6 1st accumulator spring B 2 3 0 09 9 9 0 39 49 0 1 93 4 6 2nd accumulator spring 3 5 0 14 22 0 0 87 77 0 3 03 9 5 3rd accumulator spring 2 6 0 10 17 5 0 69 91 8 3 61 15 8 4th accumulator spring 2 6 0 10 16 0 0 63 90 1 3 55 15 6 Lock up shift valve spring 0 9 0 04 7 6 0 30 73 7 2 90 32 Lock up timing valve spring 0 8 0 03 6 6 0 26 61 5 2 42 27 6 Look up control valve spring 0 9 0 04 6 6 0 26 38 4 1 51 23 3 Governor cut valve spring 0 8 0 7 6 0 30 44 5 1 75 17 CPC valve spring 0 9 0 8 4 0 33 24 9 0 98 9 8 Reverse control valve spring 0 7 0 7 1 0 28 40 0 1 57 20 8 3 2 timing valve spring 1 2 0 8 6 0 34 45 6 1 80 14 7 Servo control valve spring 0 9 0 6 4 0 25 34 1 1 34 17 5 2 1 timing valve spring 0 7
49. Driveshaft bore diameter Carrier to driveshaft clearance Differential pinion gear Backlash Pinion gear bore diameter Pinion gear to pinion shaft clearance 15 000 15 018 0 5906 0 5913 0 016 0 052 0 0006 0 0020 26 005 26 025 1 0238 1 0246 0 025 0 063 0 0010 0 0025 0 10 0 004 0 12 0 005 0 05 0 15 0 002 0 006 15 041 15 061 0 5922 0 5930 0 057 0 095 0 0022 0 0037 0 15 0 006 Set ring to bearing outer race 0 0 15 0 0 0 006 Adjust with shim 3 31 Standards and Service Limits MEASUREMENT Differential 2WD A T M24A Section 15 STANDARD NEW SERVICE LIMIT Final driven Backlash 0 071 0 129 0 0028 0 0051 Pinion shaft contact area D Carrier to pinion shaft clearance Driveshaft contact area D Carrier to driveshaft clearance Ball bearing contact area O D Differential carrier 18 000 18 018 0 7087 0 7094 0 013 0 047 0 0005 0 0019 26 005 26 025 1 0238 1 0246 0 025 0 066 0 0010 0 0026 40 002 40 018 1 5749 1 5755 0 10 0 004 0 12 0 005 Differential Backlash pinion gear Pinion gear to pinion shaft clearance 0 05 0 15 0 002 0 006 18 041 18 061 0 7103 0 7111 0 054 0 090 0 0021 0 0035 0 15 0 006 Set ring to bearing out
50. Engine 11 1 Fuel Injected Engine 11 3 Fuel and Emissions Carbureted Engine Carburetor Idle Speed Mixture D13B2 engine 11 2 Outline of Model Changes Idle speed has been changed for D13B2 engine The front fuel filter has been deleted for all models Carburetor Idle Speed Mixture D13B2 engine 5 If equipped with air conditioner check the idle speed with the A C on Do not smoke during this procedure Keep any open flame away from your work area Idle speed should be NOTE 900 50 rpm min Check that the self diagnosis indicator before making idie speed and mixture inspections Adjust the idle speed if necessary by turning the adjusting screw 1 Start the engine and warm it up to normal operating temperature the cooling fan comes twice 2 Connecta tachometer 3 Turn the ignition switch OFF Restart the engine and hold engine at idle for two minutes And hold engine at 3 000 3 500 rpm min for one minute Check idle speed with the headlights heater blower rear window defogger cooling fan and air conditioner off Idle speed should be 900 50 rpm min Adjust the idle speed if necessary by turning the throttle stop screw NOTE If the idle speed is excessively high check the ADJUSTING SCREW throttle control system THROTTLE STOP SCREW
51. FEED PIPE FUEL FILTER Replacement page 11 16 FUEL PULSATION DAMPER N FUEL TANK TOW WAY VALVE FUEL TUBE QUICK CONNECT FITTINGS except D15B7 D16Z6 engines of KM KH models Precaution page 11 13 Disconnection page 11 13 Connection page 11 14 CHARCOAL CANISTER FUEL RETURN PIPE FUEL PIPE FUEL INJECTORS PRESSURE REGULATOR 11 12 Fuel Supply System Fuel Tube Quick Connect Fittings except D15B7 D16Z6 engines of KM KH models Precautions AW Do not smoke while working on fuel system Keep open flame away from work area The fuel tube quick connect fittings assembly connects the in tank fuel pump with the fuel feed pipe For removing or installing the fuel pump and fue tank it is necessary to disconnect or connect the quick connect fittings Pay attention to following The fuel tube quick connect fittings assembly is not heat resistant be careful not to damage it during welding or other heat generating procedures The fuel tube quick connect fittings assembly is not acid proof do not touch it with a shop towel which was used for wiping away battery fluid Replace the fuel tube quick connect fittings assembly if it came into contact with battery fluid or similar When connecting or disconnecting the fuel tube quick connect fittings assembly be careful not to bend or twist it excessively Replace it in case of dama
52. GRN RED GRN BLK GRN YEL PGM FI ECU qm GRN WHT No 19 10A FUSE GRN BLK GRN BLU RED BLK SHIFT POSITION SHIFT POSITION CONSOLE POSITION Seen i 1 I RED E 1 1 1 I BLK 2 T E RI NE mus CONTROLLER E t L J G401 6401 With dashlight Without dashlight brightness brightness controller controller 23 26 DASHLIGHT BRIGHTNESS CONTROLLER brightness With dashlight controller 1 With interlock system Circuit Diagram 2WD 6 position Indicator IGNITION UNDER DASH UNDER HOOD FUSE RELAY BOX SWITCH FUSE RELAY BOX No 41 804 No 39 50A WHT BLK VHT O O BLK VEL No 19 10A PGM CARB FUSE CONTROL UNIT PGM FI ECU YEL RED BLK in the gauge assembly SHIFT LEVER POSITION INDICATOR DIMMING CIRCUIT i r d 3 GRN BLU i GRN RED GRN BLK GRN YEL EONTROL UNIT I PGM FI ECU 1 19 10 FUSE DASHLIGHT 1 BRIGHTNESS CONTROLLER GRN BLK 1 1 With dashlight RED BLK GRN BLU brightness controller SHIFT POSITION CONSOLE LIGHT SHIFT POSITION CONSOLE SWITCH v 1 1 1 1 1 l I 1 1
53. GRY Type 11 SRS unit VA 25 10A RED Type II SRS unit VA PNK or GRY Type SRS unit VB With SRS 23 5 lt 5 Under hood ABS Fuse Relay Box Not used To ABS motor relay To under hood ABS fuse relay box wire harness Fuse Number Wire color Amps WHT BLU eS CJC o Jol Loss 3 L Cd rt 9 VUE 427 ur To front fail safe relay To rear fail safe relay c 3csa o To battery terminal To main wire harness To main wire harness 4 P To main wire harness Component s or Circuit s Protected ABS motor Via ABS motor relay Not used Not used ABS control unit B2 WHT GRN ABS control unit B1 B3 Not used BRN YEL ABS control unit 23 6 Not used Power Distribution Circuit Identification NOTE This page corresponds to page 23 8 of the Shop Manual 62SR320 and reflects the model changes BATTERY BLK YEL UNDER HOOD ABS FUSE RELAY BOX No 54 15 G1 No 55 20 Q No 51 50 O No 13 7 5A FUSE ABS MOTOR RELAY No57 7 5 NO BLK YEL ABS REAR FAIL SAFE RELAY ABS FRONT FAIL SAFE RELAY V To page 23 9 a 4 Starter motor WHT WHT GRN 83 1 4 B2 ABS control unit WHT BLU ABS motor BRN YEL M ABS
54. General Info INTRODUCTION E Special Tools ai How to Use This Manual This supplement contains information for the 95 CIVIC Refer to following shop manuals for service procedures and data not included in this supplement Description Code No CIVIC MAINTENANCE REPAIR and 62SR300A Specifications Maintenance CONSTRUCTION 92 VOL 1 and VOL 2 62SR300B CIVIC SUPPLEMENT 93 62SR320 CIVIC SUPPLEMENT 94 62SR321 The first page of each section is marked with a black tab that lines up with one of the thumb index tabs on this page You can quickly find the first page of each section without looking through a full table of contents The symbols printed at the top corner of each page can also be used as a quick reference system Special Information AW ARNING Indicates a strong possibility of severe personal injury or loss of life if instructions are not followed CAUTION Indicates a possibility of personal injury or equipment damage if instructions are not followed NOTE Gives helpful information CAUTION Detailed descriptions of standard workshop procedures safety principles and service operations are not included Please note that this manual contain warnings and cautions against some specific service methods which could cause PERSONAL INJURY damage a vehicle or make it unsafe Please understand that these warnings cannot cover all conce
55. KS models recommended by manufacturer only except for KS model it is required For KS models monthly interval is recommended by manufacturer only except for KS models it is required Forcars with anti lock brake system Inspect every 10 000 km 6 000 miles or 12 months 4 5 Maintenance Schedule R Replace C Clean I Inspect After inspection clean adjust fill up repair or replace if necessary Service at the interval listed x 1 000 km or x 1 000 km 100 120 miles or after that number of months whichever comes first x 1 000 miles 60 72 months 60 72 Battery condition Rear differential oil AWD model R Tires condition wear and pressure Including spare Inspect every 10 000 km 6 000 miles or 12 months Lights operation and headlight beam Inspect every 10 000 km 6 000 miles or 12 months Paint damages and body work Test drive Noise stability dashboard operations 1 I I Cleanliness of controls door handles etc Inspect after every service Supplemental Restraint System Inspect system and replace slip ring 10 years first registration For cars with SRS 9 Except for cars with passenger airbag Severe Driving Conditions The following items must be serviced more frequently on cars normally used under severe driving conditions Refer to the chart below for the appropriate mainte
56. Limits 4WD Automatic Transmission 25 cont d Section 14 MEASUREMENT STANDARD NEW SERVICE LIMIT Transmission 3 28 Diameter of needle bearing contact area On mainshaft and stator shaft On mainshaft 2nd gear collar On mainshaft 4th gear collar On mainshaft 1st gear collar On countershaft L side On countershaft 3rd gear distance collar On countershaft 4th gear On countershaft reverse gear collar On countershaft 1st gear collar On sub shaft L side On sub shaft 4th gear collar On reverse idler gear shaft Inside diameter of needle bearing contact area On mainshaft 1st gear On mainshaft 2nd gear On mainshaft 4th gear On countershaft 1st gear On countershaft 3rd gear On countershaft 4th gear On countershaft reverse gear On sub shaft 4th gear On reverse idler gear On stator shaft R side On stator shaft stator side On reverse idler gear shaft holder End play Mainshaft 1st gear Mainshaft 2nd gear Mainshaft 4th gear Countershaft 1st gear Countershaft 3rd gear Countershaft 4th gear Reverse idler gear Countershaft reverse gear Selector hub O D Mainshaft 4th gear collar length Mainshaft 1st gear collar length Mainshaft 1st gear collar flange thickness Countershaft distance collar length 19 980 19 993 0 7866 0 7871 35 975 35 991 1 4163 1 4170 31 975 31 991 1 2589 1 2595 30 975 30 991 1 2195 1
57. Number VIN Warning Caution Label Locations SRS AIRBAG SYSTEM A DRIVER INFORMATION SUNVISOR A DRIVER INFORMATION SUNVISOR European models ALWAYS WEAR YOUR SEAT BELT THIS 15 EQUIPPED WITH DRIVER AIRBAG AS SUPPLEMENTAL RESTRAINT SYSTEM S R S IS DESIGNED TO SUPPLEMENT THE SEAT BELT YOUR SRS INDICATOR LIGHTS WHILE DRIVING SEE YOUR AUTHORIZED HONDA DEALER SRS ATTACHEZ TOUJOURS VOTRE CEITURE VEHICULE EST EQUIPE D UN COUSSIN D AIR POUR LE CONDUCTEUR QUI CONSTITUE UN SYSTEME DE RETENUE COMPLEMENTAIRE S R S CE COUSSIN D AIR COMPLETE LA FONCTION DE LA CEINTURE DE SECURITE SI LE TEMOIN SRS S ALLUME PENDANT LA CONDUITE ADRESSEZ VOUS A VOTRE CONCESSIONNAIRE HONDA OFFICIEL SICHERHEITSGURTE BEI JEDER FAHRT ANLEGEN DIESES FAHRZEUG BESITZT EINEN FAHRER AIRBAG ALS ZUSATZLICHES R CKHALTESYSTEM S R S ES IST EINE ERGANZUNG ZUM SICHERHEITSGURT WENN DIE SRS KONTROLLEUCHTE WAHREND DER FAHRT AUFLEUCHTET UMGEHEND FINEN HONDA H NDLER AUFSUCHEN sRs DRAAG ALTIJD UW VEILIGHEIDSGORDEL DIT VOERTUIG IS UITGERUST MET EEN LUCHTKUSSEN AAN DE BESTUURDERSKANT ALTS EXTRA BESCHERMING S R S DIT IS ONTWORPEN ALS EXTRA BESCHERMING BIJ DE VEILIGHEIDSGORDEL ALS HEL SRS WAARSCHUWINGSLAMPJE GAAT BRANDEN ONDER HET RIJDEN NEEM DAN KONTAKT OP MET EEN HONDA DEALER Except European models ALWAYS WEAR YOUR SEAT BELT THIS CAR IS EQUIPPED WITH A DRIVER
58. by the specified torque Thickness 31 92 31 97 1 257 1 259 31 85 1 254 Spacer collar 33 000 33 010 1 2992 1 2996 33 05 1 301 Countershaft O D 38 989 39 000 1 5350 1 5354 38 93 1 533 2nd gear Length 32 03 32 06 1 261 1 262 32 01 1 260 Spacer collar I D 27 002 27 012 1 0631 1 0635 27 06 1 065 Mainshaft 4th O D 4th 33 989 34 000 1 3381 1 3386 33 93 1 336 and 5th gear 5th 31 984 32 000 1 2592 1 2598 31 93 1 257 Length 4th 22 83 22 86 0 899 0 900 22 81 0 898 5th 23 53 23 56 0 926 0 928 23 51 0 926 Reverse idler I D 15 016 15 043 0 5912 0 5922 15 08 0 594 gear Gear to reverse gear shaft clearance 0 032 0 077 0 0013 0 0030 0 14 0 006 Synchro ring Ring to gear clearance 0 73 1 18 0 029 0 046 0 40 0 016 Ring pushed against gear Shift fork Fork finger thickness 6 40 6 50 0 252 0 256 Fork to synchro sleeve clearance 0 25 0 45 0 010 0 018 0 80 0 031 Reverse shift Fork pawl groove width 12 7 13 0 0 50 0 51 gt fork Fork to reverse idler gear clearance 0 50 1 10 0 020 0 043 1 80 0 071 L groove width 7 05 7 25 0 278 0 285 IT Fork to 5th reverse shift piece pin 0 05 0 35 0 002 0 014 0 5 0 02 clearance cont d 3 11 Standards and Service Limits 2WD Manual Transmission S20 cont d Section 13 MEASU
59. control unit YEL RED wemmer BLU BLK Q I ABS rear solenoid BLK 7 6202 ABS control unit Right ABS front solenoid Left 23 7 Power Distribution Circuit Identification cont d MID NOTE This page corresponds to page 23 17 of the Shop Manual 62SR320 and reflects the model changes No 39 50 FUSE IGNITION SWITCH WHT BLK BLK YEL WHT YEL WHT BLK BLK WHT 23 8 SRS FUSE BLOCK With 585 No 25 10A ONO No 24 15A ONO No 14 20A ONO No 15 10A 1 R RED 2 GRY or PNK 77 GRY or RED UNDER DASH FUSE RELAY BOX BLK YEL E GRN BLK GRN BLK GRN BLK Internal connection Internal connection Internal connection E E BLK YEL 1 SRS Type Il 2 SRS Type 1 3 D15B2 01521 01522 D16Z6 01627 01629 engine 4 Carbureted engine 5 Without SRS SRS UNIT SRS UNIT Type Ill Charge system light Cruise main switch indicator Cruise control unit Via main switch SRS indicator light indicator circuit ELD unit D15B4 01521 engine Device contro box 01521 engine PGM Fi main relay Cruise control unit Alternator Speed sensor control unit Control box control unit 4WD A T Purge control solenoid 3 Tandem valve control solenoid D1582 engine 2 sunroof relay Windshield washer motor Rear wind
60. low Insufficient cooling Fouled plug may be caused by Retarded ignition timing Oil in combustion chamber Incorrect spark plug gap Plug heat range too high Excessive idling low speed running Clogged air cleaner element Deteriorated ignition coil or ignition wires 2 Adjust the gap with a suitable gapping tool and replace the plug if the center electrode is rounded as shown below Electrode Gap 0 0 004 Standard 1 1 mm 0 043 ES in ROUNDED ELECTRODE 1 1 mm 0 043 in Nippondenso D15B7 except KE KG D15Z1 engine ZFR5F 11 NGK KJ16CR L11 Nippondenso ZFR6F 11 NGK For hot climates or contin KJ20CR L11 uous high speed driving Nippondenso For all normal driving D16A9 B16A2 engine BKR6E N11 NGK K20PR L 11 For all normal driving Nippondenso BKR7E N11 NGK For hot climates or contin K22PR L11 uous high speed driving Nippondenso D15B7 KE KG engine BKR5E 11 NGK ZFR5F 11 NGK K16PR U11 Nippondenso KJ16CR L11 Nippondenso BKR6E 11 NGK ZFR6F 11 NGK K20PR U11 For hot climates or contin Nippondenso uous high speed driving KJ20CR L11 Nippondenso For normal driving Apply a small quantity of anti seize compound to the plug threads before installing the plugs Screw the plugs into the cylinder head finger tight then torque them to 18 N m 1 8 kg m 13 Ib ft
61. mm 0 008 in 3RD GEAR 1ST GEAR 2 If the clearance exceeds the service limit measure 4 If the clearance exceeds the service limit measure the thicknesses of 1st gear and thrust shim the thicknesses of 2nd gear and spacer collar 1ST GEAR 2ND GEAR Standard 31 45 31 50 mm 1 238 1 240 in Standard 28 92 28 97 mm 1 139 1 141 in THRUST SHIM SPACER COLLAR Standard 1 945 1 955 mm 0 0766 0 0770 in Standard 29 07 29 09 mm 1 144 1 145 QO e f the thicknesses of 1st gear and thrust shim e If the thicknesses of 2nd gear and spacer collar are less than the standard replace with a new one less than the standard replace with a new one e If the thicknesses of 1st gear and thrust shim are e f the thicknesses of 2nd gear and spacer collar are within the standard replace the 1st 2nd synchro within the standard replace the 1st 2nd synchro hub with a new one hub with a new one 13 2 Transmission Assembly Reassembly Torque the reverse idler shaft bolt as shown Replace REVERSE IDLER SHAFT BOLT 10 x 1 25 mm 44 N m 4 5 kg m 33 lb ft 13 3 S22 Model Manual Transmission Transmission Assembly aeta 13 6 Outline of Model Change Reverse idler shaft bolt torque has been changed Transmission Assembly Reassembly Torque the reverse idler shaft bolt as shown REVERSE IDLER SHAFT BOLT 44 N m 4
62. should be more than 5 V Faulty PGM CARB control unit An open in the wire 4WD No Wire Test condition Test desired result Possible cause if result is not obtained BLK Under all conditions Check for continuity to ground Poor ground G401 There should be continuity An open in the wire 2 YEL Ignition switch ON Check for voltage to ground Blown No 15 10 A fuse in the under There should be battery voltage dash fuse relay box An open in the wire 3 GRN WHT Shift lever in position P Check for continuity to ground Faulty shift position console switch GRN RED Shift lever in position R There should be continuity Poor ground G401 GRN Shift lever in position NOTE An open in the wire GRN BLU Shift lever in position 5 There should be no continuity in GRN BLK Shift lever in position o any other position GRN YEL Shift lever in position 2 4 RED BLK Combination light switch ON Check for voltage to ground Blown No 19 10 A fuse in the under There should be battery voltage dash fuse relay box An open in the wire YEL GRN Ignition switch ON shift Check for voltage to ground Faulty s switch lever in position or There should be more than 5 V Faulty shift position console switch and s switch ON Faulty A T control unit Anopen in the wire 6 RED YEL Ignition switch ON shift Check for voltage
63. the upper channel holder then temporarily apply the bottom edge of the upper channel tape 3D 4D Front UPPER CHANNEL Temporarily apply here TAPE 4D Rear UPPER CHANNEL TAPE Temporarily apply here cont d 20 5 Doors Door Channel Tape Replacement cont d 5 Slowly press the upper channel tape against 6 Press the upper channel tape against the the upper channel holder with a plastic bottom of the upper channel holder as shown squeegee felt side NOTE NOTE To prevent air bubbles slowly press the upper Press in numbered sequence channel tape from corner as shown UPPER CHANNEL UPPER CHANNEL HOLDER HOLDER ZZ CY UPPER CHANNEL x TAPE UPPER CHANNEL 30 40 Front 30 40 Front UPPER CHANNEL TAPE B gt lt wa a IIT 4 B UPPER CHANNEL TAPE 4D Rear UPPER CHANNEL 4D Rear TAPE UPPER CHANNEL TAPE 20 6 7 Slowly press the upper channel tape against the upper channel holder from inside the door NOTE Do not roll the upper channel tape around prematurely Follow the numbered sequence faithfully UPPER CHANNEL HOLDER UPPER CHANNEL TAPE 3D 4D Front UPPER CHANNEL TAPE 4D Rear UPPER CHANNEL TAPE 5 Apply the center channel tape 1 Peel back the upper edge of the separator from the center channel tape and align the upper edge of the center channel tape as shown Overlap the upper channel
64. thickness Parking brake ratchet pawl Parking brake gear Throttle cam stopper height 5 90 6 00 0 232 0 236 18 50 18 60 0 728 0 732 5 40 0 213 Wear or other defect 14 000 14 005 0 5512 0 5514 14 006 14 010 0 5514 0 5516 14 011 14 015 0 5516 0 5518 37 000 37 039 1 4567 1 4582 37 045 1 4585 Servo body Shift fork shaft bore D A B C Shift fork shaft valve bore D Oil pump Oil pump gear side clearance Oil pump gear to body clearance Drive Driven Oil pump driven gear I D Oil pump shaft O D 0 03 0 05 0 001 0 002 0 240 0 266 0 0094 0 0105 0 063 0 088 0 0025 0 0035 14 016 14 034 0 5518 0 5525 13 980 13 990 0 5504 0 5508 0 07 0 003 Wear or damage Wear or damage cont d 3 19 Standards and Service Limits Spring 3 20 MEASUREMENT 2nd orifice control valve spring 3 4 shift valve spring 2WD Automatic Transmission M48A cont d Section 14 STANDARD NEW D12B1 D15B3 D16A9 Wire Dia 0 90 0 035 0 90 0 035 0 70 0 028 O D 6 60 0 260 6 60 0 260 Free Length 41 20 1 622 45 10 1 776 9 60 0 378 32 90 1 295 No of Coils 22 0 3 4 shift valve ball spring 0 45 0 018 4 50 0 177 12 00 0 472 6 7
65. to ground Faulty LOW switch lever in position 2 and LOW There should be battery voltage Faulty shift position console switch switch ON Faulty A T control unit An open in the wire 7 GRN ignition switch ON Check for voltage to ground Faulty PGM FI ECU There should be more than 5 V An open in the wire YEL WHT Not used 23 30 integrated Control Unit Circuit Diagram KM Without key in beeper system KM Without lights on beeper system UNDER HOOD FUSE RELAY BOX IGNITION SWITCH BATTERY No 41 80 No 39 50 O O O O WHT BLK WHT UNDER DASH FUSE RELAY BOX COMBINATION LIGHT SWITCH wo EZ RED GRN WHT RED No 40 40 No 36 50A No 15 10A BLK YEL No 14 20A YEL BRAKE SEAT BELT SYSTEM REMINDER LIGHT LIGHT 1 4W Ex 1 4W _ E WINDSHIELD WIPER CON 2 zi WASHER SWITCH 8 CONTROL No 18 7 5A FUSE m UNIT Starter signal 8 8 8 INT OFFANT 8 w 8 8 8 GRN RED GRN RED BLU WHT 2 RED BLU YEL BLU BLU GRN A7 INTEGRATED CONTROL UNIT B5 SEAT BELT REMINDER j BULB CHECK LIGHTS ON BEEPER INTERMITTENT CIRCUIT KEY IN BEEPER WIPER RELAY CIRCUIT CIRCUIT qw e CEILING LIGHT GRN RED LT GRN RED GRN BLU BLU WHT RED BLU BLU WHT LT GRN RED 1 BLK WINDSHIELD GRN RED GRN RED LT GRN RED RED BLU WIPER MOTOR
66. 0 62SR321 62SR322 and changed following Knock Sensor Idie Speed has been changed for KM model Fuel Tube Quick Connect Fittings has been added except D15B7 D16Z6 engines of KM KH models Fuel filter configuration has been changed for all models Emission Control System has been changed for KM model Component Locations Index B16A3 engine MANIFOLD ABSOLUTE PRESSURE IMA SENSOR EACV THRO ANGLE SENSOR PURGE CONTROL SOLENOID INTAKE AIR TEMPERATURE FAST IDLE VALVE TA SENSOR TDC CRANK CYL SENSOR IGNITER UNIT KNOCK SENSOR Troubleshooting page 11 9 HEATED OXYGEN 0 SENSOR COOLANT TEMPERATURE TW SENSOR 11 4 System Description Vacuum Connections B16A3 engine OXYGEN 0 SENSOR MANIFOLD ABSOLUTE PRESSURE MAP SENSOR COOLANT TEMPERATURE TW SENSOR INTAKE AIR TEMPERATURE TA SENSOR KNOCK SENSOR FAST IDLE VALVE ELECTRONIC AIR CONTROL VALVE EACV FUEL INJECTOR PRESSURE REGULATOR FUEL FILTER FUEL PUMP ENGINE COOLANT FUEL TANK AIR CLEANER RESONATOR CATALYTIC CONVERTER PCV VALVE CHARCOAL CANISTER PURGE CONTROL DIAPHRAGM VALVE PURGE CONTROL SOLENOID VALVE TWO WAY VALVE FUEL CUT VALVE 11 5 System Description Electrical Connections B16A3 engine PGM FI MAIN RELAY ad SWITCH 0 4 n nn B11 CYLP INJ1 A1 CYL SENSOR TDC SENSOR C
67. 0 095 0 0037 0 14 0 006 Differential pinion gear Backlash Pinion gear bore diameter Pinion gear to pinion shaft clearance 0 05 0 15 0 002 0 006 18 042 18 066 0 7103 0 7113 0 055 0 095 0 0022 0 0037 0 15 0 006 Set ring to bearing outer race Differential 2WD Y21 S21 Section 15 MEASUREMENT 0 0 10 0 0 0 004 STANDARD NEW Adjust with shim SERVICE LIMIT Final driven gear Backlash 0 090 0 149 0 0035 0 0059 0 200 0 0079 Differential carrier Pinion shaft bore diameter Carrier to pinion shaft clearance Driveshaft bore diameter Carrier to driveshaft clearance 18 000 18 016 0 7087 0 7093 0 013 0 045 0 0005 0 0018 28 000 28 021 1 1024 1 1033 0 025 0 066 0 0010 0 0026 Differential pinion gear Backlash Pinion gear bore diameter Pinion gear to pinion shaft clearance 0 05 0 15 0 002 0 006 18 042 18 066 0 7103 0 7113 0 055 0 095 0 0022 0 0037 0 10 0 004 0 12 0 005 0 15 0 006 Set ring to bearing outer race Differential 2WD A T M48A Section 15 MEASUREMENT 0 0 10 0 0 0 004 STANDARD NEW Adjust with shim SERVICE LIMIT Final driven gear Backlash 0 082 0 137 0 0032 0 0054 0 200 0 0079 Differential carrier Pinion shaft bore diameter Carrier to pinion shaft clearance
68. 1 10 0 043 8 50 0 335 22 30 0 878 7 6 1 00 0 039 8 50 0 335 22 20 0 874 6 0 1 00 0 039 8 50 22 10 0 870 5 5 1 00 0 039 8 50 22 20 0 874 6 0 1 00 0 039 8 50 0 335 22 10 0 870 5 5 1 00 0 039 8 50 0 335 22 50 0 886 7 3 1 00 0 039 8 50 0 335 22 30 0 878 6 6 Throttle valve A adjusting spring 1 0 80 0 031 6 20 0 244 27 00 1 063 8 5 Throttle valve D12B1 D15B3 8 50 0 335 41 50 1 634 10 5 spring 8 50 0 335 41 50 1 634 11 2 8 50 0 335 41 60 1 638 12 4 8 50 0 335 41 30 1 626 13 9 8 50 0 335 41 40 1 630 11 7 8 50 0 335 41 30 1 626 13 0 Inside Diameter 2WD Automatic Transmission M48A Section 14 Unit of STANDARD NEW ength mm in MEASUREMENT Wire Dia O D Free Length No of Coils Spring Throttle valve B adjusting spring 0 80 0 031 6 20 0 244 30 00 1 181 8 0 3rd accumulator spring 2 80 0 110 15 50 0 610 82 50 3 248 17 4 2nd accumulator spring D16A9 D12B1 D15B3 3 80 0 150 3 80 0 150 20 20 0 795 20 20 0 795 75 30 2 965 75 10 2 957 10 8 9 8 4th accumulator spring 3 20 0 126 18 60 0 732 82 70 3 256 12 0 Reverse timing valve spring 0 70 0 028 5 60 0 220 43 80 1 724 Servo control valve spring 1 00 0 039 7 60 0 299 39 40 1 551 27 1
69. 1 4134 Mid 38 107 1 5003 Secondary 36 195 1 4250 38 008 1 4964 Valve Valve clearance IN 0 18 0 22 0 007 0 009 0 23 0 27 0 009 0 011 Valve stem O D IN 5 480 5 490 0 2157 0 2161 5 450 0 2146 EX 5 450 5 460 0 2146 0 2150 5 420 0 2134 Stem to guide clearance IN 0 02 0 05 0 001 0 002 0 08 0 003 EX 0 05 0 08 0 002 0 003 0 12 0 005 Valve seat Width IN 0 85 1 15 0 033 0 045 1 60 0 063 1 25 1 55 0 049 0 061 2 00 0 079 Stem installed height IN 53 165 53 635 2 0931 2 1116 EX 53 165 53 635 2 0931 2 1116 53 885 2 1215 53 885 2 1215 2 Valve spring Free length D15Z1 IN 54 78 2 157 EX 58 23 2 293 58 26 2 294 Except D15Z1 IN 57 97 2 282 EX 58 41 2 300 Valve guide LD IN 5 51 5 53 0 217 0 218 EX 5 51 5 53 0 217 0 218 Installed height IN 17 85 18 35 0 703 0 722 EX 18 65 19 15 0 734 0 754 Rocker arm Arm to shaft clearance IN 0 017 0 050 0 0007 0 0020 1 NIHON HATSUJO manufactured valve spring EX 0 018 0 054 0 0007 0 0021 5 60 0 220 5 60 0 220 0 08 0 003 0 08 0 003 2 CHUO HATSUJO manufactured valve spring Standards and Service Limits MEASUREMENT Cylinder Head Valve Train Section 6 D16A9 Engine STANDARD NEW Compression wide open
70. 1 47 1 237 1 239 43 08 1 696 0 3 0 01 34 80 1 370 31 30 1 232 Mainshaft 5th gear I D 43 009 43 025 1 6933 1 6939 End play 0 06 0 21 0 002 0 008 Thickness 31 42 31 47 1 237 1 239 43 08 1 696 0 3 0 01 31 30 1 232 Countershaft 24 980 24 993 0 9835 0 9840 36 984 37 000 1 4561 1 4567 33 000 33 015 1 2992 1 2998 0 02 0 001 max Diameter of ball bearing contact area A Diameter of 1st gear contact area B Diameter of needle bearing contact area C Runout 24 940 0 9819 36 930 1 4539 32 950 1 2972 0 05 0 002 Countershaft 1st gear 1 D End play When tightened by the specified torque 0 045 0 205 0 0018 0 0081 42 009 42 025 1 6539 1 6545 42 08 1 657 0 265 0 0104 Countershaft 2nd gear 47 009 47 025 1 8507 1 8514 0 070 0 140 0 0028 0 0055 I D End play When tightened by the specified torque Thickness 28 920 28 970 1 1386 1 1405 47 08 1 854 0 200 0 0079 28 80 1 134 Spacer collar Countershaft 2nd gear Spacer collar Mainshaft 4th and 5th gear 3 12 36 48 36 49 1 436 1 437 41 989 42 000 1 6531 1 6535 29 070 29 090 1 1445 1 1453 36 50 1 437 41 94 1 651 31 002 31 012 1 2205
71. 1 R O N or higher may also be used 6 Premium unleaded gasoline with 95 R O N or higher may also be used NOTES Except D15Z1 01676 D16Y1 B16A2 16 D16A9 D15Z1 D16Z6 D16Y1 D16A9 B16A2 B16A3 At 6 300 min rpm At 6 800 min rpm At 7 800 min rpm 3 43 Design Specifications ITEM STARTER CLUTCH Make Type Output Normal Output Norma Voltage 12V Hour Rating 30 seconds Direction of Rotation Clockwise as viewed from gear encl Weight HITACHI 0 8 kW 3 7 kg 8 2 Ibs MITSUBA 1 0 kW 1 2 kW 3 4 kg 7 5 Ibs 1 4 kW 3 5 kg 7 7 Ibs NIPPONDENSO 3 85 kg 8 49 Ibs 3 4 Type Clutch Facing Area M T Carbureted engine engine except B16A2 B16A3 B16A2 B16A3 engine METRIC ENGLISH HITACHI Direct drive 0 8 kW MITSUBA Gear reduction 1 0 kW 1 2 kWand 1 4 kW NIPPONDENSO Gear reduction 1 0 kW 1 2 kW 0 8 kW 1 0 kW 1 2 kW 1 4 kW kg 7 5 Ibs Single plate dry diaphragm spring Torque converter 160 cm 25 sq in 176 cm 27 sq in 203 cm 31 sq in 3 44 TRANSMISSION Type M T Synchronized 5 speed forward 1 reverse A T 2WD 4 speed automatic with lock up clutch 1 reverse A T 4WD Electronically controlled 4 speed automatic 1 reverse Primary Reduction Gear Type Ratio Direct 1 1 PT Manual Transmission Engine Type D12B1 D13B2 01676 1383 01627 01582 01521 2
72. 107 pressure or P position kPa kg cm psi T D12B1 2nd clutch pressure at 2 000 min rpm 420 4 2 60 370 3 7 53 position throttle fully closed throttle fully closed 3rd clutch pressure at 2 000 min rpm position 750 7 5 107 4th clutch pressure at 2 000 min rpm 800 850 8 0 8 5 114 121 throttle more than D position throttle more than 1 4 opened 1 4 opened 2nd clutch pressure at 2 000 min rpm 800 850 8 0 8 5 114 121 750 7 5 107 2 position 1st clutch pressure at 2 000 min rpm 800 850 8 0 8 5 114 121 750 7 5 107 or D position Governor pressure at 60 km h 151 161 1 51 1 61 21 23 146 1 46 21 38 mph Throttle pressure B Throttle fully closed 0 T Throttle fully open 800 850 8 0 8 5 114 121 750 7 5 107 Throttle pressure Throttle fully closed 0 5 0 0 05 0 0 7 Throttle fully open 515 530 5 15 5 3 73 75 510 5 1 73 Hydraulic Line pressure at 2 000 min rpm 850 900 8 5 9 0 121 128 800 8 0 114 pressure or P position kPa kg cm psi D15B3 2nd clutch pressure at 2 000 min rpm 420 4 2 60 370 3 7 53 position throttle fully closed throttle fully closed 3rd clutch pressure at 2 000 min rpm position 800 8 0 114 4th clutch pressure at 2 000 min rpm 850 900 8 5 9 0 121 128 throttle more than position throttle more than 1 4 opened 1 4 opened 2nd clutch pressure at 2 000 min rpm 8
73. 13B3 D15B2 D15B3 D15B7 D15Z2 D16A7 Engines STANDARD NEW SERVICE LIMIT Compression 250 min rpm Nominal Minimum Maximum variation wide open throttle kPa kg cm psi 1 300 13 0 185 950 9 5 135 200 2 0 28 Valve spring Free length D12B1 D13B2 D13B3 D15B2 D15B3 D16A7 D15B7 01522 47 97 1 889 49 19 1 937 48 58 1 913 49 19 1 937 51 90 2 043 51 88 2 043 55 28 2 176 55 31 2 178 Valve guide LD Installed height 5 51 5 53 0 217 0 218 5 51 5 53 0 217 0 218 15 95 16 45 0 628 0 648 15 95 16 45 0 628 0 648 48 965 49 435 1 9278 1 9463 Cylinder head Warpage 0 05 0 002 Height 94 95 95 05 3 738 3 742 Camshaft End play 0 05 0 15 0 002 0 006 0 5 0 02 Camshaft to holder oil clearance 0 050 0 089 0 0020 0 0035 0 15 0 006 Total runout 0 03 0 001 max 0 04 0 002 Cam lobe D12B1 D13B2 01383 35 472 1 3965 height EX 35 693 1 4052 DIL D15B3 IN 36 603 1 4411 ect EX 36 747 1 4467 D15B2 IN 36 603 1 4411 EX 36 750 1 4468 ES D16A7 IN 36 782 1 4481 EX 36 947 1 4546 D15B7 D15Z2 IN 36 057 1 4196 EX 36 198 1 4251 NE Valve Valve clearance IN 0 18 0 22 0 007 0 009 0 23 0 27 0 009 0 011 EE Valve stem O D IN 5 480 5
74. 1626 101677 16 2 16 01583 01629 4WD 01522 D16Y1 D16A7 D16A9 Gear Ratio 1st 3 250 3 250 3 250 3 250 3 384 3 230 2nd 1 900 1 761 1 900 1 900 1 952 2 105 3rd 1 250 1 172 1 250 1 250 1 266 1 458 4th 0 909 0 909 0 937 0 909 0 942 1 107 5th 0 750 0 702 0 771 0 702 0 789 0 875 Reverse 3 153 3 153 3 153 3 153 3 000 3 000 Final Reduction Gear Ratio 4 250 3 722 4 250 4 250 4 428 4 266 4 437 L Type Single helical gear Except KS KS D13B2 only METRIC ENGLISH NOTES TRANSMISSION Automatic Transmission Engine Type 5 KS D15B2 01679 D15B7 01626 D1626 01627 2WD D16Y1 Gear Ratio 1st 2 600 2 600 2nd 1 393 1 468 3rd 0 975 0 975 4th 0 772 0 638 Reverse 1 954 1 954 Final Reduction Gear Ratio 4 333 4 333 Type Single helical gear AIR Cooling Capacity HADSYS 3 351 kcal h 13 290 BTU h CONDITIONING 3 838 kcal h 15 220 BTU h MATSUSHITA 3 851 kcal h 15 270 BTU h NIPPONDENSO 3 851 kcal h 15 270 BTU h Compressor Type Make Scroll HADSYS Except B16A2 B16A3 No of Cylinder 01582 015721 Capacity 85 7 cm rev 5 23 cu in rev Max Speed 10 000 min rpm Lubricant Type SP 10 Lubricant Capacity 120 m 2 4 fl oz 4 2 Imp oz Compressor Type Make Vane rotary MATSUSHITA D15B2 01521
75. 22 39 25 1 544 1 545 39 27 39 30 1 546 1 547 38 87 38 90 1 530 1 531 38 92 38 95 1 532 1 533 Countershaft reverse gear collar length Countershaft reverse gear collar flange thickness Countershaft 1st gear collar length Countershaft 1st gear collar flange thickness Sub shaft 4th gear collar length Sub shaft 4th gear collar length of needle bearing contact area 2 45 2 55 0 096 0 100 14 500 14 550 0 5709 0 5728 2 45 2 55 0 096 0 100 24 00 24 10 0 945 0 949 21 000 21 100 0 8268 0 8307 14 500 14 550 0 5709 0 5728 Wear or damage Wear or damage Wear or damage Wear or damage AWD Automatic Transmission M25A Section 14 Unit of length mm in MEASUREMENT STANDARD NEW SERVICE LIMIT Transmission Mainshaft 2nd gear thrust washer 3 47 3 50 0 137 0 138 Wear or damage cont d thickness 3 52 3 55 0 139 0 140 3 57 3 60 0 141 0 142 3 62 3 65 0 143 0 144 3 67 3 70 0 144 0 146 3 72 3 75 0 146 0 148 3 77 3 80 0 148 0 150 3 82 3 85 0 150 0 152 3 87 3 90 0 152 0 154 Wear or damage Thrust washer thickness Mainshaft 4th gear Mainshaft ball bearing L side Mainshaft 1st gear L side Mainshaft 1st gear R side 4 45 4 55 0 175 0 179 2 950 3 050 0 1161 0 1201 1 45 1 50 0 057
76. 34a Lubricant capacity m2 fl oz Imp oz Field coil resistance at 20 C 68 F 0 Pulley to pressure plate clearance 140 4 2 3 4 9 3 16 3 50 0 5 0 1 0 02 0 004 NIPPONDENSO Engine type B16A2 B16A3 Lubricant type ND OIL8 P N 38899 PR7 003 F Lubricant capacity m fl oz Imp oz Stator coil resistance at 20 C 68 F Q Pulley to pressure plate clearance or Refrigerant HFC 134a R 134a 120 4 1 4 2 3 4 3 8 0 5 0 15 0 02 0 006 Compressor belt SS Deflection with 98 10 kg 22 Ibs between pulleys 6 5 10 5 0 26 0 41 with used belt 5 0 7 0 0 20 0 28 with new belt Belt tension N kg Ibs Measured with belt tension gauge 350 500 35 50 77 110 with used belt 600 800 60 80 132 176 with new belt When using a new belt adjust deflection or tension to new values Run the engine for 5 minutes then turn it off Readjust deflection or tension to used belt values 3 36 Electrical Section 23 Unit of length mm in MEASUREMENT STANDARD NEW Ignition coil Rated voltage V 12 Primary winding resistance Q at 20 C 68 F 0 5 0 7 0 6 0 8 Secondary winding resistance at 20 C 68 F 14 4 21 6 13 2 19 8 Spark plug Type See Section 23 Gap 1 1 01 0 043 0 Ignition timing Atidle BTDC D15B3 A T 12 2 Red BTDC D13B2 B13B3 01572 D15B3
77. 35 0 138 Countershaft 3rd gear thrust washer thickness 35 x 52 mm 2 97 3 00 0 117 0 118 3 02 3 05 0 119 0 120 07 3 10 0 121 0 122 2 3 15 0 123 0 124 7 3 20 0 125 0 126 2 3 25 0 127 0 128 7 3 30 0 129 0 130 35 0 131 0 132 40 0 133 0 134 45 0 135 0 136 50 0 137 0 138 55 0 139 0 140 60 0 141 0 142 WWW WWW WW 1 1 2 2 32 37 42 47 52 57 Wear or damage Wear or damage Wear or damage Wear or damage Sub shaft 4th gear thrust washer thickness One way clutch contact area D Countershaft 1st gear Parking gear Mainshaft feed pipe A O D Mainshaft feed pipe B O D Countershaft feed pipe O D Sub shaft feed pipe O D Mainshaft sealing ring thickness 29 mm and 35 mm Mainshaft bushing D Mainshaft bushing D Countershaft bushing l D Sub shaft bushing 1 D Mainshaft sealing ring groove width 2 93 3 00 0 115 0 118 83 339 83 365 3 2811 3 2821 66 685 66 698 2 6254 2 6259 8 970 8 980 0 3531 0 3535 5 970 5 980 0 2350 0 2354 7 970 7 980 0 3138 0 3142 7 970 7 980 0 3138 0 3142 1 980 1 995 0 0780 0 0785 6 018 6 030 0 2369 0 2374 9 000 9 015 0 3543 0 3549 8 000 8 015 0 3150 0 3156 8 000 8 015 0 3150 0 3156 2 025 2 060 0 0797 0 0811
78. 485 500 4 85 5 00 69 71 480 4 8 68 Hydraulic pressure kPa kg cm psi D15B2 D15B7 D15B5 engines Line pressure at 2 000 min rpm or P position 800 850 8 0 8 5 114 121 750 7 5 107 2nd clutch pressure at 2 000 min rpm position 3rd clutch pressure at 2 000 min rpm position 4th clutch pressure at 2 000 min rpm position 400 4 0 57 throttle fully closed 800 850 8 0 8 5 114 121 throttle more than 1 8 opened 350 3 5 50 throttle fully closed 750 7 5 107 throttle more than 1 8 opened 2nd clutch pressure at 2 000 min rpm position 1st clutch pressure at 2 000 min rpm or 1 position 800 850 8 0 8 5 114 121 750 7 5 107 800 850 8 0 8 5 114 121 750 7 5 107 Governor pressure at 60 km h 38 mph 182 192 1 82 1 92 26 27 177 1 77 25 Set Throttle B pressure Throttle fully closed Throttle fully open Throttle A pressure Throttle fully closed Throttle fully open Stall speed min rpm check with level ground 3 22 0 15 0 0 15 0 2 1 800 850 8 0 8 5 114 121 750 7 5 107 0 5 0 0 05 0 0 7 485 500 4 85 5 00 69 71 2 600 2 400 2 800 480 4 8 68 2WD Automatic Transmission M24A Section 14 Clutch Unit of length mm in MEASUREMENT STANDARD
79. 5 435 kg 959 Ibs KS RTSi MT 675 1 488 465 kg 1 025 Ibs KG AT 695 1 532 465 kg 1 025 Ibs KG 3 40 Max permissible weight VEi DXi LSi ESi ESi with ABS VTi RTSi 1 500 kg 3 307 bs 1 530 kg 3 373 Ibs 1 545 kg 3 406 Ibs 1 520 kg 3 351 Ibs 1 640 kg 3 616 Ibs Except European Model METRIC ENGLISH 2 door Hatchback WEIGHT Curb weight EX DX Si VTi 1 000 kg 2 205 Ibs 1 013 kg 2 233 Ibs 1 039 kg 2 291 Ibs 1 051 kg 2 317 tbs 1 077 kg 2 374 Ibs 993 kg 2 189 Ibs 1 013 kg 2 233 Ibs 1 008 kg 2 222 Ibs 1 028 kg 2 266 Ibs 960 kg 2 116 ibs 990 kg 2 183 ibs 1 020 kg 2 249 Ibs 1 050 kg 2 315 Ibs Weight distributions Front Rear CX GLi VTi 1 5EL EX DX Si 610 1 345 390 kg 860 Ibs 619 1 365 394 kg 869 Ibs 647 1 426 392 kg 864 Ibs 639 1 409 412 kg 908 Ibs 665 1 466 412 kg 908 Ibs 611 1 347 382 kg 842 Ibs 635 1 400 378 kg 833 Ibs 624 1 376 384 kg 847 Ibs 648 1 429 380 kg 838 Ibs 585 1 290 375 kg 827 Ibs 615 1 356 375 kg 827 Ibs 630 1 389 390 kg 860 Ibs 660 1 455 390 kg 860 Ibs 3 41 Design Specifications Except European Model METRIC ENGLISH 4 door Sedan WEIGHT Curb weight VEi M T 1 043 kg 2 299 Ibs GLi M T 1 046 kg 2 306 Ibs A T 1 072 kg 2 363 165 VTi 1 088 kg 2 3
80. 5 0 2343 1 80 0 071 6 045 0 2380 9 030 0 356 8 030 0 3161 6 045 0 2380 2 080 0 082 Regulator valve body Sealing ring contact 1 D 35 000 35 025 1 3780 1 3789 35 050 1 3799 Shifting device and parking brake control Reverse shift fork finger thickness Parking brake ratchet pawl Parking brake gear Throttle cam stopper height 5 90 6 00 0 232 0 236 27 00 27 10 1 063 1 067 5 40 0 213 Wear or other defect 14 000 14 005 0 5512 0 5514 14 006 14 010 0 5514 0 5516 14 011 14 015 0 5516 0 5518 37 000 37 039 1 4567 1 4582 Servo body Shift fork shaft bore D A B C Shift fork shaft valve bore D Oil pump Oil pump gear side clearance Oil pump gear to body clearance Drive Driven Oil pump driven gear D Oil pump shaft O D 0 03 0 05 0 001 0 002 0 240 0 266 0 0094 0 0105 0 063 0 088 0 0025 0 0035 14 016 14 034 0 5518 0 5525 13 980 13 990 0 5504 0 5508 37 045 1 4585 0 07 0 003 Wear or damage Wear or damage 3 29 Standards and Service Limits MEASUREMENT 4WD Automatic Transmission M25A Section 14 STANDARD NEW SERVICE LIMIT Transfer shaft Diameter of needle bearing contact area Diameter of taper bearing contact area Diameter of drive bevel gear contact ar
81. 5 95 6 05 0 234 0 238 0 45 0 65 0 018 0 026 0 05 0 45 0 002 0 018 13 0 13 3 0 51 0 52 0 25 0 84 0 010 0 033 7 05 7 25 0 278 0 285 0 05 0 35 0 002 0 014 0 5 0 02 Shift arm A Diameter of shift piece contact area Shift arm to shift piece clearance LD Shift arm to shaft clearance 12 90 13 00 0 508 0 512 0 2 0 5 0 01 0 02 16 000 16 068 0 6299 0 6326 0 011 0 092 0 0004 0 0036 0 7 0 03 Shift arm Select arm Diameter of shift arm A contact area Select arm to shift arm A clearance 11 90 12 00 0 469 0 472 0 05 0 25 0 002 0 010 0 5 0 02 Diameter of shift arm A contact area Select arm to shift arm A clearance 7 95 8 00 0 313 0 315 0 10 0 25 0 004 0 010 Super low shift fork Synchro sleeve groove width Fork to synchro sleeve clearance Thrust Radial 5 95 6 05 0 234 0 238 0 45 0 65 0 018 0 026 0 05 0 45 0 002 0 018 0 5 0 02 3 15 Standards and Service Limits 2WD Automatic Transmission M48A Section 14 MEASUREMENT STANDARD NEW SERVICE LIMIT Transmission Capacity 2 US qt Imp qt 5 4 5 7 4 8 for overhaul fluid 2 4 2 5 2 1 for fluid change Hydraulic Line pressure at 2 000 min rpm 800 850 8 0 8 5 114 121 750 7 5
82. 50 900 8 5 9 0 121 128 800 8 0 114 position 1st clutch pressure at 2 000 min rpm 850 900 8 5 9 0 121 128 800 8 0 114 or D position Governor pressure at 60 km h 151 161 1 51 1 61 21 23 146 1 46 21 38 mph Throttle pressure B Throttle fully closed 0 Throttle fully open 800 850 8 0 8 5 114 121 750 7 5 107 Throttle pressure A Throttle fully closed 0 5 0 0 05 0 0 7 TE Throttle fully open 515 530 5 15 5 3 73 75 510 5 1 73 3 16 2WD Automatic Transmission M48A Section 14 Unit of length mm in MEASUREMENT STANDARD NEW SERVICE LIMIT Hydrautic Line pressure at 2 000 min rpm 850 900 8 5 9 0 121 128 800 8 0 114 pressure position kPa kg cm psi D16A9 2nd clutch pressure at 2 000 min rpm 420 4 2 60 370 3 7 53 position throttle fully closed throttle fully closed 3rd clutch pressure at 2 000 min rpm D position 800 8 0 114 4th clutch pressure at 2 000 min rpm 850 900 8 5 9 0 121 128 throttle more than position throttle more than 1 4 opened 1 4 opened 2nd clutch pressure at 2 000 min rpm 850 900 8 5 9 0 121 128 800 8 0 114 2 position tst clutch pressure at 2 000 min rpm 850 900 8 5 9 0 121 128 800 8 0 114 or D3 position Governor pressure at 60 km h 151 161 1 51 1 61 21 23 146 1 46 21 38 mph Thro
83. 50 0 295 Inside Diameter 39 00 1 535 3 21 Standards and Service Limits 2WD Automatic Transmission M24A Section 14 MEASUREMENT STANDARD NEW SERVICE LIMIT Transmission fluid Capacity 2 US at Imp qt 5 9 6 2 5 2 for overhaul 2 7 2 9 2 4 for fluid change Hydraulic pressure kPa kg cm psi 01676 D16Y1 01627 engines Line pressure at 2 000 min rpm N or P position 2nd clutch pressure at 2 000 min rpm position 3rd clutch pressure at 2 000 min rpm position 4th clutch pressure at 2 000 min rpm D position 850 900 8 5 9 0 121 128 800 8 0 114 400 4 0 57 throttle fully closed 850 900 8 5 9 0 121 128 throttle more than 1 8 opened 350 3 5 50 throttle fully closed 800 8 0 114 throttle more than 1 8 opened 2nd clutch pressure at 2 000 min rpm position 850 900 8 5 9 0 121 128 800 8 0 114 1st clutch pressure at 2 000 min rpm or 1 position 850 900 8 5 9 0 121 128 800 8 0 114 Governor pressure at 60 km h 38 mph 182 192 1 82 1 92 26 27 177 1 77 25 Throttle B pressure Throttle fully closed Throttle fully open 0 15 0 0 15 0 2 1 850 900 8 5 9 0 121 128 300 8 0 114 Throttle A pressure Throttle fully closed Throttle fully open 0 5 0 0 05 0 0 7
84. 542 1 543 39 22 39 25 1 544 1 545 39 27 39 30 1 546 1 547 38 87 38 90 1 530 1 531 38 92 38 95 1 532 1 533 Countershaft reverse gear collar length Countershaft reverse gear collar flange thickness Countershaft 1st gear collar length Countershaft 1st gear collar flange thickness Sub shaft 4th gear collar length Sub shaft 4th gear collar flange thickness 14 50 14 60 0 571 0 575 2 40 2 60 0 094 0 102 14 50 14 60 0 571 0 575 2 40 2 60 0 094 0 102 24 00 24 10 0 945 0 949 3 000 3 150 0 118 0 124 Wear or damage Wear or damage Wear or damage Wear or damage Mainshaft 2nd gear thrust washer thickness 3 47 3 50 0 137 0 138 3 52 3 55 0 139 0 140 3 57 3 60 0 141 0 142 3 62 3 65 0 143 0 144 3 67 3 70 0 145 0 146 3 72 3 75 0 146 0 148 3 77 3 80 0 148 0 150 3 82 3 85 0 150 0 152 3 87 3 90 0 152 0 154 Wear or damage Wear or damage 2WD Automatic Transmission M24A Section 14 MEASUREMENT STANDARD NEW Unit of length mm in SERVICE LIMIT Transmission cont d Thrust washer thickness Mainshaft 4th gear Mainshaft ball bearing L side Mainshaft 1st gear L side Mainshaft 1st gear R side 4 45 4 55 0 175 0 179 3 45 3 55 0 136 0 140 1 45 1 50 0 057 0 059 3 43 3 50 0 1
85. 87 22 000 0 8656 0 8661 26 980 26 993 1 0622 1 0627 33 989 34 000 1 3381 1 3386 25 977 25 990 1 0227 1 0232 21 930 0 8634 26 930 1 0602 33 930 1 3358 25 920 1 0205 Runout 0 02 0 001 max 0 05 0 002 Mainshaft 3rd D 39 009 39 025 1 5358 1 5364 39 07 1 538 and 4th gears End play 3rd 0 06 0 21 0 002 0 008 0 33 0 013 4th 0 06 0 19 0 002 0 007 0 31 0 012 Thickness 3rd 30 22 30 27 1 190 1 192 30 15 1 187 4th 30 12 30 17 1 186 1 188 30 05 1 183 Mainshaft I D 37 009 37 025 1 4570 1 4577 37 07 1 459 5th gear End play 0 06 0 19 0 002 0 007 0 31 0 012 Thickness 28 42 28 47 1 119 1 121 28 35 1 116 Countershaft Diameter of needle bearing contact area A 30 000 30 015 1 1811 1 1817 29 950 1 1791 Diameter of 1st gear contact area B 35 989 36 000 1 4169 1 4173 35 930 1 4146 Diameter of ball bearing contact area C 24 980 24 993 0 9835 0 9840 24 930 0 9815 Runout 0 02 0 001 max 0 05 0 002 Countershaft LD 41 009 41 025 1 6145 1 6152 41 07 1 617 1st gear End play 0 03 0 10 0 001 0 004 0 22 0 009 When tightened by the specified torque Thickness 30 41 30 44 1 197 1 198 30 36 1 195 Countershaft I D 44 009 44 025 1 7326 1 7333 44 07 1 735 2nd gear End play 0 03 0 11 0 001 0 004 0 23 0 009 When tightened
86. 99 165 A T 1 119 kg 2 467 Ibs 1 5EL M T 1 017 kg 2 242 Ibs A T 1 037 kg 2 286 Ibs 1 5EX M T 1 045 kg 2 304 Ibs 1 065 kg 2 348 Ibs M T 1 090 kg 2 403 Ibs A T 1 115 kg 2 458 Ibs LX M T 1 050 kg 2 315 Ibs A T 1 080 kg 2 381 Ibs EX A T 1 140 kg 2 513 Ibs Weight distributions Front Rear MT 634 1 398 409 kg 902 165 GLi M T 626 1 380 420 kg 926 Ibs A T 668 1 473 420 kg 926 Ibs VTi M T 644 1 420 444 kg 979 Ibs A T 677 1 493 442 kg 974165 1 5EL M T 625 1 378 392 kg 864 Ibs A T 649 1 431 388 kg 855 Ibs 1 5EX M T 633 1 396 412 kg 908 Ibs A T 657 1 448 408 kg 899 Ibs Si M T 649 1 431 441 kg 972 Ibs A T 680 1 499 435 kg 959 Ibs LX M T 630 1 389 420 kg 926 Ibs A T 660 1 455 420 kg 926 Ibs EX AT 3 42 705 1 554 435 kg 959 Ibs Except B16A2 16 01649 B16A2 16 D16A9 Cylinder Arrangement Bore and Stroke D12B1 D13B2 D13B3 D15B2 D15B3 D15B7 01521 01572 D16A7 D16A9 D16Z6 01627 01679 D16Y1 B16A2 B16A3 Displacement D12B1 D13B2 D13B3 D15B2 D15B3 D15B7 01521 01522 D16A7 D16A9 01626 01627 01679 D16Y1 B16A2 B16A3 Compression Ratio D12B1 D13B2 D13B3 D15B2 D15B3 D15B7 015272 01571 D16A7 D16A9 Valve Train Fuel Required 01676 01627 01629 D16Y1 B16A2 B16A3 Except B16A2 B16A3 D16A9 B16A2 B16A3 D16A9 Lubrication S
87. AIRBAG AS A SUPPLEMENTAL RESTRAINT SYSTEM SRS ITIS DESIGNED TO SUPPLEMENT THE SEAT BELT IF YOUR SRS INDICATOR LIGHTS WHILE DRIVING SEE YOUR AUTHORIZED HONDA DEALER MAINTENANCE LID CAUTION iX SRS SFFR 41Z ax AYFEINST ebe C CAUTION BEFORE MAINTENANCE SWITCH OFF THE IGNITION ATTENTION AVANT TOUT ENTRETIEN COUPER LE CONTACT ACHTUNG VOR WARTUNG Z NDUNG AUSSCHALTEN LET OP ZET HET KONTAKTSLOT AF ALVORENS MET HET ONDERHOUD TE BEGINNEN cont d Warning Caution Label Locations cont d C MONITOR NOTICE NOTICE e REFER TO SERVICE MANUAL FOR DETAILED INSTRUCTIONS REMARQUE e POUR LES INSTRUCTIONS DETAILL EES SE REPORTER AU MANUEL DE REPARATIONS LET OP RAADPLEEG WERKPLAATSHANDBOEK VOOR NADERE AANWIJZINGEN ACHTUNG AUSF HRLICHE ANWEISUNGEN SIND DEM WERKSTATTHANDBUCH ZU ENTNEHMEN D BODY COVER CAUTION CAUTION ACHTUNG eSRS 2 77 ARAH EI to REFER TO THE SERVICE SHOP MANUAL e SE REPORTER AU MANUEL D ATELIER WERKSTATTHANDBUCH LESEN e LEES HET WERKPLAATSHANDBOEK 1 10 E SRS WARNING HOOD LHD model WARNING THIS VEHICLE IS EQUIPPED WITH A DRIVER AIRBAG AS A SUPPLEMENTAL RESTRAINT SYSTEM SRS ALL S R S ELECTRICAL WIRING AND CONNECTORS APE COLORED YELLOW DO NOT USE ELECTRICAL TEST EQUIPMENT ON THESE CIRCUITS TAMPERING WITH OR DISCONNECTING THE S R S WIRING COULD RESULT IN ACCIDENTAL FIRING OF THE INFLAT
88. BATTERY No 41 80A No 39 50A O O O O WHT BLK WHT O O UNDER DASH FUSE RELAY COMBINATION LIGHT SWITCH WHT RED gt WHT GRN No 40 40 No 19 10A ONO OND ABS YEL CONTROL No 18 7 5A FUSE gaer signal LIGHT 1 4W _ e c E 2 3 GRN RED GRN RED 5 S Ki Ki E E 2 2 B4 B13 INTEGRATED CONTROL UNIT LLL BULB CHECK LIGHTS ON BEEPER CIRCUIT CIRCUIT CEILING LIGHT GRN RED LT GRN RED GRN BLU LT GRN RED GRN RED GRN RED LT GRN RED BRAKE PARKING FRONT DRIVER S FLUID BRAKE PASSENGER S DOOR LEVEL SWITCH DOOR SWITCH SWITCH SWITCH d 6301 15 10 O WASHER SWITCH rn BLK YEL No 14 20A O WINDSHIELD WIPER INT OFF INT YEL BLU BLU GRN Internal connection INTERMITTENT WIPER RELAY CIRCUIT 14 BLU WHT BLK WINDSHIELD WIPER MOTOR As G401 23 33 integrated Control Unit Control Unit Input Test CAUTION All SRS wire harnesses are covered with yellow insulation Replace the entire affected SRS harness assembly if it has an open circuit or damaged wiring Before disconnecting the SRS wire harness turn the ignition switch OFF disconnect the battery negative cable then disconnect the positive cable and wait at least three minutes SRS Type lil only Whenever the ignition switch is ON II or has been turned O
89. DE MATERIEL D ESSAI ELECTRIQUE DE SONDE ILS POURRAIENT PROVOQUER UN DEPLOIEMENT ACCIDENTEL DU COUSSIN D AIR IL N Y A PAS DE PIECES REPARABLES A L INTERIEUR NE PAS DEMONTER QUAND ON RETIRE LE COUSSIN D AIR LE TENIR A LA VERTICALE SUIVRE ATTENTIVEMENT LES INSTRUCTIONS DU MANUEL D ENTRETIEN LET OP e GEEN ONDERDELEN BINNEN DEZE UNIT WAARAAN WERKZAAMHEDEN KUNNEN WORDEN VERRICHT e RAADPLEEG WERKPLAATSHANDBOEX VOOR NADERE AANWIJZINGEN ACHTUNG DIE INNENTILE BED RFEN KEINER WARTUNG e AUSF HRLICHE ANWEISUNGEN SIND DEM WERKSTATTHANBUCH ZU ENTNEHMEN 1 15 Warning Caution Label Locations cont d SERVICE INFORMATION COOLANT INFORMATION Vol Ko AIR CLEANER Bs SS W SPARK PLUG RECOMMENDED OIL and UE gs eS INFORMATION FILTER SERVICE d EAU 8 i E SS RADIATOR CAP CAUTIO TIRE INFORMATION LHD 4 door and KY 3 door N Except KY 3 door 1 16 Special Tools Individual tool lists are located at the front of each section Specifications Standards and Service Limits 3 2 Design Specifications 3 38 Body Specifications 3 48 Standards and Service Limits MEASUREMENT Cylinder Head Valve Train Section 6 D12B1 D13B2 D
90. E MANUEL D ENTRETIEN 1 12 C DRIVER MODULE WARNING A WARNING THE AIRBAG INFLATOR IS EXPLOSIVE AND IF ACCIDENTALLY DEPLOYED CAN SERIOUSLY HURT OR KILL YOU e DO NOT USE ELECTRICAL TEST EQUIPEMENT OR PROBING DEVICES THEY CAN CAUSE ACCIDENTAI DEPLOYMENT e NO SERVICEABLE PARTS INSIDE DO DISASSEMBLE e PLACE AIRBAG UPRIGHT WHEN REMOVED e FOLLOW SERVICE SHOP MANUAL INSTRUCTIONS CAREFULLY A ATTENTION LE GONFLEUR DE COUSSIN D AIR EST EXPLOSIBLE ET SLL SE DEPLOIE ACCIDENTELLEMENT IL RISQUE DE PROVOQUER DES BLESSURES GRAVES OU DE TUER NE PAS UTILISER DE MATERIEL D ESSAI ELECTRIQUE NI DE SONDE ILS POURRAIENT PROVOQUER UN DEPLOIEMENT ACCIDENTEL DU COUSSIN D AIR e IL N Y A PAS DE PIECES REPARABLES A L INTERIEUR NE PAS DEMONTER e QUAND RETIRE LE COUSSIN D AIR LE TENIR A LA VERTICALE e SUIVRE ATTENTIVEMENT LES INSTRUCTIONS DU MANUEL D ENTRETIEN D DRIVER MODULE DANGER A DANGER EXPLOSIVE FLAMMABLE CONTACT WITH ACID WATER OR HEAVY METALS SUCH AS COPPER LEAD OR MERCURY MAY PRODUCE HARMFUL AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS STORAGE TEMPERATURES MUST NOT EXCEED 200 F 100 C FOR PROPER HANDLING STORAGE AND DISPOSAL PROCEDURES REFER TO THE HONDA SERVICE SHOP MANUAL SRS SUPPLEMENT POISON CONTAINS POISONOUS SODIUM AZIDE AND POTASSIUM NITRATE FIRST AID IF CONTENTS ARE SWALLOWED INDUCE VOMITING FOR EYE CONTACT FL
91. EARING PLAIN LOCK WASHER WASHERS LOWER ANCHOR Rear seat belt 4D 3D UPPER SAN UPPER ANCHOR ANCHOR WASHER Apply liquid thread lock TOOTHED LOCK WASHER gt w Ke SPRING WASHER BEARING x x x 3D UPPER ANCHOR SPRING WASHER BEARING COLLAR UPPER ANCHOR BOLT Apply liquid thread lock PLAIN WASHERS TOOTHED LOCK WASHER KY KM Canada produced cars models BEARING SPRING WASHER LOWER ANCHOR BOLT MEE WA ANCHOR For some models TOOTHED LOCK WASHER LOWER ANCHOR BOLT COLLARS SPRING BELT WASHER SLIDER 20 9 License Plate Trim Side Sill Planel License Plate Trim Replacement For some models 4D Clip location 1 NOTE Take care not to scratch the trunk lid LICENSE PLATE Remove the license plate GONG TRIM Disconnect the license plate light connector NOTS Remove the mounting nuts and detach the clips then remove the license plate trim 5 Instailation is the reverse of the removal procedure LICENSE PLATE LIGHT CONNECTOR Side Sill Panel Replacement p Clip locations SIDE CLIP A 6 SIDE CLIP Remove the side clips from the body by turning them 45 NOTE Loosen the screw then remove the lower clip using a clip remover SIDE CLIP NOTE When removing the side sill panel the side clips will stay in the body FRONT INNER FENDER To install t
92. ER STARTER Field winding type Permanent magnet type G201 G401 23 12 Clutch Interlock Switch Test with Interlock Switch Remove the dashboard lower cover and knee bolster then disconnect the 2 P connector from the switch Check for continuity between the terminals according to the table Terminal Clutch Pedal RELEASED PUSHED CLUTCH INTERLOCK CLUTCH PEDAL 3 If necessary replace the switch or adjust the switch position see section 12 of the Shop Manual 62SR 300 23 13 Ignition System Ignition Timing Inspection and Setting KM 1 Start the engine and allow it to warm up the radiator fan comes on 2 Connect the SCS short connector to the service check connector as shown the 2 P service check connector is located under the dashboard on the passenger side of the car DATA LINK CONNECTOR 3 P NOTE Do not use a jumper wire on this connector SERVICE CHECK Wire color BRN SCS SHORT CONNECTOR 07PAZ 0010100 3 Connect a timing light to the No 1 plug wire and point it toward the pointer on the timing belt cover TIMING LIGHT 23 14 4 Adjust ignition timing if necessary to the following specifications Ignition Timing D15B7 D16Z6 B16A3 engine 16 2 BTDC RED at idle speed NOTE shift lever is in the neutral position All electrical systems are turned OFF POI
93. FF for less than three minutes be careful not to bump the SRS unit the airbags could accidentally deploy and cause damage or injuries e Before you disconnect any part of an SRS wire harness connect the short connectors RED to the airbags e Refer to the additional precautions in the SRS sub section section 23 1 Remove the dashboard lower cover then discon nect the 10 P connector from the integrated control unit 2 Remove the integrated control unit from the under dash fuse relay box Inspect the connector and socket terminals to be sure they are all making good contact any terminals are bent loose or corroded repair them as necessary and recheck the system e If the terminals look OK make the following input tests at the connector and socket terminals test indicates a problem find and correct the cause then recheck the system if all the input tests prove OK the control unit must be faulty replace it NOTE Do not disconnect any other connectors from the under dash fuse relay box except those for the integrated control unit SRS Il SRS UNIT With built in sensors SRS MAIN HARNESS Covered with yellow insulation SRS Type Ill SRS MAIN HARNESS Covered with yellow insulation SRS UNIT With built in sensors UNDER DASH FUSE RELAY BOX aw 1 M mmm paum 10
94. For all normal driving ZFR6F 11 KJ20CR L11 Nippondenso For hot climates or contin uous high speed driving D16Z6 engine ZFR5J 11 NGK KJ16CR L11 Nippondenso For all normal driving ZFR6J 11 NGK KJ20CR L11 Nippondenso For hot climates or contin uous high speed driving B16A3 engine PFR6L 13 NGK PK20PR L13 Nippondenso For ali normal driving Apply a small quantity of anti seize compound to the plug threads before installing the plugs Screw the plugs into the cylinder head finger tight then torque them to 18 N m 1 8 kg m 13 Ib ft Spark Plug Inspection Except KM 1 Inspect the electrodes and ceramic insulator for Worn or deformed Spark Plug D12B1 D13B3 engine electrodes 9 Damaged gasket Cracked Improper Oil fouling Carbon deposits Cracked center electrode insulator BKR5E 11 NGK K16PR U11 Nippondenso For all normal driving BKR6E 11 NGK K20PR U11 For hot climates or contin uous high speed driving Nippondenso D13B2 D15B2 D15B3 D1522 16 7 01626 01627 01629 016 1 engine insulator ME ii BKR6E 11 NGK K20PR U11 Nippondenso For all normal driving BKR7E 11 NGK K22PR U11 For hot climates or contin uous high speed driving Burned or worn electrodes may be caused by Advanced ignition timing Loose spark plug Plug heat range too
95. Gearbox Angle of rack guide screw loosened M S from locked position P S LHD RHD Preload at pinion gear shaft Nem kg cm M S 5 0 10 0 0 4 13 18 1 30 1 80 2 87 3 97 Except B16A2 30 3 0 6 6 B16A2 25 2 5 5 5 25 2 5 5 5 50 10 20 7 25 0 5 1 7 5 17 4 3 14 8 0 6 1 1 6 11 5 21 9 55 Pump pressure with valve closed LHD oil temp speed 40 C 105 F min idle RHD Do not run for more than 5 seconds kPa kg cm psi 8 000 9 000 80 90 1 138 1 280 5 500 6 500 55 65 782 924 Power steering fluid Recommended power steering fluid Fluid capacity System LHD 2 US qt Imp qt RHD Reservoir HONDA Power Steering Fluid V 1 10 1 16 0 97 1 00 1 06 0 88 0 40 0 42 0 35 Power steering belt Deflection with 100 N 10 kg 22 Ibs between pulleys Except D16A9 D16A9 8 0 12 0 0 31 0 47 with used belt 6 0 9 5 0 24 0 37 with new belt 5 5 9 0 0 22 0 35 with new belt Tension measured with belt tension gauge N kg lbs Except D16A9 D16A9 M S Manual steering P S Power steering When using a new belt adjust deflection or tension to new values Run the engine for 5 minutes then turn it off Readjust the deflection or tension to used belt values 350 500 35 50 77 110 with used belt 500 700 50 70 110 154 with new belt 550 750 55 75 121 165 wit
96. MERICA MFG INC U S A HONDA Passenger car Line Body and Engine Type 4 CIVIC 4 door D15B7 EHS CIVIC 4 door D16Z6 01679 Body Type and Transmission Type 5 4 door Sedan 5 speed Manual 6 4 door Sedan 4 speed Automatic Vehicle Grade Series 4 DX EX EH4 KB 5 EX with ABS EH4 KB LX EH4 KM 6 EX EH5 KM Check Digit Model Year or Production Year R Production Year 1994 KM S Production Year 1995 KM Mode Year 1995 KB Factory Code L Ohio Factory in U S A East Liberty Serial Number KB 700001 KM 850001 Engine Number D15B7 4850001 Engine Type D15B7 1500 SOHC 16 valves Sequential Multiport Fuel injected Engine with CATA 01629 1600 SOHC 16 valves Sequential Multiport Fuel injected VTEC Engine with CATA 01626 1600 SOHC 16 valves Sequential Multiport Fuel injected VTEC Engine with CATA Serial Number D15B7 4850001 4500001 D16Z9 1100001 KB 01676 4600001 KM Manual Transmission Number 520 2000001 Transmission Type Serial Number Automatic Transmission Number S24A 4000001 Transmission Type Serial Number Identification Number Locations VIN and Engine Number LHD VIN and Engine Number RHD VIN KT and BUILT DATE VEHICLE TYPE KQ Certification Plate Z KY ch s S Uf KB Certification Plate 4 door Vehicle Identification
97. NEW SERVICE LIMIT Clutch initial clearance 1st 2nd 0 65 0 85 0 026 0 033 3rd 4th 0 40 0 60 0 016 0 024 1st hold 0 5 0 8 0 02 0 03 Clutch return spring 1st 31 0 1 22 29 0 1 14 free length 2nd 3rd 4th 30 5 1 20 28 5 1 12 1st hold 34 6 1 36 32 6 1 28 Clutch disc thickness 1 88 2 00 0 074 0 079 Until grooves worn out Clutch plate thickness 1st 1 55 1 65 0 061 0 065 Discoloration Except 1st 1 95 2 05 0 077 0 081 Discoloration Clutch end plate thickness MARK1 2 30 2 40 0 091 0 094 Discoloration except 1st hold MARK2 2 40 2 50 0 094 0 098 MARK3 2 50 2 60 0 098 0 102 2 60 2 70 0 102 0 106 MARK5 2 70 2 80 0 106 0 110 MARK6 2 80 2 90 0 110 0 114 MARK7 2 90 3 00 0 114 0 118 MARK8 3 00 3 10 0 118 0 122 MARK9 3 10 3 20 0 122 0 126 MARK10 3 20 3 30 0 126 0 130 MARK11 2 00 2 10 0 079 0 083 MARK12 2 10 2 20 0 083 0 087 MARK13 2 20 2 30 0 087 0 091 Discoloration Clutch end plate thickness MARK1 2 05 2 10 0 081 0 083 Discoloration 1st hold MARK2 2 15 2 20 0 085 0 087 MARK3 2 25 2 30 0 089 0 091 MARK4 2 35 2 40 0 093 0 094 NO MARK 2 45 2 50 0 096 0 098 MARK6 2 55 2 60 0 100 0 102 MARK7 2 65 2 70 0 104 0 106 Discoloration Transmission Diameter of needle bearing contact area On mainshaft
98. NG OF TOT UITSCHAKELEN VAN HET SYSTEEM DIT KAN TOT ERNSTIGE ONGELUKKEN LEIDEN E SRS WARNING HOOD RHD model SUPPLEMENTAL RESTRAINT SYSTEM SRS THIS VEHICLE IS EQUIPPED WITH A DRIVER SIDE AIRBAG ALL SRS ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW TAMPERING WITH DISCONNECTING OR USING ELECTRICAL TEST EQUIPMENT ON THE SRS WIRING CAN MAKE THE SYSTEM INOPERATIVE OR CAUSE ACCIDENTAL FIRING OF THE INFLATOR E SRS WARNING HOOD KS WARNING 585 THIS VEHICLE IS EQUIPPED WITH A AIRBAG SYSTEM AS A SUPPLEMENTAL RESTRAINT SYSTEM SRS ALL S R S ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW DO NOT USE ELECTRICAL TEST EQUIPMENT ON THESE CIRCUITS TAMPERING WITH OR DISCONNECTING THE S R S WIRING COULD RESULT IN ACCIDENTAL FIRING OF THE INFLATOR OR MAKE THE SYSTEM INOPERATIVE WHICH MAY RESULT IN SERIOUS INJURY VARING sns DETTA FORDON HAR EN LUFTKUDDE FOR FORARSATET SOM ETT KOMPLETTERANDE SKYDDSSYSTEM SRS SAMTLIGA ELLEDNINGAR OCH KONTAKTER SRS SYSTEMET AR GULFARGADE ANVAND INTE ELEKTRISK PROVUTRUSTNING F R DESSA KRETSAR OM DU ANDRAR ELLER LOSSAR EN SRS LEDNING KAN DET RESULTERA I EN OAVSIKTLIG UTL SNING AV TRYCKPUMPEN ELLER G RA ATT SYSTEMET SLUTAR FUNGERA DA EN ALLVARLIG OLYCKA UPPSTA VAROITUS sns TASSA AUTOSSA YLIMAARAISENA TUKIJARJESTELMANA AJAJAN ILMATYYNY SRS KAIKKI SRS S HK JOHDOT JA LIITTIMET OVAT KELTAISET ALA KAYTA SAHKOKOELAITTEITA NAISSA VI
99. NNECTOR Not used cont d 23 29 Shift Lever Position Indicator Indicator Input Test cont d 2WD Wire No Test condition Test desired result Possible cause if result is not obtained BLK Under all conditions Check for continuity to ground Poor ground G401 There should be continuity An open in the wire 2 YEL Ignition switch ON Check for voltage to ground Blown No 15 10 A fuse in the under There should be battery voltage dash fuse relay box the wire 3 GRN WHT Shift lever in position Check for continuity to ground Faulty shift position console switch GRN RED Shift lever in position R There should be continuity Poor ground G401 GRN Shift lever in position IN NOTE An open in the wire GRN BLU Shift lever in position p There should be no continuity in GRN BLK Shift lever in position p any other position GRN YEL Shift lever in position z LTGRN Shift lever in position 1 WHT 4 RED BLK Combination light switch ON Check for voltage between RED dashlight brightness control RED and dashlight brightness con BLK and RED terminals system troi dial on full bright There should be battery voltage An open in the wire 5 GRN Ignition switch ON Check for voltage to ground Faulty PGM FI ECU There
100. NTER WHITE MARK RED MARK CRANKSHAFT PULLEY 5 If it is necessary to adjust the ignition timing loosen the distributor mounting bolts and turn the distributor housing counterclockwise to advance the timing or clockwise to retard the timing To ADVANCE MOUNTING BOLTS 24 2 4 kg m 17 Ib ft 6 Tighten the adjusting bolts and recheck the timing 7 Remove the SCS short connector from the service check connector Ignition Timing Inspection and Setting D13B2 engine For the ignition timing inspection and setting of the carbureted engine refer to page 23 102 of the Shop Manual 62SR300 Idle Speed Inspection KM Start the engine and allow it to warm up the radiator fan comes on Connect a tachometer to the test tachometer connector NOTE The service check connector of the D13B2 engine carbureted engine is to be used only for SRS troubleshooting TEST TACHOMETER CONNECTOR E DATA LINK CONNECTOR 3 P NOTE Ne Ge N SERVICE CHECK CONNECTOR 2 P Wire color BRN Do not use a jumper wire on this connector TEST TACHOMETER CONNECTOR BATTERY Idle Speed rpm D15B7 D16Z6 engine 670 50 rpm A T 700 50 rpm B16A3 engine 700 50 rpm NOTE shift lever is in the neutral position All electrical systems are turned OFF Adjust the idle speed if necessary see section 11 of
101. OR OR MAKE THE SYSTEM WHICH MAY RESULT IN SERIOUS INJURY ATTENTION sns CE VEHICULE EST EQUIPE D UN COUSSIN D AIR DU COTE CONDUCTEUR QUI CONSTITUE UN SYSTEME DE RETENUE COMPLEMENTAIRE 5 5 TOUS LES FILS ET CONNECTEURS ELECTRIQUES DU SYSTEME DE RETENUE COMPLEMENTAIRE S R S SONT DE COULEUR JAUNE N UTILISEZ PAS UN EQUIPEMENT D ESSAIS ELECTRIQUES SUR CES CIRCUITS NE TOUCHEZ PAS ET NE DEBRANCHEZ PAS LES FILS DU SYSTEME S R S CAR CECI POURRAIT DE TRADUIRE PAR LE DECLENCHEMENT ACCIDENTEL DU GONFLEUR OU RENDRE LE SYSTEME INOPERANT ET VOUS EXPOSER AINSI A DE GRAVES BLESSURES WARNUNG DIESES FAHRZEUG IST MIT EINEM FAHRER AIRBAG SRS ALS ZUSATZLICHEM R CKHALTESYSTEM AUSGERUSTET ALLE ELEKTRISCHEN KABEL SOWIE DIE ZUGEHORIGEN STECKVERBINDER DES S R S SYSTEMS SIND IN GELBER FARBE AUSGEFUHRT KEINE ELEKTRISCHEN PRUFGERATE AN DIE S R S VERKABELUNG ANSCHLIEBEN VERANDERN ODER UNTERBRECHEN DER S R S VERKABELUNG KANN UNKONTROLLIERTES ZUNDEN DES GASGENERATORS AUSLOSEN ODER DAS SYSTEM AUBER FUNKTION SETZEN WAS ZU ERNSTHAFTEN VERLETZUNGEN FUHREN KANN WAARSCHUWING DIT VOERTUIG IS UITGERUST MET EEN LUCHTKUSSEN AAN DE BESTUURDERSKANT ALS EXTRA BESCHERMING S R S ALLE ELEKTRISCHE LEIDINGEN EN AANSLUITINGEN VAN DE S R S ZIJN GEEL GEKLEURD GEBRUIK GEEN ELEKTRISCHE TESTAPPARATUUR VOOR DEZE CIRCUITS KNOEIEN OF LOSKOPPELEN VAN DE 5 8 5 LEIDINGEN KAN LEIDEN TOT BRAND IN DE VULINRICHTI
102. OTE The distance of the engine compartment is described the table on page 20 12 POINT n POINT r 3 POINT q 1 DSL Unit mm 6 Inner diameter POINT y POINT s POINT 2 115 4 53 300 11 8 gt k s 6 50 POINT t POINT u S 4 als I HINE gis 8 g eux allg 58 ra ls 2 x S POINT m En p e 1 Lei a L ch LEE BE 140 POINT POINT v POINT m G 3 58 2 3 POINT p 145 ENS 83 G 3 5 71 270010 8 13 48 _253 9 96 31002 2 1350 6 2182 85 91 Ee RE l 2 11 5 70 2 8 560 22 0 0 45 Et 185 XE 3122 122 9 1 6 50 D 200 gy POINT v So 9 S 5 Q TALS 0j TAS 2 2 e POINT v POINT s POINT v 12 0 47 Upper Arm Point 84 3 SECTION EE POINT r POINT u Upper Arm Center POINT 120 47 Upper Arm Point POINT n 20 0 8 Locate Hole T LINE POINT z POINT m 20 14 Compensator Arm Center POINT o POINT t POINT p j 110 43 14 0 55 Trailing Arm Cross Beam point Point point POINT x 614 0 55 Cross Beam 20 0 8 Locate Hole POINT y a MEME ARR 92000 8 Locate Hole SUPPLEMENTAL RESTRAINT SYSTEM SRS The Civic SRS includes
103. P MANUAL INSTRUCTIONS CAREFULLY Label D location Refer to page 1 11 cont d 1 13 Warning Caution Label Locations cont d eeh F GLOVE BOX INFORMATION AIRBAG INFORMATION SUPPLEMENTAL RESTRAINT SYSTEM SRS THE SRS MUST BE INSPECTED TEN YEARS AFTER IS INSTALLED THE DATE OF INSTALLATION IS SHOWN ON THE CERTIFICATION PLATE LOCATED ON THE DRIVER S DOOR JAMB DIAGNOSTIC CHECKS AND REPLACEMENT OF SRS COMPONENTS MUST BE DONE BY AN AUTHORIZED DEALER e SEE YOUR OWNER S MANUAL FOR ADDITIONAL SRS INFORMATION 1 14 FRONT SEAT PASSENGER AIRBAG MODULE DANGER H A DANGER EXPLOSIVE FLAMMABLE CONTACT WITH ACID WATER OR HEAVY METALS SUCH AS COPPER LEAD OR MERCURY MAY PRODUCE HARMFUL AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS STORAGE TEMPERATURE MUST NOT EXCEED 200 F 100 C FOR PROPER HANDLING STORAGE AND DISPOSAL PROCEDURES REFER TO SERVICE SHOP MANUAL SRS SUPPLEMENT POISON CONTAINS POISONOUS SODIUM AZIDE AND POTASSIUM NITRATE FIRST AID IF CONTENTS ARE SWALLOWED INDUCE VOMITING FOR EYE CONTACT FLUSH EYES WITH WATER FOR 15 MINUTES IF GASES FROM ACID OR WATER CONTACT ARE INHALED SEEK FRESH AIR IN EVERY CASE GET PROMPT MEDICAL ATTENTION KEEP OUT OF REACH OF CHILDREN A DANGER EXPLOSIBLE INFLAMMABLE TOUT CONTACT AVEC L ACIDE L EAU OU DES METAUX LOURDS COMME LE CUIVRE LE PLOMB OU LE MERCURE RISQUE DE PRODUIRE DES GAZ NOCIFS ET IRRITANTS O
104. R LIGHT LIGHT 0 84W 0 84W BLU RED BLU GRN BLU GRN GRY CABLE REEL LTGRN RED No 19 10A FUSE SET RESUME SWITCH RED BLK DASH LIGHTS BRIGHTNESS ae CONTROLLER Ir CRUISE CONTROL atk DIMMING CIRCUIT BRAKE SWITCH CRUISE H LIGHT 1 12W A EE GRN WHT LT GRN RED LT GRN BLK BLK YEL RED BLU LT GRN GRN WHT 0 0 CRUISE CONTROL UNIT O O Q BRAKE Tas BRN BRN BLK BRN WHT PNK YEL BLU BLK BLU RED VEHICLE SPEED B SENSOR VSS HORN HORN 1 LT GRN RED SWITCH GRY A CLUTCH SWITCH 2 LT GRN BLK AIT A T GEAR for GRY POSITION SWITCH ACTUATOR ASSEMBLY 21 64 DJ BLK BLK 1 ACCELERATION 1 Q DEC DECELERATION Q Q Q Q G201 G301 G201 6201 201 6401 6401 6401 6401 23 40 Troubleshooting NOTE The numbers in the table show the troubleshooting sequence Before troubleshooting Check the No 15 10 A and No 24 15 A fuses in the under dash fuse relay box and the No 41 80 A No 39 50 and No 42 20 A fuses in the under hood fuse relay box Check that the horn sounds Check the tachometer to see if it works properly Items to be inspected Symptom SET RESUME switch Brake switch and mounting Clutch switch and mounting M T A T gear position switch A T Vehicle speed sensor VSS Dimming circuit in gauges Actuator and cable deflection Open circuit loose or disconnected te
105. RANK SENSOR SERVICE CHECK CONNECTOR DATA LINK oT 907 TXD RXD CONNECTOR 9 11 6 oB14 TDCM INJA A2 9 FUEL PUMP P FUEL INJECTORS Ne 1 EACV O 90 O CHECK ENGINE LIGHT To A C SWITCH O 00 O A C COMPRESSOR CLUTCH RELAY FUSES D BACK UP 7 5 BATTERY 80 IG 50 ECU 15 S 15 BACK UP LIGHTS 10 REAR DEFROSTER RELAY HEATER MOTOR RELAY COOLING FAN RELAY 7 5 STARTER SIGNAL 7 5 A OPTION 50 49 INTERIOR LIGHT 7 5 UNDER HOOD FUSE RELAY BOX 019 VCC1 020 2 Q DE MAP Y SE Ss Er THROTTLE ANGLE o 011 26 TH 8 IGP A219 SENSOR gt VALVE TIMING OIL PRESSURE SWITCH TA SENSOR TW SENSOR HEATED O SENSOR CGF 099 D ks KNOCK SENSOR PA SENSOR 1 Al 5 AD APL A13A15 AL 19 A21 23 25 OOOOOOOOOOOOO B 83 65 B7 BS BIS OOOOOOOO IGNITER UNIT SPOOL SOLENOID VALVE PURGE CONTROL SOLENOID VALVE 90 O ALTERNATOR 03 05 07 DI IDI3OISDI 2 DI9 D21 OOOOOOOOOOO OOOOOOOOOOOOO 2 Ab AB AID AI2 Al A16 AIB A20 A22 424 A26 OOOOOOOO B 56 88 BIO Bi BI Bib TERMINAL LOCATION OOOOOOOOOO00 02 24 06 DE 010012 DI4 016 D BD20 022 11 7 Troubleshooting Self diagnostic Procedures B16A3 engine When the Check Engine Light h
106. REMENT STANDARD NEW SERVICE LIMIT Shift arm A 13 05 13 13 0 514 0 517 0 05 0 23 0 002 0 009 Inner diameter of shift arm C contact point Shift arm A to shift arm C clearance 0 35 0 014 Shift arm B 13 973 14 000 0 5501 0 5512 0 013 0 070 0 0005 0 0028 0 20 0 50 0 008 0 020 12 90 13 00 0 508 0 512 Inner diameter of shift arm shaft contact point Shift arm B to shaft clearance Shift arm B to shift piece clearance Diameter of shift piece contact point 2WD Manual Transmission Y21 S21 Section 13 MEASUREMENT STANDARD NEW Transmission oil Mainshaft 4 2 0 for overhaul Capacity 3 2 2 2 2 3 1 9 for change 2 US at Imp qt 0 16 0 006 0 620 0 0244 12 780 0 5031 SERVICE LIMIT 0 11 0 18 0 004 0 007 27 977 27 990 1 1015 1 1020 End play Diameter of ball bearing contact area A Clutch housing side Diameter of 3rd gear contact area B Diameter of ball bearing contact area C Transmission housing side 37 984 38 000 1 4954 1 4961 27 987 28 000 1 1018 1 1024 Adjust 27 930 1 0996 37 930 1 4933 27 940 1 1000 0 05 0 002 Mainshaft 3rd and 4th gears Runout 0 02 0 001 max I D 43 009 43 025 1 6933 1 6939 End play 0 06 0 21 0 002 0 008 Thickness 3rd 34 92 34 97 1 375 1 377 4th 31 42 3
107. RS Type Ill only e Whenever the ignition switch is ON II or has been turned OFF for less than three minutes be careful not to bump the 585 unit the airbags could accidentally deploy and cause damage or injuries Before you disconnect any part of an SRS wire harness connect the short connectors RED to the airbags Refer to the additional precautions in the SRS sub section section 23 SRS Type Il SRS Type SRS UNIT With built in sensors SRS MAIN HARNESS Covered with yellow insulation SRS MAIN HARNESS SRS UNIT With built in sensors Covered with yellow insulation NOTE 2WD 4WD The illustration shows LHD type RHD type is similar RED BLK GRN BLU GRN BLU LTGRN WHT YEL GRN View from wire side f 1 Remove the gauge assembly and disconnect all GRN YEL RED BLK YEL connectors from it 2 Inspect the connector and socket terminals to be sure they are all making good contact RED GRN BLK 2 GRN WHT GRN BLK e If the terminals are bent loose or corroded re GRN RED pair them as necessary and recheck the system e If the terminals look OK make the following input tests at the 14 P connector lf a test indicates a problem find and correct the cause then recheck the system f all the input tests prove OK but the indicator is faulty replace the printed circuit board GRN YEL GRN RED RED YEL GRN BLK GRN WHT 14 P CO
108. RTAPIIREISAA SRS JOHTOJEN TUKKEAMINEN TAI IRROTAAMINEN SAATTAA SYTYTTAA VAHINGOSSA PUMPUN TEHDA JARJESTELMAN K YTT KELVOTTOMAKSI T ST TAAS SAATTAA AIHEUTUA VAKAVIA VAURIOITA A WARNING THE AIRBAG INFLATOR IS EXPLOSIVE AND IF ACCIDENTALLY DEPLOYED CAN SERIOUSLY HURT YOU FOLLOW SERVICE SHOP MANUAL INSTRUCTIONS CAREFULLY S R S 4215 CS PUBS Hilal ilga Call ola S R S 3 S R S grey us a icu deol Zait 9 51 SY a gt AI gly Aigle al Cad ol gall oda ela w ll UGS lune PU Ol S R S Si at had Jeitz Lao Joa Jaai 3 ai gi pipa 5 ada I pai cont d 1 11 Warning Caution Label Locations cont d SRS AIRBAG SYSTEM TYPE III A CABLE REAL CAUTION A srs REFER TO SERVICE SHOP MANUAL FOR DETAILED INSTRUCTION POUR LES INSTRUCTIONS DETAILL EES SE REPORTER AU MANUEL DE REPARATIONS RRO EE GEES Wo AUSF HRLICHE ANMEISUNGEN SIND DEM ZU RAAD PLEEG WERKPLAATSHANDBOEK VOOR NADERE AANWIJZINGEN B STEERING WHEEL NOTICE NOTICE IMPROPER STEERING WHEEL REMOVAL OR INSTALLATION CAN DAMAGE SRS COMPONENTS FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY REMARQUE UN RETRAIT OU UNE REPOSE INCORRECTS DU VOLANT RISQUENT D ENDOMMAGER LES PIECES CNSTITUTIVES DU SRS SUIVRE ATIENTIVEMENT L
109. S models monthly interval is recommended by manufacturer only except for KS models it is required R Replace C Clean I Inspect After inspection clean adjust fill up repair or replace if necessary Service at the interval listed x 1 000 km or x 1 000 km miles or after that number of months whichever comes first x 1 000 miles months Choke mechanism For European models For carburetor types For Other than European models Intake air temperature control system For carburetor types Blow by filter For carburetor types Idle speed and idle CO Evaporative emission control system For Other than European models Distributor cap and rotor For Other than European models Ignition wiring For Other than European models Front brake pads Front brake discs and calipers Rear brake discs calipers and pads Rear brake drums wheel cylinders and linings Parking brake operation Brake fluid Including ABS Brake hoses and lines Anti lock brake system operation Anti lock brake system high pressure hose Exhaust system and condition Catalytic converter heat shield For cars with catalytic converter Suspension components Steering function tie rod ends gearbox and boots Power steering function hoses and connections All fluid levels Forcars with Power steering system For
110. STER CYLINDER uci LOCKNUT C 18 1 8 kg m 13 Ib ft CLUTCH INTERLOCK SWITCH CLUTCH SWITCH or ADJUSTING BOLT LOCKNUT A 10 N m 1 0 kg m 7 amp STROKE at PEDAL 130 140 mm 5 12 5 51 in TOTAL CLUTCH PEDAL FREE PLAY 12 21 mm 0 47 0 83 in including the pedal play 1 10 mm 0 04 0 37 in CLUTCH PEDAL HEIGHT 164 mm 6 46 in to the floor O CLUTCH PEDAL DISENGAGEMENT HEIGHT 83 mm 3 27 in minimum to the floor 12 2 Manual Transmission 21 521 Model Manual 13 1 522 Model Manual Transmission 13 5 Y21 S21 Model Manual Transmission Countershaft Assembly Clearance 13 2 Transmission Assembly Reassembly 13 3 Outline of Changes 521 model has been added Specifications of the S21 is same as that of Y21 e Countershaft clearance inspection has been changed Reverse idler shaft bolt torque has been changed Countershaft Assembly Clearance Inspection 1 Measure the clearance between the 1st gear and 3 Measure the clearance between the 2nd and 3rd thrust shim gears Standard 0 045 0 205 mm Standard 0 07 0 14 0 0018 0 0082 in 0 003 0 006 Service Limit 0 265 mm 0 0104 in Service Limit 0 20
111. Springs Regulator valve spring A 1 8 0 07 14 7 0 58 87 8 3 46 16 5 D16Y1 01626 01627 engines Regulator valve spring A 1 8 0 07 14 7 0 58 85 4 3 36 16 5 D15B2 D15B7 D15B5 engines Regulator valve spring B 1 8 0 07 9 6 0 38 44 0 1 73 7 5 Stator reaction spring 5 5 0 22 26 4 1 04 30 3 1 19 2 1 Torque converter check valve spring 1 0 0 04 8 4 0 33 33 8 1 33 8 2 Modulator valve spring 1 20 0 047 7 00 0 276 27 20 1 071 8 0 1 20 0 047 7 00 0 276 26 30 1 035 8 0 Relief valve spring 1 1 0 04 8 6 0 34 37 1 1 46 13 4 Cooler check valve spring 1 0 0 04 8 4 0 33 33 8 1 33 8 2 Governor spring A 1 0 0 04 18 8 0 74 32 9 1 30 4 1 Governor spring B 0 9 0 04 11 8 0 46 27 8 1 09 6 0 0 9 0 04 11 8 0 46 29 1 1 15 6 0 2 3 orifice control valve spring 0 9 0 04 6 6 0 26 33 2 1 31 14 9 4 3 kick down valve spring 1 0 0 04 6 6 0 26 29 9 1 18 14 7 2 3 4 orifice control valve spring 1 0 0 04 8 6 0 34 51 9 2 04 19 8 2nd ON orifice control vaive spring 0 9 0 04 8 0 0 31 24 1 0 95 9 6 Throttle valve A spring 1 0 0 04 8 5 0 33 22 2 0 87 6 0 Throttle valve A spring 1 0 0 04 8 5 0 33 22 1 0 87 5 5 Throttle valve A spring 1 1 0 04 8 5 0 33 22 3 0 87 8 1 Throttle valve A spring 1 1 0 04 8 5 0 33 22 3 0 88 7 6 Throttle valve B adjusting spring 0 8 0 03 6 2 0 24 30 0 1 18 8 Throttle valve A adjusting spring 0 8 0 03 6 2 0 24 27 0 1 06 8 5 Throttle valve
112. System Control Unit Input Test 1 Disconnect the 8 P connector from the interlock control unit 2 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 lf a test indicates a problem find and correct the cause then recheck the system j If all the input tests prove OK substitute known good control unit and recheck the system If the check is OK the control unit must be faulty replace it NOTE If the shift lock solenoid clicks when the ignition switch is turned ON au and you step on the brake pedal with the shift lever in p the shift lock system is electronically normal if the shift lever cannot be shifted from test the shift position console switch INTERLOCK CONTROL UNIT KB model YEL WHT BLU YEL BLK View from wire side WHT BLK WHT YEL WHT RED 8 P CONNECTOR GRN WHT KQ model GRN WHT WHT BLU La WHT YEL GRN WHT YEL BLK View from wire side 23 24 Shift Lock System No Wire Test condition Test Desired result Possible cause if result is not obtained Ignition switch ON GRN WHT Shift lever in position Check for voltage to ground There should be batte
113. U DES COMPOSES EXPLOSIFS LES TEMPERATURES DE RANGEMENT NE DEVRONT PAS DEPASSER 200 F 100 C POUR LES PROCEDURES DE MANIPULATION DE RANGEMENT ET DE MISE AU REBUT VOIR LE SUPPLEIMENT SRS DU MANUEL D ENTRETIEN POISON RENFERME DE L ACIDE DE SOUDE ET DU NITRATE DE POTASSIUM TOXIQUES PREMIERS SECOURS SI LE CONTENU EST ABSORBE INDUIRE UN VOMISSEMENT EN CAS DE CONTACT AVEC LES YEUX LAVER A GRANDE EAU PENDANT UN QUART D HEURE EN CAS D INHALATION DES GAZ PAR CONTACT AVEC L ACIDE OU L EAU ALLER A L AIR FRAIS DANS TOUS LE CAS OBETENIR PROMPTEMENT DES SOINS MEDICAUX TENIR HORS DE PORTEE DES ENFANTS A WARNING THE AIRBAG INFLATOR IS EXPLOSIVE AND IF ACCIDENTALLY DEPLOYED CAN SERIOUSLY HURT OR KILL YOU DO NOT USE ELECTRICAL TEST EQUIPEMENT OR PROBING DEVICES THEY CAN CAUSE ACCIDENTAL DEPLOYMENT NO SERVICEABLE PARTS INSIDE DO NOT DISASSEMBLE PLACE AIRBAG UPRIGHT WHEN REMOVED FOLLOW SERVICE SHOP MANUAL INSTRUCTIONS CAREFULLY MONITOR NOTICE NOTICE NO SERVICEABLE PARTS INSIDE REFER TO SERVICE SHOP MANUAL FOR DETAILED INSTRUCTIONS o PELOT HSU e HUY E 20475415 REMARQUE AUCUNE PIECE REPARABLE A L INTERIEUR POUR LES INSTRUCTIONS DETAILL EES SE REPORTER AU MANUEL DE REPARATIONS ATTENTION LE GONFLEUR DE COUSSIN D AIR EST EXPLOSIBLE ET S LL SE DEPLOIE ACCIDENTELLEMENT IL RISQUE DE PROVOQUER DES BLESSURES GRAVES OU DE TUER NE PAS UTILISER
114. USH EYES WITH WATER FOR 15 MINUTES IF GASES FROM ACID OR WATER CONTACT ARE INHALED SEEK FRESH AIR IN EVERY CASE GET PROMPT MEDICAL ATTENTION KEEP OUT OF REACH OF CHILDREN E SRS WARNING HOOD SUPPLEMENTAL RESTRAINT SYSTEM 5 5 THIS VEHICLE 1S EQUIPPED WITH A DRIVER AND FRONT SEAT PASSENGER AIRBAG ALL SRS ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW TAMPERING WITH DISCONNECTING OR USING ELECTRICAL TEST EQUIPMENT ON THE SRS WIRING CAN MAKE THE SYSTEM INOPERATIVE OR CAUSE ACCIDENTAL FIRING OF THE INFLATOR A DANGER EXPLOSIBLE INFLAMMABLE TOUT CONTACT AVEC L ACIDE L EAU OU DES METAUX LOURDS COMME LE CUIVRE LE PLOMB OU LE MERCURE RISQUE DE PRODUIRE DES GAZ NOCIFS ET IRRITANTS QU DES COMPOSES EXPLOSIFS LES TEMPERATURES DE RANGEMENT NE DEVRONT PAS DEPASSER 200 F 100 C POUR LES PROCEDURES DE MANIPULATION DE RANGEMENT ET DE MISE AU REBUT VOIR LE SUPPLEMENT SRS DU MANUEL D ENTRETIEN POISON RENFERME DE L ACIDE DE SOUDE ET DU NITRATE DE POTASSIUM TOXIQUES PREMIERS SECOURS SI LE CONTENU EST ABSORBE INDUIRE UN VOMISSEMENT EN CAS DE CONTACT AVEC LES YEUX LAVER A GRANDE EAU PENDANT UN QUART D HEURE EN CAS D INHALATION DES GAZ PAR CONTACT AVEC L ACIDE OU L EAU ALLER A L AIR FRAIS DANS TOUS LES CAS OBTENIR PROMPTEMENT DES SOINS MEDICAUX TENIR HORS DE PORTEE DES ENFANTS A WARNING THE AIRBAG INFLATOR IS EXPLOSIVE AND IF ACCIDENTALLY DEPLOYED CAN SERIOUSLY HURT YOU FOLLOW SERVICE SHO
115. a driver s airbag located in the steering wheel hub In addition some models have also a front passenger s airbag located in the dashboard above the glove box There are two types of SRS Type ll SRS unit is part of the airbag assembly which is used for models without front passenger s airbag and Type Ill SRS unit is not part of the airbag assembly and has built in sensors which is used for models with front passenger s airbag Information necessary to safely service the SRS is included in this Shop Manual Items marked with an asterisk on the contents page include or are located near SRS components Servicing disassembling or replacing these items will require special precautions and tools and should therefore be done by an authorized Honda dealer AWARNING 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 authorized Honda dealer Improper service procedures including incorrect removal and installation of the SRS could lead to personal injury caused by unintentional activation of the airbags Do not bump the SRS unit Otherwise the system may fail in case of a collision or the airbags may deploy when the ignition switch is ON II SRS Type lll All SRS electrical wiring harnesses are covered with yellow insulation Related components are located in the steering column front console dashboard dash
116. ags could accidentally deploy and cause damage or injuries Before you disconnect any part of an SRS wire harness connect the short connectors RED to the airbags Refer to the additional precautions in the SRS sub section section 23 with built in sensors SRS MAIN HARNESS covered with yellow insulation PUSH KNOB SHIFT LEVER KNOB Apply non hardening 10 N m 1 0 kg m 7 Ib ft thread lock sealant gt 99 LOCK SHIFT INDICATOR ANEL 10 N m 1 0 kg m 7 lb ft SHIFT LOCK SOLENOID e sya LEVER COVER SILICONE GREASE 3 0 3 kg m 2 2 Ib ft Y 14 u PARKING LOCK PIN ROD PIN SWITCH i 5 0 5 kom 3 6 Ib ft CONTROL BRACKET a 10 1 0 kg m AUTOMATIC TRANSAXLE g GEAR POSITION SWITCH Testing see section 23 SHIFT LEVER BRACKET e CONTROL SEAL P um GG di 12 N m 1 2 kom 9 Ib ft 10 N m 1 0 kg m 7 Ib ft 14 10 SUPPLEMENTAL RESTRAINT SYSTEM SRS If body maintenance is required The Civic SRS includes a driver s airbag located in the steering wheel hub In addition some models have also a front passenger s airbag located in the dashboard above the glove box There are two types SRS Type SRS unit is part of the airbag assembly which is used for models without front passenger s airbag and Type lll SRS unit is not part of the a
117. al runout 54 976 55 000 2 1644 2 1654 54 970 54 994 2 1642 2 1651 44 976 45 000 1 7707 1 7717 0 005 0 0002 max 0 004 0 0002 max 0 10 0 35 0 004 0 014 0 020 0 0008 max 0 010 0 0004 0 006 0 0002 0 45 0 018 0 030 0 0012 Bearing Main bearing to journal oil clearance No 1 2 4 and 5 journals No 3 journal Rod bearing to journal oil clearance 0 024 0 042 0 0009 0 0017 0 030 0 048 0 0012 0 0019 0 032 0 050 0 0013 0 0020 3 7 Standards and Service Limits Engine Lubrication Section 8 Except B16A2 B16A3 Engines MEASUREMENT STANDARD NEW SERVICE LIMIT Engine oil Capacity 2 US qt Imp qt Except D16A9 4 0 4 2 3 5 for engine overhaul 3 3 3 5 2 9 for oil change including filter 3 0 3 2 2 6 for oil change without filter D16A9 4 3 4 5 3 8 for engine overhaul 3 5 3 7 3 1 for oil change including filter 3 2 3 4 2 8 for oil change without filter Oil pump Inner to outer rotor radial clearance 0 02 0 14 0 001 0 006 Housing to outer rotor radial clearance 0 10 0 18 0 004 0 007 Housing to rotor axial clearance 0 03 0 08 0 001 0 003 Relief valve Pressure setting 80 C 176 F kPa kg cm psi at idle 70 0 7 10 min at 3 000 min rpm 350 3 5 50 min Engine Lubrication Section 8 B16A2 B16A3 Engines MEASUREMENT STANDARD NEW
118. and stator shaft On mainshaft 2nd gear collar On mainshaft 4th gear collar On mainshaft 1st gear collar On countershaft L side On countershaft 3rd gear distance collar On countershaft 4th gear On countershaft reverse gear collar On countershaft 1st gear collar On sub shaft L side On sub shaft 4th gear collar On reverse idler gear shaft On mainshaft 1st gear On mainshaft 2nd gear On mainshaft 4th gear On countershaft 1st gear 22 980 22 993 0 9047 0 9052 35 975 35 991 1 4163 1 4170 31 975 31 991 1 2589 1 2595 30 975 30 991 1 2195 1 2201 36 004 36 017 1 4175 1 4180 31 980 31 996 1 2591 1 2597 27 980 27 993 1 1016 1 1021 31 975 31 991 1 2589 1 2595 31 975 31 991 1 2589 1 2595 25 991 26 000 1 0233 1 0236 27 980 27 993 1 1016 1 1021 13 990 14 000 0 5508 0 5512 35 000 35 016 1 3780 1 3786 41 000 41 016 1 6142 1 6148 38 000 38 016 1 4961 1 4967 38 000 38 016 1 4961 1 4967 Wear or damage Wear or damage cont d 3 23 Standards and Service Limits 2WD Automatic Transmission M24A cont d Section 14 Transmission cont d 3 24 MEASUREMENT Inside diameter of needle bearing contact area On countershaft 3rd gear On countershaft 4th gear On countershaft reverse gear On sub shaft 4th gear On reverse idler gear On stator shaft R side
119. ar according to this chart 1 Except B16A2 B16A3 D16A9 engines 2 B16A2 16 D16A9 engines CAUTION Used engine oil may causes 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 30 20 40 0 10 20 30 40c 1 L En D Lk t t it is still advisable to thoroughly wash your hands with 20 0 20 40 60 80 100 RE and water as soon as possible after handling used Ambient temperature ranges 4 2 2 door Hatchback r 5 S cu ae 8 Maintenance Schedule R Replace C Clean I Inspect After inspection clean adjust fill up repair or replace if necessary Service at the interval listed x 1 000 km or miles or after that number of months whichever comes first x 1 000 km 20 40 60 80 100 120 140 160 180 200 x 1 000 miles 12 24 36 48 60 72 84 96 108 120 months 12 72 84 96 108 120 e Transmission oil For European models R R R e Engine oil and oil filter For European models Replace every 10 000 km 6 000 miles or 12 months For Other than European models Replace every 10 000 km 6 000 miles or 6 months For Other than European models R R R R R Valve clearance For European models i For Other than European models
120. as been reported on refer to base Shop Manuals P N 62SR300 6258320 6258321 6258322 and check the code SELF DIAGNOSIS INDICATOR BLINKS SYSTEM INDICATED PAGE ECU OXYGEN SENSOR MANIFOLD ABSOLUTE PRESSURE MAP SENSOR CRANK SENSOR TW SENSOR THROTTLE SENSOR TDC SENSOR CYL SENSOR TA SENSOR PA SENSOR 14 EACV 15 IGNITER UNIT 16 FUEL INJECTOR 17 VEHICLE SPEED SENSOR 21 SPOOL SOLENOID VALVE 22 VALVE TIMING OIL PRESSURE SWITCH 23 41 KNOCK SENSOR OXYGEN SENSOR HEATER 43 FUEL SUPPLY SYSTEM For reference pages not listed with the respective Self Diagnosis Indicator Blinks refer to base Shop Manuals If codes other than those listed above are indicated verify the code If the code indicated is not listed above replace the ECU e The Check Engine Light may come on indicating a system problem when in fact there is a poor or intermittent 11 8 electrical connection First check the electrical connections clean or repair connections if necessary PGM FI System Knock Sensor B16A3 engine JC 23 j Self diagnosis Check Engine light indicates code 23 A problem in the Knock Sensor circuit 7 1 No x 9 i The Check Engine Light has been reported on With the SCS short connector connected code 23 is in
121. ase the brake the car should not move 14 5 Illustrated Index Torque Converter Housing Valve Body 9 Get 9 Si y 0 14 6 ACCUMULATOR COVER O RING Replace OIL FEED PIPE O RING Replace SERVO DETENT BASE LOCK WASHERS Replace OIL FEED PIPE BAFFLE PLATE SERVO BODY SERVO SEPARATOR PLATE THROTTLE CONTROL SHAFT E RING CHECK BALLS SECONDARY VALVE BODY DOWEL PINS SECONDARY SEPARATOR PLATE LOCK WASHERS Replace GOVERNOR BODY DOWEL PIN OIL FEED PIPE OIL FEED PIPE MODULATOR VALVE BODY DOWEL PINS MODULATOR SEPARATOR PLATE LOCK UP VALVE BODY DOWEL PINS LOCK UP SEPARATOR PLATE COOLER CHECK VALVE SPRING COOLER CHECK VALVE REGULATOR VALVE BODY O RING Replace STATOR SHAFT STOPPER SHAFT CHECK BALLS DOWEL PINS MAIN VALVE BODY OIL FEED PIPE OIL FEED PIPE DOWEL PIN MAIN SEPARATOR PLATE OIL PUMP DRIVE GEAR OIL PUMP DRIVEN GEAR SHAFT OIL PUMP DRIVEN GEAR CONTROL SHAFT DETENT ARM SHAFT DETENT SPRING DETENT ARM ATF STRAINER TORQUE CONVERTER HOUSING COUNTERSHAFT NEEDLE BEARING OIL GUIDE PLATE TORQUE CONVERTER HOUSING TORQUE CONVERTER HOUSING MAINSHAFT BALL BEARING OIL SEAL Replace LOCK UP CONTROL SOLENOID VALVE ASSEMBLY LOCK UP CONTROL SOLENOID FILTER GASKET Replace 888 996 OSSOHSHOOSSS SSS SSSOOGOS TORQUE CONVERTER CHECK VALVE SPRING STOPPER SHAFT STAY TORQUE CONVERTER CHECK VALVE 0
122. ative cable and turn the Then press the quick connect fitting onto the pipe ignition switch ON the fuel pump will work for until both retainer pawls lock with a clicking sound about two seconds and fuel pressure will rise Repeat two or three times and check that there is NOTE no leakage in the fuel supply system If it is hard to connect put a little amount of new engine oil on the pipe end Connection with new retainer CONNECTOR RETAINER PIPE Reconnection to existing retainer CONNECTOR RETAINER PIPE 11 15 Fuel Supply System Emission Control System Fuel Filter System Description KM model Replacement AW ARNING Do not smoke while working on fuel system Keep open flame away from your work area While replacing the fuel filter be careful to keep safe distance between battery terminals and any tools The emission control system includes a three way catalytic converter crankcase ventilation system and evaporative control system The fuel filter should be replaced every 2 years or 40 000 km 24 000 miles whichever comes first or whenever the fuel pressure drops below the specified value 280 330 kPa 2 8 3 3 kg cm 40 47 psi with the fuel pressure regulator vacuum hose disconnected and pinched after making sure that the fuel pump and the fuel pressure regulator are OK Tailpipe Emission Disconnect the battery negative cable from the battery n
123. board lower panel and in case of some models in the dashboard above the glove box Do not use electrical test equipment on these circuits Service work nearby and in the areas listed below may affect the SRS and must therefore be performed by an authorized Honda dealer SRS Type Il Steering wheel Be careful not to bump the steering wheel as the SRS unit sensors inflator etc are located in it Behind the dashbord Under dash fuse relay box SRS Type III Steering wheel Behind the dashboard Under dash fuse relay box Front console Car stereo unit and other accessories heater Electrical Special Tools 23 2 Interlock System Relay and Control Unit Locations Component Location Index 23 18 Trunk 23 3 Description KB KM 23 19 Fuses Circuit Diagram 23 21 Under dash Fuse Relay Box 23 4 Control Unit Input Test 23 24 Under hood ABS Fuse Relay Shift Lever Position Indicator BOX ee 23 6 Circuit Diagram 23 26 Power Distribution 23 7 Indicator Input Test 23 29 Ground Distribution 23 10 Integrated Control Unit Starting System Circuit Diagram 23 31 Description 23 11 Control Unit Input Test
124. dicated Do the ECU Reset Procedure Start the engine Hold the engine at 3 000 rpm min with no load M T in neutral until the radiator fan comes on then let it idle Hold engine at 3 000 4 000 rpm min for 10 seconds with M T in neutral the Check Engine Light Intermittent failure system is OK at this time test drive may be necessary Check for poor connections or loose wires between knock sensor and ECU does it indicate code 23 YES Turn the ignition switch OFF Connect the test harness to the engine wire harness only not to the ECU Disconnect the 2P connector from the knock sensor terminal and body ground Check for continuity between D3 YES Repair short in RED BLU wire between ECU D3 and the knock sensor lt Is there continuity NO To page 11 10 0000000000000 J 00000000 8106000000000 9900000000000 Continuity cont d 11 9 PGM FI System Knock Sensor B16A3 engine cont d From page 11 9 Check for continuity on RED BLU wire between D3 terminal and 2P connector of engine wire harness 0000000000000 00000000 269998 06000000000 9000000000000 00000000 00000000000 Continuity ET NO Repair open in RED BLU wire lt Is the
125. dth of shift fork contact area 0 30 0 004 0 012 1 10 8 20 0 319 0 323 20 0 50 0 008 0 020 1 90 12 00 0 469 0 472 1 0 7 7 0 0 05 0 45 0 002 0 018 0 8 0 1 Select arm Select arm to interlock clearance Select arm to shim clearance 0 05 0 25 0 002 0 010 0 010 0 20 0 0004 0 008 0 6 0 02 0 6 0 02 0 5 0 02 Interlock Change piece Width of select arm contact area 9 90 10 00 0 390 0 394 Change piece to shift arm holder clearance Groove width of shift arm holder contact area Change piece to select arm clearance Groove width of select arm contact area 0 05 0 35 0 002 0 014 12 05 12 15 0 474 0 478 0 05 0 35 0 002 0 014 12 05 12 15 0 474 0 478 0 8 0 03 0 8 0 03 3 13 Standards and Service Limits 4WD Manual Transmission S22 Section 13 Diameter of 63 28C ball bearing contact area Diameter of 3rd gear contact area B Diameter of 6306 25 ball bearing contact area C Diameter of 4th 5th spacer collar contact area Runout Mainshaft 3rd gear MEASUREMENT STANDARD NEW SERVICE LIMIT Transmission oil Capacity 2 US qt Imp qt 2 8 3 0 2 5 for overhaul 2 2 2 3 1 9 for oil change Mainshaft End play 0 08 0 15 0 003 0 006 Adjust 2 34 984 35 000 1 3773 1 3780 24 987
126. e Blown No 15 10A fuse under dash fuse relay box Anopenin the wire in the GRN BLU Driver s door open Check for continuity to ground There shouid be continuity Faulty driver s door switch the wire LT GRN RED Front passenger s door open Check for continuity to ground There should be continuity Faulty front passenger s door switch An open in the wire BLU WHT Ignition key is in serted into the igni tion switch Check for continuity to ground There should be continuity Faulty ignition key switch Poor ground G401 An open in the wire RED BLU 23 36 Driver s seat belt is unbuckled Check for continuity to ground There should be continuity Faulty driver s seat belt switch Poor ground 6551 5552 An open the wire Intermittent Wiper Relay System KB KM D15B7 D16Z6 engine C D E F BLU WHT ee View from wire side rt H J BLU GRN YEL BLU KP KT B D E F YEL BLU T FER H IJ K L M N BLU GRN BLU WHT KG KM 16 engine A B C D E F YEL BLU LE U View from wire side 1717 J K L BLU GRN BLU WHT Wire No Terminal Test condition Test desired result Possible cause if result is not obtained Under all conditions Check for continuity to ground There should be cont
127. e 1st 2nd 0 65 0 85 0 026 0 033 3rd 4th 0 40 0 60 0 016 0 024 1st hold 0 5 0 8 0 02 0 03 Clutch return spring 1st 31 0 1 22 29 0 1 14 free length 2nd 3rd 4th 30 5 1 20 28 5 1 12 1st hold 34 6 1 36 32 6 1 28 Clutch disc thickness Clutch plate thickness 1st Except 1st Clutch end plate thickness MARKT except 1st hold MARK2 MARK3 MARK4 MARK5 MARK6 MARK7 MARK8 MARK9 MARK10 MARK11 MARK12 MARK13 1 88 2 00 0 074 0 079 1 55 1 65 0 061 0 065 1 95 2 05 0 077 0 081 2 30 2 40 0 091 0 094 2 40 2 50 0 094 0 098 2 50 2 60 0 098 0 102 2 60 2 70 0 102 0 106 2 70 2 80 0 106 0 110 0 2 90 0 110 0 114 3 00 0 114 0 118 10 0 118 0 122 20 0 122 0 126 30 0 126 0 130 10 0 079 0 083 20 0 083 0 087 30 0 087 0 091 Clutch end plate thickness MARK1 1st hold MARK2 MARK3 MARK4 NO MARK MARK6 MARK7 0 085 0 087 0 089 0 091 0 093 0 094 0 096 0 098 0 100 0 102 0 104 0 106 NNNNNNN NNNOWANN 3 10 3 20 3 30 2 10 2 20 2 30 2 10 0 081 0 083 2 20 2 30 2 40 2 50 2 60 2 70 1 2 3 4 5 6 7 Until grooves worn out Discoloration Discoloration Discoloration Discoloration Discoloration cont d 3 27 Standards and Service
128. e 516 0 63 i 514 5 267 5 20 26 10 53 550 i 295 eS 1000 39 4 1188 46 8 500 19 7 932 36 7 869 34 2 765 30 1 9 e z 3 u N TI 7 d IE a 21 7 11 6 501 5 305 5 19 74 12 03 493 305 19 4 12 0 POINT T CENTER LINE 374 14 d N 1365 53 7 830 32 7 Distance 5 POINT GEI a Ne 846 3 j 2682 _POINT h SAT 5 105 6 en IS 51 2661 mr 104 8 IZAN E 2657 Z 27 7E y POINT c N HK T I Bar Lol a sesi Te DLL HN 86 8812 1 4 130 51 174 6 9 POINT n 102 265 10 4 350 13 81 32 1 25 14 0 550 21 7 800 31 5 d j POINT h 917 7 0 69 Upper Arm Point POINT g Front Damper Center r M12 x P1 25 13 5 0 53 Transmission Mount Center SECTION AA POINT g 453 17 8 390 15 4 9 POINT h i h e17 7 0 69 St 913 5 10 53 Engine 2 i 17 7 0 69 BASELINE Mount Center 20 5 0 81 POINT a 3 NN 611 5 0 45 Front Stopper a 4 i POINT c 5 SECTION B8 DD 11 5 0 45 L Front Stopper 917 0 66 Rear ZN POINT POINT b ez Beam Point 917 0 66 Rear Beam Point 625 1 0 611 5
129. e steering wheel as the SRS unit sensors inflator etc are located it Behind the dashbord Under dash fuse relay box SRS Type Ill Steering wheel Behind the dashboard Under dash fuse relay box Front console Car stereo unit and other accessories A C heater Body Doors Outer Handle Replacement Front DO T ae 20 2 Latch Replacement Front Door 20 3 Door Channel Tape Replacement 20 4 Emblems Installation 20 11 Frame Repair 20 12 License Plate Trim Replacement AD 20 10 Seat Belts Upper and Lower Anchor Bolt CONStTUcHONn eek 20 9 Side Sill Panel Replacement 20 10 NOTE Refer to the 1992 Civic Shop Manual P N 62SR300 and the 1994 Civic Shop Manual Supplement P N 62SR321 for the items not shown in this section Outline of Model Changes The outer handle and latch replacement procedures have been changed front door door channel tape replacement procedure has been added The emblems for KM model have been added e The frame repair chart has been changed The license plate trim replacement procedure has been changed 4D e The seat belt anchor bolt construction has been changed e The quantities of the side sill panel clips used have been changed Doors Outer Handle Replacement
130. ea Runout Transfer drive I D bevel gear Diameter of taper bearing contact area Transfer driven Backlash bevel gear Diameter of taper bearing contact area Transfer driven gear side Locknut side 54 000 54 015 2 1260 2 1266 53 94 2 124 16 989 17 000 0 6689 0 6693 16 93 0 667 24 979 25 000 0 9834 0 9843 24 92 0 981 0 02 0 001 0 05 0 002 25 000 25 021 0 9843 0 9851 25 06 0 987 35 002 35 018 1 3780 1 3787 34 95 1 376 0 10 0 15 0 004 0 006 Adjust with shim 35 002 35 018 1 3780 1 3787 34 95 1 376 27 987 28 000 1 1018 1 1024 27 93 1 100 STANDARD NEW MEASUREMENT Regulator valve spring A Regulator valve spring B Stator reaction spring Torque converter check valve spring Relief valve spring 2nd orifice control valve spring Servo orifice control valve spring Throttle control valve B spring Throttle control valve B adjuster spring 1 2 shift valve spring 2 3 shift valve spring 3 4 shift valve spring 1st accumulator spring 1st hold accumulator spring 4th accumulator spring 2nd accumulator spring 3rd accumulator spring Lock up control valve spring Lock up timing B valve spring CPC valve spring Lock up shift valve spring 4 2 kick down valve spring Cooler relief valve spring Modulator valve spring Servo control valve spring 4th exhaust valve spring 4 3 kick down valve spring Springs
131. ed washer thickness 2 87 2 90 0 113 0 114 2 92 72 95 0 115 0 116 3 05 0 119 0 120 10 0 121 0 122 15 0 123 0 124 20 0 125 0 126 25 0 127 0 128 30 0 129 0 130 35 0 131 0 132 3 37 3 40 0 133 0 134 Q C0 CO CO CO CO S Ph 253 3 3 3 3 3 Wear or damage Wear or damage Mainshaft 4th gear thrust washer thickness One way clutch contact area l D Countershaft 1st gear Parking gear Mainshaft feed pipe A O D Mainshaft feed pipe D Countershaft feed pipe O D Mainshaft sealing ring thickness Mainshaft bushing D Mainshaft bushing D Countershaft bushing 1 D Mainshaft sealing ring groove width 2 93 3 00 0 115 0 118 74 414 74 440 2 9297 2 9307 57 755 57 768 2 2738 2 2743 8 97 8 98 0 353 0 354 5 970 5 980 0 2350 0 2354 7 970 7 980 0 3138 0 3142 1 980 1 995 0 0780 0 0785 6 018 6 030 0 2369 0 2374 9 000 9 015 0 3543 0 3549 8 000 8 015 0 3150 0 3156 2 025 2 060 0 0797 0 0811 Wear or damage Wear or damage 8 95 0 352 5 95 0 234 7 95 0 313 1 80 0 071 6 045 0 2380 9 030 0 356 8 030 0 3161 2 080 0 082 Regulator valve body Sealing ring contact I D 32 000 32 025 1 2598 1 2608 32 05 1 262 Shifting device and parking brake control Reverse shift fork finger
132. egative terminal Inspection AWARNING Do not smoke during this procedure Keep any open flame away from your work area Place a shop towel under and around the fuel filter Relieve fuel pressure Support the fuel filter with a wrench as shown then remove the banjo bolt and the fuel feed pipe from the fuel filter 1 Connect a tachometer 2 Start the engine Hold the engine at 3 000 rpm min with no load A T in IN or P position M T in neutral until the radiator fan comes on then let it idle Remove the fuel filter clamp and filter When assembling use new washers as shown NOTE 3 Check and adjust the idle speed if necessary see Clean the flared joint of high pressure hoses page 11 11 thoroughly before reconnecting them 4 Warm up and calibrate the CO meter according to the meter manufacturer s instructions SERVICE BOLT 15 N m 1 5 kg m BANJO BOLT 34 N m 3 4 kg m 25 Ib ft 5 Check idle CO with the headlights heater blower rear window defogger cooling fan and air conditioner off WRENCH CO meter should indicate 0 1 maximum WRENCH 11 16 Transaxle Clutch Clutch Pedal With Clutch Interlock Switch Adjustment 12 2 Outline of Model Change cars with clutch interlock switch are added Therefore clutch pedal with clutch interlock switch adjustment has been added Clutch Pedal With Clutch Inte
133. el Year 3 1995 Serial Number 1 4 Engine Number Engine Type D13B3 D15B3 D15B7 D1522 D16A9 D16Y1 Serial Number D13B3 2300001 1300 SOHC 16 valves 1 carbureded Engine without CATA 1500 SOHC 16 valves 1 carbureded Engine without CATA 1500 SOHC 16 valves Sequential Multiport Fuel injected Engine with CATA 1500 SOHC 16 valves 1 carbureded Engine with CATA 1600 DOHC 16 valves Sequential Multiport Fuel injected Engine without CATA KR only 1600 SOHC 16 valves Sequential Multiport Fuel injected VTEC Engine with CATA D13B3 D15B3 D16A9 2300001 D15B7 4700001 01572 D16Y1 1100001 Manual Transmission Number Transmission Type Serial Number 520 2000001 Automatic Transmission Number Transmission Type S24A 4000001 S24A For D16Y1 engine 548 Except D16Y1 engine Serial Number Except European Model 4 door Sedan Vehicle Identification Number JHMEH8 5100 Manufacturer Make and Type of Vehicle JHM HONDA MOTOR CO LTD JAPAN HONDA Passenger car Line Body and Engine Type EG7 CIVIC 4 door D13B3 EG8 CIVIC 4 door D15B3 D15B7 01521 EH8 CIVIC 4 door D12B1 EH9 CIVIC 4 door D16A9 D16Y1 Body Type and Transmission Type 5 4 door Sedan 5 speed Manual 6 4 door Sedan 4 speed Automatic Vehicle Grade Series 1 1 2EL EHS KT EL EG7 KP 1 5EL EG8 KP KT KY 2 1 2EX EH8
134. er race MEASUREMENT 0 0 15 0 0 0 006 Front Differential 4WD Transmission Section 15 STANDARD NEW Final driven gear Backlash 0 017 0 129 0 0007 0 0051 Adjust SERVICE LIMIT Pinion shaft bore diameter Carrier to pinion shaft clearance Drivershaft bore diameter Carrier to driveshaft clearance Ball bearing bore diameter Differential carrier 18 000 18 018 0 7087 0 7094 0 013 0 047 0 0005 0 0019 28 005 28 025 1 1026 1 1033 0 025 0 066 0 0010 0 0026 40 002 40 018 1 5749 1 5755 0 10 0 004 0 12 0 005 Backlash Pinion gear bore diameter Pinion gear to pinion shaft clearance Differential pinion gear 0 05 0 15 0 002 0 006 18 041 18 061 0 7103 0 7111 0 054 0 090 0 0021 0 0035 0 15 0 006 Set ring to bearing outer race MEASUREMENT 0 0 15 0 0 0 006 Rear Differential 4WD Transmission Section 15 Adjust STANDARD NEW Differential carrier assembly Oil capacity 3 32 Imp qt for overhaul Imp qt for oil change Steering Section 17 MEASUREMENT Unit of length mm in STANDARD NEW Steering wheel Play at steering wheel circumference Starting load at steering wheel circumference N kg Ibs Manual steering Power steering Engine running LHD RHD
135. ey Interlock System Shift lever with shift lock Shift Lock System Key Interlock System When the shift lever is in any other position than Plor is not securely locked in P parking pin switch is ON a solenoid is activated making it impossible to remove the ignition key from the ignition switch To be able to remove the key the shift lever must be in P and must be securely locked in this position parking pin switch must be turned off by the lock pin BATTERY SOLENOID ON LOCK OFF UNLOCK c rM KEY 1 INTERLOCK SWITCH EY INTERLOCK SOLENOID INTERLOCK CONTROL UNIT INTERLOCK LEVER KEY INTERLOCK SWITCH Rosimon PARKING PIN S d Se The shift lever is any other position than P and the parking pin switch is LOCK PIN PARKING PIN SWITCH ON rm LA SOLENOID ae ON SHIFT LOCK LEVER The shift lever is in P the parking pin switch is OFF KEY CYLINDER LOCK PIN PARKING PIN SWITCH OFF M A SHIFT LOCK LEVER SOLENOID OFF cont d 23 19 Interlock System Description KB KM cont d Shift Lock System The shift lock system prevents the shift lever from moving to or D from position P unless you step on the brake pedal NOTE The shift lever cannot be shifted when the brake pedal and the accelerator are depressed at the same time In case of system malfunction the shi
136. ft lever can be released by pushing a key into the release slot near the shift lever PSOE P ION BATTERY SENSOR BATTERY SHIFT LOCK 1 SOLENOID UNLOCK PGM FI ECU INTERLOCK CONTROL UNIT Q SHIFT POSITION IW CONSOLE SWITCH ON In position P LOCK PIN SHIFT LOCK LEVER KEY LOCK PIN RELEASE LEVER SHIFT LOCK LEVER SOLENOID SOLENOID 23 20 Circuit Diagram KB KM NOTE Different wires with the same color have been given a number suffix to distinguish them for example GRN WHT and GRN WHT are not the same UNDER HOOD FUSE RELAY BOX No 42 20A O O No 41 80A BATTERY WHT GRN T j WHT GRN WHT BLK e wHT O O WHT GRN No 39 50 IGNITION BLK YEL BRAKE SWITCH SWITCH HORN CIRCUIT Joie WHT GRN 104 Box GRN WHT YEL YEL GRN WHT A THROTTLE POSITION SENSOR SHIFT LOCK SOLENOID ION UNLOCK INTERLOCK Built into PNK BLK SOLENOID steering I SC GRN WHT EI ECU Q WHT BLU WHT YEL YEL YEL BLK WHT RED BRAKE LIGHTS ABS CONTROL UNIT KEY INTERLOCK CIRCUIT INTERLOCK CONTROL UNT SKIFT LEVER POSITION INDICATOR BLK WHT BLK GRN WHT GRN WHT SHIFT POSITION PARKING PIN Sch ON in position P except P Push button pushed BLK in position BLK BLK G201 G401 23 21 Interlock System Circuit Diagram KQ NOTE Different w
137. g 2 216 Ibs KS A T 1 030 kg 2 271 ibs KG 1 035 kg 2 282 Ibs KS LSi M T 1 015 kg 2 238 Ibs KG KE KF KW 1 020 kg 2 249 165 KS A T 1 045 kg 2 304 Ibs KG KE KF KW 1 050 kg 2 315 Ibs KS ESi MT 1 050 kg 2 315 Ibs KG KF KW 1 055 kg 2 326 Ibs KS A T 1 080 kg 2 381 ibs KG KE KF KW 1 085 kg 2 392 Ibs KS ESi with ABS M T 1 065 kg 2 348 Ibs KG KE KF KW 1 070 kg 2 359 Ibs KS A T 1 095 kg 2 414 Ibs KG KE KF KW 1 100 kg 2 425 165 KS VTi M T 1 140 kg 2 513 Ibs KG KE KF KW 1 145 kg 2 524 Ibs KS RSTi M T 1 140 kg 2 513 ibs KG A T 1 160 kg 2 557 ibs KG Weight distributions Front Rear VEi M T 605 1 334 405 kg 893 Ibs KG KE KF 610 1 345 405 kg 893 Ibs KS DXi M T 595 1 312 405 kg 893 Ibs KG 600 1 323 405 kg 893 Ibs KS A T 625 1 378 405 kg 893 Ibs KG 630 1 389 405 kg 893 Ibs KS LSi M T 610 1 345 405 kg 893 Ibs KG KE KF KW 615 1 356 405 kg 893 Ibs KS A T 640 1 411 405 kg 893 Ibs KG KE KF KW 645 1 422 405 kg 893 Ibs KS ESi M T 630 1 389 420 kg 926 Ibs KG KE KF KW 635 1 400 420 kg 926 Ibs KS A T 660 1 455 420 kg 926 16 KG KE KF KW 665 1 466 420 kg 926 165 KS ESi with ABS MT 640 1 411 425 kg 937 Ibs KG KW 645 1 422 425 kg 937 Ibs KS A T 670 1 477 425 kg 937 Ibs KG KE KF KW 675 1 488 425 kg 937 Ibs KS VTi M T 705 1 554 435 kg 959 Ibs KG KE KF KW 710 1 56
138. ge A disconnected quick connect fittings can be reconnected but the retainer on the mating pipe cannot be reused once it was removed from the pipe Replace the retainer when Replacing the fuel pump Replacing the fuel feed pipe It was removed from the pipe It is damaged FUEL PUMP QUICK CONNECT FITTINGS Disconnection AW ARNING Do not smoke while working on fuel system Keep open flame away from work area 1 Disconnect the battery negative cable 2 Relieve fuel pressure 3 Remove the fuel fill cap and relieve fuel pressure in the tank 4 Check the fuel quick connect fittings for dirt and clean if necessary 5 Holding the connector with one hand and pressing down the retainer tabs with the other pull the connector off NOTE careful not to damage the pipe or other parts Do not use tools e If the connector does not move keep the retainer tabs pressed down and alternately pull and push the connector until it goes off easily eDo not remove the retainer from the pipe a removed retainer must ba replaced with a new one LOCKING PAWL RETAINER TAB PIPE CONNECTOR Press 6 Check the contact surface of the pipe for dirt and damage f the surface is dirty clean it If the surface is rusty or damaged replace the fuel pump or fuel feed pipe CONTACT SURFACE CONNECTOR RETAINER PIPE cont d 11 13 Fuel Supply System Fuel Tube Quick Con
139. h new belt 3 33 Standards and Service Limits Suspension Section 18 MEASUREMENT STANDARD NEW SERVICE LIMIT Wheel alignmelnt B16A2 B16A3 Camber Caster Total toe Front wheel turning angle Front Rear Front Front Rear Inward wheel Outward wheel 0 05 1 0 25 1 1 10 1 0 2 0 0 0 08 2 0722 0 08 29 36 2 2 30 30 2WD except B16A2 B16A3 4WD Camber Caster Total toe Front wheel turning angle Camber Caster Total toe Front wheel turning angle Front Rear Front Front Rear Inward wheel Outward wheel 0 00 1 0 20 41 1 10 1 0 2 0 0 0 08 2 0 75 008748 41 2 33 30 Front Rear Front Front Rear without ABS with ABS Inward wheel Outward wheel 0 15 4 0 25 1 1 05 1 0 2 0 00 08 2 0 35 0 08 565 0 2 0 008 41 2 33930 Wheel Rim runout Aluminum wheel Steel wheel Axial Radial Axial Radial Wheel bearing 3 34 End play Front Rear Brakes Section 19 Unit of length mm in MEASUREMENT STANDARD NEW SERVICE LIMIT Parking brake Play in stroke at 200 N 20 kg 44 Ibs lever force To be locked when lever pulled 6 10 notches Foot brake pedal Pedal height with floor mat removed M T 160 0 6 30 A T 165 0 6
140. has been changed and the KM model has been added Items related to above shown changes have been rewritten and modifications to the ABS and SRS have been reflected in Relay and Control Unit Locations Power Distribution Ground Distribution and Fuses Special Tools Tool Number Description Remark 07PAZ 0010100 SCS Short Connector 07HAZ SG00500 Deployment Tool 07MAZ SP00100 SRS Short Connector A 07MAZ SP00500 Test Harness B 07LAZ SL40300 Test Harness C 070AZ SR30100 Jumper Wire Harness Fuses Under dash Fuse Relay Box hv Spare fuse To dashboard wire harness Option Option To sunroof wire harness Option To turn signal hazard relay Nita To SRS main harness e Sa a he add r3 F1 Fe 12 13 14 15 16 17 18 19 20 21 22 23 24 25 LJLUJLILILJLJLILILILILILI LI LJ 8 III IP II MAN F 1 2 3 4 5 6 7 8 9 10 11 To power window relay qi M To ignition switch NOTE View from back side of the under dash fuse relay box To rear wire harness To main wire harness p gt N To main wire harness To rear wire harness To integrated control unit To main wire harness 23 4 Fuse Number Amps Wire Color Componentis or Circuit s Protected
141. he pedal released 9 GRN WHT Brake pedal pushed Check for voltage to ground Faulty brake switch then released There should be battery voltage An open in the wire with the pedal pushed and 0 V with the pedal released 10 RED BLU Ignition switch ON Attach to ground Indicator light Blown bulb in the gauge assembly comes Blown No 15 10 A fuse in the on under dash fuse relay box Faulty dimming circuit in the gauge assembly An open in the wire 11 BRN Connect the battery Check the operation of the Faulty actuator power to the BRN actuator motor You should be An open in the wire terminal and ground able to hear the motor 12 BRN BLK to the BRN BLK terminal 13 BRN WHT Connect the battery Check the operation of the Faulty actuator power to the BRN magnetic clutch Clutch should An open in the wire WHT terminal click and output link should be Poor ground G301 locked 14 BLK YEL Ignition switch ON Check for voltage to ground Blown No 24 15 A fuse in the There should be battery voltage under dash fuse relay box An open in the wire 23 43
142. he side sill panel remove the side clips from the SIDE SILL PANEL body install them on the side sill panel then install the side Remove the lower clips then remove the side sill panel by sliding it forward sill panel on the car NOTE Take care not to twist the side sill panel f necessary replace any damaged side and lower clips 20 10 Emblems Installation Apply the emblems where shown NOTE Unit mm in Before applying clean the body surface with a sponge dampened in alcohol After cleaning keep oil grease or water from getting on the surface When applying make sure there are no wrinkles in the emblems Attachment Points Reference 3D VERSION EMBLEM Civic EMBLEM A 27 1 06 a VERSION EMBLEM Civic EMBLEM 4D Civic EMBLEM KM model VERSION EMBLEM EE Civic EMBLEM B VERSION EMBLEM B 94 5 3 72 105 5 4 15 68 5 2 7 79 5 3 13 model 86 3 4 97 3 8 KM model Emblem A B LX 85 5 3 37 96 5 3 79 86 3 4 97 3 8 EAGLE EMBLEM EAGLE EMBLEM SIDE TURN SIGNAL LIGHT 20 11 Frame Repair Chart Unit mm in Inner diameter POINT j POINT b 102 302 111 9 271 10 7 OINT POINT m POINT a 4 0 il Distanc
143. her cap for S20 manual transmission Shift fork for Y21 manual transmission Super low shaft 2 4 select lever and transfer shaft for S22 manual transmission Added 521 manual transmission Specifications of the S21 manual transmission is same as that of the Y21 manual transmission Changed Countershaft inspection for Y21 S21 manual transmission Reverse idler shaft bolt torque for Y21 S21 and S22 manual transmissions Automatic Transmission 13 Modified Hydraulic circuit Secondary valve body Reverse idler gear Changed Drain plug Throttle pressure and governor pressure Reverse selector hub on the countershaft Modified Hydraulic circuit Changed Parking gear Reverse idler gear shaft and holder Oil guide cap of the sub shaft Secondary valve body Servo body Countershaft Clutch assemblies Abolished 4WD disengagement mechanism Modified for S24A automatic transmission Installation procedure of sub shaft oil guide cap 1st hold clutch piston Gearshift selector for KB and KM models Changed Shift schedule for S24A automatic transmission Discontinued ATF magent for 524 automatic transmission 14 Outline of Model Changes MODELS REFERENCE ITEM DESCRIPTION 93 94 95 SECTION Rear Changed Differential Rear differential assembly Driveshafts Changed Q Rear driveshaft and propeller shaft fo
144. ic hydraulic nitrogen gas filled WHEEL ALIGNMENT Camber Front VTi 2WD except VTi 4WD VTi 2WD except VTi 4WD Rear Caster Front 2WD 4WD Toe Front Rear 4WD with ABS 0205 0 00 0 15 0 25 0 20 0 25 1910 1 05 0 mm 0 in In 2 0 mm 0 08 in 0 mm 0 in BRAKE SYSTEM Type Front Rear Pad and Lining Surface Area Front Rear Parking Brake Type Power assisted self adjusting ventilated disc Power assisted self adjusting solid disc or drum 35 8 cm x 2 5 5 sq in x 2 43 2 cm x 2 6 7 sq in x 2 51 5 cm x 2 8 0 sq in x 2 21 0 cm x 2 3 26 sq in x 2 50 2 cm x 2 7 8 sq in x 2 67 2 cm x 2 10 4 sq in x 2 Mechanical actuating rear two wheel brakes Unit mm in Disc dia 190 7 5 Disc dia 191 7 5 Disc dia 211 8 3 Disc dia 208 8 2 Drum 180 7 1 Drum 200 7 9 3 46 Size and Pressure See tire information label see page 1 15 METRIC ENGLISH ELECTRICAL Battery 12 V 47 AH 36 AH 38 AH 5 HR Starter 12 V 0 8 kW 12 V 1 0kW 12 V 1 2 kW 12 V 1 4 kW Alternator 12V 70A 80A Fuses In the Uuder dash Fuse Box 7 5 10 15 20A 30A In the Under hood Fuse Relay Box 7 5 A 10A 15 A 20A 30A 40 A 50A 80A In the Under hood ABS Fuse 7 5 15A 20A 50A Relay Box Headlights High Low 12 V 60 55 W Front Turn Signal Lights 12V 21W KY model 12 V 43 3 CP
145. in no load conditions headlights blower fan rear defogger cooling fan and air conditioner are not operating Idle speed should be 420 50rpm 420 50rpm min in n or P position Adjust the speed if necessary by turning the adjusting screw NOTE After adjusting the idle speed in this step recheck the ignition timing If it is out of spec go back to step 4 IDLE ADJUSTING SCREW Turn the ignition switch OFF Reconnect the 2P connector on the EACV then remove BACK UP fuse in the under hood fuse relay box for 10 seconds to reset the ECU Restart and idle the engine with no load conditions for one minute then check the idle speed Idie speed should be 750 50rpm min 750 50rpm min N or P position Idle the engine for one minute with headlights Low ON and check the idle speed Idle speed should be 750 50rpm min 750 50 min in n or P position Turn the headlights off Idle the engine for one minute with heater fan switch at High and air conditioner on then check the idle speed Idle speed should be 810 50rpm min 810 50rpm min in N or P NOTE If the idle speed is not within specification see Idle Control System Troubleshooting Guide 11 11 Fuel Supply System Fuel Lines FUEL PUMP FUEL VAPOR PIPE FUEL FILLER CAP FUEL
146. ing contact area Diameter of drive bevel gear contact area Runout STANDARD NEW 54 000 54 015 2 1260 2 1266 16 989 17 000 0 6689 0 6693 24 979 25 000 0 9834 0 9843 0 02 0 001 Unit of length mm in SERVICE LIMIT 53 94 2 124 16 93 0 667 24 92 0 981 0 05 0 002 Transfer drive bevel gear I D Diameter of taper bearing contact area 25 000 25 021 0 9843 0 9851 35 002 35 018 1 3780 1 3787 25 06 0 987 34 95 1 376 Transfer driven bevel gear Backlash Diameter of taper bearing contact area Transfer driven gear side Locknut side Synchro ring Ring to gear clearance Ring pushed against gear 0 10 0 15 0 004 0 006 35 002 35 018 1 3780 1 3787 27 987 28 000 1 1018 1 1024 0 85 1 10 0 033 0 043 Adjust 34 95 1 376 27 93 1 100 0 4 0 02 1st 2nd shift fork and 3rd 4th shift fork Synchro sleeve groove width Shift fork to synchro sleeve clearance Thrust Radial Shift fork finger thickness 7 95 8 05 0 313 0 317 0 45 0 65 0 018 0 026 0 05 0 45 0 002 0 018 7 4 7 5 0 29 0 30 5th shift fork Reverse shift fork Synchro sleeve groove width Shift fork to synchro sleeve clearance Thrust Radial Fork pawl thickness Fork to reverse idler gear clearance L groove width Fork to 5th reverse shift piece pin clearance
147. inuity Poor ground G401 An open in the wire Ignition switch to ON Check for voltage to ground There should be battery voltage Blown No 14 20 in the under dash fuse relay box An open in the wire YEL BLU switch INT Ignition switch to ON and windshield wiper Check for voltage to ground There should be battery voltage Blown No 14 20 in the under dash fuse relay box Faulty windshield wiper switch An open in the wire BLU WHT and BLU GRN park position Windshield wiper switch OFF or INT and wiper blades in Check for continuity between the BLU WHT and BLU GRN terminals There should be continuity Faulty windshield wiper switch Faulty windshield wiper motor An open in the wire 23 37 Ceiling Trunk Cargo Area Lights Circuit Diagram UNDER HOOD FUSE RELAY BOX BATTERY No 41 80A Hatchback WHT RED GRN TRUNK INDICATOR LIGHT GRN GRN GRN LEFT RIGHT HATCH TAILGATE TAILGATE LATCH LATCH LATCH SWITCH SWITCH SWITCH 23 38 4 No 36 50 Sedan WHT RED TRUNK LIGHT 3 4W GRN TRUNK INDICATOR LIGHT GRN TRUNK LATCH SWITCH
148. irbag assembly and has built in sensors which is used for models with front passenger s airbag Information necessary to safely service the SRS is included in this Shop Manual Items marked with an asterisk on the contents page include or are located near SRS components Servicing disassembling or replacing these items will require special precautions and tools and should therefore be done by an authorized Honda dealer AW ARNING 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 authorized Honda dealer Improper service procedures including incorrect removal and installation of the SRS could lead to personal injury caused by unintentional activation of the airbag s Do not bump the SRS unit Otherwise the system may fail in case of a collision or the airbags may deploy when the ignition switch is ON II SRS Type All SRS electrical wiring harnesses are covered with yellow insulation Related components are located in the steering column front console dashboard dashboard lower panel and in case of some models in the dashboard above the glove box Do not use electrical test equipment on these circuits Service work nearby and in the areas listed below may affect the SRS and must therefore be performed by an authorized Honda dealer SRS Type li Steering wheel careful not to bump th
149. ires with the same color have been given a number suffix to distinguish them for example GRN WHT GRN WHT are not the same UNDER HOOD FUSE RELAY BOX BATTERY WHT GRN No 41 80A 39 50A WHT GRN WHT GRN BRAKE IGNITION SWITCH 2M HORN CIRCUIT GRN WHT WHT GRN BLK YEL UNDER DASH 5 EUSE RELAY b BOX YEL A KEY T INTERLOCK Built into SHIFT steering LOCK SOLENOID sies LOCK i ON UNLOCK B WHT BLU WHT YEL KEY INTERLOCK SHIFT LOCK CIRCUIT CIRCUIT INTERLOCK CONTROL UNIT SHIFT LEVER POSITION INDICATOR 2 BLK GRN WHT GRNIWHT2 SHIFT POSITION CONSOLE SWITCH In position BLK 23 22 Parking Pin Switch Test KM Remove the center console Disconnect the parking pin switch 3 P connector from the main wire harness Check for continuity between the terminals in each switch position according to the table Parking Pin Switch Replacement K 1 2 Remove the center console Disconnect the parking pin switch 3 P connector from the main wire harness Replace the self locking nut and the parking pin switch Terminal Position Shift lever in position Push button pushed Push button released View from terminal side PARKING PIN SWITCH 3 P CONNECTOR SELF LOCKING NUT Replace 3 N m 0 3 kg m 2 2 Ib ft PUSH BUTTON 3 P CONNECTOR PARKING PIN SWITCH 23 23 Interlock
150. ivable ways in which service whether or not recommended by Honda might be done or of the possible hazardous consequences of every conceivable way nor could Honda investigate all such ways Anyone using service Procedures or tools whether or not recommended by Honda must satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized Transaxle All information contained in this manual is based on the latest product information available at the time of printing We reserve the rigtht 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 i marked sections are not included in this manual As sections with include SRS components special precautions are required when servicing First Edition 9 94 196 pages HONDA MOTOR CO LTD Rights Reserved Service Publication Office Electrical Including sns Outline of Model Changes ITEM DESCRIPTION 93 MODELS REFERENCE SECTION 94 95 Engine Modified Rocker shaft collar for D15Z1 engine Adopted 01572 D15B7 and D16Y1 engines for KO model D15B7 and 01629 engines for KB model Changed Torque value of mount and bracket bolts and nu
151. lar length Mainshaft 1st gear collar flange thickness 19 980 19 993 0 7866 0 7871 35 975 35 991 1 4163 1 4170 31 975 31 991 1 2589 1 2595 27 975 27 995 1 1014 1 1022 36 004 36 017 1 4175 1 4180 31 975 31 991 1 2589 1 2595 27 980 27 993 1 1016 1 1021 29 980 29 993 1 1803 1 1808 29 980 29 993 1 1803 1 1808 13 990 14 000 0 5508 0 5512 33 000 33 016 1 2992 1 2998 41 000 41 016 1 6142 1 6148 38 000 38 016 1 4961 1 4967 35 000 35 016 1 3780 1 3786 38 000 38 016 1 4961 1 4967 33 000 33 016 1 2992 1 2998 36 000 36 016 1 4173 1 4179 18 007 18 020 0 7089 0 7094 26 000 26 013 1 0236 1 0241 24 000 24 021 0 9449 0 9457 14 416 14 434 0 5676 0 5683 0 08 0 24 0 003 0 009 0 07 0 15 0 003 0 006 0 10 0 22 0 004 0 009 0 10 0 45 0 004 0 018 0 07 0 15 0 003 0 006 0 07 0 15 0 003 0 006 0 05 0 18 0 002 0 007 0 10 0 45 0 004 0 018 51 87 51 90 2 042 2 043 40 000 40 050 1 5748 1 5768 25 000 25 150 0 9843 0 9902 2 50 2 60 0 098 0 102 Wear jd damage Wear or damage Wear or damage Wear or damage Wear or damage Wear or damage 3 18 Countershaft distance collar length Countershaft reverse gear collar length
152. le 28 5 32 5 17 7 20 2 Full opened throttle 130 1 140 6 92 5 100 0 80 8 87 4 57 5 62 1 Lock up Throttle Opening D4 Position Lock up ON Lock up OFF Lock up ON Full closed throttle 24 27 23 26 98 104 15 17 14 16 6 16 throttle 107 114 87 93 66 71 54 58 Full opened throttle 141 147 134 141 88 91 83 88 4 Accelerate to about 57 km h 35 mph so the transmission is in 4th then shift D to 2 car should immediately begin slowing down from engine braking CAUTION Do not shift from D position to 2 or 1 position at speeds over 160 km h 100 mph you may damage the transmission 5 Checkfor abnormai noise and clutch slippage in the following positions 1 1st Gear Position 1 Accelerate from a stop at full throttle Check that there is no abnormal noise or clutch slippage 2 Upshifts and downshifts should not occur with the selector in this position 2 2nd Gear Position 1 Accelerate from a stop at full throttle Check that there is no abnormal noise or clutch slippage 2 Upshifts and downshifts should not occur with the selector in this position R Reverse Position Accelerate from a stop at full throttle and check for abnormal noise and clutch slippage 6 Testin P Parking Position Park car on slope approx 16 apply the parking brake and shift into P position Rele
153. nance intervals Severe driving conditions include A B C D E F R R Repeated short distance driving Driving in dusty conditions Driving in severe cold weather Driving in areas using road salt or other corrosive materials Driving in rough and or muddy roads Towing a trailer eplace l Inspect After inspection clean adjust fill up repair or replace if necessary Condition Maintenance Item Operation Interval AB F Engine oil For European models Every 5 000 km 3 000 rniles or 6 months and oil filter For Other than European Every 5 000 km 3 000 rniles or 3 months models Transmission oil Every 20 000 km 12 000 miles or 12 months DE Air cleaner For cars with catalytic Every 20 000 km 12 000 miles or 12 months element converter For cars without catalytic Every 10 000 km 6 000 miles or 6 months converter Front brake discs and calipers Every 10 000 km 6 000 miles or 6 months Rear brake discs calipers and pads Every 20 000 km 12 000 miles or 12 months Power steering system Every 10 000 km 6 000 miles or 6 months 16 engine has been adopted For the service procedures refer to the procedures for B16A2 engine Refer to Shop Manual 62SR300A 6258320 and 6258321 for the items ur not shown in this section Outline of Model Changes B16A3 engine has been adopted Fuel and Emissions Carbureted
154. nd cooling fan off M T Neutral or P position min rpm 01582 810 50 810 50 D15B7 750 50 750 50 D16A9 01676 D16Z7 D16Y1 750 50 750 50 01521 700 50 D16A7 710 50 r B16A2 B16A3 750 50 Idle CO With CATA 0 1 max Clutch pedal Clutch Section 12 Pedal height Stroke Total free play Disengagement height MEASUREMENT to floor to floor to carpet Without 1 0 1 0 NM STANDARD NEW SERVICE LIMIT 164 0 6 46 130 0 140 0 5 12 5 51 12 21 0 5 0 8 83 0 3 27 min 55 0 2 17 min Reference Flywheel Clutch surface runout 0 05 0 002 max 0 15 0 006 Clutch disc Rivet depth Thickness 0 20 0 008 6 0 0 24 1 30 0 051 min 4 9 1 0 33 0 36 Pressure plate 3 10 Warpage Diaphragm spring finger alignment 0 15 0 006 1 0 0 04 0 001 max 0 03 max 8 0 03 0 8 2WD Manual Transmission S20 Section 13 Unit of length mm in MEASUREMENT STANDARD NEW SERVICE LIMIT Transmission oil Capacity 2 US at Imp at 1 9 2 0 1 7 for overhaul 8 1 9 1 6 for oil change Mainshaft End play 0 11 0 18 0 004 0 007 Adjust Diameter of ball bearing contact area A Transmission housing side Diameter of 4th 5th gear contact area B Diameter of 3rd gear contact area C Diameter of ball bearing contact area D Clutch housing side 21 9
155. nect Fittings except D15B7 D16Z6 engines of KM KH models cont d 7 prevent damage and the intrusion of foreign matter cover the disconnected connector and pipe end with plastic bags or similar PLASTIC BAGS NOTE The retainer cannot be reused once it was removed from the pipe Replace the retainer when replacing the fuel pump replacing the fuel feed pipe it was removed from the pipe itis damaged Connection AW ARNING Do not smoke while working on fuel system Keep open flame away from work area 1 Check the pipe end for dirt and damage and clean if necessary CONTACT SURFACE PIPE 2 Insert a new retainer into the connector if the retainer is damaged or after replacing the fuel pump replacing the fuel feed pipe removing the retainer from the pipe NEW RETAINER Insert into the connector CONNECTOR 11 14 Before connecting a new fuel tube quick connect 4 Check visually and by pulling at the connector that fitting assembly remove the retainer from the the connection is secure and that the pawls are mating pipe firmly locked into place Pull apart With the tabs pulled apart pull the retainer off CONNECTOR RETAINER NEW FUEL TUBE QUICK CONNECT PIPE FITTINGS ASSEMBLY 3 Align the quick connect fitting with the pipe and align the retainer locking pawls with the connector grooves 5 Reconnect the battery neg
156. nstallation procedure of sub shaft oil guide cap has been modified 1st hold clutch piston has been modified e Gearshift selector for KB and KM models has been modified Special Tools Tool Number Description Remark 07746 0010100 Attachment 32 x 35 mm 07749 0010000 Driver 14 2 14 3 Road Test NOTE 2 Repeat same test in position 3 Shift the selector lever to check for abnormal noise and Warm up the engine to operating temperature 01582 and D15B7 engines To or D Position 1 Apply parking brake and block the wheels Start the engine then move the selector lever to position while depressing the brake pedal Depress the accelerator pedal and release it suddenly Engine should not stall D position and check that the shift points occur at approximate speeds shown Also clutch slippage e Upshift Throttle Opening Unit of speed 1st 2nd 2nd 3rd 3rd 4th Full closed throttle Km h 15 0 19 0 36 4 40 4 49 3 53 3 mph 9 3 11 8 22 6 25 1 30 6 33 1 3 16 throttle Km h 21 0 25 0 49 4 53 4 65 8 71 8 mph 13 0 15 5 30 7 33 2 40 9 44 6 6 16 throttle Km h 25 9 33 9 60 3 72 3 82 8 94 8 mph 16 1 21 1 37 5 44 9 51 4 58 9 Full opened throttle 49 4 53 9 91 1 98 6 142 6 153 1 30 7 33 5 56 6 61 3 88 6 95 1
157. on switch is ON Il or has been turned OFF for less than three minutes be careful not to bump the SRS unit the airbags could accidentally deploy and cause damage or injuries Before you disconnect any part of an SRS wire harness connect the short connectors RED to the airbags Refer to the additional precautions in the SRS sub section section 23 SRS Type Il SRS Type Ill SRS UNIT With built in sensors SRS MAIN HARNESS Covered with yellow insulation SRS MAIN HARNESS SRS UNIT Covered with yellow insulation With built in sensors CRUISE CONTROL UNIT 1 Disconnect the 14 P connector from the control unit 2 Inspect the connector terminals to be sure they are all making good contact f the terminals are bent loose or corroded repair them as necessary and recheck the system f the terminals look OK make the following input tests at the connector terminals lf any test indicates a problem find and correct the cause then recheck the system f all the input tests prove OK the control unit must be faulty replace it GRY LT GRN RED gc BLK d E e M m Ath 4 BLU BRN BLK YEL BLU RED BLU BLK YEL LTGRN View from wire side BLU Not used 23 42 Wire Test condition Test desired result Possible cause if result is not obtained 1 BLK Under all conditions Check for con
158. ondenser fan motor G751 I BLK ve SRS unit Type Il G801 0 GRY or BLK SRS unit Type Il GRY or BLK 6801 Dashboard wire harness SRS unit sub harness Type Il SRS main harness Type Ill wire harness e E 23 10 Starting System be Description M T with Interlock Switch Starter Interlock System M T The starter interlock system prevents the engine from starting unless the clutch pedal is fully depressed The clutch interlock switch turns on at the position where the clutch disengages 15 20 mm 0 6 0 8 in from the fully depressed position NOTE A full stroke of the clutch pedal is 135 145 mm 5 3 5 7 in from the fully released position LOCKNUT 10 N m 1 0 kg m 7 Ib ft CLUTCH INTERLOCK SWITCH CLUTCH MASTER CYLINDER NIN NIN Fully Released Position X Position gt 15 20 mm 0 6 0 8 in 135 145 mm 5 3 5 7 in A S lt S NS S 5 Fully Depressed Position 23 11 Starting System Circuit Diagram M T with Interlock Switch IGNITION UNDER HOOD FUSE RELAY BOX SWITCH BATTERY No 41 80A No 39 50A O O O O WHT BLK e WHT O O BLK WHT BLK WHT BLK WHT STARTER CUT RELAY BLK RED BLU BLK BLK BLK RED UNDER DASH FUSE RELAY BOX BLK RED PGM FI ECU PGM FI MAIN RELAY INTEGRATED CONTROL UNIT BLK WHT CLUTCH INTERLOCK SWITCH O BLK START
159. ow washer motor Hatchback Integrated control unit Via windshield wiper switch Windshield wiper motor Headlight washer control unit Some model versions of KG and KS Left S Right headlight adjuster Rear window wiper motor Hatchback Integrated control unit Power window relay integrated control unit Gauges and indicator lights Turn signal hazard relay Clock Cruise indicator light circuit Shift lever position indicator Speed alarm unit Right pe Left back up light Shift lock solenoid Ln Interlock contro unit With interlock system Lock up solenoid A T Shift position console switch Integrated Control unit KE Ignition coil This page corresponds to page 23 19 of the Shop Manual 62SR320 and reflects the model changes IGNITION SWITCH ST M T with interlock switch 1 Pr HEUS CLUTCH INTERLOCK i BLK WHT SWITCH BLU BLK BLK I E 1 6201 6401 4 BLK RED 9 BLKWHT s Starter solenoid 1 BLK RED i ee Ee 1 a p BLK WHT 9 M M Starter solenoid i BLK WHT 1 E A ee ee Les
160. r 4WD model Modified Si Wire colors between solenoids and ABS control unit abe Modified O ABS for 4WD model Body Changed Fastener and spacer for rear window Limit switch position of sunroof motor unit Added Some version emblems Rear seat access cable Abolished Shim for sunroof panel glass height adjustment Changed Outer handle and latch replacement procedure front door License plate trim replacement procedure 4D Frame repair chart 20 Seat belt anchor bolt construction Quantities of side sill panel clips Added Door channel tape replacement procedure Emblems for KM model Air Adopted O ES Conditioning New refrigerant HFC 134a R 134a Electrical Changed Wire color of ignition switch Data link connector Alternator brushes Mitsuba type Terminal number of shift lock solenoid Modified Power supply circuit Changed Ignition system for KO model Integrated Control Unit for KO and KB models O Seat heater for some KS model Added Supplemental Restraint System SRS type IH Changed Wire colors for interlock system integrated control unit and ceiling trunk cargo area lights Cruise control system O 23 Spark plug and service check connector specifications Added Clutch interlock switch General Information Chassis and Engine Numbers 1 2 Identification Number Locations 1 8 Warning Caution Label Locations 1 9 Chassis and Engine Numbers European Model
161. re continuity between ECU D3 and the knock sensor YES RED BLU Substitute a known good knock sensor and recheck Start the engine Hold the engine at 3 000 rpm min with no load in neutral until the radiator fan comes on then let it idle Hold engine at 3 000 4 000 rpm min for 10 seconds with M T in neutral KNOCK SENSOR 32 3 2 Kg m 23 Ib ft Is the Check Engine Light on and NO Replace the original knock sensor does it indicate code 23 YES Substitute a known good ECU and recheck If symptom indication goes away replace the original ECU 11 10 Idle Control System Idle Speed Setting model Inspection Adjustment NOTE 1 2 4 Before the speed setting check the following items The Check Engine Light has not been reported on Ignition timing Spark plugs Air cleaner PCV system Connect a tachometer Start the engine Hold the at 3 000 rpm with no load A T in IN or P position M T in neutral until the radiator fan comes on then let it idle Disconnect the 2P connector from the EACV EACV Start the engine with the accelerator pedal slightly depressed Stabilize the engine speed at 1 000 then slowly release the pedal until the engine idles Check idling
162. ring Free length IN 40 92 1 611 40 91 1 611 36 71 1 445 41 96 1 652 41 94 1 651 Valve guide I D Installed height IN EX IN 5 51 5 53 0 217 0 218 5 51 5 53 0 217 0 218 12 55 13 05 0 494 0 514 12 55 13 05 0 494 0 514 5 55 0 219 5 55 0 219 Rocker arm Arm to shaft clearance IN EX Measuring point between camshaft and rocker arm 1 NIHON HATSUJO manufactured valve spring 0 025 0 052 0 0010 0 0020 0 025 0 052 0 0010 0 0020 0 08 0 003 0 08 0 003 2 CHUO HATSUJO manufactured valve spring 3 5 Standards and Service Limits Engine Block Section 7 Except B16A2 B16A3 Engines MEASUREMENT STANDARD NEW SERVICE LIMIT Cylinder block Warpage of deck surface Bore diameter Bore taper Reboring limit 0 07 0 003 max 0 10 0 004 75 00 75 02 2 953 2 954 75 07 2 956 mE 0 05 0 002 SSC 0 5 0 02 Skirt O D At 16 mm 0 6 in from bottom of skirt Clearance in cylinder Groove width for ring Top 01521 Except 01521 Second 01571 Except 01571 01521 01626 01627 D16Y1 01572 01582 01587 D16A7 D16A9 01281 01382 01383 01583 Piston Oil 74 980 74 990 2 9520 2 9524 74 970 2 9516 0 010 0 040 0 0004 0 0016 0 05 0 002 1 020 1 030 0 0402
163. rlock Switch Adjustment NOTE To check the clutch interlock switch and clutch switch 5 Turn the clutch switch or adjusting bolt in an see section 23 additional 3 4 to 1 full turn The clutch is self adjusting to compensate for wear 6 Tighten locknut A CAUTION If there is no clearance between the master 7 Loosen locknut B on the clutch interlock switch cylinder piston and push rod the release bearing is with clutch interlock switch held against the diaphragm spring which can result in clutch slippage or other clutch problems 8 Measure the clearance between the floor board and clutch pedal with the clutch pedal fully depressed 1 Loosen locknut A and back off the clutch switch or adjusting bolt until it no longer touches the clutch 9 Release the clutch pedal 15 20 mm 0 59 0 79 pedal in from the fully depressed position and hold it there Adjust the position of the clutch interlock 2 Loosen locknut C and turn the push rod in or out to switch so that the engine will start with the clutch get the specified stroke and height at the pedal in this position clutch pedal 10 Thread the clutch interlock switch an additional in 3 Tighten locknut C 3 4 to 1 full turn 4 Thread in the clutch switch or adjusting bolt until 11 Tighten locknut B it contacts the clutch pedal ASSIST SPRING LOCKNUT B PUSH ROD 10 N m 1 0 kg m 7 Ib ft CLUTCH MA
164. rminals Main switch Control unit Poor ground Cruise control cannot be set BLU RED LT GRN RED BLK YEL LT GRN GRY YEL BLU BRN BRN BLK BRN WHT or PNK 1 Cruise control can be set but indicator YEL or RED BLU light does not go on Cruise speed noticeably higher or lower than what was set Excessive overshooting and or under shooting when trying to set speed Steady speed not held even on a flat road with cruise control set Car does not decelerate or accelerate LT GRN BLK accordingly when SET or RESUME LT GRN RED button is pushed Set speed not cancelled when clutch pedal is pushed M T Set speed not cancelled when shift lever is moved to N A T Set speed not cancelled when brake pedal is pushed Set speed not cancelled when main Switch is pushed OFF Set speed not resumed when RE LT GRN BLK SUME button is pushed with main LT GRN RED switch but set speed temporarily cancelled 23 41 Cruise Control KM Control Unit Input Test CAUTION All SRS wire harnesses are covered with yellow insulation Replace the entire affected SRS harness assembly if it has an open circuit or damaged wiring Before disconnecting the SRS wire harness turn the ignition switch OFF disconnect the battery negative cable then disconnect the positive cable and wait at least three minutes SRS Type Ill only Whenever the igniti
165. ry voltage Blown No 15 10 A fuse in the under dash fuse relay box Anopen in the wire Check for continuity to ground There should be continuity Faulty shift position console switch Poor ground G201 G301 G401 open in the wire YEL BLK Ignition switch ON Check for voltage to ground There should be battery voltage Faulty shift lock solenoid Blown No 15 10 A fuse in the under dash fuse relay box Anopen in the wire WHT RED brake pedal pushed Ignition switch ON Check for voltage to ground There should be 1 V or less the same time Ignition switch ON brake pedal and ac celerator pushed at Check for voltage to ground There should be about 3 V Faulty PGM FI Faulty brake switch Faulty throttle position sensor An open in the wire GRN WHT Brake pedal pushed No 4 KB No 5 KO Key Interlock System No Wire Test condition Check for voltage to ground There should be battery voltage Test Desired result Faulty brake switch Blown No 42 20 A fuse in the under hood fuse relay box Anopen in the wire Possible cause if result is not obtained Under all conditions Check for continuity to ground There should be continuity Blown No 15 10 A fuse in the under dash fuse relay box An open in the wire GRN WHT Shift le
166. s 1 010 kg 2 227 Ibs 1 015 kg 2 238 Ibs 1 015 kg 2 238 Ibs 1 030 kg 2 271 Ibs 1 020 kg 2 249 Ibs 1 045 kg 2 304 Ibs 1 060 kg 2 337 lbs 1 050 kg 2 315 Ibs 1 100 kg 2 425 Ibs 1 105 kg 2 436 Ibs KG KF KE KS KG Austria KG KF KE KW KS KG KF KE KW KS Weight distributions Front Rear DX EX VEi DXi VTi 580 1 279 375 kg 827 Ibs 585 1 290 375 kg 827 Ibs 595 1 312 375 kg 827 Ibs 600 1 323 375 kg 827 Ibs 605 1 334 375 kg 827 Ibs 590 1 301 375 kg 827 Ibs 595 1 312 375 kg 827 Ibs 620 1 367 375 kg 827 Ibs 625 1 378 375 kg 827 Ibs 605 1 334 375 kg 827 Ibs 610 1 345 375 kg 827 Ibs 635 1 400 375 kg 827 Ibs 640 1 411 375 kg 827 Ibs 625 1 378 390 kg 860 Ibs 635 1 400 395 kg 871 Ibs 630 1 389 390 kg 860 Ibs 655 1 444 390 kg 860 Ibs 665 1 466 395 kg 871 1 5 660 1 455 390 kg 860 Ibs 695 1 532 405 kg 893 1 5 700 1 543 405 kg 893 Ibs KG KF KE KS KG KF KG KF KE KS KG KF KG KF KS KG KF KE KW KS KG KF KE KW KS Max permissible weight EC DX EX VEi DXi LSi VTi 1 380 kg 3 042 Ibs 1 460 kg 3 219 Ibs 1 500 kg 3 307 Ibs 3 39 Design Specifications European Model ITEM METRIC ENGLISH 4 door Sedan WEIGHT Curb weight M T 1 010 kg 2 227 Ibs KG KE KF 1 015 kg 2 238 Ibs KS DXi M T 1 000 kg 2 205 Ibs KG 1 005 k
167. se Track Ground clearance Seating capacity Except cars with B16A2 B16A3 engines Cars with B16A2 B16A3 engines 4 080 mm 160 6 in 4 090 mm 161 0 in 4 070 mm 160 2 in 4 075 mm 160 4 in 1 695 mm 66 7 in 1 700 mm 66 9 in 1 345 mm 53 0 in 1 350 mm 53 1 in 1 355 mm 53 3 in 2 570 mm 101 2 in 1 475 mm 58 1 in 1 465 mm 57 7 in 160 mm 6 3 in 150 mm 5 9 in Five 5 Four 4 Except KQ KY For Finland only KQ KM KY Except KM KM Except KM KY KM KY Except VEi model with CATA DIMENSIONS 4 door Sedan 3 38 Overall length Overall width Overall height Wheelbase Track Ground clearance Seating capacity Except cars with B16A2 B16A3 engines Cars with B16A2 B16A3 engines 4 405 mm 173 4 in 4 415 mm 173 8 in 4 395 mm 173 0 in 1 695 mm 66 7 in 1 370 mm 53 9 in 1 375 mm 54 1 in 1 390 mm 54 7 in 1 395 mm 54 9 in 2 620 mm 103 1 in 1 475 mm 58 1 in 1 465 mm 57 7 in 1 455 mm 57 3 in 160 mm 6 3 in 150 mm 5 9 in Five 5 Four 4 Except KY KM For Finland only KQ KY KM Except VEi model with CATA European Model METRIC ENGLISH 2 door Hatchback WEIGHT Curb weight VTi 955 kg 2 105 Ibs 960 kg 2 116 Ibs 970 kg 2 138 Ibs 975 kg 2 149 Ibs 980 kg 2 161 Ibs 965 2 127 Ibs 970 kg 2 138 Ibs 995 kg 2 194 Ibs 1 000 kg 2 205 165 980 kg 2 161 Ibs 985 kg 2 172 Ib
168. smission API Service Grade SF or SG SAE Viscosity 10 W 30 or 10 W 40 Automatic Honda Premium Formula or DEXRON Il Automatic transmission fluid ATF 3 Brake Line Brake fluid DOT3 or DOT4 4 Clutch Line Brake fluid DOT3 or DOT4 5 Power steering gearbox Steering grease P N 08733 070 6 Shift lever pivots Manual transmission Grease with molybdenum disulfide 7 Release fork Manual transmission Urea Grease UM264 P N 41211 PY5 305 8 Steering boots 9 Tailgate hinges and latches 2 door Hatchback 10 Steering ball joints 11 Select lever Automatic transmission 12 Pedal linkage 13 Brake master cylinder pushrod 14 Trunk hinges and latch 4 door Sedan Multi purpose grease 15 Door hinges upper and lower 16 Door opening detents 17 Fuel filler lid 18 Engine hood hinges and engine hood latch 19 Clutch master cylinder pushrod 20 Throttle cable end 21 Rear brake shoe linkages 22 Caliper Piston seal Dust seal Silicone grease Caliper pin Piston 23 Power steering system For cars with P S Honda power steering fluid V 24 Rear differential 4 WD only Honda Premium Formula or DEXRON II Automatic transmission fluid ATF 25 Air conditioning compressor Compressor oil NIPPONDENSO ND OIL8 P N 38899 PR7 003 MATSUSHITA GU10 P N 38899 P08 003 HADSYS SP 10 P N 38899 P13 003 For Refrigerant HFC 134a R 134a Recommended Engine Oil API Service Grade SF SG or SH fuel efficient oil Select the oil for the c
169. ssion Number B16A2 1300001 1600 DOHC 16 valves Sequential Multiport Fuel injected VTEC Engine with CATA 1500 SOHC 16 valves Dual point Fuel injected Engine with CATA 1500 SOHC 16 valves Sequential Multiport Fuel injected VTEC E Engine with CATA 1600 SOHC 16 valves Sequential Multiport Fuel injected Engine without CATA 1600 SOHC 16 valves Sequential Multiport Fuel injected VTEC Engine with CATA 1600 SOHC 16 valves Sequential Multiport Fuel injected VTEC Engine with CATA for Germany and 4WD 520 2000001 Automatic Transmission Number Transmission Type S24A For 2WD model M25A For AWD model Serial Number 524 4000001 1 3 Chassis and Engine Numbers Except European Model 2 door Hatchback Vehicle Identification Number JHMEG3 31005300001 Manufacturer Make and Type of Vehicle JHM HONDA MOTOR CO LTD JAPAN HONDA Passenger car Line Body and Engine Type EG3 CIVIC 3 door D13B3 4 CIVIC 3 door D15B3 D15B7 015272 CIVIC 3 door D16A9 D16Y1 Body Type and Transmission Type 3 2 door Hatchback 5 speed Manual 4 2 door Hatchback 4 speed Automatic Vehicle Grade Series 1 EL EG3 KT CX 4 1 5EL EG4 KY 2 EX EG4 KP KT KY 4 GLi EG4 8 VTi EG5 KQ 9 Si EG5 KP KT Fixed Code Auxiliary Number Factory Code S Suzuka Factory in Japan Mod
170. surface Bore diameter Bore taper Reboring limit 0 05 0 002 81 000 81 020 3 1890 3 1898 0 08 0 003 81 070 3 1917 0 05 0 002 0 25 0 010 Piston Skirt O D At 15 mm 0 59 in from bottom of skirt Clearance in cylinder Ring groove width Top 2nd Oil 80 980 80 990 3 1882 3 1886 0 010 0 035 0 0004 0 0014 1 030 1 040 0 0406 0 0409 1 230 1 240 0 0484 0 0488 2 805 2 820 0 1104 0 1110 80 970 3 1878 0 05 0 002 1 060 0 0417 1 260 0 0496 2 840 0 118 Piston ring Piston to ring clearance Top 2nd Ring end gap Top 2nd Oil 0 045 0 070 0 0018 0 0028 0 040 0 065 0 0016 0 0026 0 20 0 35 0 008 0 014 0 40 0 55 0 016 0 022 0 20 0 50 0 008 0 020 3 0 005 0 005 0 024 0 028 0 1 0 1 0 6 0 7 0 80 0 031 3 0 0 0 Piston pin Diameter Pin to piston clearance 20 994 21 000 0 8265 0 8268 0 010 0 022 0 0004 0 0009 Connecting rod Pin to rod interference Small end bore diameter Large end bore diameter Nominal End play installed on crankshaft 0 013 0 032 0 0005 0 0013 20 968 20 981 0 8255 0 8260 48 0 1 89 0 15 0 30 0 006 0 012 0 40 0 016 Crankshaft Main journal diameter No 1 2 4 and 5 journals No 3 journal Rod journal diameter Journal taper Journal out of round End play Tot
171. tape by about 1mm 0 04 in NOTE Apply the inside edge of the center channel tape 1 mm 0 04 in from the flange CENTER CHANNEL TAPE UPPER CHANNEL TAPE SEPARATOR FLANGE CENTER CHANNEL TAPE 1mm 0 04 in CENTER CHANNEL cont d 20 7 Doors Door Channel Tape Replacement cont d 2 Apply the center channel tape to the center 6 Reinstall all remaining parts channel while peeling back the separater slowly NOTE Check that the body color on the door channel is NOTE covered by the door channel tape Check that the center channel tape is parallel with the center channel 7 Check for water leaks 3 Starting at the top press the center channel NOTE tape with a plastic squeegee Do not use high pressure water NOTE Do not roll the upper channel tape around prematurely Follow the numbered sequence faithfully CENTER CHANNEL TAPE IL 4 Press the center channel tape in the groove of the center channel holder with the edge of a plastic squeegee NOTE Do not press too hard CENTER CHANNEL TAPE 20 8 Seat Belts Upper and Lower Anchor Bolt Construction NOTE Make sure you assemble the washers and collars on the upper and lower anchor bolts as shown Front seat belt 4D UPPER ANCHOR BEARING COLLAR gt PUSH NUT UPPER ANCHOR BOLT Apply liquid thread lock SPRING WASHER COLLARS 31 BOLT TOOTHED B
172. therwise the system may fail in case of a collision or the airbags may deploy when the ignition switch is ON SRS Type All SRS electrical wiring harnesses are covered with yellow insulation Related components are located in the steering column front console dashboard dashboard lower panel and in case of some models in the dashboard above the glove box Do not use electrical test equipment on these circuits Service work nearby and in the areas listed below may affect the SRS and must therefore be performed by an authorized Honda dealer SRS Il Steering wheel careful not to bump the steering wheel as the SRS unit sensors inflator etc are located in it Behind the dashbord Under dash fuse relay box SRS Type Ill Steering wheel Behind the dashboard Under dash fuse relay box Front console Car stereo unit and other accessories A C heater 2WD Automatic Transmission S24A Special Tools 2 2 2244 14 2 Test side Deo u 14 4 Illustrated Index Torque Converter Housing Valve Body 14 6 Sub Shaft Disassembly Reassembly 14 8 Clutch Illustrated 14 9 Gearshift Selector Disassembly Reassembly 14 10 Outline of Model Changes Shift schedule has been changed e ATF magnet has been discontinued I
173. throttle kPa kg cm2 psi 250 min rpm and Nominal Minimum Maximum variation 1 350 13 5 192 950 9 5 135 200 2 0 28 Cylinder head Warpage Height Camshaft End play Camshaft to holder oil clearance Total runout Cam lobe height 0 05 0 15 0 002 0 006 0 050 0 089 0 0020 0 0035 0 03 0 001 max 33 021 1 3000 32 382 1 2749 131 95 132 05 5 195 5 199 0 05 0 002 0 5 0 02 0 15 0 006 0 04 0 002 Valve clearance Valve stem O D Stem to guide clearance 0 13 0 17 0 005 0 007 0 15 0 19 0 006 0 007 6 580 6 590 0 2591 0 2594 6 550 6 560 0 2579 0 2583 0 02 0 05 0 001 0 002 0 05 0 08 0 002 0 003 6 550 0 2579 6 520 0 2567 0 08 0 003 0 11 0 004 Valve seat Valve spring Width Stem installed height Free length 1 25 1 55 0 049 0 061 1 25 1 55 0 049 0 061 45 545 46 015 1 7931 1 8116 44 735 45 205 1 7612 1 7797 47 49 1 870 46 89 1 846 2 00 0 079 2 00 0 079 46 265 1 8215 45 455 1 7896 Valve guide LD Installed height IN and EX IN and EX Measuring point between camshaft and rocker arm 3 4 6 61 6 63 0 260 0 261 19 15 19 65 0 754 0 774 6 65 0
174. tinuity to ground Poor ground G201 There should be continuity An open in the wire 2 LT GRN Ignition switch ON Check for voltage to ground Blown No 24 15 A fuse in the and main switch ON There should be battery voltage under dash fuse relay box Faulty main switch Anopen in the wire 3 LTGRN RESUME button Check for voltage to ground Blown No 42 20 A fuse in the BLK pushed There should be battery voltage under hood fuse relay box Faulty SET RESUME switch 4 LT GRN SET button pushed Faulty cable reel RED An open in the wire 5 PNK M T Clutch pedal Check for continuity to ground Faulty or misadjusted clutch switch released There should be continuity M T A T Shift lever in 2 NOTE Faulty A T gear position switch A T or Da There should be no continuity Poor ground G201 G401 when the clutch pedal is de An open inthe wire pressed or when the shift lever is in other positions 6 BLU Not used 7 YEL BLU Ignition switch ON Check for voltage between the Faulty vehicle speed sensor VSS and main switch ON YEL BLU BLK Anopenin the wire Raise the front of the terminals There sholud be 0 car rotate one wheel about 5 V 0 about 5 V re slowly peatedly 8 GRY Ignition switch ON Check for voltage to ground Faulty brake switch main switch ON and There should be 0 V with the An open in the wire brake pedal pushed pedal pushed and battery volt then released age with t
175. ts Recommended engine oil Added B16A3 engine for KM model PGM CARB Changed Wire harness color Fuel feed pipe fuel return pipe and fuel vapor pipe materials for 4WD Except European model Adopted D15Z2 engine for KO model Changed Idle speed for D13B2 engine PGM FI Changed Wire harness color Fuel feed pipe fuel return pipe and fuel vapor pipe materials for 4WD Except European model Out of use Fuel sub pump for 4WD model Added Jet pump for 4WD model Added D15B7 D16Y1 engines for model D15B7 01629 engines for KB model Modified Electronic Control Unit ECU Throttle body for B16A2 engine Changed Main wire harness Main wire harness for B16A2 engine Fuel pressure for D15B2 engine Throttle body Added B16A3 engine for KM model Fuel tube quick connect fittings Changed Fuel filter configuration Clutch Changed Torque value of clutch pipe for LHD model Recommended grease Added Clutch interlock switch for some models DESCRIPTION MODELS 93 94 Manual Transmission Changed Recommended grease Method of shift fork spring pin installing O 95 REFERENCE SECTION Modified Transmission mount right front mount bracket and rear mount bracket Changed Torque value of transmission mounting bolts Torque value of transmission mount bolt for S20 and Y21 manual transmissions Transmission breat
176. ttle pressure B Throttle fully closed 0 S Throttle fully open 800 850 8 0 8 5 114 121 750 7 5 107 Throttle pressure Throttle fully closed 0 5 0 0 05 0 0 7 TI Throttle fully open 495 510 4 95 5 1 70 73 490 4 9 70 Stall speed min rpm check with car on level ground 2 600 2 300 2 900 Clutch Clutch initial clearance 1st 2nd 0 65 0 85 0 026 0 033 D 3rd 4th 0 40 0 60 0 016 0 024 DES Clutch return spring 1st 31 0 1 22 29 0 1 14 free length 2nd 3rd 4th 30 5 1 20 28 5 1 12 Clutch disc thickness 1 88 2 00 0 074 0 079 Until grooves worn out Clutch plate thickness 1st 1 55 1 65 0 061 0 065 Discoloration 2nd 3rd 4th 1 95 2 05 0 077 0 081 Discoloration Clutch end plate thickness MARK1 2 20 2 30 0 087 0 091 Discoloration D12B1 D15B3 MARK2 2 50 2 60 0 098 0 102 MARK3 2 80 2 90 0 110 0 114 3 10 3 20 0 122 0 126 MARK5 3 40 3 50 0 134 0 138 MARK11 2 05 2 15 0 081 0 085 MARK12 2 35 2 45 0 093 0 096 MARK13 2 65 2 75 0 104 0 108 MARK14 2 95 3 05 0 116 0 120 MARK15 3 25 3 35 0 128 0 132 MARK16 3 55 3 65 0 140 0 144 Discoloration Clutch end plate thickness MARK1 2 30 2 40 0 091 0 094 Discoloration D16A9 MARK2 2 40 2 50 0 094 0 098 2 50 2 60 0 098 0 102 MARK4 2 60 2 70 0 102 0 106 MARK5 2 70 2 80
177. use a hair dryer Press the portion of the door channel tape with the symbol while heating it with a hair dryer e if there are air bubbles in the door channel tape prick them with a pin then release the air with your finger or a plastic squeegee PIN TRAPPED AIR elf the air bubble is more than 10 mm 0 4 diameter peel up the door channel tape then reapply it Remove the following parts Door panel e Power mirror Sash trim Corner sash trim 4D rear Glass 4D rear Glass run channel Weatherstrip Slowly peel up the old door channel tape while heating it with a hair dryer Clean the door channel bonding surface with a sponge dampened in alcohol NOTE After cleaning keep oil grease and water from getting on the surface Apply the upper channel tape 1 Peel the edge separator off the upper channel tape SEPARATOR UPPER CHANNEL TAPE 20 4 2 Align edge of the upper channel tape with the upper channel holder from outside the door as shown NOTE Apply the upper channel tape 1 mm 0 04 in from edge of the upper channel holder UPPER CHANNEL UPPER CHANNEL HOLDER HOLDER Contact here UPPER CHANNEL TAPE UPPER CHANNEL TAPE 3 Apply the upper channel tape to the upper channel holder while slowly peeling back the separater UPPER CHANNEL SEPARATOR TAPE 4 Check that the upper channel tape is parallel with
178. ver in position Check for continuity to ground There should be continuity Faulty shift position console switch Poor ground G201 G301 G401 An open in the wire WHT YEL I pushed in WHT BLU Ignition switch turn ed to ACC and key Check for voltage to ground There should be battery voltage Faulty key interlock solenoid in the steering lock assembly Blown No 42 20 A fuse in the under hood fuse relay box An open the wire WHT BLK in position Push button pushed Check for continuity to ground There should be continuity Faulty parking pin switch Poor ground G201 6401 Anopen in the wire in position Push button released Check for continuity to ground There should be no continuity Faulty parking pin switch Short to ground Anopen in the wire 23 25 Shift Lever Position Indicator Circuit Diagram 2WD 7 position Indicator IGNITION UNDER DASH UNDER HOOD FUSE RELAY BOX SWITCH FUSE RELAY BOX BATTERY No 41 80A No 39 50A O WHT BLK e WHT O BLK YEL FI ECU GRN In the gauge assembly O SHIFT LEVER POSITION INDICATOR DIMMING CIRCUIT 1 4Wx7 5 b amp amp amp 5 No 19 10A FUSE RED BLK C9 C10 C4 fen 77 INTERLOCK CONTROL UNIT GRN WHT GRN GRN BLU LT GRN WHT BLK
179. ystem Oil Pump Displacement Except B16A2 B16A3 D16A9 D16A9 B16A2 B16A3 Water Pump Displacement at 6 000 rpm Except B16A2 B16A3 D16A9 D16A9 B16A2 B16A3 D12B1 D13B3 D15B3 D13B2 D15B2 01522 D15B7 01521 D16Y1 01676 01627 01629 B16A2 B16A3 D16A9 D16A7 METRIC ENGLISH Water cooled 4 stroke SOHC or SOHC VTEC gasoline engine Water cooled 4 stroke or DOHC VTEC gasoline engine 4 cylinders Inline transverse 75 0 x 67 5 mm 2 95 x 2 66 in 75 0 x 76 0 mm 2 95 x 2 99 in 75 0 x 84 5 mm 2 95 x 3 33 in 75 0 x 90 5 mm 2 95 x 3 56 in 81 0 x 77 4 mm 3 19 x 3 05 in 1 193 cm 72 8 cu in 1 343 cm 82 0 cu in 1 493 cm 91 1 cu in 1 599 cm 97 6 cu in 1 595 cm 97 3 8 6 Belt driven 4 valves per cylinder SOHC or SOHC VTEC Belt driven 4 valves per cylinder or DOHC VTEC Forced and wet sump trochoid pump 450 48 US qt 40 Imp qt minute 630 67 US qt 55 Imp qt minute 730 77 US qt 64 Imp qt minute 1250 132 US qt 110 Imp qt minute 1120 118 US qt 99 Imp qt minute 1402 148 US qt 123 Imp qt minute Leaded gasoline with 85 R O N or higher Leaded gasoline with 91 R O N or higher Unleaded gasoline with 91 R O N or higher Premium unleaded gasoline with 95 R O N or higher Premium leaded gasoline with 95 R O or higher Leaded gasoline with 91 R O N or higher Unleaded gasoline with 9

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