‘SUPPLEMENTAL RESTRAINT SYSTEM (SRS) This model has an SRS which includes a driver's airbag located in the steering whee! hub and a passenger's airbag located in the dashboard above the glove box and seat belt tensioner located in the seat bet retractor. Information necessary to safely service the SRS is included in the Shop Manual, PIN 62S1E00. tems marked with an asterisk (*) on the contents page include, or are located near, SRS components. Servicing, dis- ‘assembling 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 instalation of the SRS, could lead to personal Injury caused by unintentional deployment of the airbags. + Do not bump the SRS unit. Otherwise, the system may fail in case of @ collision, or the airbags may deploy When the ignition switeh ie ON () +/SRS electrical wiring harnesses are identified by yellow color coding, Related components are located in the steering column, front console, dashboard, dashboard lower panel, and in the dashboard above the glove box. Do not use electrical test equipment on these circuits, + Before trying to remove the seat belt tensioner, first set the sensor lock pin to LOCK position,INTRODUCTION General Info (~ How to Use This Manual ‘This supplement contains information for the ’89 CIVIC Aerodeck and CIVIC Aerodeck TouboDiesel Refer to following shop manuals for service procedures and data ‘not included information in this supplement. Code No. jeck MAINTENANCE, 6281€00 REPAIR and CONSTRUCTION "98 CIVIC Aerodeck TurboDiesel 6281620 ‘SUPPLEMENT "99 CIVIC Aerodech/CIVIC Aerodeck ‘TurboDiese! SUPPLEMENT 62si€21 ‘The first page of each section is marked with a black tab that lines Lup with one the thumb index tabs on this page. You can quickly find the first page of each section without looking a full table of con- tents. The symbols printed at the comer of each page can also be used as a quick reference system. [— Special Information Indicates a strong possiity of severe personal injury Or loss of fe if instructions are not followed. CAUTION: Indicates a possibility of personal injury ot equipment damage if instructions are not followed. NOTE: Gives helpful information. CAUTION: Detailed descriptions of standard workshop procedures, safety prineiples and service operations are not included. Please note that this manual contains 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 conceivable ways in which service, whether or not recommended by HONDA, might be done, oF 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 satisty himself thoroughly that neither personal safety nor vehicle safety will be jeopardized, All information contained in this manual is based on the latest prod- uct information available at the time of printing. We reserve the Fight to make changes at any time without notice. No part of this publication may be reproduced, stored in retrieval system, or trans- mitted, in any form by any means, electronic, mechanical, photo- copying, recording, or otherwise, without the prior written permis- sion of the publisher. This includes text, figures and tables. First Edition 989 32 pages HONDA MOTOR CO., LTD. Al Right Reserved Service Publication Office iarked sections are not included in this manual ‘As sections with * include SRS components; ‘special precautions are required when servicing,Outline of Model Changes T T REFERENCE mm | DESCRIPTION 9 monet 99 monet| REFERENG | Engine Eerie’ | Changed 13 : ‘Aeator replacement procedure Ensine Ted t "D123, OMZ4, OT6N and DIGWE engines for KEJKG,XS | 0 — mods . oats 5 > 1nd operations 1101422, D424, DIGWS and DIOWE engines forkE,KG,KS | 0 | models Chick | changed Cutch assombly rps Manuel Transmission | Added — SJ grade oi [Added + Special tool for itfrenta oll seal instal Diferetial Changed + Tapered roller bearing ofthe Limited Sip Diferential Driveshatts “Added + Replacement procedure for ear clamp type boot bands + Outboard joint cisassombiy/reassembly procedure ° — Changed + Outboard boot ofthe B18C¢ engine Chong + Disassemble type outboard joint forall models except ° 6 “Turbo Diesol _— | 7S Equipped | + Electronic Brake Distribution (EBD) system Body | Ghenoed + Rear center lap belt ° | —_ + Component parts ofthe rear seats |General Information Chassis and Engine Numbers .. Abbreviations .....Chassis and Engine Numbers ;- Vehicle Identification Number (VIN) Manufacturer, Make and Type of Vehicle |_| ‘SHH: HONDA OF THE U.K. | MEG, LTD. England. | HONDA Passenger vehicle | ‘Line, Body and Engine Type ————! MBB: CIVIC S-dooriD 1423, D14z6 MB9: CIVIC 5-door/01828 MCr: CIVIC 5-door/O16W3, D16W4 MC2: CIVIC 5-doortB18C4 MC3: CIVIC 5-door?20T2N Body and Transmission Type 7:5-door Wagon! S-speed Manual 8: 5-door Wagon! 4-speed Automatic Vehicle Grade 0: 1418 214i 314i 1, 1.81 VTEC, 1.6iLS, 1.8VTi VTEC, 20770 5: 1.4), 1.81 VTEC, 1.618R, 2.0/TD 6:1.4S, 1.51 VTEC, 1.6165, 1.61 VTEC 7:1.4i8, 1.81 VTEC, 2.0/TDS, 18S, 20;TDLS 8:1.4i5R 91.48 Fixed Code Auniliary Number Factory Code — —_ U: Honda of the U.K. Manufacturing in England Model Year 4,2: 1998 Serial Number y- Engine Number 1423-00001 Engine Type — catalytic D14Zé: 1.4 SOHC 16-valves Multipor Fuel- injected 66 KW engine with catalytic converter D18ZB: 1.5 £ SOHC 16-valves Sequential Multiport Fuel-injected VTEC-E engine with catalytic converter D16W8: 1.6 £ SOHC 16-valves Multiport Fuel- Injected engine with catalytic converter IEW: 1.6 SOHC VTEC 16-valves Multiport Fuel-injected engine with catalytic converter | BISCé: 1.8£ DOHC 16-valves Sequential | Multiport Fuel-injected VTEC engine | { | | with catalytic converter 20T2N: 2.0 £ SOHC 8-valves Fuel-injected diesel engine with turbo charger, inter cooler and catalytic converter Setial Number — Except B18C4, 01528, 2072N: £100001~ ‘B18Cé: 1200001~ 15z8: £300001- 20T2N: 0000001~ [~ Transmission Number SILA. 4000001 Transmission Type SILA: 4-speed Automatic 9A: S-speed Manual ‘S98: S-speed Manuat 1-2 ‘Serial Number ‘SILA: 4000001~ 9a: 1000001- 98: 1000001-[— Model/Applicable Area Code/VIN/Engine Number/Transmission Number cic AERO- DECK ke Ks. RHO LHD \ HANDLE woon (genase Sak cto pensnse evane numsen | PANSMSSION |r| ar Sriiaraono oooor~ | braze ev0000%~ | aa Too00oT- | | val SMT | SHHMBE720vUTOOTOT~ | 01423100001~ | 9A-100000T- | 1ai| ear | SHRBe7aoXUTO000"~ | 01423-Er0000%- | 9A 1000001 | 74iS_ | BMT | SAHIBeT00vUTeoTo- {88-1000 | 14s ~Sannvee7e0x 00001~ | tao000t= | L_sais SHHMB8770XU100001~ | D14Z4-£100001~_| 9A-1000001~ | Tals sw] SHHMBE770vUTO0T0T~ | D14z4-ET00001~ | 8A-1000001~ | 1ais | sw | SHHMBeTe0vUTO0TOr. | OT4z4-ET0a00"~_| BA. T00000%~ ; oa aaT | SHHIMBBSTOX DyezeEro0001~ | STUA<000007~ . aaT | SHWMBRaTOYUTODIOK= | D14Z6ET00001- | SILA-A00000T [iaisa [wr sunmaeraoxvio0001— | oraze-er00001- | oa-100000%- | : SHAMBS7AOXT0000"- | DYE28 200001~ | BA TO0000T- | Ke LHD ‘SHHMB9750XU100001- | 016Z8-£300001- | 9A-1000001- \ Swmao7sovuo0101- | O1826 200007- | GA T000001- ‘SHHIMB9760¥U 100101~ ‘9A-1000001~ ‘SHHMCT750XU100001~ ‘SHHMB9770¥U 100101 'SHHMCT840XUT00001~ as ‘SHHMC1740XUT00001~ ‘SHHMC1760XU100001- | SHHMC2740XUT00001~ | B18C4-1200001- | S9B-1000001- [207__| 6M | SHHMCaT4OYUTOOO0I- | 20T2N-0000001- | $a-1000001- 2017 | sw | SHAMCa760vUT0000%~ [ sA-100000 “go'Tos” | sMT_| SHHIMe377ovUTa0001~ | 20T2N-o000001- | 8A-t000001- | SMT SHHMC3770vU20000"~ | 20T2N-0000001- | 8A-1000001- “aw | SHiwae740xuI00001- | D14z3-E100001- | 9A-t000001~ EMT | SHHMBB760XU100007~ | D14z5:ET00007- | 8A-1000001- [7 aat_ | Sulimgeasoxu te0001~ | 014z3-£100001~ | S1LA-4000001- SMT SHNMBS750XUT0000"~ | 016z8-E300001-| 8A-1000001- | SMT D16Ww3-E100001~ | 9A-1000001~ T6iLS | 4AT | SHHMCIe40xUT00001- | D16Wws=ET00001- | STLA-4000007- i | SHHMCI760XU 100001- | DT6W4.ET00001- | A-1000001- "SHHIMCTTTOYUTOOIOT~ | DIBW4-ETO00eT- | 94-1000001— [asics [eat | SHrimcresoxur0000%~ | DieweeT00001- | S1LA-4000001— [teres | aa” | ShiiMcte70vUto0Tor~ | D1ewe-Etooo0T~ | S1LA-so00001- ‘SHAMC2740XU100001- |. B18C4-1200001- | S9B-1000001-_| ‘SHHMGS77OXUT00001- | 20T2N-0000001- | 8A.1000001~ ‘SHHMC1740XUT00001- | D16W3-E100001~ vai | Skaes740xUt00001~ | D1423-€100001— | 9A-100000%- TaivTEC | Si760XuT0000r- |, 01828-£900001— | 9A-1000001- 1.51 VTEC SMT ‘SHHMBS750YUTOOTO1- | 618Z8-E300001- | ‘SHHMC1840XU100001- | D1EW3-ET00001~ S1LA-4000007- 1-3Abbreviations List of automotive abbr ABS. AC ‘ACL AF ALR ALT AMP ANT APL APPROX. ASSY, AT TOC. ATE at ATT. AUTO AUX BARO BAT BDC BYDC BD ECM ECT EGR LD EPR. EPs. evAP 14 Anti-lock Brake System Air Conditioning, Air Conditioner Air Cleaner Air Fuel Ratio ‘Automatic Locking Retractor Alternator | Ampere (s) Antenna ‘American Petroleum Institute Approximately | Assembly | Automatic Transmission After Top Dead Center { ‘Automatic Transmission Fluid ‘Attachment Active Torque Transfer System ‘Automatic Auxiliary Barometric Battery Bottom Dead Center Before Top Dead Center | | Carburetor | Catalytic Converter | chore | Crankshatt Speed Fluctuation | Crankshaft Position Carbon Monoxide | Complete Clutch Pressure Back up | Clutch Pressure Control Central Processing Unit Continuously Variable Transmission Cylinder Cylinder Position Distributor Ignition Differential Data Link Connector | Double Overnead Camshaft | Dual Point injection | Diagnostic Trouble Code Electronie Brake Distribution Engine Control Module Engine Coolant Temperature Exhaust Gas Recirculation Electrical Load Detector | Evaporator Pressure Regulator Electrical Power Steering Evaporative Exhaust ations which may be used in shop manual. FIA AL FR FSR Fwo GAL GND GPs HB He HID Hozs ap vac lacy aR lat icm 'D Doro. 'G or GN IMA imMosl. IN Ng iNT. Ks | Front | Fuel Injection Air | Front Lett Fuel Pump Front Right | Fail Sate Relay | Front Whee! Drive | Gallon | Ground | Global Positioning System | Hatchback | Hydrocarbons | High intensity bischerge | Heated Oxygen Sensor | intake Air Bypass Idle Air Control | idle Air Control Valve | totake Air Resonator Intake Ait Temperature Ignition Control Module ) tdontfeation | Inside Diameter ignition tale Mixture Adjustment | immobilizer (immobiliser) | Intake | Injection intermittont Knock Sensor Lert Lock-up Clutch Liquid Crystal Display Light Emitting Diode Low Emission Vehicle Left Front Left Handle Left Handle Drive Left Rear imited Slip Differential Inline Four Cylinder (engine)map MAX. MBs McK Mcu MIL MIN. MPl Mis Nox 80 02s Odor 0.0. PAIR Pom. Pom PGMIG PH PL PMR PIN PRL PIS PSF PsP Psw ‘ay R REF RGB RHO RL RON RR SAE scs SEC SOHC ‘sot. ‘SPEC SiR SRS sto sw Manifold Absolute Pressure ‘Maximum Mainshaft Brake System Motor Check ‘Moment Control Unit Malfunction Indicator Lamp Minimum | ‘Multi Point Injection Manual Steering Manual Transmission Neutrat Oxides of Nitrogen On-board Diagnostic Oxygen Sensor Outside Diameter Park Pulsed Secondary Air Injection Powertrain Control Modul Positive Crankcase Ventilation Proportioning Control Valve Programmed-fuel injection Programmed Ignition Pressure High Pilot Light or Pressure Low Pump Motor Relay Part Number Primary Power Steering Power Steering Fluid Power Steering Pressure Pressure Switch Quantity Right Reference Red, Green, Black Right Handle Drive Roar Left | Research Octane Number | Rear Right Society of Automotive Engineers Service Check Signal Second ‘Secondary ‘Single Overhead Camshaft Solenoid Specification ‘Sun Roof ‘Supplemental Restraint System Standard ‘Switch vtec wis { Torque | Throttle Body | Tino Bor Torque Convertor Transmission Control Module Traction Control System | Top Dead Center Thin Film Transistor ool Number Throti Postion | te Way Catalytic Converter | Viscous Coupling Vohicto Identification Number | Vehicle Speed Sensor Variable Valve Timing & Valve Lift | Electronic Control | Veibi Volume take Systm | with | Without Wide Open Throttle Two Wheel Drive } Four Wheel Drive Two Wheel Steering Four Wheal Steering, 4-speed Automatic Transmission 5-speed Manual Transmission 6-speed Manual Transmission Park Reverse Neutral Drive (1st through 4th gear) Drive (Ist through 3rd gear) Second First Drive Second Low Over Drive Low (gear) Second (gear) Third (gear) Fourth (gear) Fifth (gear) Sixth (gear) 1-5+ Engine Electrical ENGINE Charging System Alternator - without A/C sme vn Alternator - with AIC ... Outline of Model ChangeCharging System ALTERNATOR - WITHOUT A/C Remove 1. Disconnect battery earth lead. 2. Raise front of vehicle AWARNING 3. Remove engine acoustic cover. See ENGINE, Repairs it ie Maé 5170 4. Remove auxiliary drive belt. See this section. 5. Fit wooden block to jack and position jack to sup- port engine, P 8. Disconnect multiplug from alternator. 10. Release cover, remove nut and disconnect battery ‘cable from alternator. 6. Romove through bolt securing RH steady bar to ‘engine mounting bracket. 7. Remove nut securing RH mounting bracket to ‘engine mounting. 8. Loosen 2 nuts securing restraint bar to body. ( MN Mas 5147 11. Remove bolt securing brake servo vacuum pipe to camshaft cover. 12, Rolease clip and disconnect vacuum hose from vac- ‘uum pump, 4-2865150 18, Place absorbent cloth beneath alternator oll feed pipe, to contain spill. 14, Loosen union and disconnect oil feed pipe from ‘vacuum pump. Ax M6 5151 1. Remove 3 bolts and alternator upper mounting bracket. 16. Raise engine on jack to remove alternator bolt. Do not carry out further dism: component is removed for access only. Ma6s152A, 17. Remove nut and bott-from alternator lower mount- ing bracket. 18, Release alternator from mounting, release clip and remove oll return pipe. 18, Remove alternator from vehicié. FRONT BRAKES, 20. Transfer vacuum pump to new alternator. See , Repairs. 4-3Charging System Refit 10, n 2 3. 1“ 6 6 . Fit engine acoustic cover. See ENGINE, Repairs. 8 Clean all pipe connections. Fit ol return hose to vacuum pump and secure with Clip, fit alternator to lower mounting bracket. Fit nut and bolt to alternator lower mounting but do not tighten at this stage. Fit bolts securing alternator upper mounting bracket, ‘to coolant elbow and tighten to 2 Nem (2.5 kgm, 1B lbF#Y. Fit oil feed pipe union to vacuum pump and tighten union to 12 Nem (1.2 kgf, 9 IDF). 3. Fit and tighten alternator upper mounting bolt to 25, Nm (2.5 kgfm, 18 lbFft, Tighten alternator lower mounting bolt to 45 Nm (46 kgm, 33 IbFt) . Connect vacuum hose to vacuum pump and secure hose with clip. ‘Align vacuum pipe bracket to camshaft cover and tighten bo. Connect battery cable to alternator stud tighten nut to 4Nem (0.4 kgm, 3 Ibfft) and position cover. Connect multiplug to alternator. Lower engine, fit nut securing RH mounting bracket to engine mounting and tighten to 85 Nem (8.7 kgf, 63 bf. Tighten engine mounting cestraint bar nuts to 45 Nem (4.6 kam, 33 IDE Connect steady bar to engine mounting bracket, fit through bolt and tighten to 60 N-m (8.2 kgm, 59 tet. Remove jeck positioned to support engine. Fit auxiliary drive belt. Connect battery earth lead. 44 ALTERNATOR - WITH A/C Remove 1. Disconnect Battery earth lead. 2. Raise front of vehicle. AWARNING 3. Remove engine acoustic cover. See ENGINE, Repairs, 4, Remove auxiliary drive belt. See this section. 5. Remove receiver drier. See AIR CONDITIONING, Repairs. 6. Fit wooden block to jack and position jack to sup- port engine. Mee 5145, 7. Remove through bolt securing RH steady bar to engine mounting bracket. 8. Remove nut securing RH mounting bracket 10 engine mounting. 9. Loosen 2 nuts securing restraint bar to body,10. Remove bolt securing low pressure AVC pipe, to ‘alternator upper mounting bracket. 11, Disconnect multiplug from alternator. 12, Release cover, remove nut and disconnect battery cable from alternator. 13, Release clip and remove intake hose from plenum ‘chamber for access. 416. Remove bolt securing brake servo vacuum pipe to ‘camshaft cover. 117, Release clip and disconnect vacuum hose from vac~ uum pump. Mae 5160 14, Remove bolt, release AIC pipes from compressor and discard ‘0' rings. PNT Te Immediately cap all A/C pipes to prevent ingress of dirt and moisture into the system. 15, Tie AIC pipe aside to clear altornator. 865150 18. Place absorbent cloth beneath slternstor oll feed pipe, to contain spill. 19. Loosen union and disconnect oil feed pipe from vacuum pump. (cont'd) 45Charging System ALTERNATOR - WITH A/C (cont'd) 2. 2, 4-6 1. Remove 3 bolts and alternator upper mounting bracket ‘M865 152A Raise engine on jack, remove nut and bolt from alternator lower mounting bracket, Release alternator from mounting, release clip and remove oil return pipe. Remove alternator from vehicle. ACAUTION Transfer vacuum pump to new alternator. See BRAKES, Repairs. Refit 10. 1, 12, 13, 4, 16, ”. 18. 0 21. ). Fit receiver dri |. Clean all pipe connections, 2. Fit ol return hose to vacuum pump and secure with clip, ft alternator to lower mounting brecket. . Fit nut and bolt to alternator lower mounting but do ‘not tighten at this stage. Fit bolts securing alternator upper mounting bracket, to coolant elbow and tighten to 25 Nem (2.5 kgm, re ibtn. Fit ol feed pipe union to vacuum pump and tighten union to 12 Nem (1.2 kgfm, 9Ibf). Fit and tighten alternator upper mounting bolt to 25 Nem (2.5 kgf, 18 IbFft. . Tighten alternator tower mounting bolt to 45 Nm (4.6 kgém, 33 IbFt. Connect vacuurn hose to vacuum pump and secure with clip. Align vacuum pipe bracket to camshaft cover and tighten bolt. Clean A/C pipe connections and compressor mount. ing face, Lubricate new ‘O' rings with refrigerant oil and fit to compressor. Connect A/C pipe union to compressor ‘and tighten bolt to 35 Nm (3.6 kgfim, 26 IDFA) Fit bolt retaining AIC low pressure pipe, to alterna: tor upper mounting bracket and tighten bolt to 10, Nom (1.0 kote, 7 IBF. Connect battery cable to alternator stud, tighten nut 10 4 Nim (0.4 kgf, 8 IbFt) and position cover Connect muttiplug to alternator. Lower engine, fit nut sacuring RH mounting bracket to engine mounting and tighten to 85 Nem (8.7 kgtm, 63 IDF. Tighten engine mounting restraint bar nuts to 45 Nem (8.6 kgfm, 33 IbF Connect steady bar to engine mounting bracket, fit ‘through bolt and tighten to 80 Nm (8.2 kgm, 58 Ite, Fit air intake hose to plenum and tighten clip. Remove jack positioned to support engine. . See AIR CONDITIONING, Repairs. Fit auxiliary drive belt. Fit engine acoustic cover. See ENGINE, Repairs. Connect battery earth lead,Cooling CONTENTS DESCRIPTION AND OPERATION COOLING SYSTEM COMPONENTS COOLING SYSTEM OPERATION 2 103 Outline of Model Change [ The cooling system components and operation have been changed (20T2N engine!COOLING COOLING SYSTEM COMPONENT 1. Cooling fan and cow! 10. Expansion tank 2. Coolant pump 11. Hose - heater matrix return 3. Top hose 12. Coolant rail 4 EGR cooler 18. Engine oil cooler 5. Hose - coolant ral to EGR cooler 14. Elbow - radiator to expansion pipe 8. Heater temperature control valve 15. Hose - engine oll cooler to coolant pump 7. Hose - heater matrix feed 16. Bottom hose 8. Pipe - expansion 17. Radiator 9. Elbow - expansion tank to expansion pipe 10-2‘COOLING SYSTEM OPERATION 5. Engine oll cooler 6 Coolant pump 7. Top hose 4. Bottom hose 8. EGR cooler 1. Hoater matrix 2. Pipe - expansion 3. Expansion tank (cont'd) 10-3COOLING ‘COOLING SYSTEM OPERATION (cont'd) ‘The cooling system employed is the bypass type, which allows coolant te circulate around the engine while the thermostat is closed, When the engine is cold the thermostat in the base of the engine oil cooler closes off the coolant feed from the radiator bottom hose. The pump draws coolant from the top of the cylinder block via the engine oil cooler and the circuit through the Exhaust Gas Recirculation (EGR) cooler. f the heater temperature control valve is open, coolant also flows through the heater matrix. Circulating ‘2 small amount of coolant prevents localised over-heat- ing while retaining the majority of the heat within the engine, and so reduces the engine warm up time. The siting of the thermostat in the inlet rather than the outlet side of the system provides a more stable control of the coolant tamperature in the engine. ‘As the coolant temperature increases the thermostat gradually opens, bleeding cold coolant from the bottom hose into the pump via the oil cooler, and allowing hot coolant from the top of the cylinder block to flow to the radiator Via the top hose. The thermostat then balances the proportion of hot and cold coolant flowing through the oll cooler and into the pump, to maintain the opti- ‘mum engine operating temperature. Any excess coolant created by heat expansion is returned to the expansion tank via the expansion pipe {rom the top of the radiator. The radiator is a cross flow type with a fin and tube core between moulded plastic end tanks. The bottom of the radiator is located in rubber bushes mounted on the. front body member. The top of the radiator is located in rubber bushes mounted in brackets attached to the bon- ‘et locking platform. For additional air flow through the radiator, particularly when the vehicle is stationary, an electric cooling fan is fitted. Operation of the cooling fan is controlled by the Engine Control Module (ECM). See ENGINE MANAGE- ‘MENT SYSTEM, Description and Operation. The coolant pump is a rotor type pump which draws coolant from the engine oil cooler and from the EGR. cooler heater matrix circuit, and supplies it directly into the cylinder block. The pump is driven by the auxiliary rive belt vis the Power Assisted Steering (PAS) pump. 10-4Transaxle (TurboDiesel) Clutch ..... Manual Transmission ...CLUTCH (TurboDiesel) REPAIR CLUTCH ASSEMBLY AND RELEASE BEARING ... 122 NOTE: Refer to the 98 Civic Aerodeck TurboDiesel Shop Manual ‘Supplement (P/N 6251E20} for the item not shown in this section, Outline of Model ChangeCLUTCH (TurboDiesel) CLUTCH ASSEMBLY AND RELEASE BEARING Service repair no - 33.10.07 Refit |. Clean pressure plat dowel holes. 2. Inspect fiywheel for signs of scoring or other dam- age. Renew if worn or damaged. 3, ‘Smear clutch drive plate splines with Molybdenum disulphide greas 4. Position drive plate to flywheel with ‘FLYWHEEL SIDE’ marking towards flywheol 1nd flywheel, dowels and 18G 1767 33M0383 5. Fit pressure plate to flywheel and ensure located on dowels. 6. Fit 6 bolts securing pressure plate to flywheel but do not tighten. 7. Fit alignment tool 18G 1767 and secure to gearbox adaptor plate with 3 bolts, 8. Rotate centre screw of 186 1767 clockwise untit clutch is fully depressed 9. Working in diagonal sequence, progressively tight ‘en bolts to 26 Nem. 10. Rotate centre screw of 186 1767 anti-clockwise to release clutch, 12-2 1" 2, 13. 1“ 16. 16. ”. Remove 3 bolts and remove 18G 1767, Remove flywheel locking pin tool 18G 1823. Clean clutch release fork and release bearing guide sleeve. ‘Smear release fork shaft and bore of release bear- ing with Molybdenum disulphide grease. Fit release bearing to release fork and slide onto guide sleeve. Operate release lever to ensure that release bearing is correctly located on release fork and slides smoothly on guide sleeve. Fit gearbox assembly. See MANUAL GEARBOX - ‘PGI, Repairs.Manual Transmission (TurboDiesel) REPAIRS DIFFERENTIAL OIL SEAL - LH .. 13-2 DIFFERENTIAL OIL SEAL - RH .. 13-2 NOTE: Refer to the 98 Civic Aerodeck TurboDiesel Shop Manual ‘Supplement (P/N 62S1E20) for the item not shown in this section. [ Outline of Model Change ‘The special tool of refit ofthe differential oil seals has been added.Manual Transmission (TurboDiesel) DIFFERENTIAL OIL SEAL - LH Service repair no - 54.10.18 Romove 1. Remove drive shaft. See DRIVE SHAFTS, Repairs. 2 Carefully remove oil seal from differential housing, discard oil seal. Refit 1. Thoroughly clean oil seal recess in differential hous: ing, splines and oil seal running surface on drive shott. | M54 0166 2. Locate new seal on 186 1354/21 with sealing tip facing towards differential housing. 3. Carefully drift oll seal into di Its fully seated in recess. 4. Remove 186 1354/21. '5. Fit LH drive shaft. See DRIVE SHAFTS, Repaics. ential housing until 13-2 DIFFERENTIAL OIL SEAL - RH Service repair no - 54.10.21 Remove 1. Remove drive shaft. See DRIVE SHAFTS, Repairs. 2. Carefully prise oil seal out of differential housing and discard oil seal Refit 1. Thoroughly clean oil seal recess in differential hous- ing, splines and oil seal running surface on shaft M4 0167 Fit 186 1354-16 onto 186 1354, Position new seal onto 18G 1354-16 with sealing ip facing towards differential housing. 4. Carefully drift oll seal into differential housing until itis fully seated in recess. Remove 186 1354 and 186 1354-16. Fit RH drive shaft. See DRIVE SHAFTS, Repairs.[ Driveshafts NOTE: Refer to the 1998 CIVIC Aerodeck Shop Manual (P/N 62S1E00), 1999 CIVIC Aerodeck/CIVIC Aerodeck TurboDiesel Shop Manual ‘Supplement (PIN 62S1E21] for the items not shown in this section. Outline of Model Change ‘The decompositions of outboard joint have been to all grade (Excopt TurboDiese?.HONDA : Shop ‘Manual News Civic Aerodeck/ 7 ~ a ; Automobile Civic Aerodeck Turbo Diesel Twa Namibor | —lesoe Date cos oose | __JAN, 2000 ‘This news provides the following information for the 99 Civic AerodecW/Civic Aerodeck Turbo Diesel Shop Manual. Please revise your shop manual by using the following information. See ——ipart of attached pages. Applicable Shop Manual Stop WancalNome [Gods Naber ovata Pane New Page 99 Cie Anode ie Zof8 Civic Aerodeck Turbo Diese! ‘aaa er} ats HONDA MOTOR CO., LTD. SERVICE PUBLICATION OFFICE 1of3Chassis and Engine Numbers r Vehicle Identification Number (VIN) ‘Type of Vehicle ‘SHH: HONDA OF THE U.K. MFG, LTD. England. HONDA Passenger vehicle Line, Body and Engine Type MBB: CIVIC §-door/D14Z3, D14Z4 (MB9: CIVIC 5-door/D15z8 MCI: CIVIC S:door/D16W3, DIEWS MIC2: CIVIC S-door/B18C4 "5-d00r Wagon S speed Manual 8: 5.d00r Wogan apeed Automatic Vehicle Grace Ons pai sai 14, 15: VTEC, 16is, .avTi VTEC, Lomo S115 VTEC, 18i6R, 20770 6: 1.48, 1.51 VTEC, 1.6168, {1.6iSR} 7: 1ais, 18i VTEC, 207708, 18, 2ovrois eetaisk eas Fixed Code Aunilary Number Factory Code U Honde ofthe UC Manufacturing ta England Mode! Yeor 12 1999 I Number [covai-bxcopt 36ND, 3OTOS ZOOS) fooon1-: 20170, 2078, 2070S. | Engine Type Serial Number [- Engine Number 01423 - £10001 D14Z3: 1.42 SOHC 16-valves Multiport Fuel- Injected 85 KW engine with catalytic converter (1424: 1.4 f SOHC 16-valves Multiport Fuel- injected 66 KW engine with catalytic converter DISZB: 1.5 ¢ SOHC 16-valves Sequential Multiport Fuebinjected VTEC engine with catalytic converter D16W3: 1.6 € SOHC 16-valves Multiport Fuel- injected engine with catalytic converter| D16Wé: 1.6 £ SOHC VTEC 16-valves Multiport Fuel-injected engine with catalytic converter B1BCé: 1.8 € DOHC 16-valves Sequential ‘Multiport Fuet-injected VTEC engine with catalytic converter 2OT2N: 2.0 SOHC B-valves Fuetinjected diesel engine with turbo charger, cooler and catalytic converter Except B18C4, 01528, 20T2N: £100001~ ‘B18Cé: 1200001~ ‘D15ze: £300001~ 20T2N: 0900001~ [— Transmission Number ‘Sorial Number 1-2 S1LA- 4000001 econ | SILA: &-speed Automatic 9A: S-speed Manual S9B: S-speed Manuat ‘SILA: 4000001- 94: 1000001- S98: 1000001- 2of3[- Model/Applicable Area Code/VIN/Engine Number/Transmission Number Rave [TRANSMISSION ropes |*2Ptcasue| HANDLE [vente joeNTIRCATION| «cave wunagen | TRANSMISSION Jaren cove) OVE | wae |" TPE NUMBER NUMBER, j Tai Suir | SHnaBara0vUTooTOT~ | D1sz3Eto000T~ | BA 1000007 | 1.44 SMT D14Z3-E100001~ | 9A-1000001~ Tas [SMT] Srimasroovutootot~ | 1aze-ET00001~ | 8A1000007~ 14S SMT MIBTEOVUTOOIOT-|| O14Z4-E100001- | 9A-1000001~ 18 | SMT | SHHMBerrovUtoot0r- | Dt4za-€100001- | 8A-100000T~ 1iS_| SMT | SHHMBs7e0YUTOO101- | D1aze-ETODDO1- | 9A-TO0000T- 1s ar Disze-Ero000T~ | S1A-400000T- 1aish| SMT DrazeEro0007~ | 9A 100000%- 1.81 VTEC SMT __| SHHMB9740YU700101-/| D1Sze-£900001- | 9A-1000001- TSiVIEC | SMT] SHiMB97sovUtootar~ | D1szsE30000T~ | BA 1000007 ko | uo [asiviec | swt” | sWrMBsveovuTooror- | o1sz6-e900001-_| 9A-1000001~ asivrec | smr_| Suuwaa77avuio0v01- | 01523-£900001- | 9A-T000007~ 18ISR HAMCITEOYUTO0T01~1| DTeWwaeETO0001- | SA-T000007— MCIT6OYU00T0 3100000 TaiUs aRNMC17«0YUI00707-{[ DTewWs-ETOO001- | BA-1o0D001- Tits | 4a | SHMCresovUT0O10T=|| Diews-Eto0001— | STLA-400000T~ 1.87; VTEC] SMT ISHHMC2740YU100101~!| 818C4-1200001- | S9B-1000001~ ZiT [swt | /SHHMGs7aovUz00001-|| 20T2N-o000001~ | 8a1000001— ome Zaio [amt |/Shumcs7sovuzoooer=|| zoran-aoooooT= | 8A. to0000%- eno. | —. 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