HONDA CIVIC Turbo Diesel PDF

SERVICE
MANUAL
CIVIC
2002 CIVIC TURBO DIESEL
0-1_Introduction_How to Use This Manual
Introduction
How to Use This Manual
This supplement contains information for the 2002 General Info

HONDA CIVIC Turbo Diesel. Refer to the following shop Specifications
manuals for service procedures and data not included in
Maintenance
this supplement.
Engine Electrical
Description Code. No.
Engine
HONDA CIVIC MAINTENANCE, REPAIR
and CONSTRUCTION 2001 Cooling
VOLUME 1 62S5A00A Fuel and Emissions
VOLUME 2 62S5A00B *Transaxle
HONDA CIVIC COUPE SUPPLEMENT 62S5A200 *Steering
HONDA CIVIC 5-door SUPPLEMENT 62S5A210 Suspension
HONDA CIVIC 3-door SUPPLEMENT 62S5A220 *Brakes (Including ABS)
HONDA CIVIC SUPPLEMENT 62S5A230 *Body
HONDA CIVIC Type R SUPPLEMENT 62S5A240 *Heating, Ventilation and Air Conditioning
*Body Electrical
Click on the chapter you want from the opening screen,
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this is followed by a contents list of the chapter, click on
the page you require.
Safety Messages
Your safety and the safety of others, is very important.
To help you make informed decisions, we have
provided safety messages and other safety information
throughout this manual. Of course, it is not practical or
possible to warn you about all the hazards associated
with servicing this vehicle. You must use your own
good judgement.
You will find important safety information in a variety
of forms including:
Safety Labels – on the vehicle.
Safety Messages – preceded by a safety
alert symbol and one of three signal
words, DANGER, WARNING, or CAUTION.
These signal words mean:
DANGER
You WILL be KILLED or SERIOUSLY HURT if
you do not follow instructions.
WARNING
You CAN be KILLED or SERIOUSLY HURT if
you do not follow instructions.
CAUTION
You CAN be HURT if you do not follow
instructions.
Instructions – how to service this vehicle

correctly and safely.
All information contained in this manual is based on the
latest product information available at the time of printing.
We reserve the right to make changes at any time without
0-1_Introduction_How to Use This Manual
notice. No part of this publication may be reproduced, or

stored in a retrieval system, or transmitted, in any form by
any means, electronic, mechanical, photocopying,
recording, or otherwise, without the prior written
permission of the publisher. This includes text, figures
and tables.
As you read this manual, you will find information that is
preceded by a symbol. The purpose of this
message is to help prevent damage to your vehicle, other
property, or the environment.
First Edition 11/2001 568 pages
All Rights Reserved
HONDA MOTOR CO.,LTD.
Service Publication Office
As sections with *include SRS components;
special precautions are required when
servicing.
file:///C|/...U3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/Civ41Html/0-1.htm[8/25/2012 6:35:19 PM]

0-2__SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
This model has an SRS which includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above
the glove box, seat belt tensioners in the front seat belt retractors and some models include side airbags in the front seat-backs.
Information necessary to safely service the SRS is included in the Shop Manual, P/N 62S5A00 on this CD. Items marked with an
asterisk (*) on the contents page include, or are located near, SRS components. Servicing, disassembling or replacing these items
will require special precautions and tools and should therefore be done by an authorised Honda dealer.
WARNING
To avoid rendering the SRS inoperative, which could lead to personal injury or death in
the event of a severe frontal collision, all SRS service work must be performed by an
authorised Honda dealer.
Improper service procedures, including incorrect removal and installation of the SRS,
could lead to personal injury caused by unintentional deployment of the airbags.
Do not bump the SRS unit. Otherwise, the system may fail in a collision, or airbags may
deploy when the ignition switch is ON (II).
SRS electrical wiring connectors are identified by yellow colour coding. Related
components are located in the steering column, front console, dashboard, dashboard
lower panel and in the dashboard above the glove box. Do not use electrical test
equipment on these circuits.
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0-3_A Few Words About Safety_Service Information
A Few Words About Safety

Service Information
The service and repair information contained in this Some of the most important general service safety
manual is intended for use by qualified, professional precautions are given below. However, we cannot warn
technicians. Attempting service or repairs without the you of every conceivable hazard that can arise in
proper training, tools and equipment could cause injury to performing service and repair procedures. Only you can
you or others. It could also damage the vehicle or create decide whether or not you should perform a given task.
an unsafe condition. IMPORTANT SAFETY PRECAUTIONS
This manual describes the proper methods and Make sure you have a clear understanding of
procedures for performing service, maintenance and all basic shop safety practices and that you are
repairs. Some procedures require the use of specially wearing appropriate clothing and using safety
designed tools and dedicated equipment. Any person who equipment. When performing any service task,
intends to use a replacement part, service procedure or a be especially careful of the following:
tool that is not recommended by Honda, must determine Read all of the instructions before you begin
the risks to their personal safety and the safe operation of and make sure you have the tools, the
the vehicle. replacement or repair parts and the skills
If you need to replace a part, use genuine Honda parts required to perform the tasks safely and
with the correct part number or an equivalent part. We completely.
strongly recommend that you do not use replacement Protect your eyes by using proper safety
parts of inferior quality. glasses, goggles or face shields any time you
FOR YOUR CUSTOMER'S SAFETY hammer, drill, grind, or work around
pressurised air or liquids and springs or other
Proper service and maintenance are essential to the
stored-energy components. If there is any
customer's safety and the reliability of the vehicle. Any
doubt, put on eye protection.
error or oversight while servicing a vehicle can result in
Use other protective wear when necessary,
faulty operation, damage to the vehicle, or injury to
for example gloves or safety shoes. Handling
others.
hot or sharp parts can cause severe burns or
cuts. Before you grab something that looks
WARNING
like it can hurt you, stop and put on gloves.
Improper service or repairs can create an
Protect yourself and others whenever you
unsafe condition that can cause your
have the vehicle up in the air. Any time you
customer or others to be seriously hurt or
lift the vehicle, either with a hoist or a jack,
killed.
make sure that it is always securely
Follow the procedures and precautions in supported. Use jack stands.
this manual and other service materials
Make sure the engine is off before you begin
carefully.
any servicing procedures, unless the instruction
tells you to do otherwise. This will help
FOR YOUR SAFETY eliminate several potential hazards:
Because this manual is intended for the professional Carbon monoxide poisoning from engine
service technician, we do not provide warnings about exhaust. Be sure there is adequate ventilation
many basic shop safety practices (e.g., Hot parts - wear whenever you run the engine.
gloves). If you have not received shop safety training or Burns from hot parts or coolant. Let the
do not feel confident about your knowledge of safe engine and exhaust system cool before
servicing practices, we recommend that you do not working in those areas.
attempt to perform the procedures described in this Injury from moving parts. If the instruction tells
manual. you to run the engine, be sure your hands,
fingers and clothing are out of the way.
WARNING Gasoline vapours and hydrogen gases from
Failure to properly follow instructions and batteries are explosive. To reduce the
precautions can cause you to be seriously possibility of a fire or explosion, be careful
hurt or killed. when working around gasoline or batteries.
Follow the procedures and precautions in Use only a non-flammable solvent, not
this manual carefully. gasoline to clean parts.
Never drain or store gasoline in an open
container.
Keep all cigarettes, sparks and flames away

0-3_A Few Words About Safety_Service Information
from the battery and all fuel-related parts.

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0-4_Introduction_Outline of Model Changes
Introduction
Outline of Model Changes
ITEM DESCRIPTION 2001 2001 2001 2001 2002 REFERENCE

2-door 5-door 3-door 3-door 3-door/5- SECTION
(Made- (Made-in- TYPE-R door
in- England) (Made-in- Turbo
England) England) Diesel
General Coupe model added O -
D17A8, D17A9
engines added
5-door LHD model added O -
3-door model added O O -
3-door TYPE-R O -
model added
K20A2 engine
added
Engine D17A8, D17A9 engines added O -
Electrical D14Z6, D16V1 and D16V3 engines O -
added to suit 5-door LHD model
K20A2 engine added O -
Diesel engine added O 4
Engine D17A8, D17A9 engines added O -
D14Z6, D16V1 and D16V3 engines O -
added to suit 5-door LHD model
Diesel engine added O 5-10
Fuel and Coupe model added O -
Emissions KG, KS, KY models added O -
Diesel engine added O 11
Clutch MD4 manual transmission added O 12
Manual X2M5 6-speed manual transmission O -
Transmission added
MD4 manual transmission added O 13
Automatic Shift schedule added O -
Transmission 5-door LHD model added, equipped O -
with 7-position transmission
Shift schedule and stall speed O O -
changed
Driveline/Axle 5-door LHD model added O -
MD4 manual transmission added O 16
Steering 3-door TYPE-R model added O -
Rack guide adjustment procedures O 17
changed
Suspension 3-door TYPE-R model added O -
Front damper changed O 18
Brake 3-door TYPE-R model added O -
Conventional brake components O 19
modified
Body Coupe model added O -

0-4_Introduction_Outline of Model Changes
3-door TYPE-R model added O -

Diesel model emblem added O 20
Heating, System for diesel model added O 21
Ventilation and
Air
Conditioning
Body Electrical Coupe model added O -
3-door TYPE-R model added O -
Diesel model added O 22
Restraints Coupe model added O -
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1-1_General Information
General Information
Chassis and Engine Numbers 1-2

Identification Number Locations 1-4
Abbreviations 1-5
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1-2_General Information_Chassis and Engine Numbers
1-2
General Information
Chassis and Engine Numbers
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1-3_General Information_Chassis and Engine Numbers (cont'd)
1-3
General Information
Chassis and Engine Numbers (cont'd)
Model/Applicable Area Code/VIN/Engine Number/Transmission Number List

MODEL APPLICABLE GRADE TRANSMISSION VEHICLE ENGINE TRANSMISSION
AREA CODE NAME TYPE IDENTIFICATION NUMBER NUMBER
NUMBER
CIVIC KE 1.7S 5MT SHHEP43202U000001- 4EE2-0000001- MD4-0000001-
3-door 1.7SE SHHEP43502U000001- 4EE2-0000001- MD4-0000001-
KG 1.7S 5MT SHHEP43202U000001- 4EE2-0000001- MD4-0000001-
1.7LS SHHEP43502U000001- 4EE2-0000001- MD4-0000001-
1.7ES SHHEP43802U000001- 4EE2-0000001- MD4-0000001-
KR 1.7S 5MT SHHEP43202U000001- 4EE2-0000001- MD4-0000001-
1.7LS SHHEP43502U000001- 4EE2-0000001- MD4-0000001-
1.7ES SHHEP43802U000001- 4EE2-0000001- MD4-0000001-
CIVIC KE 1.7S 5MT SHHEU97202U000001- 4EE2-0000001- MD4-0000001-
5-door 1.7SE SHHEU97502U000001- 4EE2-0000001- MD4-0000001-
KG 1.7S 5MT SHHEU97202U000001- 4EE2-0000001- MD4-0000001-
1.7LS SHHEU97502U000001- 4EE2-0000001- MD4-0000001-
1.7ES SHHEU97802U000001- 4EE2-0000001- MD4-0000001-
KR 1.7S 5MT SHHEU97202U000001- 4EE2-0000001- MD4-0000001-
1.7LS SHHEU97502U000001- 4EE2-0000001- MD4-0000001-
1.7ES SHHEU97802U000001- 4EE2-0000001- MD4-0000001-
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1-4_General Information_Identification Number Locations (cont'd)
1-4
General Information
Identification Number Locations (cont'd)
1. Vehicle Identification Number (VIN)

2. Vehicle Identification Number (VIN),
Engine Number and Line type
3. Manual Transmission Number
4. Engine Number
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1-5_General Information_Abbreviations
1-5
General Information
Abbreviations
List of automotive abbreviations which may be used in EPR Evaporator Pressure Regulator
shop manual. EPS Electrical Power Steering
ABS Anti-lock Brake System EVAP Evaporative
A/C Air Conditioning, Air Conditioner EX Exhaust
ACL Air Cleaner
A/F Air Fuel Ratio F Front
ALR Automatic Locking Retractor FIA Fuel Injection Air
ALT Alternator FL Front Left
AMP Ampere(s) FP Fuel Pump
ANT Antenna FR Front Right
API American Petroleum Institute FSR Fail Safe Relay
APPROX. Approximately FWD Front Wheel Drive
ASSY Assembly
A/T Automatic Transmission GAL Gallon
ATDC After Top Dead Centre GND Ground
ATF Automatic Transmission Fluid GPS Global Positioning System
ATT Attachment
ATTS Active Torque Transfer System H/B Hatchback
AUTO Automatic HC Hydrocarbons
AUX Auxiliary HID High Intensity Discharge
HO2S Heated Oxygen Sensor
BARO Barometric
BAT Battery IAB Intake Air Bypass
BDC Bottom Dead Centre IAC Idle Air Control
BTDC Before Top Dead Centre IACV Idle Air Control Valve
IAR Intake Air Resonator
CARB Carburettor IAT Intake Air Temperature
CAT Catalytic Converter ICM Ignition Control Module
or CATA ID Identification
CHG Charge ID or I.D. Inside Diameter
CKF Crankshaft Speed Fluctuation IG or IGN Ignition
CKP Crankshaft Position IMA Idle Mixture Adjustment
CO Carbon Monoxide Integrated Motor Assisted
COMP Complete IMMOBI. Immobiliser
CPB Clutch Pressure Back up IN Intake
CPC Clutch Pressure Control INJ Injection
CPU Central Processing Unit INT Intermittent
CVT Continuously Variable Transmission
CYL Cylinder KS Knock Sensor
CYP Cylinder Position
L Left
DI Distributor Ignition L/C Lock-up Clutch
DIFF Differential LCD Liquid Crystal Display
DLC Data Link Connector LED Light Emitting Diode
DOHC Double Overhead Camshaft LEV Low Emission Vehicle
DPI Dual Point Injection LF Left Front
DTC Diagnostic Trouble Code LH Left Handle
LHD Left Handle Drive
EBD Electronic Brake Distribution LR Left Rear

1-5_General Information_Abbreviations
ECM Engine Control Module LSD Limited Slip Differential

ECT Engine Coolant Temperature L-4 In-line Four Cylinder (engine)
EGR Exhaust Gas Recirculation
ELD Electrical Load Detector aaa

1-6_General Information_Abbreviations (cont'd)
1-6
General Information
Abbreviations (cont'd)
MAP Manifold Absolute Pressure STD Standard

MAX. Maximum SW Switch
MBS Mainshaft Brake System
MCK Motor Check T Torque
MCU Moment Control Unit TB Throttle Body
MIL Malfunction Indicator Lamp T/B Timing Belt
MIN. Minimum TC Torque Converter
MPI Multi Point Injection TCM Transmission Control Module
M/S Manual Steering TCS Traction Control System
M/T Manual Transmission TDC Top Dead Centre
TFT Thin Film Transistor
N Neutral T/N Tool Number
NOx Oxides of Nitrogen TP Throttle Position
TWC Three Way Catalytic Converter
OBD On-board Diagnostic
O2S Oxygen Sensor VC Viscous Coupling
OD or O.D. Outside Diameter VDP Variable Displacement Pump
VFV Variable Force Control Valve
P Park VGR Variable Gear Ratio
PAIR Pulsed Secondary Air Injection VIN Vehicle Identification Number
PCM Powertrain Control Module VSS Vehicle Speed Sensor
PCV Positive Crankcase Ventilation VTEC Variable Valve Timing & Valve Lift
Proportioning Control Valve Electronic Control
PDU Power Drive Unit VVIS Variable Volume Intake System
PGM-FI Programmed-fuel Injection V-6 V-type Six Cylinder (engine)
PGM-IG Programmed Ignition
PH Pressure High W With
PL Pilot Light or Pressure Low W/O Without
PMR Pump Motor Relay WOT Wide Open Throttle
P/N Part Number
PRI Primary 2WD Two Wheel Drive
P/S Power Steering 4WD Four Wheel Drive
PSF Power Steering Fluid 2WS Two Wheel Steering
PSP Power Steering Pressure 4WS Four Wheel Steering
PSW Pressure Switch 4AT 4-speed Automatic Transmission
5AT 5-speed Automatic Transmission
Qty Quantity 5MT 5-speed Manual Transmission
6MT 6-speed Manual Transmission
R Right Park
REF Reference Reverse
RGB Red, Green, Black Neutral
RH Right Handle Drive (1st through 4th gear)
RHD Right Handle Drive Drive (1st through 3rd gear)
RL Rear Left Second
RON Research Octane Number First
RR Rear Right Drive
Second
SAE Society of Automotive Engineers
Low
SCS Service Check Signal

1-6_General Information_Abbreviations (cont'd)
O/D Over Drive

SEC Second
1ST Low (gear)
Secondary
2ND Second (gear)
SOHC Single Overhead Camshaft 3RD Third (gear)
SOL Solenoid 4TH Fourth (gear)
SPEC Specification 5TH Fifth (gear)
S/R Sun Roof 6TH Sixth (gear)
SRS Supplemental Restraint System
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2-1_Specifications
Specifications
Standards and Service Limits

Engine Electrical 2-2
Engine Assembly 2-2
Cylinder Head 2-2
Engine Block 2-3
Engine Lubrication 2-4
Cooling 2-4
Fuel and Emissions 2-4
Clutch 2-4
Manual Transmission and Differential 2-5
Steering 2-6
Suspension 2-6
Brakes 2-7
Air Conditioning 2-7
Design Specifications
Dimensions 2-8
Weight 2-8
Engine 2-8
Starter 2-8
Clutch 2-9
Manual Transmission 2-9
Steering 2-9
Suspension 2-9
Wheel Alignment 2-9
Brakes 2-9
Tyres 2-9
Air Conditioning 2-9
Electrical Ratings 2-10
Body Specifications
3-door Model 2-11
5-door Model 2-12
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2-2_Standards and Service Limits_Engine Electrical
2-2
Engine Electrical
Item Measurement Qualification Standard or New Service Limit

Alternator Output 100 A
Coil (rotor) resistance 2.45 – 2.75 ohms
Slip ring O.D. 31.7 mm (1.25 in.) 30.7 mm (1.21 in.)
Brush length 25.0 mm (0.97 in.) 6.5 mm (0.26 in.)
Starter Output 1.4 kW
Commutator mica depth 0.5 – 0.8 mm (0.020 – 0.032 in.) 0.2 mm (0.008 in.)
Commutator runout 0.05 mm (0.002 in.) max. 0.1 mm (0.004 in.)
Commutator O.D. 29.0 mm (1.14 in.) 28.0 mm (1.10 in.)
Brush length 15.5 mm (0.61 in.) 10.5 mm (0.41 in.)
Engine Assembly
Compression Pressure check at 200 rpm (min -1 ) 2.8 MPa (28.6 kgf/cm 2 , 406 psi) 2.5 MPa (25.5 kgf/cm 2 , 363 psi)
Cylinder Head
Head Warpage – 0.1 mm (0.04 in.)
Height Reference: 95.0 mm (3.74 in.) –
Camshaft Camshaft-to-holder oil clearance 0.040 – 0.082 mm (0.0016 – 0.0032 0.11 mm (0.004 in.)
in.)
Total runout 0.03 mm (0.001 in.) 0.05 mm (0.002 in.)
Valves Clearance (cold) Intake 0.40 mm (0.016 in.) –
Exhaust 0.40 mm (0.016 in.) –
Stem O.D. Intake 5.959 – 5.977 mm (0.2346 – 0.2353 5.945 mm (0.2341 in.)
in.)
Exhaust 5.954 – 5.972 mm (0.2344 – 0.2351 5.940 mm (0.2339 in.)
in.)
Stem-to-guide clearance Intake 0.023 – 0.056 mm (0.0009 – 0.0022 0.080 mm (0.0031 in.)
in.)
Exhaust 0.028 – 0.061 mm (0.0011 – 0.0024 0.095 mm (0.0037 in.)
in.)
Valve seats Width Intake – 1.7 mm (0.07 in.)
Exhaust – 1.5 mm (0.06 in.)
Valve springs Free length 44.63 mm (1.757 in.) 44.13 mm (1.737 in.)
Valve guides Installed height Reference 11.7 mm (0.46 in.) –
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2-3_Standards and Service Limits_Engine Block
2-3
Engine Block

Block Warpage of deck 0.05 mm (0.002 in.) max. 0.10 mm (0.004 in.)
Bore diameter Bore grade: A 79.001 – 79.010 mm (3.1102 – 3.1106 –
in.)
Bore grade: B 79.011 – 79.020 mm (3.1107 – 3.1110 –
in.)
Bore grade: C 79.021 – 79.030 mm (3.1111 – 3.1114 –
in.)
Piston Skirt O.D. at 57 mm (2.2 in.) Piston grade: A 78.930 – 78.939 mm (3.1075 – 3.1078 –
from top of piston in.)
Piston grade: B 78.940 – 78.949 mm (3.1079 – 3.1082 –
in.)
Piston grade: C 78.950 – 78.959 mm (3.1083 – 3.1086 –
in.)
Clearance in cylinder 0.061 – 0.079 mm (0.0024 – 0.0031 in.) –
Piston rings Ring-to-groove clearance Top 0.090 – 0.122 mm (0.0035 – 0.0048 in.) 0.15 mm (0.006 in.)
Second 0.070 – 0.110 mm (0.0028 – 0.0043 in.) 0.15 mm (0.006 in.)
Oil 0.025 – 0.065 mm (0.0010 – 0.0026 in.) 0.15 mm (0.006 in.)
Ring end gap Top 0.25 – 0.35 mm (0.010 – 0.014 in.) 0.8 mm (0.03 in.)
Second 0.20 – 0.30 mm (0.008 – 0.012 in.) 0.8 mm (0.03 in.)
Oil 0.20 – 0.40 mm (0.008 – 0.016 in.) 0.8 mm (0.03 in.)
Piston pin O.D. 26.995 – 27.000 mm (1.0628 – 1.0630 26.985 mm (1.0624 in.)
in.)
Pin-to-piston clearance 0.004 – 0.014 mm (0.0002 – 0.0006 in.) –
Connecting rod Pin-to-rod clearance 0.008 – 0.020 mm (0.0003 – 0.0008 in.) 0.05 mm (0.002 in.)
Large-end bore diameter 46.003 – 46.045 mm (1.8111 – 1.8128 –
in.)
Crankshaft Main journal diameter Size mark: 51.918 – 51.928 mm (2.0440 – 2.0444 51.912 mm (2.0438 in.)
in.)
Size mark: 51.928 – 51.938 mm (2.0444 – 2.0448 51.922 mm (2.0442 in.)
in.)
Rod journal diameter 45.930 – 45.945 mm (1.8083 – 1.8089 45.926 mm (1.8081 in.)
in.)
Rod/main journal taper 0.05 mm (0.002 in.) max. 0.08 mm (0.003 in.)
End play 0.05 – 0.15 mm (0.002 – 0.006 in.) 0.2 mm (0.008 in.)
Runout 0.05 mm (0.002 in.) max. 0.06 mm (0.002 in.)
Crankshaft bearings Main bearing-to-journal oil 0.030 – 0.058 mm (0.0012 – 0.0023 in.) 0.08 mm (0.003 in.)
clearance
Rod bearing clearance 0.025 – 0.058 mm (0.0010 – 0.0023 in.) 0.1 mm (0.004 in.)
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2-4_Standards and Service Limits_Engine Lubrication
2-4
Engine Lubrication

Engine oil Capacity 5.75 l (6.08 US qt, 5.06 lmp qt) –
Oil pump Inner-to-outer rotor clearance 0.13 – 0.15 mm (0.005 – 0.006 in.) 0.20 mm (0.008 in.)
Outer rotor-to-cylinder block clearance 0.24 – 0.36 mm (0.009 – 0.014 in.) 0.40 mm (0.016 in.)
Oil pump-to-cylinder block axial clearance 0.035 – 0.100 mm (0.0014 – 0.0039 0.15 mm (0.006 in.)
in.)
Oil pressure with oil temperature at 80°C At idle 127 kPa (1.3 kgf/cm 2 , 18 psi) –
(176°F)
Cooling
Thermostat Opening temperature Begins to open 83 – 87°C (181 – 189°F) –
Fully open 100°C (212°F) –
Valve lift at fully open 8.0 mm (0.31 in.) min.
Fuel and Emissions

Fuel tank Capacity 50 l (13.2 US gal, 11.0 lmp
gal)
Engine idle 850 rpm (min -1 ) +50 rpm (min -1 )
Clutch
Clutch disc Rivet depth – 0.87 mm (0.034 in.) or 0.22 mm (0.009 in.)
more
Pressure plate Height of diaphragm spring – 1.0 mm (0.039 in.) or less
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2-5_Standards and Service Limits_Manual Transmission and Differential
2-5
Manual Transmission and Differential
Item Measurement Qualification Standard or Service Limit

New
Transmission oil Lubricant capacity 2.0 l (2.1 US qt) –
Input shaft Run out – 0.02 mm (0.0008 in.) or less
Play in splines between 5th gear and – 0.15 mm (0.0059 in.) or less
input shaft
Input shaft 3rd and 4th gears I.D. – 41.05 mm (1.6161 in.) or less
Output shaft Run out – 0.02 mm (0.0008 in.)
Output shaft 1st and 2nd gears I.D. – 40.04 mm (1.7736 in.) or less
Output shaft 5th gear I.D. – 41.05 mm (1.6161 in.) or less
Reverse idle gear Clearance between reverse idle gear – 0.15 mm (0.0059 in.) or less
and shaft
Synchronisers Clearance between blocker ring and 1st/2nd – 3.9 mm (0.154 in.) or less
inserts 3rd/4th, 5th – 3.7 mm (0.146 in.) or less
Clearance between blocker ring and 3rd/4th, 5th 1.5 mm (0.059 in.) 0.8 mm (0.031 in.) or more
gear
Clearance between blocker ring and 1st/2nd 1.5 mm (0.059 in.) 0.8 mm (0.031 in.) or more
synchronising cone
Detent spring Spring length Except reverse – 25.5 mm (1.004 in.) or more
Reverse – 59.5 mm (2.343 in.) or more
Shift forks Shift fork pad thickness Except reverse – 7.5 mm (0.295 in.) or more
Reverse – 7.4 mm (0.291 in.) or more
Clearance between hub and inserts – 0.25 mm (0.0098 in.) or less
Differential case Clearance between pinion gear and – 0.2 mm (0.008 in.) or less
cross pin
Clearance between differential case – 0.15 mm (0.0059 in.) or less
and side gear (A – B)
Diameter in differential case for axle – 30.10 mm (1.1850 in.) or less
shaft
Backlash between side gear and – 0.3 mm (0.0118 in.) or less
pinion gear
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2-6_Standards and Service Limits_Steering
2-6
Steering
Item Measurement Qualification Standard or New Service

Limit
Steering wheel Rotational play measured at outside edge With engine running 0 – 10 mm (0 – 0.39 in.) –
Starting load measured at outside edge With engine running 29 N (3.0 kgf, 6.6 lbs) –
Gearbox Angle of rack guide screw loosened from locked 5° Max.
position
Suspension
Wheel alignment Camber Front 0°00'+45°
Rear –0°45'+45'
Caster Front 1°33'+1°
Total Toe Front 0+3 mm (0+0.12 in.)
Rear Adjust: IN 2 +2/-1mm (0.08 +0.08/-0.04 in.)
Inspect: IN 2 + 3 mm (0.08+0.12 in.)
Front wheel turning angle Inside wheel 40°00'+2°
Outside wheel 31°00' (Reference)
Aluminium wheel Runout Axial 0 – 0.7 mm (0 – 0.03 in.) 2.0 mm (0.08 in.)
Radial 0 – 0.7 mm (0 – 0.03 in.) 1.5 mm (0.06 in.)
Steel wheel Runout Axial 0 – 1.0 mm (0 – 0.04 in.) 2.0 mm (0.08 in.)
Radial 0 – 1.0 mm (0 – 0.04 in.) 1.5 mm (0.06 in.)
Wheel bearings End play Front 0 – 0.05 mm (0 – 0.002 in.)
Rear 0 – 0.05 mm (0 – 0.002 in.)
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2-7_Standards and Service Limits_Brakes
2-7
Brakes

Parking brake lever Distance travelled when pulled 3-door 7 – 8 clicks
with 196 N (20 kgf, 44 lbs) of 5-door 7 – 8 clicks
force
Brake pedal Pedal height (Carpet removed) 3-door 184 mm (7.24 in.)
5-door 180 mm (7.09 in.)
Free play 0.4 – 3.0 mm (0.016 – 0.118 in.)
Master cylinder Piston-to-pushrod clearance 0 – 0.4 mm (0 – 0.02 in.)
Brake disc Thickness Front 20.9 – 21.8 mm (0.82 – 0.86 21.0 mm (0.83 in.)
in.)
Rear 8.9 – 9.1 mm (0.350 – 0.358 9.0 mm (0.35 in.)
in.)
Runout – 0.10 mm (0.004 in.)
Parallelism – 0.015 mm (0.0006 in.)
Brake pads Thickness Front 10.5 – 11.5 mm (0.41 – 0.45 1.6 mm (0.06 in.)
in.)
9.0 – 10.0 mm (0.35 – 0.39 1.6 mm (0.06 in.)
in.)
Thickness Rear 9.5 – 10.5 mm (0.37 – 0.41 1.6 mm (0.06 in.)
in.)
Brake booster Vehicle with Characteristics at 196 N (20 kgf, Vacuum N (kgf, lbf) kPa (kgf/cm 2 , psi)
ABS 44 lbf) pedal force kPa (mmHg, inHg)
0 (0, 0) 98 (10, 22) 0 (0, 0)
294 (30, 66) 1700 (17, 240)
66.7 (500, 19.7) 98 (10, 22) 4600 (47, 670)
294 (30, 66) 10500 (107, 1500)
Air Conditioning
Item Measurement Qualification Standard or New
Refrigerant Type HFC-134 a (R-134 a)
Capacity or system 500 – 550 g (17.6 – 19.4 oz)
Refrigerant oil Type DH-PS
Capacity of components Condenser 25 ml (5/6 fl oz, 0.9 lmp oz)
Evaporator 45 ml (1 1/2 fl oz, 1.3 lmp oz)
Each line and hose 10 ml (1/3 fl oz, 0.4 lmp oz)
Receiver 10 ml (1/3 fl oz, 0.4 lmp oz)
Compressor 140 – 150 ml (4 2/3 fl oz, 4.9 lmp oz – 5 fl oz, 5.2 lmp
oz)
Compressor Clutch coil resistance at 68°F (20°C) 3.57 – 3.79 ohms
Pulley-to-pressure plate clearance 0.3 – 0.6 mm (0.01 – 0.02 in.)
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2-8_Design Specifications
2-8
Item Measurement Qualification Specification

DIMENSIONS Overall length 4,140 mm (163.0 in.)
3-door Overall width 1,695 mm (66.7 in.)
Overall height without roof antenna 1,425 mm (56.1 in.)
with roof antenna 1,550 mm (61.0 in.)
Wheelbase 2,570 mm (101.2 in.)
(MPW condition)
Track Front 1,469 mm (57.8 in.)
(MPW condition) Rear 1,472 mm (58.0 in.)
Ground clearance 129.7 mm (5.11 in.)
Seating capacity Four (4)
DIMENSIONS Overall length 4,285 mm (168.7 in.)
5-door Overall width 1,695 mm (66.7 in.)
Overall height without roof antenna 1,495 mm (58.9 in.)
with roof antenna 1,585 mm (62.4 in.)
Wheelbase 2,685 mm (105.7 in.)
Track Front 1,472 mm (58.0 in.)
Rear 1,489 mm (58.6 in.)
Ground clearance 104 mm (4.10 in.)
Seating capacity Five (5)
WEIGHT Curb weight 1,199 – 1,208 kg (2,643 – 2,663 lbs)
Max. permissible weight 1,550 kg (3,417 lbs)
ENGINE Type 4EE2 Water-cooled, Turbocharged, 4-stroke
DOHC direct injection diesel engine
Cylinder arrangement Inline 4-cylinder, transverse
Bore and stroke 79 x 86 mm (3.11 x 3.39 in.)
Displacement 1,686 cm3 (103 cu in.)
Compression ratio 18.4
Valve train Belt driven, DOHC 4 valves per cylinder
Lubrication system Forced wet sump, with trochoid pump
Oil pump displacement at 2,000 rpm (min -1 ) 32.1 l (33.9 US qt, 28.2 Imp qt)/minute
Water pump displacement at 5,200 rpm (min -1 ) 185 l (195 US qt, 163 Imp qt)/minute
Fuel required EC REF. Fuel
STARTER Type Gear reduction
Normal output 1.4 kW
Hour rating 30 seconds
Direction of rotation Clockwise as viewed from gear end
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2-9_Design Specifications_(cont'd)
2-9
(cont'd)

CLUTCH Clutch Single plate dry, diaphragm spring
MANUAL TRANSMISSION Type Synchronised, 5-speed forward, 1 reverse
Primary reduction Direct 1:1
Gear ratio 1st 3.545
2nd 2.055
3rd 1.333
4th 0.923
5th 0.744
Reverse 3.583
Final reduction Type Single helical gear
Gear ratio 3.578
STEERING Type Rack and pinion, with electrical power assistance
Over ratio 14.49
Turns, lock-to-lock 2.83
Steering wheel diameter 380 mm (15.0 in.)
SUSPENSION Type Front Strut
Rear Double wishbone
Shock absorber Front and rear Telescopic, hydraulic, nitrogen gas-filled
WHEEL ALIGNMENT Camber Front 0°
Rear – 0°45'
Caster Front 1°33'
Total toe Front 0 mm (0 in.)
Rear In 2 mm (1/16 in.)
BRAKES Type of service brake Front Power-assisted self-adjusting ventilated disc
Rear Power-assisted self-adjusting solid disc
Type of parking brake Mechanical actuating, rear wheels
Pad friction surface area Front 40 cm2 x 2 (6.3 sq in. x 2)
Rear 28 cm2 x 2 (4.3 sq in. x 2)
TYRES Size of front and rear 195/60R15 88H
Size of spare T125/70D15 95M
AIR CONDITIONING Cooling capacity 3,612 kcal/h (14,370 BTU/h)
Compressor Type/manufacturer Swash plate/DELPHI
Number of cylinders 6
Capacity 135 ml/rev. (5.23 cu in./rev.)
Maximum speed 8,000 rpm
Lubricant capacity 150 ml (5 fl oz)
Lubricant type DH-PS
Condenser Type Multi flow
Evaporator Type Laminate
Blower Type Sirocco fan
Motor type 220 W/12 V
Speed control 9-speed
Maximum capacity 470 m3/h (16,900 cu ft/h)
Temperature clutch Air-mix type
Compressor clutch Type Dry, single plate, poly-V belt drive
Refrigerant Type HFC-134a (R-134a)
Quantity 500 – 550 g (17.5 – 19.5 oz)
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2-10_Design Specifications_(cont'd)
2-10
(cont'd)

ELECTRICAL RATINGS Battery 12 V – 45 AH/20 hours
Starter 12 V – 1.4 kW
Alternator 12 V – 80 A
Fuses Under-hood fuse/relay box 80 A, 40 A, 30 A, 20 A, 15 A, 7.5 A
Under-dash fuse/relay box 20 A, 15 A, 10 A, 7.5 A
Light bulbs Headlight high beam 12 V – 60 W
Headlight low beam 12 V – 55 W
Front turn signal/Front side marker lights 12 V – 21 W/5 W
Front position lights 12 V – 5 W/3 CP (candlepower)
Side turn signal lights 12 V – 5 W
Rear turn signal lights 12 V – 21 W
Brake/Taillights/Rear side marker light 12 V – 21W/5 W
Rear fog light 12 V – 21 W
Taillights 12 V – 5 W
High mount brake light 12 V – 21 W
Back-up light 12 V – 21 W
License plate light 12 V – 3 CP
Ceiling light 12 V – 8 W, 5 W
Luggage area light 12 V – 5 W
Individual map light 12 V – 8 W
Spotlights 14 V – 8 W
Gauge light 14 V – 1.4 W
Indicator light 12 V – 1.12 W
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2-11_Body Specifications
2-11
Body Specifications
3-door Model
Unit: mm (in)
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2-12_Body Specifications_(cont'd)
2-12
Body Specifications
(cont'd)
5-door Model
Unit: mm (in)
*1: With Roof Antenna

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3-1_Maintenance
Maintenance
Lubricants and Fluids 3-2

Maintenance Schedule Normal Conditions 3-4
Maintenance Schedule Severe Conditions 3-6
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3-2_Lubricants and Fluids
3-2
Lubricants and Fluids
For the details of lubrication points and type of lubricants to be applied, refer to the illustrated index and various work procedures
(such as Assembly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section.
NO. LUBRICATION POINTS LUBRICANT
1 Engine ACEA B3: 5W-40
Engine oil viscosity for ambient temperature ranges
2 Transmission Genuine Honda Manual Transmission Fluid (MTF) *1

3 Brake system (includes ABS line) Brake fluid DOT 3 or DOT 4 *2
4 Clutch line Brake fluid DOT 3 or DOT 4 *2
5 Release fork Super High Temp Urea Grease (P/N 08798-9002)
6 Shift and select cable ends
7 Throttle cable end (dashboard lower panel hole) Silicon grease
8 Throttle cable end (throttle link) Multi-purpose grease
9 Brake master cylinder pushrod
10 Clutch master cylinder pushrod
11 Shift lever
12 Pedal linkage
13 Battery terminals
14 Fuel fill lid
15 Hood hinges and latch Honda White Lithium Grease
16 Tailgate hinges
17 Door hinges, upper and lower
18 Door opening detent
19 Caliper piston boot, caliper pins and boots Silicon grease
20 Brake line joints (front and rear wheelhouse) Rust preventives
21 Air conditioning compressor Compressor oil: DH-PS
For refrigerant: HFC-134a (R-134a)
CAUTION
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged
periods.
Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to
thoroughly wash your hands with soap and water as soon as possible after handling used oil.
*1 : Always use genuine Honda Manual Transmission Fluid (MTF). Using motor oil can cause stiffer shifting because it does not
contain the proper additives.
*2 : We recommend Genuine Honda Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the
system.
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3-3_Lubrication and Fluids_(cont'd)
3-3
Lubrication and Fluids
(cont'd)
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3-4_Maintenance Schedule_Normal Conditions
3-4
Maintenance Schedule
Normal Conditions
Follow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe Conditions
Maintenance Schedule (see page 3-6) do not apply.
Service at the indicated distance km x 1,000 15 30 45 60 75 90 105 120 135 150 165
or time whichever comes first. miles x 1,000 9 18 27 36 45 54 63 72 81 90 99
months 12 24 36 48 60 72 84 96 108 120 132
Replace engine oil
Replace engine oil filter
Replace air cleaner element
Inspect valve clearance
Replace fuel filter
Drain fuel filter (water)
Replace timing belt
Inspect and replace drive belts Inspect every 30,000 km (18,000 miles) or 2 years, replace every
150,000 km (90,000 miles) or 10 years
Replace engine coolant
Replace transmission fluid
Inspect front and rear brakes
Replace brake fluid Every 3 years
Check parking brake adjustment
Replace pollen filter Every 30,000 km (18,000 miles) or 1 year
Check lights alignment
Test drive (noise, stability, dashboard operations)
Visually inspect the following items:
Tie rod ends, steering gearbox and boots
Suspension components
Driveshaft boots
Brake hoses and lines (including ABS)
All fluid levels and condition of fluid
Exhaust system
Fuel lines and connections
Tyre condition
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3-5_Maintenance Schedule_Normal Conditions (cont'd)
3-5
Normal Conditions (cont'd)
NOTES SECTION and PAGE

(see page 8-5)
(see page 8-5)
(see page 11-170)
Check the valve clearance. (see page 6-4)
(see page 11-158)
(see page 11-158)
(see page 6-7)
(see page 4-20)
Use genuine Honda All Season Antifreeze/Coolant Type 2. (see page 10-6)
Use genuine Honda MTF (Manual Transmission Fluid). (see page 13-4)
Check the brake pad and disc thickness. Check for damage or cracks. (see page 19-3)*1 (see page 19-6)
Check the wheel cylinder for leaks.
Check the brake linings for cracking, glazing, wear or contamination.
Check the calipers for damage, leaks and tightness.
Use only DOT 3 or DOT 4 brake fluid. (We recommend Genuine Honda Brake Fluid.) (see page 19-7)*1
Check that Brake fluid level is between the upper and lower marks on the reservoir.
Check the parking brake operation. (see page 19-6)*1
(see page 21-53)*1
Check the position of the headlight. (see page 22-114)*1
Check for road stability, noise, vibrations and dashboard operation. -
Check for correct installation and position, check for cracks, -
deterioration rust and leaks.
Check tightness of screws, nuts and joints. If necessary, retighten.
Check rack grease and steering linkage. Check the boot for damage (see page 17-5)*1
and leaking grease.
Check the fluid line for damage and leaks.
Check the bolts for tightness. (see page 18-3)*1
Check all dust covers for deterioration and damage.
Check the boot and boot band for cracks (see page 16-3)
Check rack grease.
Check the master cylinder, proportioning control valve and ABS modulator and leakage. (see page 19-48)*1
Check for leaks. -
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, leaks (see page 9-9)
and tightness.
Check fuel lines for loose connections, cracks and deterioration. Retighten loose (see page 11-156)
connections and replace any damaged parts
Check for pressure, puncture or cuts and irregular tread wear. -
*1: Refer to shop manual: 2001 CIVIC MAINTENANCE, REPAIR and CONSTRUCTION Code No. 62S5A00 on this CD.
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3-6_Maintenance Schedule_Severe Conditions
3-6
Severe Conditions
Service at the indicated km x 1,000 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120
distance or time miles x 1,000 4.5 9 13.5 18 22.5 27 31.5 36 40.5 45 49.5 54 58.5 63 67.5 72
whichever comes first.
months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96
Replace engine oil
Replace engine oil filter
Replace air cleaner element
-Use normal schedule except in dusty
conditions
Inspect valve clearance
Replace fuel filter
Drain fuel filter (water)
Replace timing belt Every 150,000 km (90,000 miles) or 10 years
Inspect and replace drive belts Inspect every 30,000 km (18,000 miles) or 2 years, replace every 150,000 km (90,000 miles)
or 10 years
Replace engine coolant
Replace transmission fluid
Inspect front and rear brakes
Replace brake fluid Every 3 years
Check parking brake adjustment
Replace pollen filter Every 30,000 km (18,000 miles) or 1 year
Check lights alignment
Test drive (noise, stability, dashboard
operations)
Visually inspect the following items:
Tie rod ends, steering gearbox and boots
Suspension components
Driveshaft boots
Brake hoses and lines (including ABS)
All fluid levels and condition of fluid
Exhaust system
Fuel lines and connections
Tyre condition
Follow the Severe Conditions Maintenance Schedule if the customer's vehicle is driven MAINLY under one or more of the following
conditions:
Driving less than 8 km (5 miles) per trip or, in freezing temperatures, driving less than 16 km (10 miles) per trip.
Driving in extremely hot [over 35°C (95°F)] conditions.
Extensive idling or long periods of stop-and-go driving.
Trailer towing, driving with a car-top carrier, or driving in mountainous conditions.
Driving on muddy, dusty, or de-iced roads.
NOTE: If the customer's vehicle is driven OCCASIONALLY under severe conditions, follow the Normal Conditions Maintenance
Schedule (see page 3-4).
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3-7_Maintenance Schedule_Severe Conditions (cont'd)
3-7
Severe Conditions (cont'd)
NOTES SECTION and PAGE

(see page 8-5)
(see page 8-5)
(see page 11-170)
Check the valve clearance. (see page 6-4)
(see page 11-158)
(see page 11-158)
(see page 6-7)
(see page 4-20)
Use genuine Honda All Season Antifreeze/Coolant Type 2. (see page 10-6)
Use genuine Honda MTF (Manual Transmission Fluid). (see page 13-4)
Check the brake pad and disc thickness. Check for damage or cracks. (see page 19-3)*1 (see page 19-6)
Check the wheel cylinder for leaks.
Check the brake linings for cracking, glazing, wear or contamination.
Check the calipers for damage, leaks and tightness.
Use only DOT 3 or DOT 4 brake fluid. (We recommend Genuine Honda Brake Fluid.) (see page 19-7)*1
Check that Brake fluid level is between the upper and lower marks on the reservoir.
Check the parking brake operation. (see page 19-6)*1
(see page 21-53)*1
Check the position of the headlight. (see page 22-114)*1
Check for road stability, noise, vibrations and dashboard operation. -
Check for correct installation and position, check for cracks, -
deterioration rust and leaks.
Check tightness of screws, nuts and joints. If necessary, retighten.
Check rack grease and steering linkage. Check the boot for damage (see page 17-5)*1
and leaking grease.
Check the fluid line for damage and leaks.
Check the bolts for tightness. (see page 18-3)*1
Check all dust covers for deterioration and damage.
Check the boot and boot band for cracks (see page 16-3)
Check rack grease.
Check the master cylinder, proportioning control valve and ABS modulator and leakage. (see page 19-48)*1
Check for leaks. -
Check the catalytic converter heat shield, exhaust pipe and muffler for damage, leaks (see page 9-9)
and tightness.
Check fuel lines for loose connections, cracks and deterioration. Retighten loose (see page 11-156)
connections and replace any damaged parts
Check for pressure, puncture or cuts and irregular tread wear. -
*1: Refer to shop manual: 2001 CIVIC MAINTENANCE, REPAIR and CONSTRUCTION Code No. 62S5A00 on this CD.
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4-1_Engine Electrical
Engine Electrical
Starting System
Component Location Index 4-2
Circuit Diagram 4-3
Starter Circuit Troubleshooting 4-4
Starter Replacement 4-6
Starter Overhaul 4-7
Charging System
Circuit Diagram 4-18
Charging Troubleshooting 4-19
Drive Belt Inspection 4-20
Drive Belt Replacement 4-20
Alternator Replacement 4-21
Alternator and Vacuum Pump Overhaul 4-23
Alternator and Vacuum Pump Performance Test 4-30
Outline of Model Change

The 4EE2 engine has been added.
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4-2_Starting System_Component Location Index
4-2
Starting System
Component Location Index
1. STARTER MOTOR
Starter Circuit Troubleshooting,
page 4-4
Replacement, page 4-6
Overhaul, page 4-7
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4-3_Starting System_Circuit Diagram
4-3
Starting System
Circuit Diagram
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4-4_Starting System_Starter Circuit Troubleshooting
4-4
Starting System
Starter Circuit Troubleshooting
1. 1. Remove the No. 6 (20A) fuse from the under- 1. 7. Check the rotation sound of the starter.
hood fuse/relay. Can the rotation sound of the starter be heard?
2. 2. Turn the ignition switch to start (III). YES – Go to step 8.
Does the engine crank?
NO – Go to step 11.
YES – Go to step 3.
2. 8. Turn the ignition switch OFF.
NO – Go to step 7. 3. 9. Remove the starter from the engine.
3. 3. Check the engine cranking speed with the scan 4. 10. Check the engagement of pinion and ring gear.
tool. Turn the engine cranking. Is the engagement normal?
Is the engine cranking speed about 200 rpm? YES – Repair as necessary. (Pinion assembly or
YES – Intermittent failure, system is OK at this time. planetary gear.)
Check for poor connections or loose wires at the NO – Repair the engagement of pinion and ring gear
starter. or the shift lever.
NO – Go to step 4. 5. 11. Inspect the battery charging condition, poor
4. 4. Turn the ignition switch OFF. connections or loose wires at the battery.
5. 5. Inspect the battery charging condition, poor Was a problem found?
connections or loose wires at the battery. YES – Repair as necessary.
Was a problem found?
YES – Repair as necessary.
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6. 6. Check the engine oil viscosity.
YES – Replace as necessary.
NO – Substitute a known-good starter and recheck. If
symptom/indication goes away, replace the original
starter.

4-5_Starting System_Starter Circuit Troubleshooting (cont'd)
4-5
Starting System
Starter Circuit Troubleshooting (cont'd)
1. 12. Check the operation sound of magnetic switch 1. 16. Inspect the yoke assembly and armature
(SW). condition.
Can the operation sound of magnetic SW be heard? Was problem found in the yoke assembly or
YES – Go to step 15. armature?
NO – Go to step 13. YES – Replace as necessary.
2. 13. Check for the following conditions: NO – Go to step 17.
Damaged or faulty magnetic SW. 2. 17. Turn the ignition switch OFF.
Open circuit between magnetic SW and Key 3. 18. Disconnect the battery B+ terminal.
SW. 4. 19. Disconnect the battery B- terminal.
Was a problem found? 5. 20. Check the starter relay circuit for a short.
NO – Substitute a known-good starter relay and
3. 14. Connect the starter connector to B+ and B-.
recheck. If symptom/indication goes away, replace the
Does the starter rotate?
original starter relay.
YES – The magnetic SW is OK.
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4. 15. Inspect the brushes condition.
YES – Replace as necessary.

4-6_Starting System_Starter Replacement
4-6
Starting System
Starter Replacement
1. 1. Disconnect the negative cable from the battery 1. 4. Remove the splash shield (see step 19 on page
first, then the positive cable. 5-5).
2. 2. Disconnect the mass air flow (MAF) sensor 2. 5. Disconnect the starter cable (A) and BLK/WHT
connector (A) and remove the vacuum hose wire (B).
(B), then remove the air intake duct (C) and air
cleaner housing (D).
3. 6. Remove the harness bracket (C), then remove

3. 3. Remove the starter mounting bolt. the starter.
4. 7. Install in the reverse order of removal. Make
sure the crimped side of the ring terminal (A) is
facing out.
5. 8. Connect the positive cable and negative cable

to the battery.
6. 9. Retest starter performance.
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4-7_Starting System_Starter Overhaul
4-7
Starting System
Starter Overhaul
Exploded View
Part name
(1) Nut M8 (13) Dust Cover
(2) Nut M5 (14) Shift Lever
(3) Magnetic Switch Assembly (15) Internal Gear
(4) Screw M4 (16) Planetary Gear
(5) Through Bolt M5 (17) Pinion Stopper Clip
(6) Rear Cover Assembly (18) Pinion Stopper
(7) Thrust Washer B (19) Pinion Assembly
(8) Brush Holder Assembly (20) E Ring
(9) Yoke Assembly (21) Thrust Washer (A)
(10) Armature Assembly (22) Centre bracket (P)
(11) Centre Bracket (A) (23) Pinion Shaft
(12) Gear Case Assembly
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4-8_Starting System_Starter Overhaul (cont'd)
4-8
Starting System
Starter Overhaul (cont'd)
1. 1. Remove the nut M8 from the connecting wiring 1. 3. Remove the screw M4 (A) from the rear cover
harness on the magnetic switch. Remove the and the through bolts (B) from the starter
wiring harness from magnetic switch. assembly, then remove the rear cover (C).
2. 2. Remove the nut M5 (A) from magnetic switch.

Remove magnetic switch assembly (B) from
starter assembly. 2. 4. Remove the thrust washer B (A). Push up the
brushes then remove the brush holder
assembly (B).
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4-9
Starting System
1. 5. Remove the yoke assembly (A), armature 1. 7. Remove the internal gear (A) and the planetary
assembly (B) and the centre bracket (C). gears (B).
2. 6. Remove the gear case assembly (A), dust

cover (B) and shift lever (C).
2. 8. Remove the pinion stopper clip (A).
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4-10
Starting System
1. 9. Remove the pinion stopper (A). Remove the Inspection

pinion assembly (B). 1. 1. Measure the commutator outside diameter. If
the measurement is less than limit, replace the
commutator assembly.
Out side diameter:
Standard:
29 mm (1.1417 in.)
Limit:
28 mm (1.1024 in.)
2. 10. Remove the E ring (A) from pinion shaft.
2. 2. Use a circuit tester to measure the armature for

continuity.
There should be continuity between all
segments of the commutator.
If the circuit tester indicates not continuity, the
armature is open circuit, replace the armature
3. 11. Remove the thrust washer A (A). Remove the assembly.
centre bracket (p) (B). Remove the pinion shaft 1. Hold circuit tester probes against two
(C). commutator segments.
2. Repeat step 1 at different segments of the
commutator.
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4-11
Starting System
1. 3. Use a circuit tester to measure the armature for 1. 5. If there is rough surface on the commutator,
grounding. use sand paper number 500 to 600 for
If the circuit tester indicates continuity, the correction.
armature is grounded, replace the armature
assembly.
1. Hold one probe of the circuit tester against
the commutator segment.
2. Hold the other circuit tester probe against
the armature shaft.
2. 6. Inspect the commutator mica segment for

excessive wear. If the mica segment depth is
less than the limit, replace the commutator.
Measure the mica segment depth.
Mica segment depth:
Standard:
0.5 – 0.8 mm (0.0197 – 0.0315 in.)
2. 4. Measure the armature and commutator run-out.
If the measurement is out of limit, correct the Limit:
commutator and/or replace the armature 0.2 mm (0.0079 in.)
assembly.
Armature run-out:
Standard:
0.05 mm (0.0020 in.) max.
Limit:
0.1 mm (0.0039 in.)
Commutator run-out:
Standard:
0.05 mm (0.0020 in.) max.
Limit:
0.1 mm (0.0039 in.) aaa

4-12
Starting System
1. 7. Measure the brush length. Replace the brushes 1. 9. Use a circuit tester to inspect the magnetic
as a set if one more of the brush length is less switch continuity. Touch one probe to the S
than limit. connector and the other probe to the magnetic
Brush length: switch body. There should be continuity. If there
Standard: is no continuity, replace the magnetic switch
15.5 mm (0.6102 in.) assembly.
Limit:
10.5 mm (0.4134in.)
2. 10. Use a circuit tester to inspect the magnetic

switch continuity. Touch one probe to the S
connector and the other probe to the M
2. 8. Use a circuit tester to inspect the brush holder connector. There should be continuity. If there
insulation. Touch one probe to the holder plate is no continuity, replace the magnetic switch
and the other probe to positive brush holder. assembly.
There should be no continuity.
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4-13
Starting System
1. 11. Put plunger on lower side on the table. Use a 1. 13. Visually inspect yoke inside magnet. If there is
circuit tester to inspect the magnetic switch any damage, replace the yoke assembly.
continuity while pushing magnetic switch
downward. Touch one probe to the B connector
and other probe to the M connector. There
should be continuity. If there is no continuity,
replace the magnetic switch assembly.
2. 14. Measure the inside diameter of bearing on the

gear case. If measurement is more than limit,
replace the gear case assembly.
Inside diameter:
Standard:
12.47 – 12.49 mm (0.4909 – 0.4917 in.)
Limit:
12.59 mm (0.4957 in.)
2. 12. Inspect the pinion teeth for excessive wear and
damage. Rotate the pinion in the drive
direction, it should turn smoothly. Rotate the
pinion in the opposite direction, the pinion
should lock. If there is any abnormality, replace
the pinion assembly.
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4-14
Starting System
1. 15. Measure the inside diameter of bearing on the 1. 17. Measure the inside diameter of bearing on the
rear cover. If measurement is more than limit, pinion shaft. If measurement is more than limit,
replace the rear cover assembly. replace the pinion shaft.
Inside diameter: Inside diameter:
Standard: Standard:
12.018 – 12.029 mm 6.725 – 6.77mm (0.2648 – 0.2665 in.)
(0.4731 – 0.4736 in.) Limit:
Limit: 6.87 mm (0.2705 in.)
12.129 mm (0.4775 in.)
aaa
2. 16. Measure the inside diameter of the centre
bracket (p). If measurement is more than limit,
replace the centre bracket (P).
Inside diameter:
Standard:
18.035 – 18.060 mm
(0.7100 – 0.7110 in.)
Limit:
18.160 mm (0.7150 in.)

4-15
Starting System
Tightening Torque
aaa

4-16
Starting System
Starter Reassembly aaa

The reassembly manner is reverse procedure of the
disassembly procedure.
1. 1. Apply grease to the following portions.
Bearings of gear case, rear cover, centre
bracket and pinion shaft.
Mesh area on the reduction gear.
Shift lever.
Sliding portion on the pinion.
2. 2. Make sure without metals from inside yoke
when reassembly the yoke.
3. 3. Refer to the tightening torque chart for tighten
parts.

4-17_Charging System_Component Location Index
4-17
Charging System
1. CHARGING SYSTEM INDICATOR

(In the gauge assembly)
2. UNDER-HOOD FUSE/RELAY BOX
(Has built-in ELECTRICAL LOAD
DETECTOR (ELD) UNIT)
3. BATTERY
Test, page 22-79 in the '01 Civic
Shop Manual on this CD
4. ALTERNATOR
Troubleshooting, page 4-19
Overhaul, page 4-23
5. DRIVE BELT
Inspection, page 4-20
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4-18_Charging System_Circuit Diagram
4-18
Charging System
Circuit Diagram
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4-19_Charging System_Charging Circuit Troubleshooting
4-19
Charging System
Charging Circuit Troubleshooting
1. 1. Turn the ignition switch ON. 1. 6. Check the fan belt and tension.
Does the charge lamp come ON? Is a problem found?
YES – Go to step 5. YES – Repair as necessary.
NO – Go to step 2. NO – Check for poor connections or loose wires at
2. 2. Disconnect the alternator connector. the L terminal and battery terminal.
3. 3. Connect the alternator connector (Chassis 2. 7. Stabilise the engine speed at 1500 rpm.
harness side) terminal L and body ground with 3. 8. Measure the battery voltage.
a jumper wire. Is the battery voltage more than 15.5 V?
4. 4. Check the charge lamp circuit for an open. YES – Replace the rear cover.
Does the charge lamp come ON?
YES – Replace the rear cover.
4. 9. Measure the battery voltage.
NO – Repair as necessary. (Replace the charge lamp Is the battery voltage within 12.5 to 15.0 V?
bulb or repair the wire for an open.)
5. 5. Start the engine at idle speed.
Does the charge lamp go OFF?
5. 10. Turn the head lamp switch ON at the engine
idling.
NO – Go to step 6. Does the charge lamp come ON?
NO – Intermittent failure, system is OK at this time.
Check for poor connections or loose wires at the
alternator connector.
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4-20_Charging System_Drive Belt Inspection
Drive4-20
Belt Replacement
Charging System
Drive Belt Inspection
1. 1. Inspect the belt for cracks and damage. If the 1. 1. Remove the splash shield (see step 19 on page
belt is cracked or damaged, replace it. 5-5).
2. 2. Check the pointer (A) on the automatic belt 2. 2. Move the automatic belt tensioner to relieve
tensioner is not beyond the edge of the tension from the drive belt and install the lock
indicator (B) on the tensioner bracket. If pointer pin (A) through the automatic belt tensioner
is beyond the indicator, replace the drive belt. arm and tensioner bracket then remove the
drive belt.
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4-21_Charging System_Alternator Replacement
4-21
Charging System
Alternator Replacement
1. 1. Disconnect the negative cable from the battery 1. 5. Remove the two bolts and loosen the two bolts
first, then the positive cable. securing the condenser fan shroud, then
2. 2. Remove the drive belt (see page 4-20). remove the condenser fan shroud.
3. 3. Disconnect the fan motor connectors (A), hood
switch connector (B) and compressor clutch
connector (C), then remove the harness clamps
(D).
4. 4. Remove the condenser brackets (A) and the 2. 6. Remove the turbocharger cover.
upper bracket and cushions (B), then remove
the bulkhead (C).
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4-22_Charging system_Alternator Replacement (cont'd)
4-22
Charging system
Alternator Replacement (cont'd)
1. 7. Disconnect the alternator connector (A) and aaa

WHT wire (B) from the alternator.
2. 8. Remove the oil feed hose (C), vacuum pump

return hose (D) and vacuum hose (E).
3. 9. Remove the two bolts securing the alternator.
4. 10. Remove the alternator.

5. 11. Install the alternator and drive belt in the
reverse order of removal.
6. 12. Install the bulkhead in the reverse order of
removal. Apply body paint to the bulkhead
mounting bolts.

4-23_Charging System_Alternator and Vacuum Pump Overhaul
4-23
Charging System
Alternator and Vacuum Pump Overhaul
Exploded View
1. PULLEY
2. ROTOR ASSEMBLY
3. FRONT COVER ASSEMBLY
4. REAR COVER ASSEMBLY
5. VACUUM PUMP ASSEMBLY
6. THROUGH BOLT
7. PULLEY NUT
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4-24_Charging System_Alternator and Vacuum Pump Overhaul (cont'd)
4-24
Charging System
Alternator and Vacuum Pump Overhaul (cont'd)
Alternator and Vacuum Pump Overhaul 1. 6. Remove the pulley nut.

1. 1. Drain the engine oil from vacuum pump
assembly.
2. 7. Remove the pulley.

3. 8. Remove the front cover assembly.
4. 9. Remove the rotor assembly.
2. 2. Remove the vacuum pump fixing screws (M6). aaa
3. 3. Remove the vacuum pump assembly.
4. 4. Remove the through bolts (M5).

5. 5. Use screw driver to insert clearance between
front cover and stator core to divide front side
and rear side.
NOTE: Do not make damage stator coil by
screw driver. If do not drive them, catch the
rear cover then hit the rotor shaft by plastic
hammer.

4-25
Charging System
Alternator and Vacuum pump Inspection Rotor Coil Insulation Test

Rotor Assembly 1. 3. Use a circuit tester to measure continuity
1. 1. Measure the slip ring outside diameter. between the rotor coil and the rotor shaft. If
If measuring value is without limit, replace the there is continuity, replace the rotor assembly.
rotor assembly.
Inspection Slip Ring Surface Condition
If there is rough surface on the slip ring, use sand
paper of #500 to #600 to polish the slip ring surface.
Wipe away dirt on the slip ring surface by a cloth
dampened with alcohol.
Slip ring outside diameter:
Standard:
31.7 mm (1.2480 in.)
Limit: Inspection Ball Bearing
30.7 mm (1.2087 in.) 2. 4. Inspect rear ball bearing for rotation condition.
If it find not smooth rotation and/or abnormal
noise on the rear ball bearing, replace the rotor
assembly.
Rotor Coil Continuity Test

2. 2. Use a circuit tester to measure continuity
between both slip rings for the rotor coil
continuity. If there is not continuity, replace the
rotor assembly. aaa

4-26
Charging System
1. 5. Inspect the front cover bearing rotation aaa

condition with rotor assembly. If it find not
smooth rotation and/or abnormal noise on the
front cover bearing, replace the front cover
assembly.
2. 6. Measure the brush length. If measuring value is

without limit, replace the rear cover assembly.
Bush length:
Standard:
25 mm (0.9743 in.)
Limit:
6.5 mm (0.02559 in.)

4-27
Charging System
Tighten torque
Part name
(1) Screw (M6) (5) Pulley Nut
(2) Vacuum Pump Assembly (6) Pulley
(3) Through Bolt (7) Front Cover Assembly
(4) Rear Cover (8) Rotor Assembly
aaa

4-28
Charging System
Alternator and Vacuum Pump Reassembly 1. 4. The rear side of ball bearing has a ring inserted
Alternator in the eccentric groove of outer race and so the
protruding part of the ring sticks out of the outer
For reassembly, follow the disassembly procedures in
race. Start assembly after turning the ring to a
reverse order, paying attention to the following points.
position where protrusion is minimised. Further,
Spline cap check the bearing case of rear cover assembly
and if there is a abnormality, replace with a
new rear cover assembly.
1. 1. Tightening torque for each threaded part.

2. 2. Front and rear sides of assembly.
2. 5. Insert a pin into the rear cover assembly from

its outside to push brush into brush holder.
Then assemble the rear cover.
(Pin diameter: 2 mm)
3. 1. Spline cap
4. 3. Be sure to start assembly after spline cap (see

above drawing) into the spline of rotor shaft. If
no spline cap is provided, conduct the work with
plastic tape wound around the spline.
If the work is conducted without protecting the
spline, oil seal maybe damaged. Therefore, 3. 1. Pin
never fail to observe the workshop standard.
aaa

4-29
Charging System
1. 6. Remove the pin after assembling the rear 1. 2. Set O-ring correctly in the O-ring groove of the
cover. rear cover assembly, install the aligned vacuum
pump assembly to generator and tighten firmly
with M6 screws.
2. 1. Pin
Vacuum pump
2. 3. On completion of assembly, pour 5 cc of engine
3. 1. When installing the vacuum pump assembly to oil #30 from the oiling port. Then turn generator
the generator, turn the lower left side of the pulley by hand and make sure of its smooth
three point installing section of the vacuum turn.
pump assembly (as viewed from the direction
indicated by the arrow) downward for centre
plate rotor alignment.
aaa

4-30_Charging System_Alternator and Vacuum Pump Performance Test
4-30
Charging System
Alternator and Vacuum Pump Performance Test
Alternator
1. 1. Precaution for performance test.
1. The lead wires for use between the alternator terminal B and the battery positive terminal and between the terminal E
and the battery negative terminal should be used 8 mm2 or more in cross section and 2.5 meter or less in length,
(Use thick wire).
2. Use the small contact resistance switches in the circuit.
3. Do not mistake connection the terminal polarity in battery.
2. 2. Alternator speed at 13.5 V.
In the test circuit illustration above, gradually increase the generator speed with SW1 closed and SW2 open until the lamp off
and measure the generator speed.
The standard working generator speed is 900 – 1,200 rpm.
3. 3. Measurement of adjustable voltage.
In the test circuit illustration above, increase the rated speed of the generator to 5,000 rpm and measure the voltage.
Adjustable voltage: 14.1 V – 14.7 V.
4. 4. Measurement of output current.
In the test circuit illustration above, set the variable resistance at maximum and increase the generator speed with SW2 close to
each output speed. Adjust the variable resistance so that the voltmeter shows 13.5 V.
The current obtained current is output current value.
Measuring Device Specification Quantity
DC Volt meter 0 V – 30 V 1
DC Ampere meter 0 A – 150 A for 100 A specification meter 1
Variable Resistance 0 ohm – 0.25 ohm for 1 kW 1
Switch 1 & Switch 2 80 A – 100 A Each 1
Resister 0.25 ohm 25 W (use for discharged battery) 1
Lamp 12 V 3 W 1
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4-31
Charging System
Vacuum pump
The vacuum pump performance test should be conducted by means of a vacuum pump oil tester as follows.
1. 1. Open the oil supply valve and make sure that oil flows out. Fill the vacuum pump tester with a suitable amount of engine
oil (SAE #10 to #30). Then set the vacuum pump tester at a place a little higher than the alternator so as to facilitate
oiling.
2. 2. Increase the alternator speed gradually and make sure that oil flows through oiling hose and the vacuum pump to the
exhaust hose.
3. 3. After making sure of full circulation of oil, close the release valve and measure the vacuum characteristic by a vacuum
gauge and a clock.
4. 4. Measure the vacuum drop (air-tightness) characteristic. To be more specific, stop the alternator at the vacuum of -53.3
kPa (-400 mmHg) and make sure the vacuum drop after 15 sec. is -2.67 kPa (-20 mmHg) or less.
aaa

5-1_Engine Mechanical
Engine Mechanical
Engine Assembly
Engine Removal 5-2
Engine Installation 5-9
Cylinder Head 6-1
Engine Block 7-1
Engine Lubrication 8-1
Intake Manifold/Exhaust System 9-1
Engine Cooling 10-1

aaa

5-2_Engine Assembly_Engine Removal
5-2
Engine Assembly
Engine Removal
NOTE: 1. 6. Disconnect the mass air flow (MAF) sensor

Use fender covers to avoid damaging painted connector (A) and remove the vacuum hose
surfaces. (B), then remove the intake air duct (C) and air
To avoid damage, unplug the wiring connectors cleaner housing (D).
carefully while holding the connector portion.
Mark all wiring and hoses to avoid
misconnection. Also, be sure that they do not
contact other wiring or hoses, or interfere with
other parts.
1. 1. Secure the hood in the wide open position
(support rod in the lower hole).
2. 2. Disconnect the negative cable from the battery
first, then the positive cable.
3. 3. Remove the battery.
4. 4. Remove the battery cables (A) from the under-
hood fuse/relay box, then remove the battery
cable (B) from the battery negative cable
clamp.
2. 7. Remove the harness clamps (A) and ground

cable (B), then remove the battery base (C).
5. 5. Remove the sub-fuse box from the bracket.
aaa

5-3_Engine Assembly_Engine Removal (cont'd)
5-3
Engine Assembly
Engine Removal (cont'd)
1. 8. Remove the shift cables. 1. 10. Remove the expansion tank hoses (A) and
brake booster vacuum hose (B).
2. 9. Remove the clutch slave cylinder (A) and clutch

line bracket mounting bolt (B).
2. 11. Remove the intercooler inlet hose (A) and

intercooler outlet hose (B).
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5-4
Engine Assembly
1. 12. Disconnect the harness connectors (A) and 1. 14. Remove the lower panel, then disconnect the
remove the harness clamp (B). main wire harness connectors (A).
2. 13. Remove the fuel feed hose (A) and fuel return
hose (B).
2. 15. Remove the glove box stops and open the

glove box.Disconnect the engine control
module (ECM) connectors (B) and ground cable
(C).
3. 16. Remove the harness clamp (A) and disconnect
the accelerator panel sensor connector (B).
aaa

5-5
Engine Assembly
1. 17. Remove the expansion tank cap. 1. 22. Loosen the drain plug in the radiator to drain
2. 18. Raise the hoist to full height. the engine coolant (see page 10-6).
3. 19. Remove the front tyres/wheels. 2. 23. Drain the transmission fluid (see page 13-4).
4. 20. Remove the splash shields. 3. 24. Drain the engine oil (see page 8-5).
4. 25. Remove the drive belt (see page 4-20).
5. 26. Remove the exhaust pipe A/three way catalytic
converter (TWC) assembly.
5. 21. Remove the harness clamp (A) and grommet

(B), then pull the engine wire harness through
the bulkhead.
6. 27. Disconnect the stabiliser links, refer to the '01
Civic Shop Manual on this CD (see page 18-
18).
7. 28. Disconnect the suspension lower arm ball
joints, refer to the '01 Civic Shop Manual on
this CD (see step 3 on page 18-19).
8. 29. Remove the driveshafts (see page 16-3). Coat
all precision finished surfaces with clean engine
oil. Tie plastic bags over the driveshaft ends.
9. 30. Lower the hoist.
aaa

5-6
Engine Assembly
1. 31. Disconnect the compressor clutch connector 1. 33. Remove the water inlet hose (A), water outlet
(A), then remove the harness clamp (B) and hose (B), expansion tank hose (C) and water
A/C compressor mounting bolts (C). hose (D).
2. 34. Remove the upper radiator hose (A) and lower

2. 32. Remove the A/C compressor bracket, then radiator hose (B).
remove the A/C compressor without
disconnecting the A/C hoses.
aaa

5-7
Engine Assembly
1. 35. Attach the chain to the engine as shown. 1. 37. Remove the transmission mount bracket
support bolt and nuts.
2. 38. Make sure the hoist brackets are positioned

properly. Raise the hoist to full height.
2. 36. Remove the ground cable (A), then remove the
3. 39. Remove the rear mount mounting bolts.
upper bracket (B).
aaa

5-8
Engine Assembly
1. 40. Remove the front mount mounting bolt. 1. 43. Check that the engine/transmission is
completely free of vacuum hoses, fuel and
coolant hoses and electrical wiring.
2. 44. Slowly lower the engine about 150 mm (6 in.).
Check once again that all hoses and wires are
disconnected from the engine/transmission.
3. 45. Lower the engine all the way. Remove the
chain hoist from the engine.
4. 46. Remove the engine from under the vehicle.
aaa
2. 41. Use a marker to make alignment marks on the

reference lines (A) that align with the centres of
the rear sub-frame mounting bolts (B).
3. 42. Remove the front sub-frame (C).

5-9_Engine Assembly_Engine Installation
5-9
Engine Assembly
Engine Installation
1. 1. Install the accessory brackets and tighten their bolts and nuts to the specified torques.
1. ENGINE MOUNT BRACKET

2. ALTERNATOR BRACKET
aaa

5-10_Engine Assembly_Engine Installation (cont'd)
5-10
Engine Assembly
Engine Installation (cont'd)
1. 2. Position the engine under the vehicle. Attach 1. 4. Tighten the front mount mounting bolt.
the chain hoist to the engine, then lift the
engine into position in the vehicle.
Reinstall the mounting bolts/support nuts in the

sequence given. Failure to follow this sequence may
cause excessive noise and vibration and reduce
bushing life.
2. 3. Install the sub-frame (A). Align the reference
lines (B) on the sub-frame with the bolt head
centre, then tighten the bolts.
2. 1. 12 x 1.25 mm
64 Nm (6.5 kgf/m, 47 lbf/ft)
Replace.
3. 5. Tighten the rear mount mounting bolts.
3. 1. 10 x 1.25 mm
59 Nm (6.0 kgf/m, 43 lbf/ft)
2. 14 x 1.5 mm
103 Nm (10.5 kgf/m, 76 lbf/ft)
Replace. 4. 1. 10 x 1.25 mm
59 Nm (6.0 kgf/m, 43 lbf/ft)
aaa

5-11
Engine Assembly
1. 6. Lower the hoist. 1. 10. Remove the chain hoist from the engine.
2. 7. Install the upper bracket (A), then tighten the 2. 11. Raise the hoist to full height.
bolt/nut in the numbered sequence shown. 3. 12. Install a new spring clip on the end of each
driveshaft, then install the driveshafts. Make
sure each clip ''clicks'' into place in the
differential and intermediate shaft.
4. 13. Connect the suspension lower arm ball joints,
refer to the '01 Civic Shop Manual on this CD
(see step 3 on page 18-19).
5. 14. Connect the stabiliser links, refer to the '01
18).
6. 15. Install the exhaust pipe A/three way catalytic
converter (TWC) assembly (A); use new
gaskets (B) and new self locking nuts (C).
3. 8. Install the ground cable (B).

4. 9. Tighten the support bolt and nuts.
aaa

5-12
Engine Assembly
1. 16. Push the ECM connectors through the 1. 20. Connect the engine control module (ECM)
bulkhead, then install the grommet (A). connectors (A) and main wire harness
connector (B), then install the ground cable (C).
2. 17. Install the harness clamps (B).

3. 18. Install the splash shield.
2. 21. Connect the accelerator pedal sensor

connector (A), then install the harness clamp
(B).
4. 19. Lower the hoist.
aaa

5-13
Engine Assembly
1. 22. Install the fuel feed hose (A) and fuel return 1. 24. Install the upper radiator hose (A) and lower
hose (B). radiator hose (B)
2. 25. Install the water inlet hose (A), water outlet

hose (B), expansion tank hose (C) and water
hose (D).
2. 23. Connect the harness connectors (A) and install

the harness clamp (B).
aaa

5-14
Engine Assembly
1. 26. Install the A/C compressor bracket. 1. 28. Install the intercooler inlet hose (A) and
intercooler outlet hose (B)
2. 29. Install the expansion tank hoses (A) and brake

2. 27. Install the A/C compressor and harness clamp booster vacuum hose (B).
(A), then connect the compressor clutch
connector (B).
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5-15
Engine Assembly
1. 30. Install the shift cables using the plastic washers 1. 32. Install the battery base (A), then install the
(A), washers (B), new cotter pins (C) and harness clamps (B) and ground cable (C).
change wire plate (D).
2. 31. Install the clutch slave cylinder (A) and clutch

line bracket mounting bolt (B).
2. 33. Install the air cleaner housing (A) and intake air
duct (B), then connect the mass air flow (MAF)
sensor connector (C) and install the vacuum
hose (D).
aaa

5-16
Engine Assembly
1. 34. Install the battery cables (A) to the under-hood aaa

fuse/relay box, then install the battery cable (B)
to the battery positive cable clamp.
2. 35. Clean the battery posts and cable terminals

with sandpaper, then assemble them and apply
grease to prevent corrosion.
3. 36. Check that the transmission shifts into gear
smoothly.
4. 37. Refill the engine with engine oil (see page 8-5).
5. 38. Refill the transmission with fluid (see page 13-
4).
6. 39. Refill the radiator with engine coolant and bleed
air from the cooling system with the heater
valve open (see page 10-6).
7. 40. Inspect the idle speed (see page 11-154).
8. 41. Check the wheel alignment, refer to the '01
Civic Shop Manual on this CD (see page 18-4).

Engine Mechanical
Cylinder Head
Special Tools 6-2
Engine Compression Inspection 6-4
Valve Clearance Adjustment 6-4
Timing Belt Inspection 6-6
Timing Belt Removal 6-7
Timing Belt Installation 6-9
Timing Pulleys Removal 6-12
Timing Pulleys Installation 6-13
Cylinder Head Removal 6-15
Cylinder Head Inspection 6-18
Camshaft Carrier Inspection 6-19
Camshaft Inspection 6-19
Valves, Springs and Valve Stem Seals Removal 6-21
Valve, Spring, Guide, Tappet and Adjust Shim Inspection 6-22
Valve Guide Replacement 6-24
Valve Seat Insert Reconditioning 6-25
Valves, Springs, Split Collars, Tappets and Adjust Shims Installation 6-26
Cylinder Head Installation 6-27
Camshaft and Camshaft Carrier Installation 6-28
Cylinder Head Cover Installation 6-31

aaa

6-2_Cylinder Head_Special Tools
6-2
Cylinder Head
Special Tools
Ref. No. Tool Number Description Qty

1 5-8840-7002-0 Remover Fuel Supply Pump Pulley 1
2 5-8840-7003-0 Adapter Valve Spring 1
3 5-8840-7008-0 Crankshaft Pulley Fixing Wrench 1
4 5-8840-9041-0 Remover/Installer Valve Guide 1
5 5-8840-9046-0 Valve Compressor (Intake) 1
6 5-8840-9047-0 Valve Compressor (Exhaust) 1
7 5-8840-9048-0 Adapter Compression Pressure 1
8 5-8840-9049-0 Lever Camshaft Sub Gear 1
9 5-8840-9050-0 Installer Valve Stem Seal 1
10 5-8840-9051-0 Installer Camshaft Oil Seal 1
aaa

6-3_Cylinder Head_Component Location Index
6-3
Cylinder Head
1. RETAINER
2. CAMSHAFT PULLEY
Removal, Page 6-12
Installation, Page 6-13
3. CAMSHAFT OIL SEAL
4. CAMSHAFT (IN)
Removal, Page 6-15
Inspection, Page 6-19
5. RETAINER CAMSHAFT OIL SEAL
6. BRACKET: CAMSHAFT
7. CAMSHAFT (EX)
8. INJECTOR
9. BRACKET
10. INJECTOR RETAINER
11. BRACKET
12. CAMSHAFT CARRIER
Removal, Page 6-15
13. GASKET
14. SHIM
15. TAPPET
16. SPLIT COLLAR
17. VALVE SPRING SEAT UPPER
18. VALVE SPRING
19. VALVE SPRING SEAT LOWER
20. VALVE STEM SEAL
21. VALVE GUIDE
22. O-RING
23. INJECTOR SLEEVE
24. CYLINDER HEAD
Removal, Page 6-15
25. VALVE EXHAUST
Removal, Page 6-21
26. GASKET; CYLINDER HEAD
27. VALVE INTAKE
28. CYLINDER HEAD BOLT
29. GLOW PLUG
30. BELT TENSIONER
31. TIMING BELT
Removal, Page 6-7
32. CRANKSHAFT PULLEY
Removal, page 6-12
33. IDLE PULLEY
34. OIL PUMP PULLEY
Removal, Page 6-12
Installation, page 6-13
35. FUEL SUPPLY PUMP PULLEY
Removal, Page 6-12
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6-4_Cylinder Head_Engine Compression Inspection
Valve 6-4
Clearance Adjustment
Cylinder Head
Engine Compression Inspection
Special Tool Required Special Tool Required

Adapter compression pressure 5-8840-9048-0 Valve compressor for intake 5-8840-9046-0, for exhaust
1. 1. Start the engine and allow it to run for several 5-8840-9047-0
minutes to warm it up. NOTE: The valve clearances are checked on a cold
2. 2. Stop the engine and remove the connector on engine condition.
the injectors. Inspection
3. 3. Remove all of the glow plugs from the engine.
4. 4. Set a compression gauge to the No. 1 cylinder
2. 2. Disconnect the connectors (A), (B) from top of
glow plug hole (5-8840-9048-0 Adapter for
the injector.
compression gauge).
3. 3. Remove the leak off hose (C) from the

5. 5. Turn the engine over with the starter motor and injectors.
take the compression gauge reading. 4. 4. Remove the injection pipes (A).
Measure the compression pressure of all Use the vinyl tape (or something similar) to
cylinders. seal the fuel delivery ports to prevent entry
of foreign materials.
Compression pressure MPa at 200 min-1
Standard:
2.8 MPa (28.6 kg/cm2 , 406 psi)
Limit:
2.5 MPa (25.5 kg/cm2 , 363 psi)
aaa

6-5_Cylinder Head_Valve Clearance Adjustment (cont'd)
6-5
Cylinder Head
Valve Clearance Adjustment (cont'd)
1. 5. Remove the injector seals from top of the Adjustment

cylinder head cover (A) and side of the cylinder 1. 1. Press down tappet using special tool (5-8840-
head cover (B). 9046-0 for intake) (5-8840-9047-0 for exhaust).
Use different tool versions for exhaust and
intake sides.
It must be ensured that the valves are not
adjusted when the pistons are at ''TDC''.
The valves can strike the pistons.
2. 6. Remove the cylinder head cover.

3. 7. Turn engine in direction of engine rotation to
''1st Cylinder TDC''.
4. 8. Turn crankshaft in direction of engine rotation
until cam pairs (A) and (B) point upwards.
These valves are thus closed and can be 2. 2. Lever out shim using a small screwdriver and
checked. remove.
3. 3. Example for determination of shim thickness:

1. Measurement between cam and tappets
0.45 mm
5. 9. The valve clearance is checked using a feeler 2. Thickness of installed shim +
gauge. 3.15 mm
Valve clearance: =3.6 mm
Intake valves:
3. Nominal valve clearance (in) -
0.40 + 0.05 mm 0.40 mm
Exhaust valves: 4. Thickness of new shim =
0.40 + 0.05 mm 3.20 mm
6. 10. If you feel too much or too little drag, turn aaa
tappet until tappet groove points outwards.

6-6_Cylinder Head_Valve Clearance Adjustment (cont'd)
Timing Belt Inspection

6-6
Cylinder Head
Valve Clearance Adjustment (cont'd)
1. 4. Coat new shim with engine oil and insert tappet 1. 1. Remove the drive belt (see page 4-20).
with identification mark facing downwards. 2. 2. Remove the earth cable bolt and upper bracket
2. 5. Remove the special tool. (see step 2 on page 6-7).
3. 6. Turn the crankshaft 180° in direction of engine 3. 3. Remove the side engine mount bracket (see
rotation-check and adjust valve pair (A) and (B). step 3 on page 6-7).
4. 4. Remove the harness clamp and upper cover
(see step 4 on page 6-7).
5. 5. Inspect the timing belt for cracks and oil or
coolant soaking. Replace the belt if it is oil or
coolant soaked. Remove any oil or solvent that
gets on the belt.
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4. 7. Turn the crankshaft 180° in direction of engine

rotation-check and adjust valve pair (C) and
(D).
5. 8. Turn the crankshaft 180° in direction of engine
rotation-check and adjust valve pair (E) and (F).
6. 9. Valve clearance must be checked again for all
adjusted valves.

6-7_Cylinder Head_Timing Belt Removal
6-7
Cylinder Head
Timing Belt Removal
1. 1. Remove the drive belt (see page 4-20). 1. 4. Disconnect the cam position (CMP) sensor
2. 2. Remove the ground cable (A), then remove the connector (A) and remove the harness clamps
upper bracket (B). (B).
3. 3. Remove the side engine mount bracket.
2. 5. Remove the upper cover (A) and engine foot

(B).
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6-8_Cylinder Head_Timing Belt Removal (cont'd)
6-8
Cylinder Head
Timing Belt Removal (cont'd)
1. 6. Remove the water pump pulley. 1. 8. Remove the crankshaft position (CKP) sensor.
2. 9. Before removing the timing belt to inspect
timing belt for cracks, worn out timing belt
teeth, engine oil or coolant stuck on the timing
belt.
3. 10. Loosen the fixing bolt of timing belt tensioner
(A) and turn belt tension counter clockwise,
then retighten the fixing bolt.
2. 7. Remove the crankshaft damper pulley (A) and

lower cover (B).
4. 11. Remove the timing belt (B).

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6-9_Cylinder Head_Timing Belt Installation
6-9
Cylinder Head
Timing Belt Installation
1. 1. Align the pin on the crankshaft pulley upward of 1. 5. Install the timing belt with correct routing.
the cylinder block.
2. 2. Use M8 bolt to lock the fuel supply pump pulley
to cylinder block to align the pump phase.
3. 3. Use M6 bolt to lock the camshaft pulley on the
camshaft carrier through the camshaft lock hole
(A).
2. 6. Loose the bolt: tension pulley slowly and touch

it to timing belt gently.
3. 7. After making balance between the timing belt
and belt tensioner bolt: tension pulley with
specified torque.
(use suitable tool to prevent movement of the
tension pulley).
Specified torque: 49 Nm (5.0 kgf/m, 36.2
lbf/ft)
4. 8. Turn the crankshaft pulley two turns clockwise
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4. 4. Move the belt tensioner counterclockwise and

tighten to 4.9 Nm temporally.

6-10_Cylinder Head_Timing Belt Installation (cont'd)
6-10
Cylinder Head
Timing Belt Installation (cont'd)
1. 9. Install the lower cover (A), then install the 1. 11. Install the engine foot (A) and upper cover (B).
crankshaft damper pulley (B).
2. 10. Install the water pump pulley. 2. 12. Install the harness clamps (A) and connect the
cam position (CMP) sensor connector (B).
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6-11_Cylinder Head_Timing Belt Installation (cont'd)
6-11
Cylinder Head
Timing Belt Installation (cont'd)
1. 13. Install the side engine mount bracket. aaa
2. 14. Install the upper bracket (A), then tighten the

bolt/nuts in the numbered sequence shown.
3. 15. Install the drive belt (see page 4-20).

6-12_Cylinder Head_Timing Pulleys Removal
6-12
Cylinder Head
Timing Pulleys Removal
Special Tools Required Oil Pump Pulley Removal

Crankshaft pulley fixing wrench 5-8840-7008-0 1. 3. Remove the fixing nut.
Remover fuel supply pump pulley 5-8840-7002- 2. 4. Remove the oil pump pulley (A).
0
Crankshaft Pulley Removal
1. 1. Remove fastening bolt for the timing belt drive
pulley-counter hold using the special tool (A)
(5-8840-7008-0).
Idle Pulley Removal

3. 5. Remove the fixing bolt.
2. 2. Remove the crankshaft pulley (A) from the

crankshaft using puller (B).
4. 6. Remove the idle pulley.

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6-13_Cylinder Head_Timing Pulleys Removal (cont'd)
Timing Pulleys Installation

6-13
Cylinder Head
Timing Pulleys Removal (cont'd)
Fuel Supply Pump Pulley Removal Special Tool Required

1. 7. Lock fuel supply pump pulley using TDC fixing Crankshaft pulley fixing wrench 5-8840-7008-0
bolt (A), then remove the fuel supply pump Front Dust Cover Installation
pulley fixing nut.
1. 1. Install the front dust cover (A) and tighten the
bolts (B), (C).
Tightening torque: 9.8 Nm (1.0 kgf/m,
7.2 lbf/ft)
2. 8. Use special tool 5-8840-7002-0 to remove the

fuel supply pump pulley (B).
Camshaft Pulley Removal
3. 9. Lock the camshaft pulley with TDC fixing bolt
(A).
Crankshaft Pulley Installation

2. 2. Insert the flange (A) to face the flange limb
towards pulley side, then install the crankshaft
pulley (B).
4. 10. Remove the camshaft pulley fixing bolt (B).

5. 11. Remove the camshaft pulley (C).
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6-14_Cylinder Head_Timing Pulleys Installation (cont'd)
6-14
Cylinder Head
Timing Pulleys Installation (cont'd)
1. 3. Tighten bolt to the specified torque using the Idle Pulley Installation
special tool (A) (5-8840-7008-0). 1. 5. Install the idle pulley.
Tightening torque: 196 Nm (20.0 kgf/m, 145 Tightening torque: 80 Nm (8.2 kgf/m, 59
lbf/ft) lbf/ft)
Oil Pump Pulley Installation Fuel Supply Pump Pulley Installation

2. 4. Install oil pump pulley (A) to oil pump shaft 2. 6. Install the fuel supply pump pulley (A).
correctly. Tighten fastening nut to the specified Lock fuel supply pump pulley using TDC fixing bolt (B).
torque. Tighten fastening nut to the specified torque.
Tightening torque: 44 Nm (4.5 kgf/m, 32.5 Tightening torque: 69 Nm (7.0 kgf/m, 50.6
lbf/ft) lbf/ft)
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6-15_Cylinder Head_Timing Pulleys Installation (cont'd)
Cylinder
6-15Head Removal
Cylinder Head
Timing Pulleys Installation (cont'd)
Camshaft Pulley Installation NOTE: Lay cylinder head assembly on the wooden block
1. 7. Install the camshaft pulley (A). as otherwise glow plugs or valves may be damaged.
2. 2. Remove the timing belt (see page 6-7).
3. 3. Remove the exhaust manifold (see page 9-4).
4. 4. Remove the intake manifold (see page 9-2).
5. 5. Remove the upper radiator hose (A), water
hose (B), water pipe mounting bolt (C), vacuum
pipe mounting bolt (D) and disconnect the glow
plug thermo sensor connector (E).
2. 8. Lock the camshaft pulley with TDC fixing bolt

(B).
3. 9. Tighten the fastening bolt (C) to the specified
torque, then remove TDC fixing bolt.
Tightening torque: 64 Nm (6.5 kgf/m, 47
lbf/ft)
6. 6. Remove the water inlet hose and water outlet

hose from the thermostat housing (A) and water
grow plug harness (B).
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6-16_Cylinder Head_Cylinder Head Removal (cont'd)
6-16
Cylinder Head
Cylinder Head Removal (cont'd)
1. 7. Remove the injector seals from top of the 1. 10. Loosen bolts (A).
cylinder head cover (A) and side of the cylinder
head cover (B).
2. 8. Remove the cylinder head cover.

3. 9. Remove the bolts (A) from the dust cover.
2. 11. Loosen bolts; bracket fixing (B).

3. 12. Loosen bolt; bracket fixing (C).
4. 13. Remove bracket (D).
5. 14. Remove retainer; injector (E).
6. 15. Remove injector assembly (F).
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6-17_Cylinder Head_Cylinder Head Removal (cont'd)
6-17
Cylinder Head
Cylinder Head Removal (cont'd)
1. 16. Remove the Following Parts for Removal of the Cylinder Head:
Remove brackets (A)
Remove retainer; injector (B)
Remove injectors (C)
Remove bracket (D)
Remove retainer camshaft oil seal (E)
Remove brackets; camshaft (F)
Remove camshaft assembly: intake (G)
Remove camshaft assembly: exhaust (H)
Remove bolts camshaft carrier fixing (I)
Remove camshaft carrier (J)
Remove gasket: camshaft carrier (K)
Remove bolts: cylinder head fixing (L)
Remove cylinder head assembly (M)
Remove gasket: cylinder head (N)
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6-18_Cylinder Head_Cylinder Head Inspection
6-18
Cylinder Head
Cylinder Head Inspection
Cylinder Head Lower Face Distortion Exhaust & Intake Manifold Fitting Face
1. 1. Use a straight edge and a feeler gauge to Distortion
measure the four sides and the two diagonals 1. 1. Use a straight edge and a feeler gauge to
of the cylinder head lower face. measure the manifold cylinder head fitting face
warpage.
2. 2. Regrind the manifold cylinder head fitting faces

if the measured values are greater than the
specified limit but less than the maximum
2. 2. Regrind the cylinder head lower face if the grinding allowance. If the measured values
measured values are greater than the specified exceed the maximum grinding allowance, the
limit but less than the maximum grinding cylinder head must be replaced.
allowance. If the measured values exceed the Manifold fitting face distortion:
maximum grinding allowance, the cylinder head Standard:
must be replaced. 0.05 mm (0.001 in.) or less
NOTE: If the cylinder head lower face is
Limit:
reground, valve depression must be checked.
0.15 mm (0.005 in.)
Cylinder head lower face distortion:
Maximum grinding allowance:
Standard:
0.4 mm (0.01 in.)
0.075 mm (0.003 in.) or less
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Limit:
0.1 mm (0.004 in.)
Cylinder head height (Reference):
Standard:
95 mm (3.7 in.)

6-19_Cylinder Head_Camshaft Carrier Inspection
Camshaft
6-19 Inspection
Cylinder Head
Camshaft Carrier Inspection
1. 1. Make the necessary adjustments, repairs and 1. 1. Visually inspect the journals, the cams and the
parts. Replace if excessive wear or damage is camshaft bearing bracket for excessive wear
discovered during inspection. and damage. The camshaft and the camshaft
2. 2. Use a straight edge and a feeler gauge to carrier must be replaced if these conditions are
measure the four sides and the two diagonals discovered during inspection.
of the camshaft carrier lower face. 2. 2. Use a micrometer to measure each camshaft
journal diameter in two directions ((X - X) and
(Y - Y)). If the measured value is less than the
specified limit, the camshaft must be replaced.
Camshaft journal diameter:
Standard:
26.939 – 26.960 mm
(1.0606 – 1.0614 in.)
3. 3. Measure the cam height (H) with a micrometer.
If the measured value is less than the specified
limit, the camshaft must be replaced.
Cam height H:
Standard:
IN:
3. 3. Replace camshaft carrier if deformed or 7.80 mm (0.307 in.)
distorted. EX:
Camshaft carrier lower face warpage:
7.95 mm (0.312 in.)
Standard:
Limit:
0.05 mm (0.001 in.) or less
IN:
4. 4. Clean sealing surfaces and remove liquid
7.68 mm (0.302 in.)
gasket residue.
5. 5. Measure height of camshaft carrier (upper EX:
surface to lower surface). 7.77 mm (0.306 in.)
Carrier height (Reference):
Standard:
29.62 mm (1.166 in.)
4. 4. Mount the camshaft on V-blocks.

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6-20_Cylinder Head_Camshaft Inspection (cont'd)
6-20
Cylinder Head
Camshaft Inspection (cont'd)
1. 5. Measure the run-out with a dial indicator. If the 1. 8. Remove the bracket.
measured value exceeds the specified limit, the 2. 9. Compare the width of the plastigage attached
camshaft must be replaced. to either the camshaft or the bracket against
Camshaft run-out (TIR): the scale printed on the plastigage container.
Standard: If clearance between cam journal and bracket
0.03 mm (0.001 in.) exceed the limit, the camshaft and/or camshaft
carrier assembly must be replaced.
Limit:
Clearance between cam journal and
0.05 mm (0.002 in.)
bracket:
Standard:
0.04 – 0.082 mm (0.002 – 0.003 in.)
Limit:
0.11 mm (0.004 in.)
2. 6. Clean the camshaft journal and bracket.

3. 7. Place the plastigage (A) over the camshaft
journal across the full width of the bracket, then
install the bracket (B).
NOTE: Do not allow the camshaft to turn during
bracket installation and tightening.
Tightening torque:
M8 22 Nm (2.2 kgf/m, 16 lbf/ft)
M10 43 Nm (4.4 kgf/m, 32 lbf/ft) aaa

6-21_Cylinder Head_Valves, Springs and Valve Stem Seals Removal
6-21
Cylinder Head
Valves, Springs and Valve Stem Seals Removal
Special Tools Required 1. 2. Remove the split collar and valve spring using
Remover/Installer valve guide 5-8840-9041-0 special tool (5-8840-7003-0).
Adapter valve spring 5-8840-7003-0
1. 1. Remove the shim (A) and tappet (B).
Be sure to keep the tappet and shim in order to
reassemble in the original position.
2. 3. Remove valves.
3. 4. Be sure to keep the valve in order to
reassemble in the original position.
4. 5. Remove the valve stem seal.

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6-22_Cylinder Head_Valve, Spring, Guide, Tappet and Adjust Shim Inspection
6-22
Cylinder Head
Valve, Spring, Guide, Tappet and Adjust Shim
Inspection
Valve Stem Outside Diameter Measurement Valve Spring Free Height Measurement
1. 1. Measure the valve stem diameter at three 1. 3. Use a vernier caliper to measure the valve
points. If the measured value is less than the spring free height.
specified limit, the valve and the valve guide If the measured value is less than the specified
must be replaced as a set. limit, the valve spring must be replaced.
Valve stem outside diameter: Valve spring free height:
Intake valve: Standard:
Standard: 44.63 mm (1.757 in.)
5.959 – 5.977 mm (0.2346 – 0.2353 in.) Limit:
Limit: 44.13 mm (1.737 in.)
5.945 mm (0.2341 in.)
Exhaust valve:
Standard:
5.954 – 5.972 mm (0.2344 – 0.2351 in.)
Limit:
5.940 mm (0.2339 in.)
Valve Spring Inclination Measurement

2. 4. Use a surface plate and a square to measure
the valve spring inclination.
If the measured value exceeds the specified
limit, the valve spring must be replaced.
Valve spring inclination:
Standard:
1.01 mm (0.04 in.)
2. 2. Measure the valve thickness.
Limit:
If the measured value is less than the specified
limit, the valve and the valve guide must be 2.2 mm (0.09 in.)
replaced as a set.
Intake and exhaust valve thickness:
Standard:
1.2 – 1.4 mm (0.05 – 0.06 in.)
Limit:
1.0 mm (0.04 in.)
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6-23_Cylinder Head_Valve, Spring, Guide, Tappet and Adjust Shim Inspection (cont'd)
6-23
Cylinder Head
Valve, Spring, Guide, Tappet and Adjust Shim
Inspection (cont'd)
Valve Spring Tension Measurement Tappet and Adjust Shim Inspection

1. 5. Use a spring tester to measure the valve spring 1. 7. Visually inspect the shim camshaft contact
tension. If the measured value is less than the surfaces for pitting, cracking and other
specified limit, the valve spring must be abnormal conditions. The tappet must be
replaced. replaced if any of these conditions are present.
Valve spring tension:
Compressed height:
33.3 mm (1.31 in.)
Standard:
160 N (16.3 kgf, 73 lbf)
aaa
Valve Guide Measurement

2. 6. Measure the valve stem outside diameter. Refer
to the item ''Valve Stem Outside Diameter''. Use
a caliper calibrator or a telescoping gauge to
measure the valve guide inside diameter. If the
measured values exceed the specified limit, the
valve and the valve guide must be replaced as
a set.
Valve stem clearance:
Intake valve:
Standard:
0.023 – 0.056 mm (0.001 – 0.002 in.)
Limit:
0.080 mm (0.0031 in.)
Exhaust valve:
Standard:
0.028 – 0.061 mm (0.001 – 0.002 in.)
Limit:
0.095 mm (0.0037 in.)

6-23_Cylinder Head_Valve, Spring, Guide, Tappet and Adjust Shim Inspection (cont'd)

6-24_Cylinder Head_Valve Guide Replacement
6-24
Cylinder Head
Valve Guide Replacement
Special Tool Required 1. 4. Measure the height of the valve guide upper
Remover/Installer valve guide 5-8840-9041-0 end (H) from the upper face of the cylinder
head.
NOTE: If the valve guide has been removed, both the
Valve guide upper end height (Reference):
valve and the valve guide must be replaced as a set.
11.7 mm(0.46 in.)
Removal
Use a hammer and the valve guide remover (5-8840-
9041-0) to drive out the valve guide from the cylinder
head lower face.
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Valve Guide Installation

1. 1. Apply engine oil to the valve guide outer
circumference.
2. 2. Attach the valve guide installer (5-8840-9041-0)
to the valve guide.
3. 3. Use a hammer to drive the valve guide into
position from the cylinder head upper face.

6-25_Cylinder Head_Valve Seat Insert Reconditioning
6-25
Cylinder Head
Valve Seat Insert Reconditioning
Valve seat Insert Replacement 1. 8. Use a valve cutter to minimise scratches and
1. 1. Arc weld the rod at several points. Be careful other rough areas. This will bring the contact
not to damage the cylinder head. width back to the standard value. Remove only
the scratches and rough areas. Do not cut
away too much. Take care not to cut away
unblemished areas of the valve seat surface.
Valve seat angle degree:
89.5°
2. 2. Allow the rod to cool for a few minutes. This

will cause the valve seat to shrink.
3. 3. Strike the rod and pull it out.
2. 9. Apply abrasive compound to the valve seat
4. 4. Carefully clean the valve seat press-fit section
insert surface.
on the cylinder head side.
3. 10. Insert the valve into the valve guide.
5. 5. Heat the press-fit section with steam or some
4. 11. Turn the valve while lapping it to fit the valve
other means to cause expansion. Cool the
seat insert.
valve seat with dry ice or some other means.
5. 12. Check that the valve contact width is correct.
6. 6. Insert the press-fit section into the valve seat
6. 13. Check that the valve seat insert surface is in
horizontally.
contact with the entire circumference of the
Standard fitting interference:
valve.
0.06 mm – 0.08 mm (0.0024 in – 0.0031 in)
Valve Seat Insert Correction
7. 7. Remove the carbon from the valve seat insert
surface.
aaa

6-26_Cylinder Head_Valves, Springs, Split Collars, Tappets and Adjust Shims Installation
6-26
Cylinder Head
Valves, Springs, Split Collars, Tappets and
Adjust Shims Installation
Special Tools Required Split Collar Installation

Installer valve stem seal 5-8840-9050-0 1. 8. Use the spring compressor with adapter (5-
Adapter valve spring 5-8840-7003-0 8840-7003-0) to push the valve spring into
Valve Stem Oil Seal Installation position.
1. 1. Install the value spring lower seat. 2. 9. Install the split collar to the valve stem.
2. 2. Apply a coat engine oil to the oil seal inner 3. 10. Set the split collar by tapping around the bead
face. of the collar with a rubber hammer.
3. 3. Use an oil seal installer (5-8840-9050-0) to
install the oil seal to the valve guide.
Tappet and Shim Installation

4. 11. Apply engine oil to tappet (A) and shim (B),
then install tappet and shim.
Intake and Exhaust Valve Installation
4. 4. Apply a coat of engine oil to valve stem.
5. 5. Install the intake and exhaust valves.
6. 6. Turn the cylinder head up to install the valve
springs. Take care not to allow the installed
valves to fall down.
Valve Spring Installation
7. 7. Turn the cylinder head up to install the valve
springs. Take care not to allow the installed
valves to fall free.
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6-27_Cylinder Head_Cylinder Head Installation
6-27
Cylinder Head
Cylinder Head Installation
Cylinder Head Gasket Grade Selection 1. 4. Select a cylinder head gasket of the appropriate
1. 1. Carefully remove carbon deposits and gasket thickness.
residue from the piston top face and the
cylinder body upper surface.
2. 2. Use a dial indicator to measure the piston head

Cylinder Head Installation
projection at measuring points (A) and (B) on
the piston head and measuring points (C) and 2. 5. Align the cylinder body dowels and the cylinder
(D) on the cylinder body. Measure piston head dowel holes. Carefully set the cylinder
projection for each cylinder. head to the cylinder head gasket.
3. 6. Apply engine oil to the cylinder head fixing bolt
threads and setting faces.
4. 7. Tighten the cylinder head bolts to the specified
torque in three steps following the numerical
order shown in the illustration.
NOTE: Cylinder head bolt can not be reused.
Cylinder head bolt specified torque:
39 Nm (4.0 kgf/m, 29 lbf/ft) + 60° + 60°
3. 3. Note the highest measured value. This will

determine the cylinder head gasket thickness.
Piston head projection must be within the range
shown in the above table.
If the piston head projection is beyond the above
range, engine must not be reassembled.
Piston head projection:
0.58 – 0.78 mm
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6-28_Cylinder Head_Camshaft and Camshaft Carrier Installation
6-28
Cylinder Head
Camshaft and Camshaft Carrier Installation
Exploded View
1. CAMSHAFT OIL SEAL
2. CAMSHAFT (IN)
3. BRACKET ; CAMSHAFT
4. CAMSHAFT (EX)
5. CAMSHAFT CARRIER
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6-29_Cylinder Head_Camshaft and Camshaft Carrier Installation (cont'd)
6-29
Cylinder Head
(cont'd)
Special Tools Required 1. 4. Clean sealing surface and remove the residual
Lever camshaft sub gear 5-8840-9049-0 sealant.
Installer camshaft oil seal 5-8840-9051-0 2. 5. Check camshaft and bearing bracket for wear
Camshaft carrier installation and replace if necessary.
3. 6. Apply engine oil to camshaft journals.
1. 1. Install the camshaft carrier with new gasket.
4. 7. Install camshafts in camshaft carrier.
2. 2. Tighten bolts with tightening order as in
5. 8. When installing the camshafts, it must be
illustration.
ensured that the mark (A) on the exhaust
Torque:
camshaft gear align between both marks (B) on
22 Nm (2.2 kgf/m, 16 lbf/ft) the intake camshaft gear and that the marks
are about level with the upper edge of the
camshaft carrier.
Camshaft Installation 6. 9. Apply a bead of surface liquid gasket to sealing

3. 3. Before reassembling the exhaust camshaft, the surfaces (A) of 1st camshaft bearing bracket.
sub gear (A) teeth surface must be aligned to
the exhaust camshaft main gear (B) teeth
surface using special tool (C) (5-8840-9049-0)
and connected to the sub gear and main gear
with pin (D).
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6-30_Cylinder Head_Camshaft and Camshaft Carrier Installation (cont'd)
6-30
Cylinder Head
(cont'd)
Camshaft Bracket Installation aaa

1. 10. Install camshaft bearing brackets 1 - 4 on
camshaft carrier - note identification marks -
arrows on bearing brackets point towards
engine front side.
2. 11. Remove setting pin from exhaust camshaft gear
and install camshaft bearing bracket 5-
moderately tighten fastening nuts.
Tighten camshaft bearing brackets in sequence
illustrated ((1)) – ((13)) in steps of 1/2 to 1 turn.
Tightening torque:
(M8 Nut):
22 Nm (2.2 kgf/m, 16 lbf/ft)
(M10 Nut):
43 Nm (4.4 kgf/m, 32 lbf/ft)
Camshaft Oil Seal Installation

3. 12. Install camshaft oil seal using special tool (5-
8840-9051-0).

6-31_Cylinder Head_Cylinder Head Cover Installation
6-31
Cylinder Head
Cylinder Head Cover Installation
1. 1. Clean sealing surfaces and remove liquid 1. 3. Tighten cylinder head cover with tightening
gasket residue. order in the illustration.
2. 2. Apply liquid gasket (A) and (B) to sealing Tightening torque:
surfaces on the camshaft carrier. 9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
Note: Oil return bore must not be covered with
liquid gasket. Install the head cover with new
gasket to camshaft carrier and install the upper
part of timing cover.
aaa


Engine Mechanical
Engine Block
Special Tools 7-2
Flywheel Removal and Installation 7-4
Crankshaft End Play Inspection 7-4
Crankshaft Main Bearing Replacement 7-5
Crankshaft and Piston Removal 7-8
Crankshaft Inspection 7-10
Block and Piston Inspection 7-11
Piston, Pin and Connecting Rod Replacement 7-12
Piston Installation 7-17
Crankshaft Installation 7-18
Oil Pan Installation 7-20

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7-2_Engine Block_Special Tools
7-2
Engine Block
Special Tools

1 5-8840-7005-0 Installer crankshaft rear oil seal (Without crankshaft) 1
2 5-8840-7006-0 Installer crankshaft rear oil seal (With crankshaft) 1
3 5-8840-7007-0 Stopper flywheel 1
4 5-8840-9054-0 Aligner 1
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7-3_Engine Block_Component Location Index
7-3
Engine Block
2. CRANKSHAFT TIMING PULLEY
3. CRANKSHAFT MAIN BEARING
Replacement, Page 7-5
4. FLYWHEEL
Removal, Page 7-4
5. CONNECTING ROD CAP AND
LOWER BEARING
6. PISTON
Removal, Page 7-8
7. PISTON RINGS
8. PISTON PIN
9. CONNECTING ROD AND UPPER
BEARING
10. CYLINDER BLOCK
11. CRANKSHAFT ROTOR
12. CRANKSHAFT
End play, Page 7-4
Removal, Page 7-8
13. OILING JET
14. BAFFLE PLATE
15. OIL PAN UPPER AND LOWER
16. OIL STRAINER
17. CRANKSHAFT BEARING CAP
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7-4_Engine Block_Flywheel Removal and Installation
Crankshaft
7-4 End Play Inspection
Engine Block
Flywheel Removal and Installation
Special Tools Required 1. 1. Set the dial indicator as shown in the

Stopper 5-8840-7007-0 illustration and measure the crankshaft thrust
clearance.
1. 1. Lock the flywheel with the special tool and
remove the fastening bolts.
2. 2. If the thrust clearance exceeds the specified

limit, replace the thrust bearing as a set.
Crankshaft end play:
Standard (New):
2. 2. Apply Locktite to the top thread of the new
0.05 – 0.15 mm (0.002 – 0.006 in.)
fastening bolts.
Service Limit:
0.2 mm (0.008 in.)
aaa
3. 3. Install the flywheel and the fastening bolts then

lock the flywheel with the stopper.
4. 4. Tighten the fastening bolts in numerical order
as shown in the illustration.
NOTE: The installation time including the torque
check is max. 10 min.

7-5_Engine Block_Crankshaft Main Bearing Replacement
7-5
Engine Block
Crankshaft Main Bearing Replacement
Main Bearing Clearance Inspection (with 1. 7. Tighten the bearing caps to the specified
plastigage) torque.
1. 1. Clean the cylinder block, the journal bearing NOTE: Do not allow the crankshaft to turn
fitting surface, the bearing caps and the during bearing cap installation and tightening.
bearings. Tightening torque:
2. 2. Install the bearings to the cylinder block. 88 Nm (9.0 kgf/m, 65.1 lbf/ft)
3. 3. Carefully place the crankshaft on the bearings.
2. 8. Remove the bearing cap.
4. 4. Rotate the crankshaft about 30° to seat the
3. 9. Compare the width of the Plastigage attached
bearings.
to either the crankshaft or the bearing against
5. 5. Place the Plastigage (arrow) over the
the scale printed on the Plastigage container.
crankshaft journal across the full width of the
Main bearing-to-journal oil clearance:
bearing.
Standard (New):
0.030 – 0.058 mm
(0.0012 – 0.0023 in.)
Service limit:
0.08 mm (0.003 in.)
6. 6. Install the bearing caps with the bearing.
aaa

7-6_Engine Block_Crankshaft Main Bearing Replacement (cont'd)
7-6
Engine Block
Crankshaft Main Bearing Replacement (cont'd)
Crankshaft Bearing Grade Selection

1. 1. When installing the new crankshaft bearings or replacing old bearings, refer to the selection table below.
Cylinder Block Journal Crankshaft Journal Crankshaft Oil Clearance
Bearing Grade (Reference)
Grade Diameter Grade Diameter
Mark Mark Mark
1 55.992 – 56.000 mm 51.918 – 51.928 mm Blue 0.032 – 0.058 mm

51.928 – 51.938 mm Black 0.030 – 0.056 mm
2 55.984 – 55.992 mm 51.918 – 51.928 mm 0.032 – 0.058 mm
51.928 – 51.938 mm Brown 0.030 – 0.056 mm
3 55.976 – 55.984 mm 51.918 – 51.928 mm 0.032 – 0.058 mm
51.928 – 51.938 mm Green 0.030 – 0.056 mm
2. 2. Select and install the new crankshaft bearings, paying close attention to the cylinder block journal hole diameter grade
mark and the crankshaft journal diameter grade mark.
3. 3. Check to see if the bearing has enough tension, so that a good finger pressure is needed to fit the bearing into position.

aaa

7-7
Engine Block
Main Bearing Clearance Inspection (with 1. 3. If the clearance between the measured bearing
micrometer) inside diameter and the crankshaft journal
1. 1. Measure the crankshaft journal diameter. exceeds the specified limit, the bearing and/or
the crankshaft must be replaced.
1. Use a micrometer to measure the crankshaft
Crankshaft journal and bearing clearance:
journal diameter across points (''A – A'') and
(''B – B''). Standard (New):
2. Use the micrometer to measure the 0.030 – 0.058 mm
crankshaft journal diameter at the two points (0.0012 – 0.0023 in.)
(I and II). Service limit:
Crankshaft journal diameter: 0.08 mm (0.003 in.)
Standard (New): Crankpin and Bearing Clearance Inspection
Size mark (with plastigage)
51.918 – 51.928 mm 2. 1. Clean the crankshaft, the connecting rod, the
(2.0440 – 2.0444 in.) bearing cap and the bearings.
3. 2. Install the bearing to the connecting rod and the
Size mark bearing cap.
51.928 – 51.938 mm NOTE: Do not allow the crankshaft to move
(2.0444 – 2.0448 in.) when installing the bearing cap.
Service limit: 4. 3. Prevent the connecting rod from moving.
Size mark 5. 4. Attach the Plastigage to the crankpin. Apply
engine oil to the Plastigage to keep it from
51.912 mm (2.0438 in.)
falling.
Size mark 6. 5. Install the bearing cap and tighten it to the two
51.922 mm (2.0442 in.) steps specified torque.
NOTE: Do not allow the connecting rod to move
when installing and tightening the bearing cap.
1st step torque:
25 Nm (2.5 kgf/m, 18 lbf/ft)
2nd step:
100°
7. 6. Remove the bearing cap.
8. 7. Compare the width of the Plastigage attached
to either the crankshaft or the bearing against
the scale printed on the Plastigage container.
2. 2. Measure the main bearing inside diameter. Crankpin and bearing clearance:
Standard (New):
0.025 – 0.058 mm
(0.0010 – 0.0023 in.)
Service limit:
0.1 mm (0.004 in.)
aaa

Crankshaft
7-8 and Piston Removal
Engine Block
Crankpin and Bearing Clearance Inspection NOTE: Measure crankshaft thrust play, before removing
(with micrometer) crankshaft bearing cap.
1. 1. Using a micrometer, measure the crankpin 1. 1. Remove the crankshaft pulley and the
diameter. crankshaft timing pulley.
Crankpin diameter: 2. 2. Remove the oil pan upper and lower.
Standard (New): 3. 3. Remove the oil pump.
45.930 – 45.945 mm 4. 4. Remove the oil strainer and the baffle plate.
5. 5. Remove connecting rod bearing cap nut (A)
(1.8083 – 1.8089 in.)
from connecting rod.
Service limit:
45.926 mm (1.8081 in.)
2. 2. Install the bearing cap and tighten it to the two
steps specified torque.
1st step torque:
25 Nm (2.5 kgf/m, 18 lbf/ft)
2nd step:
100°
3. 3. Measure the crankpin bearing inside diameter.
aaa
4. 4. If the clearance between the measured bearing

inside diameter and the crankpin exceeds the
specified limit, the bearing and/or the crankshaft
must be replaced.
Crankpin and bearing clearance:
Standard (New):
0.025 – 0.058 mm
(0.0010 – 0.0023 in.)
Service limit:
0.1 mm (0.004 in.)

7-9_Engine Block_Crankshaft and Piston Removal (cont'd)
7-9
Engine Block
Crankshaft and Piston Removal (cont'd)
1. 6. Remove connecting rod bearing cap (A) from 1. 7. Loosen fastening bolts for crankshaft bearing
connecting rod. caps in sequence illustrated ((1) - (10)) and
NOTE: If the connecting rod lower bearings are remove bearing caps that are marked with the
to be reinstalled, mark their fitting positions by relevant bearing number.
tagging each bearing with the cylinder number
from which it was removed.
2. 8. Remove the crankshaft from the cylinder block.

3. 9. Push the connecting rod with piston and
remove the piston and the connecting rod from
cylinder block.
NOTE: Mark, sort, or organise the piston,
connecting rod and bearing for assembly to the
original location.
aaa

7-10_Engine Block_Crankshaft Inspection
7-10
Engine Block
Crankshaft Inspection
NOTE: Tufftriding Inspection

Inspect the surface of the crankshaft journals NOTE: To increase crankshaft strength, tufftriding
and crankpins for excessive wear and damage. (Nitriding Treatment) has been applied. Because of this, it
Inspect the oil seal fitting surfaces for excessive is not possible to regrind the crankshaft surfaces.
wear and damage. 1. 4. Use an organic cleaner to thoroughly clean the
Inspect the oil ports for obstructions. crankshaft. There must be no traces of oil on
Run-out the surfaces to be inspected.
1. 1. Set a dial indicator to the centre of the 2. 5. Prepare a 5 - 10 % solution of ammonium
crankshaft journal. cuprous chloride (dissolved in distilled water).
3. 6. Use a syringe to apply the solution to the
surface to be inspected.
Hold the surface to be inspected perfectly
horizontal to prevent the solution from running.
NOTE: Do not allow the solution to come in contact
with the oil ports and their surrounding area.
2. 2. Gently turn the crankshaft in the normal

direction of rotation. Read the dial indicator as
you turn the crankshaft. If the measured value
exceeds the specified limit, the crankshaft must
be replaced.
4. 7. Wait for thirty to forty seconds. If there is no
Crankshaft run-out:
discoloration after thirty or forty seconds, the
Standard (New): crankshaft is usable. If discoloration appears
0.05 mm or less (0.002 in.) (the surface being tested will become the
Service limit: colour of copper), the crankshaft must be
0.06 mm (0.002 in.) replaced.
Crankshaft Journal and Crankpin Uneven Wear 5. 8. Steam clean the crankshaft surface immediately
after completing the test.
3. 3. Use the micrometer to measure the crankshaft NOTE: The ammonium cuprous chloride
journal and the crankpin uneven wear. solution is highly corrosive. Because of this it is
Crankshaft journal and crankpin uneven imperative that the surfaces being tested be
wear: cleaned immediately after completing the test.
Standard (New):
aaa
0.05 mm (0.002 in.) or less
Service limit:
0.08 mm (0.003 in.)

7-11_Engine Block_Block and Piston Inspection
7-11
Engine Block
Block and Piston Inspection
1. 1. Check the cylinder block upper face distortion. 1. 3. Measure the cylinder block bore.
Use a straight edge and a feeler gauge to 1. Take measurements at measuring point (A)
measure the four sides and the two diagonals across positions (''W – W''), (''X – X''), (''Y –
of the cylinder block upper face. Y'') and (''Z – Z'').
Cylinder block upper face distortion:
Measuring point (A):
Standard (New):
12, 55 and 95 mm
0.05 mm (0.002 in.) or less
2. Calculate the average value of the four
Service limit:
measurements to determine the correct
0.1 mm (0.004 in.) cylinder grade.
NOTE: It is most important that the correct
piston grade be used. Failure to select the
incorrect piston grade will result in engine
failure.
Cylinder block bore grade:
Grade A:
79.001 – 79.010 mm
(3.1102 – 3.1106 in.)
Grade B:
79.011 – 79.020 mm
(3.1107 – 3.1110 in.)
Grade C:
79.021 – 79.030 mm
2. 2. Check the cylinder block height. (3.1111 – 3.1114 in.)
Standard (New):
272 mm (10.71 in.)
aaa

7-12_Engine Block_Block and Piston Inspection (cont'd)
Piston, Pin and Connecting Rod

7-12
Engine Block Replacement
Block and Piston Inspection (cont'd)
1. 4. Measure the piston outside diameter. Disassembly

Measuring Point (A): 1. 1. Remove the snap ring (A) from piston (B).
57 mm (2.2 in.)
Piston outside diameter:
Grade A:
78.930 – 78.939 mm
(3.1075 – 3.1078 in.)
Grade B:
78.940 – 78.949 mm
(3.1079 – 3.1082 in.)
Grade C:
78.950 – 78.959 mm
(3.1083 – 3.1086 in.) 2. 2. Push to remove the piston pin (C), then remove
the connecting rod (D).
3. 3. Remove the piston rings (E).
Inspection
4. 1. Use a micrometer to measure the piston pin
outside diameter at several points.
Piston pin outside diameter:
Standard (New):
26.995 – 27.000 mm
(1.0628 – 1.0630 in.)
2. 5. Calculate the cylinder block and the piston Service limit:
clearance 26.985 mm (1.0624 in.)
Cylinder block and piston clearance:
Standard:
0.061 – 0.079 mm
(0.0024 – 0.0031 in.)
aaa

7-13_Engine Block_Piston, Pin and Connecting Rod Replacement (cont'd)
7-13
Engine Block
Piston, Pin and Connecting Rod Replacement
(cont'd)
1. 2. Use an inside dial indicator to measure the Connecting Rod Small End Bushing
piston pin hole (in the piston). Replacement
Piston pin hole: 1. 1. Set connecting rod small end to the bench
Standard: press V-block (A).
27.004 – 27.009 mm
(1.0631 – 1.0633 in.)
2. 3. Calculate the piston pin and the piston pin hole 2. 2. Use the bench press (B) and the bar (C) to
clearance. slowly force the bushing from the connecting
Piston pin and piston pin hole clearance: rod (D).
Standard: NOTE: Take care not to damage the connecting
rod with the bar when removing the bushing.
0.004 – 0.014 mm
3. 3. Set the connecting rod small end (A) to the
(0.00015 – 0.00055 in.)
bench press V-block.
3. 4. Use a caliper calibrator and a dial indicator to
measure the piston pin and connecting rod
small end bushing clearance.
Piston pin and connecting rod small end
bushing Clearance:
Standard (New):
0.008 – 0.020 mm
(0.0003 – 0.0008 in.)
Service limit:
0.05 mm (0.002 in.)
4. 4. Use the bench press (B) and the bar (C) to

slowly force the bushing with oil hole position.
NOTE: Align the bushing with the connecting
rod oil port. After installing a new bushing,
finish the bushing bore with a pin hole grinder.
aaa

7-14
Engine Block
(cont'd)
1. 5. Use a pin hole grinder (A) fitted with a reamer 1. 3. Use your fingers to force the piston pin into the
(B) to ream the piston pin hole. piston until it makes contact with the snap ring.
Small end bushing inside diameter:
Standard (New):
27.008 – 27.015 mm
(1.0633 – 1.0636 in.)
2. 4. Use your fingers to force the piston pin snap

ring into the piston snap ring groove.
3. 5. Check that the connecting rod moves smoothly
on the piston pin.
4. 6. Use a pair of snap ring pliers to install the
piston pin snap ring to the piston.
Reassembly
2. 1. Install the piston to the connecting rod. The
piston head front mark (A) and the connecting
rod front casting mark (B) must be facing the
same direction.
aaa
3. 2. Apply a coat of engine oil to the piston pin and

the piston pin hole.

7-15
Engine Block
(cont'd)
Piston Ring Replacement

1. 1. Use a piston ring replacer to remove the piston
rings.
2. 2. Check the piston ring gap.

1. Insert the piston ring horizontally into the
cylinder bore.
2. Use a piston inserted upside down to push
the piston ring into the cylinder bore until it
reaches either measuring point (A) or
measuring point (B). Cylinder bore diameter
is the smallest at these two points.
aaa
NOTE: Do not allow the piston ring to slant
to one side or the other. It must be perfectly
horizontal.
3. Use a feeler gauge to measure the piston
ring gap.
Small end bushing inside diameter:
Measuring point (A):
11 mm or
Measuring point (B):
97 mm
If the piston ring gap exceeds the specified
limit, the piston ring must be replaced.
Piston ring gap:
1st compression ring
Standard (New):
0.25 – 0.35 mm
(0.010 – 0.014 in.)
Service limit:
0.8 mm (0.03 in.)
2nd compression ring
Standard (New):
0.20 – 0.30 mm
(0.008 – 0.012 in.)
Service limit:
0.8 mm (0.03 in.)
Oil ring
Standard (New):
0.20 – 0.40 mm
(0.008 – 0.016 in.)
Service limit:

0.8 mm (0.03 in.)

7-16
Engine Block
(cont'd)
1. 3. Check the piston ring and the piston ring groove 1. 5. Use a piston ring replacer to install the three
clearance. Use a feeler gauge to measure the piston rings. Install the piston rings in the order
clearance between the piston ring and the shown in the illustration.
piston ring groove at several points around the A 1st compression ring (Barrel face type)
piston. If the clearance between the piston ring B 2nd compression ring
and the piston ring groove exceeds the
C Oil ring (Coil expander type)
specified limit, the piston ring must be replaced.
Piston ring and piston ring groove clearance: NOTE:
1st compression ring Install the compression rings with the
Standard (New): stamped side facing up.
Insert the expander coil into the oil ring
0.090 – 0.122 mm
groove so that there is no gap on either side
(0.0035 – 0.0048 in.) of the expander coil before installing the oil
Service limit: ring.
0.15 mm (0.006 in.)
2nd compression ring
Standard (New):
0.070 – 0.110 mm
(0.0028 – 0.0043 in.)
Service limit:
0.15 mm (0.006 in.)
Oil ring
Standard (New):
0.025 – 0.065 mm
(0.0010 – 0.0026 in.)
Service limit:
0.15 mm (0.006 in.)
aaa
2. 4. Visually inspect the piston. If a piston ring

groove is damaged or distorted, the piston must
be replaced.

7-17_Engine Block_Piston Installation
7-17
Engine Block
Piston Installation
1. 1. Carefully wipe any oil or other foreign material 1. 5. Position the piston ring gaps as shown in the
from the connecting rod bearing back face and illustration.
the connecting rod bearing fitting surface.
2. 2. Select the connecting rod bearing grade.

2. 6. Apply a coat of molybdenum disulphide grease
1. Confirm the connecting rod bearing grade to the two piston skirts. This will facilitate
mark (A) on the connecting rod. smooth break-in when the engine is first started
2. Select the connecting rod bearing grade after reassembly.
colour (B) on the connecting rod bearing. 3. 7. Apply a coat of engine oil to the upper bearing
surfaces.
NOTE: Do not apply engine oil to the bearing
back faces and the connecting rod bearing
fitting surfaces.
4. 8. Apply a coat of engine oil to the cylinder wall.
5. 9. Position the piston head front mark so that it is
facing the front of the cylinder block.
6. 10. Use a piston ring compressor to compress the
piston rings.
aaa
3. 3. Install the connecting rod upper bearing to

connecting rod.
4. 4. Apply a coat of engine oil to the circumference
of each piston ring and piston.

7-18_Engine Block_Piston Installation (cont'd)
Crankshaft
7-18 Installation
Engine Block
Piston Installation (cont'd)
1. 11. Use a hammer grip to push the piston in until Special Tools Required
the connecting rod makes contact with the Crankshaft rear oil seal installer (without
crankpin. crankshaft) 5-8840-7005-0
Crankshaft rear oil seal installer (with
crankshaft) 5-8840-7006-0
1. 1. Use compressed air to thoroughly clean the
inside and outside surfaces of the cylinder
block, the oil holes and the water jackets.
CAUTION
Wear safety glasses when using compressed
air, as flying dirt particles may cause eye
injury.
2. 12. At the same time, rotate the crankshaft until the 2. 2. Install crankshaft upper bearing.
crankpin is at BDC. NOTE: The crankshaft upper bearings have an
3. 13. Install the connecting rod bearing caps. The oil hole and an oil groove. The lower bearings
bearing cap number (at the side of the bearing do not.
cap) and the connecting rod number must be
the same.
NOTE: It is absolutely essential that the bearing
caps be installed in the correct direction.
Reversing the bearing cap direction will result in
serious engine damage.
3. 3. Carefully wipe any foreign material from the

crankshaft upper bearing and the crankshaft
upper bearing fitting surfaces.
4. 4. Locate the position mark applied at disassembly
if the removed crankshaft upper bearings are to
be reused.
5. 5. Install the crankshaft. Apply an ample coat of
4. 14. Apply a coat of engine oil to the threads and engine oil to the crankshaft journals and the
setting faces of each connecting rod cap bolt. crankshaft bearing surfaces before installing the
5. 15. Tighten the connecting rod cap nuts to the two crankshaft.
steps specified torque. NOTE: Do not apply engine oil to the bearing
1st step torque: back faces and the cylinder block bearing fitting
25 Nm (2.5 kgf/m, 18 lbf/ft) surfaces.
2nd step: aaa
100°

7-19_Engine Block_Crankshaft Installation (cont'd)
7-19
Engine Block
Crankshaft Installation (cont'd)
1. 6. Install the rotor (A) on the rear of crankshaft (B) 1. 8. Install the crankshaft bearing cap with the lower
and tighten screw (C). bearing.
NOTE:
The bearing cap arrow marks must be
facing the front of the engine.
The arrow mark journal number must
correspond to the journal to which the
bearing cap is installed.
2. 7. Apply an ample coat of engine oil to the

crankshaft thrust bearings. Install the crankshaft
thrust bearings to No. 2 crankshaft journal. The
crankshaft thrust bearing oil groove must be
facing the sliding face.
2. 9. Apply a coat of engine oil to the bearing cap

bolts. Tighten the crankshaft bearing cap bolts
to the specified torque a little at a time in the
sequence shown in the illustration.
Crankshaft bearing cap torque:
88 Nm (9.0 kgf/m, 65.1 lbf/ft)
3. 10. Check to see that the crankshaft turns smoothly
by rotating it manually.
4. 11. Clean sealing surface and remove liquid gasket
residue.
aaa

7-20_Engine Block_Crankshaft Installation (cont'd)
Oil Pan Installation

7-20
Engine Block
Crankshaft Installation (cont'd)
1. 12. Apply a bead (A) of liquid gasket to sealing Special Tool Required
surfaces of crankshaft seal ring retainer (B). Aligner 5-8840-9054-0
1. 1. Clean the sealing surfaces of the upper oil pan
and remove the sealant residue.
2. 2. Apply a bead of liquid gasket to sealing
surfaces on the oil pan upper.
2. 13. Install crankshaft seal retainer to rear of cylinder

block.
Specified torque:
9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
NOTE: Recut thread before re-use and insert bolts
with screw locking compound. The installation time
including the torque check is max. 10 min.
3. 14. Apply engine oil to oil seal lip.
4. 15. Install oil seal to oil seal retainer using special
tool (5-8840-7005-0; without crankshaft or 5-
8840-7006-0; with crankshaft). 3. 3. Install aligner (special tool) (A) (5-8840-9054-0)
to oil pan upper with tightening torque 9.8 Nm
(1.0 kgf/m, 7.2 lbf/ft).
aaa

7-21_Engine Block_Oil Pan Installation (cont'd)
7-21
Engine Block
Oil Pan Installation (cont'd)
1. 4. Install the oil pan upper according to the 1. 10. Install drain plug (A) in the oil pan lower with
installation direction of the oil pan upper (B). new seal ring.
2. 5. After installing oil pan upper to cylinder block, Specified torque:
push oil pan upper to engine front side, see 39 Nm (4.0 kgf/m, 29 lbf/ft)
illustration (C) moving direction of oil pan upper,
tighten each bolt and nut with specified torque.
In this time, different value (D) between cylinder
block and oil pan upper is less than 0.2 mm.
3. 6. Tighten oil pan upper with tightening order as
illustration.
Specified torque:
9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
2. 11. Install oil pan lower (B) to oil pan upper (C).
Specified torque:
9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
aaa
4. 7. Remove the aligner (special tool).

5. 8. Clean sealing surfaces of the lower oil pan and
remove sealant residue.
6. 9. Apply a bead of liquid gasket to sealing
surfaces of oil pan lower.


Engine Mechanical
Engine Lubrication
Special Tools 8-2
Lubricating System Oil Flow 8-3
Oil Pressure Switch Test 8-4
Oil Pressure Test 8-4
Engine Oil Replacement 8-5
Engine Oil Filter Assembly Replacement 8-5
Oil Pump Overhaul 8-6
Main Release Valve and Check Valve Inspection and Repair 8-9
Oil Jet Installation Procedure 8-9
Oil Filter Element Replacement 8-10
Oil Pressure Switch Replacement 8-10
Outline Model Change

aaa

8-2_Engine Lubrication_Special Tools
8-2
Engine Lubrication
Special Tools
Number Tool Number Description Qty

1 5-8840-9042-0 Installer crankshaft front oil seal (Without crankshaft) 1
2 5-8840-9043-0 Installer crankshaft front oil seal (With crankshaft) 1
3 5-8840-9045-0 Installer oil pump seal 1
4 5-8840-9056-0 Installer oil jet 1
aaa

8-3_Engine Lubrication_Lubricating System Oil Flow
8-3
Engine Lubrication
Lubricating System Oil Flow
aaa

8-4_Engine Lubrication_Oil Pressure Switch Test
Oil Pressure
8-4 Test
Engine Lubrication
Oil Pressure Switch Test
1. 1. Remove the oil pressure switch harness (A) The oil pressure warning light stays on with the engine
from the oil pressure switch (B) and turn up the running, check the engine oil level.
cover boot. If the engine oil level is correct, check the engine oil
pressure.
1. 1. Connect a tachometer.
2. 2. Remove the engine oil pressure switch and
install the oil pressure gauge (A).
2. 2. Check for continuity between the positive

terminal (C) and the engine (ground).
There should be continuity when the engine
stopped.
There should not be continuity when engine
running.
3. 3. If the oil pressure switch fails to operate, check
the engine oil level.
If the engine oil lever is Ok, check the engine oil 3. 3. Start the engine. Shut if off immediately if the
pressure. oil pressure gauge registers no oil pressure.
If the engine oil pressure is OK, replace the oil Repair the problem part before continuing test.
pressure switch. 4. 4. Allow the engine to reach operating
temperature. The oil pressure should be:
Oil pressure switch tightening torque:
Engine oil temperature: 80°C (176°F)
21 Nm (2.1 kgf/m, 15 lbf/ft)
Engine oil pressure:
At idle: 127 kPa (1.3 kg/cm2 , 18.4 psi)
At 4,400 min-1 : 392 kPa (4 kg/cm2 , 56.8 psi)
5. 5. The oil pressure is not within specifications,
inspect the oil pump.
aaa

8-5_Engine Lubrication_Engine Oil Replacement
Engine Oil Filter Assembly Replacement

8-5
Engine Lubrication
Engine Oil Replacement
1. 1. Warm up the engine. 1. 1. Drain the engine coolant.

2. 2. Remove the drain plug (A) for drain the engine 2. 2. Disconnect the hoses (A) from oil cooler side.
oil.
3. 3. Install the drain plug with a new gasket (B).

The drain plug tighten torque:
78 Nm (8.0 kgf/m, 57.9 lbf/ft) 3. 3. Remove the oil filter tightening bolt (B) then
4. 4. Refill with the recommended oil (see page 3-2). remove the engine oil filter assembly.
Capacity 4. 4. Replace the new gasket for oil filter assembly.
4.8 l (5.1 US qt, 4.2 Imp qt) at oil change. 5. 5. Install the oil filter assembly to the engine
block.
5.0 l (5.3 US qt, 4.4 Imp qt) at oil change.
Tightening torque:
including filter.
110 Nm (11.2 kgf/m, 81 lbf/ft).
5.75 l (6.1 US qt, 5.1 Imp qt) after engine
6. 6. Connect the hoses to the oil cooler.
overhaul.
7. 7. Fill the engine coolant and check leakage.
5. 5. Run the engine for more than 3 minutes, then aaa
check for oil leakage.

8-6_Engine Lubrication_Oil Pump Overhaul
8-6
Engine Lubrication
Oil Pump Overhaul
Special Tool Required 1. 3. Remove gasket (A) from groove in oil pump
Installer oil pump seal 5-8840-9045-0 retainer (B).
Installer crankshaft front oil seal 5-8840-9042-0
(without C/shaft)
Installer crankshaft front oil seal 5-8840-9043-0
(with C/shaft)
Oil Pump Disassembly
1. 1. Remove oil pump retainer (A).
Clean
gasket residue.
Oil Seal Replacement
3. 5. Coat with silicon grease on the sealing lips of
the oil seal. Install the oil pump oil seal using
the special tool (5-8840-9045-0).
2. 2. Remove inner rotor (A) and outer rotor (B) from Install the crankshaft front oil seal using the
cylinder block (C). Edge out crankshaft front special tool (5-8840-9042-0 or 5-8840-9043-0
seal ring and oil pump seal ring using suitable for with crankshaft).
tool.
aaa

8-7_Engine Lubrication_Oil Pump Overhaul (cont'd)
8-7
Engine Lubrication
Oil Pump Overhaul (cont'd)
Inspection 1. 8. Clearance between outer rotor and cylinder

1. 6. Check oil pump shaft (A), rotors (B), (C) and block.
cylinder block (D) for damage. Clearance between outer rotor and cylinder
If excessive wear or damage is discovered, the block:
oil pump assembly must be replaced. New rotors:
Clearance the oil pump shaft in cylinder 0.24 – 0.36 mm
block: (0.009 – 0.014 in.)
New rotors: Run-in rotors:
0.040 – 0.125 mm 0.40 mm (0.016 in.) Max
(0.002 – 0.005 in.)
Run-in rotors:
0.200 mm (0.008 in.) Max
2. 9. Chip clearance between inner and outer rotor.

Chip clearance between inner and outer
rotor:
New rotors:
End Play 0.13 – 0.15 mm
2. 7. Inspect end play. (0.005 – 0.006 in.)
End play between oil pump retainer and Run-in rotors:
rotors (A + B - C):
0.20 mm (0.008 in.) Max
New rotors:
0.035 – 0.100 mm
(0.001 – 0.004 in.)
Run-in rotors:
0.150 mm (0.006 in.) Max
aaa

8-8_Engine Lubrication_Oil Pump Overhaul (cont'd)
8-8
Engine Lubrication
Oil Pump Overhaul (cont'd)
Oil Pump Reassembly 1. 16. Apply a bead of liquid gasket to sealing surface
1. 10. Install the outer rotor (A) into the cylinder block. (crosshatched) of oil pump retainer.
Install oil pump retainer (A) to cylinder block.
Tightening torque;
9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
2. 11. Install the inner rotor (B) into the outer rotor.
3. 12. Install the oil pump retainer (C) on the cylinder aaa
block.
gasket residue.
5. 14. Coat inner and outer rotor with oil and insert in
cylinder block.
6. 15. Insert new gasket (A) in groove in oil pump

8-9_Engine Lubrication_Main Release Valve and Check Valve Inspection and Repair
Oil Jet8-9
Installation Procedure
Engine Lubrication
Main Release Valve and Check Valve
Inspection and Repair
1. 1. Make the necessary adjustment, repairs and Special Tool Required

parts replacement if excessive wear or damage Installer oil jet 5-8840-9056-0
is discovered during inspection.
1. 1. Apply Locktite 262 or TB1386 to the oil jet
Tightening Torque:
fixing area in the cylinder block.
Main release valve: 2. 2. Set the oil jet setting tool (A) (5-8840-9056-0)
39 Nm (4.0 kgf/m, 28.9 lbf/ft) with oil jet (B) and the position pin of the oil jet
Check valve: setting tool into the cylinder block crankshaft
29 Nm (3.0 kgf/m, 21.7 lbf/ft) bearing cap bolt holes.
2. 2. Check valve for easy operation when pushing

valve by screwdriver.
3. 3. Set the oil jet holder (C) on the oil jet and hit
the head of the oil jet holder with a hammer
until it reaches the oil jet flange to the cylinder
block
aaa

8-10_Engine Lubrication_Oil Filter Element Replacement
Oil pressure
8-10 Switch Replacement
Engine Lubrication
Oil Filter Element Replacement
1. 1. Remove the oil filter housing cover, then 1. 1. Disconnect the mass air flow (MAF) sensor
separate the oil filter housing cover and oil filter connector (A) and remove the vacuum hose
element. (B), then remove the intake air duct (C) and air
2. 2. Install the new O-rings (A) and oil filter element cleaner housing (D).
(B) to the oil filter housing cover (C).
2. 2. Disconnect the oil pressure switch harness,

3. 3. Install the oil filter housing cover to the oil filter then remove the oil pressure switch.
housing.
3. 3. Apply liquid gasket to the oil pressure switch

threads, then install the oil pressure switch.
aaa

Engine Mechanical
Intake Manifold and Exhaust System

Intake Manifold and EGR Valve Removal 9-2
Intake Manifold and EGR Valve Inspection 9-3
Intake Manifold and EGR Valve Installation 9-3
Turbocharger and Exhaust Manifold Removal 9-4
Turbocharger and Exhaust Manifold Installation 9-6
Intake Pipe and Exhaust Muffler Replacement 9-9

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9-2_Intake Manifold and Exhaust System_Intake Manifold and EGR Valve Removal
9-2
Intake Manifold and EGR Valve Removal
1. 1. Remove the acoustic cover. 1. 9. Remove the bolts (A) and nuts (B) then remove
the intake manifold assembly (C).
aaa
2. 2. Remove the air cleaner housing (see step 6 on

page 5-2).
3. 3. Remove the intake manifold pipe.
4. 4. Remove the EGR valve.
5. 5. Remove the EGR pipe.
6. 6. Remove the oil filter assembly (see page 8-5).
7. 7. Remove the four injection pipes (see page 11-
160).
8. 8. Remove the three bolts (A) securing the engine
wire harness, three bolts (B) securing the hose
bracket, then disconnect the fuel leak rubber
hose (C) and vacuum hose (D).

9-3_Intake Manifold and Exhaust System_Intake Manifold and EGR Valve Inspection
Intake9-3
Manifold and EGR Valve Installation
Intake Manifold and EGR Valve Inspection
1. 1. Connect the vacuum pump and gauge to the 1. 1. Apply liquid gasket to the VSS.
actuator of EGR valve assembly. 2. 2. Install the intake manifold assembly with gasket
to cylinder head.
Tighten the fixing bolts and nuts with the
specified torque.
Tightening torque:
24.5 Nm (2.5 kgf/m, 18 lbf/ft)
3. 3. Connect the vacuum hose, fuel rubber hose
and install the hose bracket and engine wire
harness with specified torque.
Tightening torque:
7.4 Nm (0.75 kgf/m, 5.4 lbf/ft)
4. 4. Install the four injection pipes (see page 11-
160).
5. 5. Install the oil filter assembly (see page 8-5).
6. 6. Install the EGR valve assembly with specified
torque.
Tightening torque:
24.5 Nm (2.5 kgf/m, 18 lbf/ft)
7. 7. Install the EGR pipe and gasket with specified
2. 2. Apply 0 kPa to 25 kPa (0.25 kgf/cm 2 , 1.8 lbf/ft) torque.
vacuum and check EGR valve moving Tightening torque:
condition. 24.5 Nm (2.5 kgf/m, 18 lbf/ft)
3. 3. If there is abnormal moving conditions on the 8. 8. Install the intake manifold pipe with specified
EGR valve, replace the EGR valve assembly. torque.
4. 4. Inspect VSS (Variable Swirl System) for Tightening torque:
damage or any other problems and push the
24.5 Nm (2.5 kgf/m, 18 lbf/ft)
valve with your finger to inspect normal
condition or valve sticking. 9. 9. Install the air cleaner housing (see step 6 on
5. 5. Inspect the EGR valve for damage or any other page 5-2).
problems. 10. 10. Install the acoustic cover with specified torque.
Tightening torque:
7.4 Nm (0.75 kgf/m, 5.4 lbf/ft)
aaa

9-4_Intake Manifold and Exhaust System_Turbocharger and Exhaust Manifold Removal
9-4
Turbocharger and Exhaust Manifold Removal
1. 1. Remove the splash shield (see step 19 on page 1. 4. Remove the A/C compressor bracket.
5-5).
2. 2. Remove the harness clamp (A) and the
intercooler inlet hose (B).
2. 5. Remove the oil return hose (A) and two bolts

(B) securing the alternator, then move the
alternator (C).
3. 3. Remove the A/C compressor clutch connector

(A), then remove the harness clamp (B) and
A/C compressor mounting bolts (C).
aaa

9-5_Intake Manifold and Exhaust System_Turbocharger and Exhaust Manifold Removal (cont'd)
9-5
(cont'd)
1. 6. Remove the three bolts securing the oil level 1. 8. Remove the exhaust manifold cover.
gauge pipe, then move the oil level gauge.
2. 9. Remove the two bolts (A) securing the EGR

pipe, PCV tube (B) and remove the air flow
tube assembly (C).
2. 7. Remove the turbocharger cover.
3. 10. Remove the acoustic cover (see step 1 on

page 9-2).
aaa

9-6_Intake Manifold and Exhaust System_Turbocharger and Exhaust Manifold Removal (cont'd)
9-6
Turbocharger and Exhaust Manifold Installation
(cont'd)
1. 11. Remove the exhaust pipe A (A) from the 1. 1. Install the turbocharger exhaust pipe (A) with
turbocharger. gasket to turbocharger (B) and install the
turbocharger with gasket to exhaust manifold
(C). Tighten fastening nuts (D) to the specified
torque.
Specified torque:
Temporary tightening 38.8 Nm (4.0 kgf/m, 29
lbf/ft)
Fully tightening 77.5 Nm (7.9 kgf/m, 57 lbf/ft)
2. 12. Remove the oil feed pipe (B) and disconnect

the turbocharger return hose (C) from the
turbocharger (D).
3. 13. Remove the exhaust manifold fixing nuts and
remove the exhaust manifold (E).
4. 14. Remove the turbocharger fixing nuts (A) and
turbocharger exhaust pipe fixing nuts (B), then
remove the turbocharger assembly (C).
2. 2. Install the exhaust manifold with gasket.
aaa

9-7_Intake Manifold and Exhaust System_Turbocharger and Exhaust Manifold Installation (cont'd)
9-7
(cont'd)
1. 3. Tighten the exhaust manifold fastening nuts (A). 1. 7. Install the exhaust manifold cover.
Connect the turbocharger return hose (B) with
new gasket (C) and connect the oil feed pipe
(D) with new gaskets (E) .
2. 8. Install the turbocharger cover.
2. 4. Install the exhaust pipe A (F) with new gasket.

3. 5. Install the acoustic cover with specified torque.
Tightening torque: 3. 9. Install the three bolts securing the oil level
7.4 Nm (0.75 kgf/m, 5.4 lbf/ft) gauge pipe with new O-ring (A).
4. 6. Install the two bolts (B) securing the EGR pipe
with gasket and install the PCV tube (B) and
the air flow tube assembly (C).
aaa

9-8_Intake Manifold and Exhaust System_Turbocharger and Exhaust Manifold Installation (cont'd)
9-8
(cont'd)
1. 10. Install the oil return hose (A) and the alternator 1. 12. Install the A/C compressor (A) and harness
(B). clamp (B).
2. 11. Install the A/C compressor bracket.

2. 13. Install the harness clamp (A) and the
intercooler inlet hose (B).
3. 14. Install the splash shield (see step 18 on page

5-12).
aaa

9-9_Intake Manifold and Exhaust System_Exhaust Pipe and Muffler Replacement
9-9
Exhaust Pipe and Muffler Replacement
NOTE: Use new gaskets and self-locking nuts when reassembling.

1. GASKET
Replace.
2. SELF-LOCKING NUT
10 x 1.25 mm
54 Nm (5.5 kgf/m, 40 lbf/ft)
Replace.
3. MUFFLER
4. HEAT SHIELD
5. 6 x 1.0 mm
9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
6. EXHAUST PIPE B
7. GASKET
Replace.
8. THREE WAY CATALYTIC
CONVERTER (TWC)
9. GASKET
Replace.
10. SELF-LOCKING NUT
10 x 1.25 mm
33 Nm (3.4 kgf/m, 25 lbf/ft)
Replace.
8 x 1.25 mm
18 Nm (1.8 kgf/m, 13 lbf/ft)
Replace.
10 x 1.25 mm
33 Nm (3.4 kgf/m, 25 lbf/ft)
Replace.
10 x 1.25 mm
54 Nm (5.5 kgf/m, 40 lbf/ft)
Replace.
14. EXHAUST PIPE A
15. GASKET
Replace.
16. 8 x 1.25 mm
22 Nm (2.2 kgf/m, 16 lbf/ft)
10 x 1.25 mm
33 Nm (3.4 kgf/m, 25 lbf/ft)
Replace.
aaa

10-1_Engine Cooling
Engine Cooling
Cooling System
Expansion Tank Cap Test 10-3
Expansion Tank Test 10-3
Expansion Tank Replacement 10-4
Fan Motor Test 10-4
Coolant Check 10-5
Coolant Replacement 10-6
Water Glow Plug Test 10-7
Water Glow Plug Replacement 10-7
Water Pump and Thermostat Inspection 10-8
Radiator Replacement 10-12
Fan Controls
Symptom Troubleshooting Index 10-15
Radiator and Condenser Fans Circuit Troubleshooting A 10-17
Radiator and Condenser Fans Circuit Troubleshooting B 10-18
Radiator and Condenser Fans Circuit Troubleshooting C 10-19
Radiator and Condenser Fans High Speed Circuit Troubleshooting 10-19
Radiator Fan Switch Test 10-20
Radiator Fan Switch A Replacement 10-21
Radiator Fan Switch B Replacement 10-21

aaa

10-2_Cooling System_Component Location Index
10-2
Cooling System
1. RADIATOR FAN SWITCH B

Test, page 10-20
2. RADIATOR FAN SWITCH A
Test, page 10-20
3. WATER PUMP
Removal, page 10-9
4. EXPANSION TANK
Cap Test, page 10-3
Test, page 10-3
5. WATER GLOW PLUG
Test, page 10-7
6. THERMOSTAT
7. RADIATOR FAN
Fan Motor Test, page 10-4
8. RADIATOR
aaa

10-3_Cooling System_Expansion Tank Cap Test
10-3 Expansion Tank Test

Cooling System
Expansion Tank Cap Test
1. 1. Remove the radiator cap (A), wet its seal with 1. 1. Wait until the engine is cool, then carefully
engine coolant, then install it on the pressure remove the expansion tank cap and fill the
tester (B) (commercially available). Use a small expansion tank with engine coolant to the top
adapter H-901122-09 (C) (commercially of the filler neck.
available) to install the radiator cap. 2. 2. Attach the pressure tester (A) (commercially
available) to the expansion tank. Use a small
adapter H-901122-09 (B) (commercially
available) to attach the pressure tester.
2. 2. Apply a pressure of 93 - 123 kPa (0.95 - 1.25

kgf/cm 2 , 14 - 18 psi).
3. 3. Check for a drop in pressure.
4. 4. If the pressure drops, replace the cap.
3. 3. Apply a pressure of 93 - 123 kPa (0.95 - 1.25

kgf/cm 2 , 14 - 18 psi).
4. 4. Inspect for engine coolant leaks and drop in
pressure.
5. 5. Remove the tester and reinstall the expansion
tank cap.
6. 6. Check for engine oil in the and/or coolant in the
engine oil.
aaa

10-4_Cooling System_Expansion Tank Replacement
10-4 Fan MotorTest

Cooling System
Expansion Tank Replacement
1. 1. Drain the engine coolant (see page 10-6). 1. 1. Disconnect the 2P connectors from the radiator
2. 2. Remove the expansion tank hoses, then fan motor and condenser fan motor.
remove the expansion tank.
2. 2. Test the motor by connecting battery power to

the B terminal and ground to the A terminal.
3. 3. If the motor fails to run or does not run
smoothly, replace it.
3. 3. Install the expansion tank in the reverse order aaa
of removal.
4. 4. Refill the radiator with engine coolant and bleed
air from the cooling system with the heater
valve open (see page 10-6).

10-5_Cooling System_Coolant Check
10-5
Cooling System
Coolant Check
1. 1. Look at the coolant level in the expansion tank. aaa

Make sure it is between the MAX mark (A) and
MIN mark (B).
2. 2. If the coolant level in the expansion tank is at

or below the MIN mark, add coolant to bring it
up to the MAX mark and inspect the cooling
system for leaks.

10-6_Cooling System_Coolant Replacement
10-6
Cooling System
Coolant Replacement
1. 1. Start the engine. Set the heater temperature 1. 6. Pour genuine Honda All Season
control dial to maximum heat, then turn the Antifreeze/Coolant Type 2 into the expansion
ignition switch OFF. Make sure the engine and tank up to the MAX mark.
radiator are cool to the touch. NOTE:
2. 2. Remove the expansion tank cap. Always use genuine Honda All Season
3. 3. Loosen the drain plug (A) and drain the coolant. Antifreeze/Coolant Type 2. Using a non-
Honda coolant can result in corrosion,
causing the cooling system to malfunction or
fail.
Genuine Honda All Season
Antifreeze/Coolant Type 2 is a mixture of 50
% antifreeze and 50 % water. Pre-mixing is
not required.
Engine Coolant Refill Capacity [including the
expansion tank capacity of 0.73 l (0.77 US
qt, 0.64 lmp qt)]:
5.33 l (5.63 US qt, 4.69 lmp qt)
4. 4. When the coolant stops draining, tighten the

drain plug securely.
5. 5. Remove the expansion tank and drain the
inside coolant and reinstall the expansion tank.
2. 7. Install the expansion tank cap loosely.

3. 8. Start the engine and let it run until it warms up
(the radiator fan comes on at least twice).
4. 9. Turn off the engine. Check the level in the
expansion tank and add genuine Honda All
Season Antifreeze/Coolant Type 2 if needed.
5. 10. Put the expansion tank cap on tightly, then run
the engine again and check for leaks.
aaa

10-7_Cooling System_Water Glow Plug Test
10-7 Water Glow Plug Replacement

Cooling System
Water Glow Plug Test
1. 1. Remove the water glow plug harness (A) from 1. 1. Disconnect the mass air flow (MAF) sensor
the water glow plug. connector (A) and remove the vacuum hose
(B), then remove the intake air duct (C) and air
cleaner housing (D).
2. 2. Measure resistance between the positive

terminal (A) and body ground.
Resistance:
Green colour (200W): 2. 2. Remove the water glow plug harness (A), then
0.91 ohms remove the water glow plug (B).
Silver colour (300W):
0.61 ohms
3. 3. Install the water glow plug in the reverse order

of removal.
aaa

10-8_Cooling System_Water Pump and Thermostat Inspection
10-8
Cooling System
Water Pump and Thermostat Inspection
Exploded View
Water Pump
1. WATER PUMP ASSEMBLY
2. GASKET
3. PULLEY
4. BOLT
Thermostat
1. BOLT
2. WATER OUTLET PIPE
3. GASKET
4. THERMOSTAT
5. GASKET
6. WATER GLOW PLUG
7. THERMOSTAT HOUSING
8. CLAMP
9. WATER INLET HOSE
10. BOLT
aaa

10-9_Cooling System_Water Pump and Thermostat Inspection (cont'd)
10-9
Cooling System
Water Pump and Thermostat Inspection (cont'd)
Water Pump Removal Water Pump Installation

1. 1. Drain coolant-collect coolant. 1. 1. Install the water pump assembly (A) with a new
2. 2. Loosen fastening bolts (A) before removing gasket (B) to the cylinder block.
drive-belt (B).
3. 3. Remove drive-belt. 2. 2. Tighten fastening bolts (C) to the specified

4. 4. Remove the water pump assembly (C) and torque.
gasket (D). Tightening Torque:
24 Nm (2.4 kgf/m, 17.4 lbf/ft).
3. 3. Install the water pump pulley (D) to the water
pump. Install the drive-belt (E).
4. 4. Tighten fastening bolts (F) to the specified
torque.
Tightening Torque:
9.8 Nm (1.0 kgf/m, 7.2 lbf/ft).
aaa

10-10
Cooling System
Water Pump Inspection Thermostat Inspection

Bearing unit inspection Removal
1. 1. Check the bearing unit for remarkable play in 1. 1. Remove the two bolts to the fixing water outlet
radial direction and for abnormal noise when pipe then remove the thermostat.
turning the shaft. Installation
2. 2. Install the thermostat to thermostat housing.
Install the water outlet pipe and tighten fixing
bolts.
Tightening torque:
24 Nm (2.4 kgf/m, 17 lbf/ft)
Specification
3. 3. Valve opening temperatures 85 + 2°C
Valve lift:
External Inspection 8.0 mm
2. 2. Check the pump body for cracks.
3. 3. Check the seal unit for leakage.
4. 4. Check the impeller for cracks, corrosion or
damage.
Inspection and Repair

4. 4. Make the necessary adjustments, repairs and
part replacements if excessive wear or damage
is discovered during inspection.
Operating Test
5. 5. Completely submerge the thermostat in water.
6. 6. Heat the water. Stir the water constantly to
avoid direct heat being applied to the
thermostat.
7. 7. Check the thermostat initial opening
temperature.
Thermostat initial opening temperature:
85 + 2 °C
aaa
file:///C|/...3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/Civ41Html/10-10.htm[8/25/2012 6:35:20 PM]

10-11
Cooling System
1. 8. Check the thermostat full opening temperature. aaa

Thermostat full opening temperature:
100 °C
Valve lift at fully open position:
Min 8.0 mm

10-12_Cooling System_Radiator Replacement
10-12
Cooling System
Radiator Replacement
1. 1. Drain the engine coolant (see page 10-6). 1. 4. Remove the intercooler inlet hose (A) and
2. 2. Disconnect the fan motor connectors (A), hood intercooler outlet hose (B).
switch connector (B) and compressor clutch
connector (C), then remove the harness clamps
(D).
2. 5. Remove the upper radiator hose (A), lower

radiator hose (B) and water bypass hoses (C).
3. 3. Remove the condenser brackets (A) and the

upper bracket and cushions (B), then remove
the bulkhead (C).
aaa

10-13_Cooling System_Radiator Replacement (cont'd)
10-13
Cooling System
Radiator Replacement (cont'd)
1. 6. Pull up the radiator, then remove the fan shroud assemblies and other parts from the radiator.
1. INTERCOOLER INLET HOSE

2. UPPER RADIATOR HOSE
3. INTERCOOLER OUTLET HOSE
4. INTERCOOLER
24 Nm (2.4 kgf/m, 17 lbf/ft)
6. O-RING
Replace.
24 Nm (2.4 kgf/m, 17 lbf/ft)
8. RADIATOR
9. O-RING
Replace.
10. DRAIN PLUG
11. LOWER CUSHION
12. LOWER RADIATOR HOSE
13. A/C CONDENSER FAN
ASSEMBLY
14. RADIATOR FAN ASSEMBLY
2. 7. Install the radiator in the reverse order of removal. Make sure the upper and lower cushions are securely.
3. 8. Install the bulkhead in the reverse order of removal. Apply body paint to the bulkhead mounting bolts.
aaa

10-14_Fan Controls_Component Location Index
10-14
Fan Controls
1. RADIATOR FAN RELAY

Test, page 22-80 in the '01Civic Shop
Manual on this CD
2. FAN CONTROL RELAY
Test, page 22-80 in the '01 Civic Shop
Manual on this CD
3. CONDENSER FAN RELAY
Test, page 22-80 in the '01 Civic Shop
Manual on this CD
4. RADIATOR FAN
5. CONDENSER FAN
Test, page 10-20
Test, page 10-20
aaa

10-15_Fan Controls_Symptom Troubleshooting Index
10-15
Fan Controls
Symptom Troubleshooting Index
Symptom Diagnostic procedure Also check for

Radiator fan does not run at all, but condenser fan Radiator and condenser fans circuit troubleshooting
runs with A/C ON A (see page 10-17).
Both radiator fan and condenser fan do not run with Check the No. 14 (10A) fuse in the under-dash
A/C ON and when the engine coolant temperature is fuse/relay box.
above 95°C (203°F) If the fuse is faulty, replace it.
If the fuse is OK, repair the open in the
wire between the No. 14 (10A) fuse in the
under-dash fuse/relay box and the
radiator and condenser fan relays.
Condenser fan runs but radiator fan does not run Replace the radiator fan control relay.
when the engine coolant temperature is above 95°C
(203°F), but both fans run with A/C ON
Both radiator fan and condenser fan do not run when Radiator and condenser fans circuit troubleshooting
the engine coolant temperature is above 95°C B (see page 10-18).
(203°F), but both fans run with A/C ON
Both radiator and condenser fans do not run when Radiator and condenser fans low speed circuit
the engine coolant temperature is above 95°C troubleshooting (see page 21-13).
(203°F), but radiator fan runs with A/C ON
Both radiator fan and condenser fan run with ignition Radiator and condenser fans circuit troubleshooting
switch ON (II), with A/C OFF and when the engine C (see page 10-19).
temperature is below 95°C (203°F)
Both radiator fan and condenser fan do not run at Radiator and condenser fans high speed circuit
high speed with the A/C ON troubleshooting (see page 21-17).
Both radiator fan speed and condenser fan speed do Radiator and condenser fans high speed circuit
not change from Low to Hi when the engine coolant troubleshooting (see page 10-19).
temperature 100°C (212°F), but both fan's speed
change with A/C ON
Condenser fan speed does not change from Low to Condenser fan high speed circuit troubleshooting
Hi with A/C ON and the engine coolant temperature (see page 21-17).
above 100°C (212°F)
aaa

10-16_Fan Controls_Circuit Diagram
10-16
Fan Controls
Circuit Diagram
aaa

10-17_Fan Controls_Radiator and Condenser Fans Circuit Troubleshooting A
10-17
Fan Controls
Radiator and Condenser Fans Circuit
Troubleshooting A
1. 1. Check the No. 5 (30A) fuse in the under-hood 1. 4. Connect a jumper wire between radiator fan
sub fuse box. relay 4P socket terminals No. 1 and No. 3.
Is the fuse OK? RADIATOR FAN RELAY 4P SOCKET
NO – Check for a short in the wire between the
radiator fan relay, radiator fan motor and fan control
relay and condenser fan motor or a faulty fan motor. Terminal side of male terminals
2. 2. Remove the radiator fan relay from the multi- Does the radiator fan run?
relay box and test it, refer to the '01 Civic Shop YES – Go to step 5.
Manual on this CD (see page 22-80). NO – Go to step 7.
Is the relay OK?
2. 5. Disconnect the jumper wire, and turn the
YES – Go to step 3. ignition switch ON (II).
NO – Replace radiator fan relay. 3. 6. Measure the voltage between radiator fan relay
3. 3. Measure the voltage between radiator fan relay 4P socket terminal No. 2 and body ground.
4P socket terminal No. 1 and body ground. RADIATOR FAN RELAY 4P SOCKET
RADIATOR FAN RELAY 4P SOCKET
Terminal side of male terminals

Terminal side of male terminals Is there the battery voltage?
Is there battery voltage? YES – Repair an open in the wire between the
YES – Go to step 4. radiator fan relay and the A/C pressure switch.
NO – Repair an open in the wire between the under- NO – Repair an open in the wire between the under-
hood sub fuse box and the radiator fan relay 4P dash fuse/relay box and the radiator fan relay 4P
socket terminal No.1. socket terminal No.2.
aaa

10-18_Fan Controls_Radiator and Condenser Fans Circuit Troubleshooting A (cont'd)
10-18
Fan Controls Troubleshooting B
Troubleshooting A (cont'd)
1. 7. Disconnect the radiator fan motor 2P connector. 1. 1. Disconnect the radiator fan switch A 2P
2. 8. Measure the voltage between fan motor 2P connector.
connector terminal No. 2 and body ground. 2. 2. Turn the ignition switch ON (II).
RADIATOR FAN MOTOR 2P CONNECTOR 3. 3. Measure the voltage between the radiator fan
switch A 2P connector terminal No. 1 and body
ground.
RADIATOR FAN SWITCH A 2P CONNECTOR
Wire side of female terminals

Is there battery voltage?
NO – Repair an open in the wire between radiator fan
relay 4P socket terminal No. 3 and radiator 2P Wire side of female terminals
connector terminal No. 2. Is there battery voltage?
3. 9. Disconnect the jumper wire. YES – Go to step 4.
4. 10. Test the radiator fan motor (see page 10-4). NO – Repair open in the wire between the radiator
Is the fan motor OK? fan switch A connector and under-hood fuse/relay
YES – Repair an open in the wire between radiator box.
fan motor 2P connector terminal No. 1 and body 4. 4. Turn the ignition switch OFF and check for
ground G301. continuity between the radiator fan switch A 2P
NO – Replace the radiator fan motor. connector terminal No. 2 and body ground.
RADIATOR FAN SWITCH A 2P CONNECTOR

Is there continuity?
YES – Replace radiator fan switch A.
NO – Check for open in the wire between the radiator
fan switch A connector and body ground. If the wire is
OK, check for poor ground at G301.
aaa

10-19_Fan Controls_Radiator and Condenser Fans Circuit Troubleshooting C
10-19
Radiator and Condenser Fans High Speed
Fan Controls Circuit Troubleshooting
Troubleshooting C
1. 1. Remove the condenser fan relay, and test it, 1. 1. Remove the radiator fan relay from the multi-
refer to the '01 Civic Shop Manual on this CD relay box and condenser fan relay from the
(see page 22-80). under-hood fuse/relay box.
Is the relay OK? 2. 2. Disconnect the radiator fan switch B 2P
YES – Go to step 2. connector.
3. 3. Turn the ignition switch ON (II).
NO – Replace the relay.
4. 4. Measure the voltage between radiator fan
2. 2. Disconnect radiator fan switch B 2P connector switch B 2P connector terminal No. 1 and body
and turn the ignition switch ON (II). ground.
Does the radiator fan stop? RADIATOR FAN SWITCH B 2P CONNECTOR
YES – Replace radiator fan switch B and recheck.
4. 4. Remove the radiator fan relay from the multi-
relay box.
5. 5. Check for continuity between radiator fan switch
B 2P connector terminal No. 1 and body
ground.
RADIATOR FAN MOTOR 2P CONNECTOR Is there the battery voltage?
NO – Repair an open in the wire between fan control
relay 5P socket terminal No. 1 and radiator fan switch
B terminal No. 1.
5. 5. Install the radiator fan relay and condenser fan
relay.
aaa
YES – Repair a short in the wire between radiator fan
relay 4P socket terminal No. 4, radiator fan switch B
2P connector terminal No. 1 and A/C pressure switch.
6. 6. Disconnect the radiator fan switch A 2P
connector and turn the ignition switch ON (II).
Does the radiator fan stop?
YES – Replace radiator fan switch A.
NO – Repair a short in the wire between radiator fan
relay 4P socket terminal No. 4, condenser fan relay 4P
socket terminal No. 4.

10-20_Fan Controls_Radiator and Condenser Fans High Speed Circuit Troubleshooting (cont'd)
10-20
Radiator Fan Switch Test
Fan Controls
Circuit Troubleshooting (cont'd)
1. 6. Connect a jumper wire between radiator fan NOTE: Bleed air from the cooling system after installing
switch B 2P connector terminals No. 1 and No. the radiator fan switch (see page 10-6).
2. 1. 1. Remove radiator fan switch A and radiator fan
RADIATOR FAN SWITCH B 2P CONNECTOR switch B from the radiator (see page 10-2).
2. 2. Suspend each radiator fan switch (A) in a
container of water (C) as shown.

Do the radiator and condenser fans run?
YES – Replace radiator fan switch B.
NO – Repair an open in the wire between radiator fan
switch B 2P connector terminal No. 2 and ground
G301.
3. 3. Heat the coolant and check the temperature

with a thermometer (B). Do not let the
thermometer touch the bottom of the hot
container.
4. 4. Measure the continuity between terminal (No.
1) and terminal (No. 2) according to the table.
aaa

10-21_Fan Controls_Radiator Fan Switch A Replacement
Radiator
10-21Fan Switch B Replacement
Fan Controls
Radiator Fan Switch A Replacement
1. 1. Disconnect the radiator fan switch A connector, 1. 1. Disconnect the radiator fan switch A connector,
then remove the radiator fan switch A (A). then remove the radiator fan switch A (A).
2. 2. Install the radiator fan switch A with a new O- 2. 2. Install the radiator fan switch A with a new O-
ring (B). ring (B).
aaa

11-1_Fuel and Emissions
Fuel and Emissions
Fuel and Emissions Systems

Special Tools 11-2
General Troubleshooting Information 11-3
DTC Troubleshooting Index 11-6
System Descriptions 11-14
Diesel Engine Management System

DTC Troubleshooting 11-47
OBD System Troubleshooting 11-146
Injector Spray Condition Check 11-152
Accelerator Pedal Position Sensor Replacement 11-153
Idle Control System

Idle Speed Inspection 11-154
Fuel Supply System

Fuel Line Inspection 11-156
Fuel System Bleeding 11-157
Fuel Filter Water Bleeding 11-158
Fuel Filter Replacement 11-158
Injector Replacement 11-159
Fuel Supply Pump and Common Rail Replacement 11-160
Fuel Gauge Sending Unit Test 11-162
Fuel Gauge Sending Unit Replacement 11-164
Fuel Tank Replacement 11-165
Intake Air System

VSV Inspection 11-169
Air Cleaner Element Replacement 11-170
Throttle Cable Adjustment 11-171
Throttle Cable Removal/Installation 11-172
EGR System
Catalytic Converter System

Catalytic Converter Inspection 11-177
PCV System
PCV Valve Inspection and Test 11-178

11-1_Fuel and Emissions
NOTE: Refer to the '01 CIVIC Shop Manual on this CD, P/N 62S5A00, for the items not shown in this section.
Outline of CIVIC Model Change
4EE2 engine has been added.
aaa

11-2_Fuel and Emissions Systems_Special Tools
11-2
Special Tools

1 07WAA-0010100 Adjustable ring wrench 1
2 5-8840-7002-0 Remover fuel supply pump pulley 1
3 5-86751-052-0 Injection fixing tool 1
4 07XAZ-0010100 Test pin box (Pin box 130 seem) 1
5 070AZ-PLZE100 Test harness 1
6 5-8840-7010-0 Injector test harness 1
aaa

11-3_Fuel and Emissions Systems_General Troubleshooting Information
11-3
General Troubleshooting Information
Intermittent Failures 1. 2. If the MIL stays on, connect a scan tool (A) to
The term ''intermittent failure'' means a system may have the Data Link Connector (DLC) (B) located
had a failure, but it checks OK now. If the Malfunction under the driver's side of the dashboard.
Indicator Lamp (MIL) on the dash does not come on,
check for poor connections or loose wires at all
connectors related to the circuit that you are
troubleshooting.
Opens and Shorts
''Open'' and ''Short'' are common electrical terms. An open
is a break in a wire or at a connection. A short is an
accidental connection of a wire to ground or to another
wire. In simple electronics, this usually means something
will not work at all. In complex electronics (like ECM's)
this can sometimes mean something works, but not the 2. 3. Turn the ignition switch ON (II).
way it is supposed to. 3. 4. After turning the ignition switch ON (II) for more
How to Use the PGM Tester or a Scan Tool than 5 seconds, check the Diagnostic Trouble
If the MIL (Malfunction Indicator Lamp) has Code (DTC) and note it. Also check the freeze
come on frame data. Refer to the DTC Troubleshooting
Index and begin the appropriate troubleshooting
1. 1. Start the engine and check the MIL (A) and procedure.
glow lamp (B). NOTE:
Freeze frame data indicates the engine
conditions when the first malfunction.
The scan tool can read the DTC, freeze frame
data, current data and other Engine Control
Module (ECM) data.
For specific operations, refer to the user's
manual that came with the scan tool or Honda
PGM Tester.
ECM performs an after check for about 5
seconds after an engine stop.
If the MIL did not come on
If the MIL did not come on but there is a driveability
problem, refer to the Symptom Troubleshooting Index in
this section.
If you can not duplicate the DTC
Some of the troubleshooting in this section requires you
to reset the ECM and try to duplicate the DTC. If the
problem is intermittent and you can not duplicate the
code, do not continue through the procedure. To do so
will only result in confusion and, possibly, a needlessly
replaced ECM.
aaa

11-4_Fuel and Emissions Systems_General Troubleshooting Information (cont'd)
11-4
General Troubleshooting Information (cont'd)
How to Reset the ECM How to Remove the ECM for Testing
You can reset the ECM in only one way: If the inspection for a trouble code requires voltage or
Use the scan tool to clear the ECM's memory. resistance checks at the ECM connectors, remove the
See the scan tool user's manuals for specific ECM and test it:
instructions. 1. 1. Remove the passenger's dashboard lower
How to End a Troubleshooting Session cover (A) and the glove box, refer to the 2001
(required after any troubleshooting)
79).
1. 1. Reset the ECM as described above.
3. 3. Disconnect the scan tool or Honda PGM Tester
from the DLC.
NOTE: The ECM is part of the immobiliser
system. If you replace the ECM, it will have a
different immobiliser code. In order for the
engine to start, you must rewrite the immobiliser
code with the Honda PGM Tester.
2. 2. Remove the ECM mounting bolts (B), relay

mounting nut (C) ground nut (D).
3. 3. Remove the ECM (E) from the bracket (F).
aaa

11-5_Fuel and Emissions Systems_General Troubleshooting Information (cont'd)
11-5
General Troubleshooting Information (cont'd)
How to Troubleshoot at the ECM How to Substitute the ECM

Special Tools Required 1. 1. Remove the ECM from the vehicle.
Test pin box (pin box 130 seem) 07XAZ- 2. 2. Install a known-good ECM in the vehicle.
0010100 3. 3. Rewrite the immobiliser code with the ECM
Test harness 070AZ-PLZE100 replacement procedure on the Honda PGM
Tester. It allows you to start the engine.
1. 1. In case you measured the standard voltage of
4. 4. After completing your tests, reinstall the original
ECM, remove a connector and use the Test pin
ECM and rewrite the immobiliser code with the
box and Test harness.
ECM replacement procedure on the Honda
PGM Tester again.
aaa
2. 2. If you cannot get to the wire side of the

connector or the wire side is sealed (A),
disconnect the connector and probe the
terminals (B) from the terminal side. Do not
force the probe into the connector.
Do not puncture the insulation on a wire. Punctures

can cause poor or intermittent electrical connections.
Do not force the probe into the ECM connector.

11-6_Fuel and Emissions Systems_DTC Troubleshooting Index
11-6
DTC Troubleshooting Index
DTC Indicate Lamp Detection Item Page

Scan Honda MIL (Check Glow Lamp
tool DTC DTC Engine Lamp)
P0101 - On - MAF System Performance (see page 11-47)
P0102 - On - MAF Sensor Circuit Low Voltage (see page 11-49)
P0103 - On - MAF Sensor Circuit High Voltage (see page 11-51)
P0112 - On - IAT Sensor Circuit Low Voltage (see page 11-53)
P0113 - On - IAT Sensor Circuit High Voltage (see page 11-54)
P0117 - On - ECT Sensor Circuit Low Voltage (see page 11-55)
P0118 - On - ECT Sensor Circuit High Voltage (see page 11-56)
P0192 - On On RP Sensor Circuit Low Voltage (see page 11-57)
P0193 - On On RP Sensor Circuit High Voltage (see page 11-59)
P0223 - On On Accelerator Pedal Position (APP) (see page 11-60)
Sensor 1 Circuit High Voltage
Sensor 2 Circuit High Voltage
P0236 - On - MAP System Performance (see page 11-63)
P0237 - On - MAP Sensor Circuit Low Voltage (see page 11-65)
P0238 - On - MAP Sensor Circuit High Voltage (see page 11-66)
P0335 - On On CKP-CMP Correlation Error (see page 11-67)
P0338 - On On Over Speed Detection (see page 11-69)
P0341 - On On CMP Sensor Circuit Performance (see page 11-70)
P0343 - On On CMP Sensor Signal Too High (see page 11-72)
Frequency
P0501 - On On Vehicle Speed Sensor (VSS) Signal Too (see page 11-74)
High Frequency
P0502 - On On VSS Circuit Low Input (see page 11-75)
P0503 - On On Vehicle Speed Sensor (VSS) Signal (see page 11-76)
Above Upper Limit
P0562 - On - System Voltage Low (see page 11-77)
P0563 - On - System Voltage High (see page 11-79)
P0601 - On - ECM Memory (Checksum Error) (see page 11-81)
P0606 - On On Redundant Overrun Monitoring (see page 11-81)
P0704 - On On No Clutch SW Signal (see page 11-82)
P1000 - On On Injector Low Side Circuit Over Current (see page 11-83)
(Short to Bolt)
P1001 - On On Injector High Side Circuit Over Current (see page 11-85)
(Short to ground)
P1002 - On On Injector 1 Low Current Open Circuit (see page 11-87)
P1003 - On On Injector Performance Malfunction (see page 11-88)
aaa

11-7_Fuel and Emissions Systems_DTC Troubleshooting Index (cont'd)
11-7
DTC Troubleshooting Index (cont'd)
DTC Indicator Lamp Detection Item Page

P1086 - On On Rail Pressure Control System High (see page 11-92)
Performance
P1087 - On On Rail Pressure Low (see page 11-94)
P1088 - On On Rail Pressure High (see page 11-96)
P1091 - On On Rail Pressure Control Valve (Fuel (see page 11-98)
Metering Unit) Circuit Open
P1092 - On On Rail Pressure Control Valve (Fuel (see page 11-99)
Metering Unit) Circuit Short
P1095 - On On Rail Pressure Control System Low (see page 11-100)
Performance
P1100 - On - MAF Sensor Supply Voltage High/Low (see page 11-102)
P1101 - On - Incorrect MAF High Range (see page 11-104)
P1104 - On - Incorrect MAF Low Range (see page 11-106)
P1107 - On - BARO Sensor Circuit Low Voltage (see page 11-107)
P1108 - On - BARO Sensor Circuit High Voltage (see page 11-108)
P1112 On - Variable Swirl Control Valve Circuit (see page 11-167)
Open
P1113 - On - Variable Swirl Control Valve Circuit (see page 11-168)
Short
P1195 - On On Fuel Pressure Sensor Supply Voltage (see page 11-108)
High/Low
Sensor 1 Supply Voltage High/Low
Sensor 2 Supply Voltage High/Low
P1235 - On - MAP Sensor Supply Voltage High/Low (see page 11-114)
P1236 - On - Boost Pressure Control Negative (see page 11-115)
Deviation
P1237 - On - Boost Pressure Control Positive (see page 11-116)
Deviation
P1238 - On - Boost Pressure Control Circuit Open (see page 11-117)
P1239 - On - Boost Pressure Control Circuit Short (see page 11-118)
Sensor 1 and 2 Comparison
P1331 - On On CKP-CMP Correlation Dynamic (see page 11-120)
Implausible
P1377 - On - Glow Time Control Circuit Open (see page 11-122)
P1378 - On - Glow Time Control Circuit Short (see page 11-123)
P1401 - On - EGR Valve Control Negative Deviation (see page 11-173)
P1403 - On - EGR Valve Control Circuit Open (see page 11-175)
P1404 - On - EGR Valve Control Circuit Short (see page 11-176)
aaa

11-8_Fuel and Emissions Systems_DTC Troubleshooting Index (cont'd)
11-8
DTC Troubleshooting Index (cont'd)
DTC Indicate Lamp Detection Item Page

P1535 - On On Incorrect Main Relay Performance (see page 11-124)
(Switches off too early)
P1536 - On On Incorrect Main Relay Performance (see page 11-125)
(Switches off too late)
P1550 - On On Brake SW Signal Correlation Error (After (see page 11-127)
Restart Memory)
P1551 - On On Brake SW Signal Correlation Error (see page 11-129)
P1610 - On - EEPROM Communication Error (see page 11-130)
P1611 - On - EEPROM Write Error (see page 11-131)
P1612 - On On Gate Array Quantity Stop (see page 11-131)
P1613 - On On Gate Array Communication (see page 11-132)
P1614 - On On Injector drive Circuit Voltage Too High (see page 11-133)
P1615 - On On Injector drive Circuit Voltage Too Low (see page 11-134)
P1616 - On On RAM Performance (see page 11-135)
P1617 - On On ECM Internal Ground Connection Error (see page 11-135)
P1618 - On On Reference #1 And #2 Circuit Low/High (see page 11-136)
Voltage
(APS1, APS2, RP, MAP, MAF sensor)
P1619 - On On Injector driver Circuit Shut Off Error (see page 11-137)
(Error at shut off via zero quantity)
P1620 - On On Injector driver Circuit Shut Off Error (see page 11-138)
(Error at shut off via injector power
stage (OFF))
P1621 - On On Shut Off Error (5 V power supply Circuit (see page 11-139)
Low, stabiliser limit exceeded)
P1622 - On On Shut Off Error (5 V power supply Circuit (see page 11-140)
High, stabiliser limit exceeded)
P1623 - On On Ignition Switch Circuit Low (see page 11-141)
P1625 - On On Reference #1 Circuit Low Voltage (see page 11-142)
(APS1, MAF sensor)
P1626 - On On Reference #1 Circuit High Voltage (see page 11-143)
(APS1, MAF sensor)
P1627 - On On Reference #2 Circuit Low Voltage (see page 11-144)
(APS2, RP sensor, MAP sensor)
P1628 - On On Reference #2 Circuit High Voltage (see page 11-145)
(APS2, RP sensor, MAP sensor)
aaa

11-9_Fuel and Emissions Systems_Symptom Troubleshooting Index
11-9
When the vehicle has one of these symptoms, check Diagnostic Trouble Code (DTC) with scan tool. If there is no DTC, to the
diagnostic procedure for the symptom, in the sequence listed, until you find the cause.
Symptom Diagnostic Procedure Also check for
Malfunction Indicator Lamp Immobiliser System
(MIL) turns ON
Excessive vibration 1. 1. Engine Mount Contaminated
2. Fuel filter, Fuel Line, Fuel, Fuel Condition. Fuel
3. Injection Timing System. Engine
(CKP Sensor, CMP sensor, Mechanical timing) Mechanical
4. Fuel Injection System. Chassis Parts
(Injector, Supply Pump, Common Rail) Error
Excessive smell 1. 1. Injection Timing System. Low

(CKP Sensor, CMP Sensor, Mechanical timing) Compression
2. Fuel filter, Fuel Line, Fuel, Fuel Condition. Engine
3. Catalyst Converter. Mechanical
Engine will not start 1. 1. Starter System. Low
2. Immobiliser System. Compression
3. Injection Timing System. Contaminated
(CKP Sensor, CMP Sensor, Mechanical timing) Fuel
4. Fuel filter, Fuel Line, Fuel, Fuel Condition. Engine
5. Fuel Injection System. Mechanical
(Injector, Supply Pump, Common Rail)
6. ECM (ECM, Fail Safe Mode)
Difficult to start when cold 1. 1. Starter System. Low
2. Immobiliser System. Compression
3. Injection Timing System. Contaminated
(CKP Sensor, CMP Sensor, Mechanical timing) Fuel
4. Fuel filter, Fuel Line, Fuel, Fuel Condition.
5. Glow System.
(Glow Relay, Glow Plug)
6. Fuel Injection System.
7. ECM (ECT Sensor, ECM, Fail Safe Mode)
aaa

11-10_Fuel and Emissions Systems_Symptom Troubleshooting Index (cont'd)
11-10
Symptom Troubleshooting Index (cont'd)

When cold idle out of spec. 1. 1. Intake System.
(Intake manifold, air cleaner, MAF sensor)
2. Glow System.
(Glow Relay, Glow Plug)
3. Injection Timing System.
(CKP Sensor, CMP Sensor, Mechanical timing)
4. Fuel filter, Fuel Line, Fuel, Fuel Condition.
Rough idle 1. 1. Intake System. Low
(Intake manifold, air cleaner) Compression
2. Fuel filter, Fuel Line, Fuel, Fuel Condition. Contaminated
3. Throttle System. Fuel
(AP Sensor, Throttle cable) Chassis Parts
Error
5. Exhaust System.
(EGR system, Turbocharger, Vacuum system)
When warm engine speed 1. 1. Throttle System.
too high (AP Sensor, Throttle cable)
(Injector, Common Rail)
When warm engine speed 1. 1. Oil viscosity.
too low 2. Intake System.
3. Throttle System.
(AP Sensor, Throttle cable)
Over Heat 1. 1. Thermostat, Radiator, Cooling Fan, Coolant
(Injector, Common Rail, ECM)
Over Run 1. 1. Operation Error
(Injector, Common Rail, ECM)
aaa

11-11

Warming up 1. 1. Intake System. Low
(Intake manifold, air cleaner, MAF sensor) Compression
3. Glow System. Fuel
(Glow Relay, Glow Plug) Engine
Mechanical
4. Exhaust System.
Chassis Parts
Error
After warm up 1. 1. Intake System. Low
3. Exhaust System. Fuel
(EGR system, Turbocharger, Vacuum system) Engine
Mechanical
Chassis Parts
Error
aaa

11-12

Misfire or rough 1. 1. Intake System. Low
2. ECM (ECT Sensor, ECM) Engine
3. Vehicle Speed Sensor Mechanical
4. Exhaust System.
5. BARO Sensor
6. Injector
Fail emission test 1. 1. Intake System. Contaminated
(Intake manifold, air cleaner, MAF sensor) Fuel
2. Oil viscosity Engine Oil
3. BARO Sensor Quality
4. Exhaust System.
6. Catalyst Converter.
Loss of power 1. 1. Fuel filter, Fuel Line, Fuel, Fuel Condition. Low
2. Throttle System. Compression
(AP Sensor, Throttle cable) Engine
3. Intake System. Mechanical
(Intake manifold, air cleaner, MAF sensor) Chassis Parts
Error
(Injector, Supply Pump, Common Rail with RP
sensor)
5. Exhaust System.
6. BARO Sensor
7. Vehicle Speed Sensor
8. Air Condition System
Hesitation/Surging 1. 1. Fuel filter, Fuel Line, Fuel, Fuel Condition. Engine
2. Exhaust System. Mechanical
(EGR system, Turbocharger, Vacuum system) Chassis Parts
3. Intake System. Error
(Intake system, filter)
5. Vehicle Speed Sensor
6. Air Condition System
aaa

11-13

Black smoke 1. 1. Intake System. Engine
(Intake manifold, air cleaner, MAF sensor) Mechanical
2. Exhaust System. Engine Oil
(EGR system, Turbocharger, Vacuum system) Quality
3. BARO Sensor
6. ECM (ECT Sensor, ECM)
White smoke 1. 1. Intake System. Engine Mechanical
2. Exhaust System.
3. BARO Sensor
6. ECM (ECT Sensor, ECM)
aaa

11-14_Fuel and Emissions Systems_System Descriptions
11-14
System Descriptions
Electronic Control System

The functions of the fuel and emission control systems are managed by the Engine Control Module (ECM).
Fail-safe Function
When an abnormality occurs in the signal from a sensor, the ECM ignores that signal and assumes a pre-programmed value for
that sensor that allows the engine to continue to run.
Self-diagnosis
When an abnormality occurs in the signal from a sensor, the ECM supplies ground for the Malfunction Indicator Lamp (MIL) and
stores the Diagnostic Trouble Code (DTC) in erasable memory. When the ignition is first turned on, the ECM supplies ground to
the MIL, start the engine to check the MIL bulb condition.
After check Function
The ECM performs an after check for about 5 seconds after an engine stop.
aaa

11-15_Fuel and Emissions Systems_System Descriptions (cont'd)
11-15
System Descriptions (cont'd)
ECM Data
You can retrieve data from the ECM by connecting the scan tool to the Data Link Connector (DLC). The items listed in the table
below conform to SAE recommended practice.
NOTE:
The ''operating values'' listed are approximate and may vary depending on the environment and the individual vehicle.
Unless noted otherwise, ''at idle speed'' means idling with the engine completely warmed up, transmission in neutral
position and the A/C and all accessories turned off.
Data Description Operating Value Freeze
Data
Engine Speed Engine speed is computed by the ECM from the signals sent Nearly the same as tachometer
from the Crank Position (CKP) sensor. indication at idle speed: 850 +
This data is used for determining the time and amount of 50 rpm (min -1 )
injected fuel.
Engine Coolant The ECT sensor converts coolant temperature into voltage and With cold engine: Nearly the
Temperature (ECT) signals the ECM. The sensor is a thermistor whose internal same as ambient temperature
resistance changes with coolant temperature. The ECM uses and IAT.
the voltage signals from the ECT sensor to determine the With engine warmed up: about
amount of injected fuel. 80 – 100 °C (176 – 212 °F), 0.8
– 0.5 V.
Vehicle Speed The ECM converts pulse signals from vehicle speed sensor Nearly the same as
(VSS). speedometer indication.
Engine Load The ECM calculates engine load based on injection rate. About 17 – 23 % at idle speed
Final injection (Q-Final)/Maximum permission injection (Q-Full)
x 100 % = Engine load
Manifold Absolute Boot pressure governing is used to control an exhaust With engine stopped: Nearly the
Pressure (MAP) turbocharger with Waste-Gate as well as a turbocharger with same as atmospheric pressure.
variable turbine geometry (VTG-turbocharger). At idle engine: About 20 – 30
For governing an exhaust turbocharger with Waste-Gate the kPa (150 – 260 mmHg, 6 – 10
actuator is a bypass valve through which the exhaust flow is in. Hg), 0.7 – 1.1 V.
directed to or past the turbine. For governing a VTG-
turbocharger the actuator is the variable turbine geometry.
Boost pressure governing is subdivided into recognition of
driving habits, setpoint valve calculation, boost pressure
governor (closed-loop control), boost pressure open loop
control, controlled adaption of governor parameters and
monitoring and shut off.
Mass air Flow (MAF) The ECM converts frequency signals from mass air flow sensor About 8 – 13 g/sec at idle speed
(MAF).
This indicates the amount of air entering the engine.
Throttle Position (TP) Based on the accelerator pedal position, the opening angle of About 0 – 10 % at idle speed
Sensor (Accelerator the throttle valve is indicated.
Pedal Position (APP)
Sensor)
Intake Air The IAT sensor converts intake air temperature into voltage With cold engine: Same as
Temperature (IAT) and signals the ECM. When intake air temperature is low, the ambient temperature and ECT.
internal resistance of the sensor increases, and the voltage
signal is higher.
Stored DTCs Stored DTCs are used to detect to stored DTC quantity 0 at normal
OBD Not used Not used

11-16
ECM Inputs and Outputs at Connector A (81P)

Terminal Wire Terminal Name Description Signal Condition
No. Colour
1 BLK Battery minus Ground for the ECM circuit 0 V at all times
4 LT GRN Battery plus Power source for the ECM Battery voltage with the ignition switch ON (II)
circuit About 0 V with the ECM power OFF
5 RED Battery plus Power source for the ECM Battery voltage with the ignition switch ON (II)
circuit of drivers injector About 0 V with the ignition switch OFF
11 RED/BLU Vehicle immobilisation Detects immobiliser signal Pulses signal with the immobiliser
system communication ON
12 GRN Coolant temperature Output coolant temperature to Pulses signal with the ignition switch ON (II)
output signal meter
13 YEL/BLK System power relay Drivers main relay Battery voltage with the main relay OFF
About 0 V with the main relay ON
15 GRN/RED Malfunction indication Drivers MIL Battery voltage with the MIL turned OFF
lamp (MIL) About 0 V with the MIL turned ON
16 YEL EGR valve Drivers EGR valve About 0 V to 12 V pulses signal
17 WHT Variable geometric Driven variable turbine About 0 V to 12 V pulses signal
turbine
18 BRN/GRN Variable swirl control Drivers variable swirl control Battery voltage with the variable swirl control
valve valve valve not operating
About 0 V with the variable swirl control
valve operating
19 PNK Glow relay Drivers glow relay Battery voltage with the glow plug OFF
About B+ with the glow plug ON
20 RED A/C compressor relay Drivers A/C clutch Battery voltage with the A/C compressor OFF
(compressor) relay About 0 V with the A/C compressor ON
NOTICE
In case you measure the standard voltage of ECM, remove a connector and use the Test pin box and Test harness.
The battery power supply short circuit to 5 V power supply damages the ECM.
aaa

11-17

No. Colour
22 ORN Glow lamp/fault lamp Drivers glow lamp/fault lamp Battery voltage with the glow lamp/fault lamp
turned OFF
About 0 V with the glow lamp/fault lamp
turned ON
47 BLU Engine speed output Output engine speed to meter Pulses signal with the engine running
signal
48 Silver BLK ISO-K interface Communicates with scan tool Pulses signal with the scan tool
(PGM tester) communicating
49 BLU/WHT Vehicle speed sensor Detects VSS signal Pulses signal with the vehicle running
(VSS) signal
54 GRY/BLU Redundant brake switch Detects redundant brake Battery voltage with the brake pedal (B/P)
signal switch signal depressed
About 0 V with the B/P released
58 YEL Terminal 15 (switch bat. Detects ignition switch signal Battery voltage with the ignition switch ON (II)
+)
59 WHT/BLK Brake switch signal Detects brake switch signal Battery voltage with the brake pedal (B/P)
depressed
About 0 V with the B/P released
60 PUR/WHT A/C on switch signal Detects A/C ON switch signal Battery voltage with the A/C OFF
About 0 V with the A/C ON
61 Silver BLK Clutch switch signal Detects clutch switch signal About 0 V with the clutch pedal (C/P)
depressed
Battery voltage with the C/P released
76 BLK Accelerator pedal (AP) Ground for the AP sensor 1 0 V at all times
sensor 1, ground
77 YEL/BLU Accelerator pedal (AP) Detects AP sensor 1 signal About 3.1 V with the AP fully open
sensor 1, signal About 0.7 V with the AP fully closed
78 RED/YEL Accelerator pedal (AP) Provides AP sensor 1 About 5 V with the ignition switch ON (I)
sensor 1, supply About 0 V with the ignition switch OFF
79 BLK/WHT Accelerator pedal sensor Ground for the AP sensor 2 0 V at all times
2, ground
80 YEL/GRN Accelerator pedal sensor Detects AP sensor 2 signal About 1.5 V with the AP fully open
2, signal About 0.37 V with the AP fully closed
81 RED/WHT Accelerator pedal sensor Provides AP sensor 2 About 5 V with the ignition switch ON (I)
2, supply About 0 V with the ignition switch OFF
aaa

11-18
ECM Inputs and Outputs at Connector B (40P)

No. Colour
84 WHT Engine coolant Detects ECT sensor signal About 0.1 V – 4.8 V with the ignition switch
temperature (ECT) ON (II) (depending on ECT)
sensor signal
85 GRY Engine coolant Ground for the ECT sensor 0 V at all times
temperature (ECT)
sensor ground
86 YEL Rail pressure (RP) Detects RP sensor signal About 1 V with the engine running at idle
sensor signal (depending on RP)
88 BLK Mass air flow (MAF) Ground for the MAF sensor 0 V at all times
sensor ground
89 BRN Mass air flow (MAF) Detects MAF sensor signal About 2 V – 3 V with the engine running at
sensor signal idle
90 RED/YEL Rail pressure (RP) Provides RP sensor About 5 V with the ignition switch ON (II)
sensor supply About 0 V with the ignition switch OFF
91 YEL/RED Intake air temperature Detects IAT sensor signal About 0.1 V – 4.8 V with the ignition switch
(IAT) sensor signal ON (II) (depending on IAT)
92 BLK/RED Rail pressure (RP) Ground for the RP sensor 0 V at all times
sensor ground
93 RED/BLU Manifold absolute Provides MAP sensor About 5 V with the ignition switch ON (II)
pressure (MAP) sensor
supply
94 YEL/RED Manifold absolute Detects MAP sensor signal About 2 V with the ignition switch ON (II)
pressure (MAP) sensor About 2 V with the engine running at idle
signal
95 BLK/YEL Manifold absolute Ground for the MAP sensor 0 V at all times
pressure (MAP) sensor
ground
97 WHT/RED Mass air flow (MAF) Provides MAF sensor About 5 V with the ignition switch ON (II)
sensor supply
99 WHT/BLU Crank position (CKP) Detects CKP sensor plus Pulses signal with the engine running
sensor plus signal signal
100 ORN/BLU Crank position (CKP) Detects CKP sensor minus Pulses signal with the engine running
sensor minus signal signal
NOTICE
In case you measure the standard voltage of ECM, remove a connector and use the Test pin box and Test harness.
The battery power supply short circuit to 5 V power supply damages the ECM.
aaa

11-19

No. Colour
101 BLK Crank position (CKP) Ground for the CKP sensor 0 V at all times
sensor ground/shield
103 BRN/WHT Camshaft position Detects CMP sensor signal Pulses signal with the engine running
(CMP) sensor signal
104 WHT Camshaft position Ground for the CMP sensor 0 V at all times
(CMP) sensor ground
105 PUR Request input cabin Detects cabin heater ON switch Battery voltage with the cabin heater OFF
heater signal About 0 V with the cabin heater ON
108 RED Fuel metering unit (FMU) Power source for the FMU Battery voltage with the ignition switch ON (II)
''high side'' circuit
109 GRN Fuel metering unit (FMU) Drivers FMU About 7 V with the ignition switch ON (II) and
''low side'' engine OFF
110 GRY Cabin heater relay 1 Drivers cabin heater relay 1 Battery voltage with the cabin heater OFF
(500 W) About 0 V with the cabin heater ON
111 GRY/RED Cabin heater relay 2 Drivers cabin heater relay 2 Battery voltage with the cabin heater OFF
(200 W) About 0 V with the cabin heater ON
114 BLU Injector for cylinder 4 Drivers injector 4 About 0 V with the engine running
117 RED Injector ''high bank'' f. Power source injector 1 and 4 About 0 V with the ignition switch ON (II) and
cyl. 1 and 4 engine OFF
118 YEL Injector ''high bank'' f. Power source injector 2 and 3 About 0 V with the ignition switch ON (II) and
cyl. 2 and 3 engine OFF
119 WHT Injector for cylinder 1 Drivers injector 1 About 0 V with the engine running
120 BLU Injector for cylinder 3 Drivers injector 3 About 0 V with the engine running
121 GRY Injector for cylinder 2 Drivers injector 2 About 0 V with the engine running
aaa

11-20
Vacuum Hose Routing
No. Part Name QTY Remarks

(1) JOINT; 4WAY 1
(2) HOSE; VACUUM, V/PIPE-4WAY 1 ø7
(3) HOSE; VACUUM, TURBO-EVRV 1 ø10
(4) HOSE; VACUUM, 4WAY-EVRV (TURBO) 1 ø7-ø8 4WAY-EVRV (TURBO)
(5) HOSE; VACUUM, 4WAY-EVRV (EGR) 1 ø7-ø8 4WAY-EVRV (EGR)
(6) HOSE; VACUUM, 4WAY-VSV 1 ø7-ø8 4WAY-VSV
(7) HOSE; VACUUM, VSS-VSV 1 ø7-ø8 VSS-VSV
(8) HOSE; VACUUM, EGR V-EVRV 1 ø10
(9) JOINT; 3WAY 1
(10) HOSE; VACUUM, EGR-3WAY 1 ø10
(11) HOSE; VACUUM, 3WAY-A/C 1 ø10
(12) CLIP; HOSE, VACUUM 1 ø7-ø7
aaa

11-21
Vacuum Hose Routing

aaa

11-22
Vacuum Hose Routing (cont'd)

a. a. CLAMP TO HARNESS
b. HARNESS; P/P
c. EVRV
d. EGR VALVE
e. INSERTION LENGTH IS
MORE THAN 15mm
f. VSS
g. MUST INSERT TO THE END.
h. ASSEMBLE TO 3WAY.
i. INSERTION LENGTH IS
MORE THAN 10mm.
j. 4WAY
k. ASSEMBLE TO EVRV.
l. MUST INSERT TO THE END.
m. 3WAY
n. EVRV

(8) HOSE; VACUUM, EGR V-EVRV 1 ø10
(10) HOSE; VACUUM, TURBO-3WAY 1 ø10
aaa

11-23

a. a. 4WAY
b. VSS
c. ASSEMBLE TO VSV.
d. MUST INSERT TO THE END.
e. VSV
f. ASSEMBLE TO 4WAY.
g. INSERTION LENGTH IS
MORE THAN 10mm.
h. CLAMP TO HARNESS; P/P
i. EVRV
j. VSV
k. 4WAY
l. ASSEMBLE TO EVRV.
m. MUST INSERT TO THE END.
n. EVR
o. 3WAY
p. INSERTION LENGTH IS
MORE THAN 10mm
q. ASSEMBLE TO 3WAY

(1) JOINT; 4WAY 1
(4) HOSE; VACUUM, 4WAY-EVRV (TURBO) 1 ø7-ø8 4WAY-EVRV (TURBO)
(5) HOSE; VACUUM, 4WAY-EVRV (EGR) 1 ø7-ø8 4WAY-EVRV (EGR)
(6) HOSE; VACUUM, 4WAY-VSV 1 ø7-ø8 4WAY-VSV
(9) JOINT; 3WAY 1
(10) HOSE; VACUUM, TURBO-3WAY 1 ø10
aaa

11-24

a. a. TURBO
b. HOSE; V/PIPE
c. PIPE; VACUUM
d. MUST INSERT TO THE END.

aaa

11-25

a. a. MUST INSERT TO THE END.
b. PIPE; VACUUM

aaa

11-26
Fuel System Outline

System Outline
This system also provides the following functions:
A self-diagnosis and alarm function that uses a computer to diagnose the system' s major components and to alert the
driver in case of a problem.
A fail-safe function to stop the engine, depending upon the location of the problem.
A backup function to change the fuel regulation method, thus enabling the vehicle to continue operating.
System Configuration
Divided by function, the system can be classified according to the fuel system and the control system.
Fuel System
The high-pressure fuel that is generated by the supply pump is distributed to the cylinders by way of a common rail.
Then, the electromagnetic valves in the injectors open and close the nozzle needle valve to control the starting and ending of the
injection of fuel.
Control System
Based on the signals received from sensors that are mounted on the engine and on the vehicle, the ECM controls the timing of the
current and the length of time that the current is applied to the injectors, thus ensuring that an optimal amount of fuel is injected at
an optimal time.
The control system can be broadly classified according to the following electronic components; sensors, computers, and actuators.
aaa

11-27
System configuration
aaa

11-28
Construction and Operation of the System aaa

The common rail system consists of supply pump,
common rail, injector, ECM and sensors. The supply
pump generates the fuel pressure in the common rail.
Fuel pressure is controlled depending on the fuel amount
discharged from the supply pump. The fuel discharge
amount is controlled by means of a fuel metering unit
provided in the supply pump which is opened/closed in
response to electric signals from the ECM.
The common rail receives and distributes the fuel
pressure made by the supply pump to each cylinder. Fuel
pressure is detected by means of a common rail pressure
sensor installed to the common rail and is feedback
controlled so that the instructed pressure value set
according to engine speed and load can agree with an
actual pressure value.
The fuel pressure in the common rail is applied through
the injection pipe of each cylinder to the nozzle side and
control chamber of the injector.
The injector controls injection amount and time by
switching on and off a injector. When the injector is
switched on (to carry current), the fuel circuit is changed
over to such a status that the high pressure fuel in the
control chamber may flow out through the outlet orifice.
Owing to nozzle valve opening force caused by the
nozzle side of high pressure fuel, the needle valve is
lifted to start fuel injection.
When the injector is switched off (to cut current), the fuel
circuit is changed over to such a status that the high
pressure fuel is flowed back through the inlet orifice into
the control chamber.
Therefore, the needle valve comes down to stop fuel
injection.
Thus, fuel injection time can be electronically controlled
by injector switching on and fuel injecting amount, by
injector switching off.

11-29
Construction and Operation of Supply Pump aaa

Outline
The function of the supply pump is to regulate the fuel
discharge volume, thus generating the internal fuel
pressure in the common rail.
Construction
The supply pump consists of a feed pump, which is
similar to that of the conventional inline pump and the fuel
metering unit (pump control valves), which are provided at
each cylinder, to regulate the fuel discharge volume.
Operation
The fuel metering unit remains open during the plunger's
downward stroke, allowing the low-pressure fuel to be
drawn into the plunger chamber by way of the fuel
metering unit.
Even after the plunger begins its upward stroke, if the
valve remains open because current is not applied to the
fuel metering unit, the fuel that was drawn in returns via
the fuel metering unit, without becoming pressurised.
When current is applied to the fuel metering unit in order
to close the valve at the timing that accommodates the
required discharge volume, the return passage closes,
causing the pressure in the plunger chamber to rise.
Accordingly, the fuel passes through the delivery valve
(check valve) to the common rail. As a result, the amount
of fuel that corresponds with the lifting of the plunger after
the fuel metering unit closes becomes the discharge
volume and varying the timing of the closing of the fuel
metering unit (plunger pre-stroke) causes the discharge
volume to vary, thus regulating the common rail pressure.
After surpassing the cam' s maximum lift, the plunger
begins its downward stroke, causing the plunger chamber
pressure to decrease. At this time, the delivery valve
closes, thus stopping the pumping of the fuel. In addition,
because the current to the fuel metering unit valve is
stopped, the fuel metering unit opens, allowing the low-
pressure fuel to be drawn into the plunger chamber.

11-30
Barometric Pressure (BARO) Sensor Engine Coolant Temperature (ECT) Sensor

The BARO sensor is inside the ECM. It converts The ECT sensor is a temperature dependent resistor
atmospheric pressure into a voltage signal that modifies (thermistor). The resistor of the thermistor decreases as
the basic duration of the fuel injection discharge. the engine coolant temperature increases.
Crankshaft Position (CKP) Sensor
The CKP sensor detects engine speed and determines
ignition timing and timing for fuel injection of each
cylinder.
1. 1. THERMISTOR
MAF/Intake Air Temperature (IAT) Sensor

The IAT sensor is a temperature dependant resistor
(thermistor). The resistance of the thermistor decreases
as the intake air temperature increases.
1. 1. SHIM
2. CKP SENSOR
2. 1. MAF/IAT SENSOR
2. AIR CLEANER CASE
3. AIR DUCT
aaa

11-31
Manifold Absolute Pressure (MAP) Sensor Fuel Supply System

The MAP sensor converts manifold absolute pressure Supply Pump Control
into electrical signals to the ECM. When the ignition is turned on, the ECM grounds the
main relay which feeds current to the supply pump for 2
seconds to pressurise the fuel system. With the engine
running, the ECM grounds the main relay and feeds
current to the supply pump. When the engine is not
running and the ignition is ON (II), the ECM cuts ground
to the main relay which cuts current to the supply pump.
1. 1. MAP SENSOR
2. SENSOR UNIT
Accelerator Pedal Position (APP) Sensor 1. 1. SUPPLY PUMP
The APP sensor is a potentiometer connected to the Intake Air System

accelerator. As the accelerator pedal position changes, Refer to the System Diagram to see the functional layout
the sensor varies the signal voltage to the ECM. of the system.
Vehicle Speed Sensor (VSS) Exhaust Gas Recirculation (EGR) System
The VSS is driven by the differential. It generates a Refer to the System Diagram to see the functional layout
pulsed signal from an input of 12 volts. The number of of the system.
pulses per minute increases/decreases with the speed of
the vehicle. EGR Valve
Brake Pedal Position Switch The EGR valve is designed to lower peak combustion
temperatures and reduce oxides of nitrogen emissions
The brake pedal position switch signals the ECM when (NOx) by recalculating exhaust gas through the intake
the brake pedal is pressed. manifold and into the combustion chambers.
Positive Crankcase Ventilation (PCV) System
The PCV valve prevents blow-by gasses from escaping
into the atmosphere by venting them into the intake
manifold.
aaa

11-32
EGR System Diagram

Exhaust gas recirculation consists of the following three tasks:
Setpoint value calculation.
Airmass calculation.
Governing resp, controlling and monitoring.
1. EGR VALVE
2. INTAKE MANIFOLD
EGR Control
The main element of the system is the EGR valve. The EGR valve feeds small amounts of the exhaust gas back into the intake
manifold.
The EGR valve is controlled by the ECM and the ECM uses information from the following sensors to control the EGR valve.
ECT sensor
CKP sensor
BARO sensor
MAF sensor
The setpoint value calculation provides the setpoint value and the airmass calculation provides the actual value for controlling.
During control of EGR the actual value of the air quantity for other subsystems (e.g. fuel quantity governing) is furthermore
calculated. In order to reduce the run-time load, the circulation of the exhaust gas recirculation can be limited via the engine speed
threshold.
EGR valve Operation and Results of Incorrect Operation
The EGR valve is designed to accurately supply EGR to the engine independent of the intake manifold to the intake manifold with
an ECM controlled Electrical Vacuum Regulating Valve (EVRV).
The ECM monitors related sensor or switch condition, if EVRV solenoid has incorrect operation, DTCs P1401, P1403 or P1404 will
be set.
If DTCs P1401, P1403 or P1404 are set, refer to the DTC charts.
aaa

11-33
Variable Swirl System (VSS)

The inlet passage shut-off is a pure open loop control. Depending on the air temperature the shut-off can be switched on and off
by a hysteresis. If the air temperature falls below the threshold or a flame start command is activated depending on the switches
the flap is controlled with the on/off ration. If the air temperature exceeds the threshold, the on/off ratio is calculated again.
The setpoint value for the flap is calculated from a map depending on engine speed and the sum of demand and low-idle quantity,
which have been corrected using the curve depending on the atmospheric pressure.
aaa

11-34
ECM Circuit Diagram (Connector A)
aaa

11-35
aaa

11-36
ECM Circuit Diagram (Connector A) (cont'd)
aaa

11-37
ECM Circuit Diagram (Connector B)
aaa

11-38
ECM Circuit Diagram (Connector B) (cont'd)
aaa

11-39
aaa

11-40_Diesel Engine Management System_Component Location Index
11-40
1. ACCELERATOR PEDAL POSITION

(APP) SENSOR
2. MANIFOLD ABSOLUTE PRESSURE
(MAP) SENSOR
3. VEHICLE SPEED SENSOR (VSS)
4. MASS AIR FLOW (MAF) SENSOR
INTAKE AIR TEMPERATURE (IAT)
SENSOR
5. ENGINE COOLANT
TEMPERATURE (ECT) SENSOR
6. CRANKSHAFT POSITION (CKP)
SENSOR
7. EXHAUST GAS RECIRCULATION
(EGR) VALVE
8. INJECTORS
9. RAIL PRESSURE SENSOR
10. EVRV
11. CAMSHAFT POSITION (CMP)
SENSOR
aaa

11-41_Diesel Engine Management System_Component Location Index (cont'd)
11-41
Component Location Index (cont'd)
1. DATA LINK CONNECTOR (DLC)

General Troubleshooting
Information, page 11-3
2. MAIN RELAY
3. ENGINE CONTROL MODULE
General Troubleshooting
Information, page 11-3
4. INERTIA SWITCH
aaa

11-42
Engine right side view

1. TIMING BELT COVER UPPER
2. CAMSHAFT POSITION (CMP)
SENSOR
3. A/C COMPRESSOR
4. IDLER PULLEY
5. AUTO BELT TENSIONER
6. A/C GENERATOR
7. WATER PUMP PULLEY
9. OIL PAN LOWER
10. TIMING BELT COVER LOWER
aaa

11-43
Engine front view

1. ACOUSTIC COVER
2. OIL LEVEL GAUGE
3. ENGINE HANGER LH
(EGR) PIPE
5. WATER OUTLET PIPE
7. HEAT PROTECTOR
8. TURBOCHARGER
9. HEAT PROTECTOR;
TURBOCHARGER
10. ACTUATOR FOR WASTE GATE
VALVE
11. FLYWHEEL
12. OIL PAN UPPER
13. OIL PAN LOWER
14. CYLINDER BLOCK
15. VACUUM PUMP
aaa

11-44
Engine rear view

1. ENGINE HARNESS ASSEMBLY
2. ENGINE OIL FILTER
(EGR) VALVE
4. VARIABLE SWIRL SYSTEM (VSS)
ACTUATOR
5. MANIFOLD ABSOLUTE PRESSURE
(MAP) SENSOR
6. RAIL PRESSURE SENSOR
7. COMMON RAIL ASSEMBLY
8. FUEL SUPPLY PUMP
9. FUEL METERING UNIT
10. EVRV FOR TURBOCHARGER
11. ENGINE OIL DRAIN PLUG
12. VACUUM SWITCHING VALVE VSV
FOR VVS
13. EVRV FOR EXHAUST GAS
RECIRCULATION EGR VALVE
14. CRANK POSITION (CKP) SENSOR
15. OIL COOLER ASSEMBLY
aaa

11-45
Engine left side view

1. ENGINE COOLANT
TEMPERATURE (ECT) SENSOR
3. WATER GLOW PLUG
4. STARTER MOTOR
aaa

11-46
Engine upper view

(EGR) VALVE ASSEMBLY
2. AIR INTAKE PIPE
3. ENGINE OIL FILLER CAP
aaa

11-47_Diesel Engine Management System_DTC Troubleshooting
11-47
DTC Troubleshooting
DTC P0101: MAF System Performance Is a problem found?

1. 1. Check the ''On Board Diagnostic (OBD) System YES – Repair as necessary.
Check''. NO – Go to step 5.
Was the ''OBD System Check'' performed?
1. 5. Start the engine and allow it to idle.
YES – Go to step 2. 2. 6. Turn the ignition switch OFF.
NO – Go to OBD System Check. 3. 7. Disconnect the MAF sensor 5P connector.
2. 2. Check the DTC. 4. 8. Disconnect ECM connector.
Are there any other (beside DTC P0101) being output? 5. 9. Check the MAF sensor signal and +5 V circuits
for an open or short to ground.
YES – Go to relevant DTC chart.
MAF/IAT sensor 5P connector
3. 3. Check the MAF with the scan tool.
Is about 8 – 13 g/sec indicated at idling?
YES – Intermittent failure, system is OK at this time.
Check for poor connections or loose wires at the MAF
sensor and at the ECM.
NO – Go to step 4. JUMPER WIRE
4. 4. Check for the following conditions:
Damaged MAF sensor
MAF/IAT sensor 5P connector (A)
Air Cleaner (B)
MAF/IAT sensor (C)
Duct (D)
The duct work at the MAF sensor for leaks
PCV system vacuum leaks
Incorrect PCV valve
Vacuum leaks in EGR valve flange and
pipes
Intake manifold vacuum leaks
Is a problem found?
YES – Repair the MAF signal or +5 V circuit.
aaa

11-48_Diesel Engine Management System_DTC Troubleshooting (cont'd)
11-48
DTC Troubleshooting (cont'd)
1. 10. Check the MAF sensor B+ circuit for an open, 1. 14. Check the MAF with the scan tool.
or short to ground. Is about 225 g/sec (811 kg/h) indicated?
Wire side of female terminals YES – Replace the IAT/MAF sensor.
MAF/IAT sensor 5P connector NO – Substitute a known good ECM and recheck. If
ECM.
NOTICE
The battery power supply short circuit to 5 V power

supply damages the ECM.
JUMPER WIRE
aaa
Is a problem found?
YES – Repair the MAF B+ circuit.
2. 11. Connect ECM connector.
3. 12. Connect the MAF sensor 5P connector
terminals No. 4 and No. 5 with a jumper wire.
JUMPER WIRE

11-49
DTC P0102: MAF Sensor Circuit Low Voltage

1. 1. Check the ''On Board Diagnostic (OBD) System
Check''.
NO – Go to OBD System Check.
2. 2. Check the DTC.
Are there other DTCs P1625, P1618 or P0113 (beside
DTC P0102) being output?
YES – Go to DTC P1625, P1618, or P0113 chart (5 V
reference #1 circuit or ground circuit failure).
NO – Go to step 3. Is a problem found?
3. 3. Start the engine and allow it to idle. YES – Repair the MAF signal or +5 V circuit.
4. 4. Check the MAF with the scan tool. NO – Go to step 9.
Is about 8 – 13 g/sec indicated? (Sea level of 0 m at 1. 9. Check the MAF sensor B+ circuit for an open
room temperature: about 20 °C.) or short to ground.
YES – Intermittent failure, system is OK at this time. Wire side of female terminals
Check for poor connections or loose wires at the MAF MAF/IAT sensor 5P
6. 6. Disconnect the MAF sensor 5P connector.
7. 7. Disconnect ECM connector.
8. 8. Check the MAF sensor signal and +5 V circuits
for an open or short to ground.
Wire side of female terminals Is a problem found?
MAF/IAT sensor 5P connector YES – Repair the MAF +B circuit.
2. 10. Connect the ECM connector.
JUMPER WIRE MAF/IAT sensor 5P connector
JUMPER WIRE
aaa

11-50
1. 13. Check the MAF with the scan tool. aaa

Is about 225 g/sec indicated?
YES – Replace the MAF/IAT sensor.
NO – Substitute a known good ECM and recheck. If
ECM.
NOTICE


11-51
DTC P0103: MAF Sensor Circuit High Voltage

Check''.
YES – Go to DTC P1618, P1626 or P0113 chart (5 V
reference #1 circuit or ground circuit failure).
3. 3. Start the engine and allow it to idle. YES – Repair the MAF signal or +5 V circuit.
Is about 8 – 13 g/sec indicated? (Sea level of 0 m at 1. 9. Check the MAF sensor B+ circuit for a short to
room temperature: about 20°C (68°F)). ground.
Check for poor connections or loose wires at the MAF MAF/IAT sensor 5P connector
7. 7. Disconnect ECM connector. JUMPER WIRE
for a short to ground.
JUMPER WIRE
Is a problem found?
aaa

11-52
1. 11. Connect the MAF sensor 5P connector aaa

JUMPER WIRE
Is about 5 V indicated?
NO – Substitute a known-good ECM and recheck. If
ECM.
NOTICE


11-53
DTC P0112: IAT Sensor Circuit Low Voltage 1. 9. Check the temperature reading on the scan
1. 1. Check the ''On Board Diagnostic (OBD) System tool. Be aware that if the engine is warm, the
Check''. reading will be higher than the ambient
Was the ''OBD System Check'' performed? temperature. If the engine is cold, the IAT and
ECT will have the same value.
Is the correct ambient temperature indicated?
2. 2. Turn the ignition switch ON (II). Check for poor connections or loose wires at the IAT
3. 3. Check the IAT with the scan tool. sensor and at the ECM.
Is there more than 120°C (248°F)?
NO – Replace the MAF/IAT sensor.
NOTICE
4. 4. Disconnect the IAT sensor 5P connector. The battery power supply short circuit to 5 V power
5. 5. Check the IAT with the scan tool. supply damages the ECM.
Is about 215°C (419°F) indicated?
aaa
YES – Replace the IAT/MAF sensor.
8. 8. Check the IAT sensor signal circuit for a short
to ground.
Is a problem found?
YES – Repair the IAT signal circuit.
ECM.

11-54
DTC P0113: IAT Sensor Circuit High Voltage 1. 9. Check the IAT with the scan tool.
1. 1. Check the ''On Board Diagnostic (OBD) System Is about 215°C (419°F) indicated?
Check''. YES – Go to step 10.
Was the ''OBD System Check'' performed? NO – Intermittent failure, system is OK at this time.
YES – Go to step 2. Check for poor connections or loose wires at the IAT
NO – Go to OBD System Check. sensor and at the ECM.
2. 2. Check the DTC. 2. 10. Turn the ignition switch OFF.
Are there other DTCs (P0101/P0103) being output? 11. Disconnect the IAT sensor 5P connector.
3. 12. Connect the IAT sensor 5P connector terminals
No. 1 and No. 3 with a jumper wire.
NO – Go to step 8. Wire side of female terminals
3. 3. Turn the ignition switch OFF. MAF/IAT sensor 5P connector
4. 4. Disconnect the IAT sensor 5P connector.
6. 6. Check the IAT sensor signal and ground circuits
for an open.
JUMPER WIRE
5. 14. Check the IAT with the scan tool.
Is there more than 120°C (248°F)?
YES – Replace the IAT/MAF sensor.
JUMPER WIRE ECM.
NOTICE

aaa
Is a problem found?
YES – Repair the IAT/MAF signal or ground circuit.
7. 7. Connect the IAT/MAF sensor 5P connector and
the ECM connector.

11-55
DTC P0117: ECT Sensor Circuit Low Voltage 1. 9. Check the temperature reading on the scan
1. 1. Check the ''On Board Diagnostic (OBD) System tool.
Check''. Be aware that if the engine is warm, the reading will
Was the ''OBD System Check'' performed? be higher than ambient temperature.
YES – Go to step 2. If the engine is cold, the IAT and ECT will have the
same value.
Is the correct ambient temperature indicated?
3. 3. Check the ECT with the scan tool. YES – Intermittent failure, system is OK at this time.
Is about 140°C (284°F) indicated? Check for poor connections or loose wires at the ECT
NO – Replace the ECT sensor.
aaa
4. 4. Disconnect the ECT sensor 2P connector.
5. 5. Check the ECT with the scan tool.
YES – Replace the ECT sensor.
8. 8. Check the ECT sensor signal circuit for a short
to ground.
Is a problem found?
YES – Repair the ECT signal circuit.
ECM.

11-56
DTC P0118: ECT Sensor Circuit High Voltage 1. 11. Check the ECT sensor circuit for an open.
1. 1. Check the ''On Board Diagnostic (OBD) System Wire side of female terminals
Check''. ECT sensor 2P connector
3. 3. Check the ECT with the scan tool. JUMPER WIRE
Check for poor connections or loose wires at the ECT
5. 5. Disconnect the ECT sensor 2P connector.
6. 6. Connect the ECT sensor 2P connector
Injector 2P connector
Is a problem found?
YES – Repair the ECT open circuit.
JUMPER WIRE ECM.
7. 7. Turn the ignition switch ON (II). aaa
8. 8. Check the ECT with the scan tool.
YES – Replace the ECT sensor.

11-57
DTC P0192: Rail Pressure (RP) Sensor Circuit Low Voltage 1. 7. Turn the engine ON at idling.
1. 1. Check the ''On Board Diagnostic (OBD) System 2. 8. Check the RP sensor signal voltage.
Check''.
Are there other DTCs P1627, P1618 (beside DTC P0192)
being output?
YES – Go to DTC P1627, P1618 chart (5 V reference #2
circuit failure).
Damage to the RP sensor. Is about 1 V indicated?
Is a problem found? YES – Intermittent failure, system is OK at this time. Check
YES – Repair as necessary. for poor connections or loose wires at the RP sensor and at
the ECM.
NO – Replace the RP sensor.
5. 5. Disconnect ECM connector. 3. 9. Disconnect the RP sensor 3P connector.
6. 6. Measure the resistance of RP sensor as below. 4. 10. Check the RP sensor signal circuit for short.
Between terminal 86 and 90. Turn the ignition switch ON (II).
Is there about 0.9 – 1.3 Kohms (At room temperature: about

20°C (68°F))?
Is a problem found?
YES – Repair the RP sensor signal circuit for short.
aaa

11-58
1. 11. Turn the ignition switch OFF. aaa

2. 12. Check the RP sensor ground circuit for open.
RP sensor 3P connector
JUMPER WIRE
Is a problem found?
YES – Repair the RP sensor ground circuit.
3. 13. Measure the resistance of RP sensor.
Is there 0.9 – 1.3 kohms
YES – Substitute a known-good ECM and recheck. If
ECM.
NOTICE


11-59
DTC P0193: Rail Pressure (RP) Sensor Circuit High 1. 8. Check the RP sensor signal voltage.
Voltage
Check''.
Are there other DTCs P1627, P1618 (beside DTC
P1092) being output?
YES – Go to DTC P1627, P1618 chart (5 V reference
#2 circuit failure).
NO – Go to step 3. Is about 1 V indicated?
3. 3. Check for the following conditions: YES – Intermittent failure, system is OK at this time.
Damaged the RP sensor. Check for poor connections or loose wires at the RP
Is a problem found?
2. 9. Disconnect the RP sensor 3P connector
NO – Go to step 4. terminals No. 1 and No. 2 with a jumper wire.
4. 4. Turn the ignition switch OFF. Wire side of female terminals
5. 5. Disconnect ECM connector. RP sensor 3P connector
6. 6. Measure the resistance of RP sensor as below.
Between terminal 86 and 90.
JUMPER WIRE
3. 10. Check the RP sensor signal circuit, +5 V circuit
for open.
Is there about 0.9 – 1.3 kohms (At room temperature:

about 20°C (68°F))?
7. 7. Turn the engine ON at idling.
Is a problem found?
YES – Repair the RP sensor signal or +5 V circuit.
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11-60
1. 11. Check the RP sensor signal voltage. DTC P0223: Accelerator Pedal Position (APP) Sensor 1
Circuit High Voltage
#1 circuit failure)
Damaging APP sensor
An incorrect APP sensor fixing
Damaging accelerator pedal and wire
Is about 5 V indicated? Is a problem found?
YES – Substitute a known-good ECM and recheck. If YES – Repair as necessary.
symptom/indication goes away, replace the original NO – Go to step 3.
ECM.
NO – Go to step 12. 4. 4. Check the TP (APP) with the scan tool.
2. 12. Turn the ignition switch OFF. Is about 0 % indicated?
3. 13. Measure the resistance of RP sensor. YES – Go to step 5.
Is there 0.9 – 1.3 Kohms (At room temperature: about
20°C (68°F))? NO – Go to step 6.
YES – Substitute a known-good ECM and recheck. If 5. 5. Press the accelerator pedal.
symptom/indication goes away, replace the original Is about 0 (idle) – 100 % (WOT) indicated?
ECM. YES – Intermittent failure, system is OK at this time.
NO – Replace the RP sensor. Check for poor connections or loose wires at the APP
NOTICE
The battery power supply short circuit to 5 V power 6. 6. Turn the ignition switch OFF.
supply damages the ECM. 7. 7. Disconnect the APP sensor 6P connector.
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11-61
1. 9. Measure voltage between the APP sensor 6P 1. 11. Check the APP sensor signal circuit for short.
connector terminals No. 1 and No. 2.
(For example; Right handle)

Is there about 5 V?
2. 10. Measure voltage between the ECM connector YES – Repair open in the signal wire between ECM
terminal A 76 and 78. and the APP sensor 1.
NO – Replace the APP sensor 1.
NOTICE

aaa
Is there about 5 V?
YES – Repair open in the wire between ECM and the
APP sensor.
ECM.

11-62
DTC P0228: Accelerator Pedal Position (APP) Sensor 2 1. 9. Measure voltage between the APP sensor 6P
Circuit High Voltage connector terminals No. 4 and No. 6.
1. 1. Check the DTC. (For example; Right handle)
#2 circuit failure)
Damaging APP sensor
An incorrect APP sensor fixing Wire side of female terminals
Damaging accelerator pedal Is there about 5 V?
Is a problem found? YES – Go to step 11.
YES – Repair as necessary. NO – Go to step 10.
NO – Go to step 3. 2. 10. Measure voltage between the ECM connector
3. 3. Turn the ignition switch ON (II). terminals A 79 and 81.
4. 4. Check the APP with the scan tool.
Is about 0 % indicated?
5. 5. Press the accelerator pedal.
Is about 0 (Idle) – 100 % (WOT) indicated?
Check for poor connections or loose wires at the APP
6. 6. Turn the ignition switch OFF. Is there about 5 V?
7. 7. Disconnect the APP sensor 6P connector.
8. 8. Turn the ignition switch ON (II). YES – Repair open in the wire between ECM and the
APP sensor.
ECM.
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11-63
1. 11. Check the APP sensor signal circuit for short. DTC P0236: Manifold Absolute Pressure (MAP) System
Performance
Check''.
Are there any other (beside DTC P0236) being
output?
Is a problem found?
YES – Repair open in the signal wire between ECM 4. 4. Check the MAP with the scan tool.
and the APP sensor 2. Is about atmospheric pressure indicated?
NO – Replace the APP sensor 2. YES – Go to step 5.
NOTICE NO – Go to step 7.
5. 5. Start the engine at idling.
The battery power supply short circuit to 5 V power 6. 6. Check the MAP with the scan tool.
supply damages the ECM. Is about 20 – 30 kPa (150 – 225 mmHg, 5.9 – 8.9 in.
Hg) indicated?
Check for poor connections or loose wires at the MAP
Damaging MAP sensor
The vacuum hose work at the MAP sensor
for leaks
The PCV system vacuum leaks
An incorrect PCV valve
Vacuum leaks EGR valve flange and pipes
Intake manifold vacuum leaks
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11-64
Is a problem found? Wire side of female terminals

YES – Repair as necessary. MAP sensor 3P connector
2. 9. Disconnect the MAP sensor 3P connector
Wire side of female terminals JUMPER WIRE
MAP sensor 3P connector
JUMPER WIRE
4. 11. Check the MAP with the scan tool.
Is about 250 kPa (1,877 mmHg, 73 in. Hg) indicated?
YES – Replace the MAP sensor.
Is a problem found?
YES – Replace the MAP sensor circuit.
6. 13. Check the MAP sensor signal circuit, +5 V
circuit and ground circuit for open/short to NO – Go to step 14.
ground. 1. 14. Substitute a known-good ECM and recheck. If
Wire side of female terminals symptom/indication goes away, replace the
MAP sensor 3P connector original ECM.
NOTICE

JUMPER WIRE aaa

11-65
DTC P0237: Manifold Absolute Pressure (MAP) Sensor 1. 8. Check for the following conditions:
Circuit Low Voltage Damaged MAP sensor
1. 1. Check the ''On Board Diagnostic (OBD) System The vacuum hose work at MAP sensor for
Check''. leaks
Was the ''OBD System Check'' performed? The PCV system vacuum leaks
An incorrect PCV valve
NO – Go to OBD System Check. pipes
2. 2. Check the DTC. Intake manifold vacuum leaks
Are there any other (beside DTC P0237) being output? Is a problem found?
YES – Go to relevant DTC chart. YES – Repair as necessary.
NO – Go to step 3. NO – Go to step 9.
3. 3. Check the DTC. 2. 9. Turn the ignition switch OFF.
Are there other DTCs P1627, P1618 (beside DTC 3. 10. Disconnect the MAP sensor 3P connector.
P0237) being output? 4. 11. Measure voltage between the MAP sensor 3P
YES – Go to DTC P1627, P1618 chart (5 V reference connector terminals No. 1 and No. 3.
#2 circuit failure). Wire side of female terminals
NO – Go to step 4. MAP sensor 3P connector
Is about atmospheric pressure indicated?
Is there about 5 V?
YES – Replace the MAP sensor.
Is about 20 – 30 kPa (150 – 225 mmHg, 5.9 – 8.9 in. NO – Go to step 12.
Hg) indicated? aaa

11-66
1. 12. Measure voltage between the ECM connector DTC P0238: Manifold Absolute Pressure (MAP) Sensor
terminals B93 and B95. Circuit High Voltage
Wire side of female terminals 1. 1. Check the ''On Board Diagnostic (OBD) System
MAP sensor 3P connector Check''.
JUMPER WIRE Are there other DTCs P1628, P1618 (beside DTC
Is about atmospheric pressure indicated?
Is there about 5 V? Is about 20 – 30 kPa (150 – 225 mmHg, 5.9 – 8.9 in.
YES – Repair the wire between ECM and the MAP Hg) indicated?
sensor. YES – Intermittent failure, system is OK at this time.
NO – Substitute a known-good ECM and recheck. If Check for poor connections or loose wires at the MAP
symptom/indication goes away, replace the original sensor and at the ECM.
ECM. NO – Go to step 7.
NOTICE 7. 7. Turn the ignition switch OFF.
8. 8. Disconnect the MAP sensor 3P connector.
The battery power supply short circuit to 5 V power aaa

11-67
1. 9. Check the MAP with the scan tool. DTC P0335: Crankshaft Position (CKP)-Camshaft
Is about 250 kPa (1,877 mm Hg, 73 in. Hg) indicated? Position (CMP) Correlation Error
YES – Go to step 10. 1. 1. Check the ''On Board Diagnostic (OBD) System
NO – Substitute a known-good ECM and recheck. If Check''.
symptom/indication goes away, replace the original Was the ''OBD System Check'' performed?
ECM. YES – Go to step 2.
2. 10. Check the MAP sensor signal circuit for short. NO – Go to OBD System Check.
Is a problem found? 2. 2. Attempt to start the engine.
YES – Repair open in the signal wire between ECM Did the engine start and continue to run?
and the MAP sensor. YES – Intermittent failure, system is OK at this time.
NO – Substitute a known-good ECM and recheck. If Check for poor connections or loose wires at the CKP
symptom/indication goes away, replace the original sensor and at the ECM.
ECM. NO – Go to step 3.
NOTICE 3. 3. Check the engine speed (cranking speed) with
the scan tool.
The battery power supply short circuit to 5 V power Turn the ignition switch to start (III).
Is about 0 rpm (min -1 ) indicated?
5. 5. Disconnect the CKP sensor 3P connector.
6. 6. Disconnect the ECM connector.
7. 7. Check the CKP sensor signal circuit for open or
short to ground.
CKP sensor 3P connector
JUMPER WIRE
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11-68
Is a problem found? 1. 12. Replace the CKP sensor.

YES – Repair open in the signal wire between ECM 2. 13. Check the engine speed (cranking speed) with
and the CKP sensor. the scan tool.
Turn the ignition switch to start (III).
1. 8. Connect the CKP sensor 3P connector. Is about 0 rpm (min -1 ) indicated?
2. 9. Turn the ignition switch ON (II). YES – Substitute a known-good ECM and recheck. If
3. 10. Check the CKP sensor ground circuit for open symptom/indication goes away, replace the original
or short to ground. ECM.
NO – Repair the CKP signal plate.
NOTICE

aaa
NO – Repair open in the ground wire between ECM
and the CKP sensor.
Damaged the CKP sensor (A)
CKP sensor fixing condition
Is a problem found?

11-69
DTC P0338: Over Speed Detection aaa

Check''.
Is there other DTC P0335 (beside DTC P0338) being
output?
YES – Go to DTC P0335 chart.
4. 4. Review and record scan tool failure records
data.
5. 5. Check the engine speed in failure records data.
Is there more than 6,000 rpm (min -1 )?
YES – Contact the customer.
NO – Verify the customer complaint.

11-70
DTC P0341: Camshaft Position (CMP) Sensor 1. 7. Check the CMP sensor signal and ground
Performance circuit for short.
Check''.
2. 2. Attempt to start the engine.
Did the engine start and continue to run?
Check for poor connections or loose wires at the CMP
Is a problem found?
4. 4. Disconnect the CMP sensor 3P connector. YES – Repair open in the signal or ground wire
5. 5. Turn the ignition switch ON (II). between the ECM and the CMP sensor.
6. 6. Measure voltage between the CMP sensor 3P NO – Go to step 8.
connector terminals No. 3 and body ground. 2. 8. Check the CMP sensor signal and ground
Wire side of female terminals circuit for open.
CMP sensor 3P connector Wire side of female terminals
CMP sensor 3P connector
JUMPER WIRE
NO – Repair open in the wire between the main relay
and the CMP sensor.
Is a problem found?
YES – Repair open in the signal or ground wire
between the ECM and the CMP sensor.
aaa

11-71
1. 9. Replace the CMP sensor. aaa

If the problem found, substitute a known-good ECM
and recheck.
If symptom/indication goes away, replace the original
ECM.
NOTICE


11-72
DTC P0343: Camshaft Position (CMP) Sensor Too High 1. 7. Check the CMP sensor signal and ground
Frequency circuit for short.
Check''.
2. 2. Attempt to start the engine.
Did the engine start and continue to run?
Check for poor connections or loose wires at the CMP
Is a problem found?
4. 4. Disconnect the CMP sensor 3P connector. YES – Repair open in the signal or ground wire
5. 5. Turn the ignition switch ON (II). between the ECM and the CMP sensor.
6. 6. Measure voltage between the CMP sensor 3P NO – Go to step 8.
connector terminals No. 3 and body ground. 2. 8. Check the CMP sensor signal and ground
Wire side of female terminals circuit for open.
CMP sensor 3P connector Wire side of female terminals
CMP sensor 3P connector
Is there battery voltage? JUMPER WIRE

and the CMP sensor.
Is a problem found?
YES – Repair open in the signal or ground wire
between the ECM and the CMP sensor.
aaa

11-73
1. 9. Replace the CMP sensor. aaa

If the problem found, substitute a known-good ECM
and recheck.
If symptom/indication goes away, replace the original
ECM.
NOTICE


11-74
DTC P0501: Vehicle Speed Sensor (VSS) Frequency 1. 8. Measure at the VSS connector between ground
Too High and the wire from the speedometer.
1. 1. Test-drive the vehicle. Is there about 11 – 13 V? (At peak voltage.)
Is the speedometer indication correct? YES – Repair open or short circuit between the
YES – Intermittent failure, system is OK at this time. speedometer and the VSS.
Check for poor connections or loose wires at the VSS NO – Replace the speedometer.
and at the ECM. 2. 9. Check at the ECM connector between No. A49
NO – Go to step 2. terminal and the wire from the speedometer.
2. 2. Check the vehicle speed with the scan tool. Was a problem found?
Is the correct speed indicated? YES – Repair open or short circuit between the
YES – Go to step 3. speedometer and the ECM.
NO – Replace the VSS. NO – Go to step 10.
3. 3. Turn the ignition switch OFF. 3. 10. Test-drive the vehicle.
4. 4. Disconnect the VSS 3P connector. Is the speedometer indication correct?
5. 5. Turn the ignition switch ON (II). YES – System OK.
6. 6. Using a DVM to battery +, probe the connector NO – Substitute a known-good ECM and recheck. If
ground wire (terminal No. 2). symptom/indication goes away, replace the original
ECM.
NOTICE
Wire side of female terminals The battery power supply short circuit to 5 V power
Is there B+?
aaa
NO – Repair open in the ground wire.
7. 7. Measure at the VSS connector between voltage
supply (terminal No. 1) and ground (terminal
No. 2).
Is there about B+?
NO – Repair open or short to ground which may have
blown meter fuse.

11-75
DTC P0502: Vehicle Speed Sensor (VSS) Circuit Low 1. 8. Measure at the VSS connector between ground
Input and the wire from the speedometer.
ECM.
NOTICE
Is there B+?
aaa
No. 2).
Is there about B+?
a blown meter fuse.

11-76
DTC P0503: Vehicle Speed Sensor (VSS) Signal Above 1. 8. Measure at the VSS connector between ground
Upper Limit and the wire from the speedometer.
ECM.
NOTICE
Is there B+?
aaa
No. 2).
Is there about B+?
a blown meter fuse.

11-77
DTC P0562: System Voltage Low 1. 12. Connect the ECM A connector terminals No. 13
1. 1. Turn the ignition switch OFF. and No. 1 with a jumper wire.
2. 2. Wait 5 seconds. JUMPER WIRE
Is DTC P0562 indicated?
Check for poor connections or loose wires at the main
relay and at the ECM.
5. 5. Check the main relay and ignition feed fuses
(20 A and 7.5 A).
Are both fuses OK?
3. 14. Measure voltage between the ECM A connector
YES – Go to step 6. terminals No. 4 and No. 2.
NO – Replace the fuse.
6. 6. Measure the battery voltage at the battery.
Is the battery voltage greater than 9 V?
NO – Change the battery.
8. 8. Check the battery voltage with the scan tool.
9. 9. Start the engine and raise the engine speed to
2,000 rpm (min -1 ).
and the ECM, if a problem is not found, replace the
main relay.
aaa

11-78
1. 15. Measure voltage between the ECM A connector aaa

terminals No. 5 and No. 2.

and the ECM, if a problem not found, replace the main
relay.
2. 16. Go to the Starting/Charging System.
3. 17. Substitute a known-good ECM and recheck. If
symptom/indication goes away, replace the
original ECM.
NOTICE


11-79
DTC P0563: System Voltage High 1. 12. Connect the ECM A connector terminals No. 13
1. 1. Turn the ignition switch OFF. and No. 1 with a jumper wire.
(20 A and 7.5 A).
Are both fuses OK?
NO – Charge the battery.
2,000 rpm (min -1 ).
11. 11. Disconnect the ECM connector A.
main relay.
aaa

11-80
1. 15. Measure voltage between the ECM A connector aaa

terminals No. 5 and No. 2.

and the ECM. If a problem is not found, replace the
main relay.
original ECM.
NOTICE


11-81
DTC P0601: ECM Memory (Checksum Error) DTC P0606: Redundant Overrun Monitoring (ECM
1. 1. Check the ''On Board Diagnostic (OBD) System Internal Error)
Check''. 1. 1. Check the ''On Board Diagnostic (OBD) System
Was the ''OBD System Check'' performed? Check''.
YES – Substitute a known-good ECM and recheck. If Was the ''OBD System Check'' performed?
symptom/indication goes away, replace the original YES – Substitute a known-good ECM and recheck. If
ECM. symptom/indication goes away, replace the original
NO – Go to OBD System Check. ECM.
aaa

11-82
DTC P0704: Incorrect Clutch SW Signal 1. 7. Check the clutch SW signal circuit for open or
1. 1. Check the ''On Board Diagnostic (OBD) System short to ground.
Check''. Was a problem found?
Was the ''OBD System Check'' performed? YES – Repair the signal wire between ECM and the
YES – Go to step 2. clutch SW.
NO – Go to OBD System Check. NO – Substitute a known-good ECM and recheck. If
ECM.
3. 3. Disconnect the clutch connector.
5. 5. Measure voltage between the clutch SW 2P

YES – Replace the clutch SW.
6. 6. Measure voltage between the clutch SW 2P
connector terminals No. 1 and body ground.

YES – Repair open in the ground wire.

11-83
DTC P1000: Injector Low Side Circuit Over Current

Check''.
4. 4. Measure resistance between the all injector
circuit.
Is there about 0.2 – 0.3 ohms (At room temperature:

about 20°C (68°F))?
YES – Replace applicable injector.
1. 5. Disconnect all injector connectors.
2. 6. Check the all injector power supply circuit and
ground circuit for short.
aaa

11-84
aaa
Is a problem found?
YES – Repair short in injector circuit wire.
1. 7. Measure resistance between the injectors
Is there about 0.2 – 0.3 &ohm; (At room temperature:
about 20°C (68°F))?
NO – Replace applicable injector.
2. 8. Clear all DTCs.
Was a problem complete?
YES – System OK.
ECM.

11-85
DTC P1001: Injector High Side Circuit Over Current

Check''.
4. 4. Measure resistance between the all injector
circuit.
Is there about 0.2 – 0.3 &ohm; (At room temperature:

about 20°C (68°F))?
YES – Replace applicable injector.
1. 5. Disconnect all injector connectors.
2. 6. Check the all injector power supply circuits and
ground circuit for short.
aaa

11-86
aaa
Is a problem found?
YES – Repair short in injector circuit wire.
1. 7. Clear all DTCs.
2. 8. Install the cylinder head cover insulator.
Was a problem complete?
YES – System OK.
ECM.

11-87
DTC P1002: Injector 1 Low Current Performance 1. 8. Check the injector 1 power supply and ground
1. 1. Check the ''On Board Diagnostic (OBD) System circuit for an open.
Check''. Wire side of female terminals
Was the ''OBD System Check'' performed? Injector 2P connector
Is there other DTCs P1017 being output?
5. 5. Measure resistance between the injector 1
connector circuit.
Is a problem found?
YES – Repair the injector circuit.
Is there about 0.2 – 0.3 ohms (At room temperature: 2. 9. Measure resistance between the injectors
about 20°C (68°F))? connector terminals No. 1 and No. 2.
YES – Substitute a known-good ECM and recheck. If Is there about 0.2 – 0.3 ohms (At room temperature:
symptom/indication goes away, replace the original about 20°C (68°F))?
ECM. YES – Substitute a known-good ECM and recheck. If
NO – Replace the injector 1. symptom/indication goes away, replace the original
ECM.
NOTICE
NO – Replace injector 1.
The battery power supply short circuit to 5 V power NOTICE
6. 6. Remove the cylinder head cover insulator. The battery power supply short circuit to 5 V power
7. 7. Disconnect the injector 1 connector. supply damages the ECM.
aaa

11-88
DTC P1003: Injector Performance Malfunction aaa

Check''.
Are there other DTCs (beside P1003) being output?
5. 5. Remove the cylinder head cover insulator.
Damaged injection pipe.
Damaged injector.
Is a problem found?
YES – Replace the injector or injection pipe.
7. 7. Perform injector spray condition check.
Is a problem found?
YES – Clean or replace relevant injector.
ECM.

11-89
Is there other DTC P1012 being output?
4. 4. Disconnect the ECM B connector.
connector circuit.
Is a problem found?
YES – Repair the injector ground circuit.
Is there 0.2 – 0.3 ohms (At room temperature: about 2. 9. Measure resistance between the injectors
20°C (68°F))? connector terminals No. 1 and No. 2.
NO – Go to step 6. symptom/indication goes away, replace the original
ECM.
NOTICE
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11-90
connector circuit.
Is a problem found?
ECM.
NOTICE
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11-91
connector terminals.
Is a problem found?
ECM.
NOTICE
NO – Replace applicable injector.
aaa

11-92
DTC P1086: Rail Pressure (RP) System Performance 1. 6. Check the RP sensor signal voltage.
Check''.
Are there any other DTC (beside DTC P1086) being
output?
3. 3. Disconnect the ECM connector. Is about 1 V indicated?
4. 4. Measure resistance of RP sensor as below.
Between terminal 86 and 90. YES – Intermittent failure, system is OK at this time.
Check for poor connections or loose wires at the RP
Damaged supply pump.
Damaged common rail.
Damaged fuel metering unit.
Fuel leaks injection pipes.
Damaged the RP sensor.
Is a problem found?
Is there 0.9 – 1.3 ohms? (At indoor temperature) NO – Go to step 8.
5. 5. Turn the engine ON at idling. Wire side of female terminals
JUMPER WIRE
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11-93
1. 10. Check the RP sensor signal circuit, +5 V circuit 1. 14. Recheck the DTC P1086 troubleshooting.
for open. Was a problem completed?
YES – System is OK.
NO – Replace the supply pump.
NOTICE

aaa
Is a problem found?
2. 11. Check the RP sensor signal voltage.
ECM.
Is there 0.9 – 1.3 ohms (At room temperature; about
20°C (68°F))?

11-94
DTC P1087: Rail Pressure (RP) High 1. 6. Check the RP sensor signal voltage.
Check''.
Are there other DTCs (beside DTC P1807) being
output?
3. 3. Disconnect ECM connector. Is about 1 V indicated?
Is a problem found?
Is there 0.9 – 1.3 ohms? (At indoor temperature)
NO – Go to step 8. terminals No.1 and No.2 with a jumper wire.
JUMPER WIRE
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11-95
1. 10. Check the RP sensor signal circuit, +5V circuit 1. 14. Recheck the DTC P1087 troubleshooting.
for open. Was a problem completed?
NOTICE

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Is a problem found?
YES – Repair the RP sensor signal or +5V circuit.
Is about 5V indicated?
ECM.
20°C (68°F))?

11-96
DTC P1088: Rail Pressure (RP) Low 1. 6. Check the RP sensor signal voltage.
Check''.
output?
3. 3. Disconnect ECM connector. Is about 1 V indicated?
4. 4. Measure resistance of RP sensor as below.
Is a problem found?
Is there 0.9 – 1.3 ohms? (At indoor temperature) NO – Go to step 8.
JUMPER WIRE
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11-97
1. 10. Check the RP sensor signal circuit, +5 V circuit 1. 14. Recheck the DTC P1088 troubleshooting.
for open. Was a problem completed ohm?
NOTICE

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Is a problem found?
ECM.
20°C (68°F))?

11-98
DTC P1091: Rail Pressure (RP) Control Valve Circuit

Open
Check''.
Are there any other DTCs (beside DTC) being output?
YES – Go to relevant chart.
3. 3. Check for the following conditions: YES – Repair the fuel metering unit circuit.
Damaged the fuel metering unit.
Is a problem found?
1. 7. Measure the resistance of fuel metering unit as
YES – Repair as necessary (Replace the fuel supply below.
pump).
6. 6. Check the fuel metering unit signal circuit for an
open.
Injector 2P connector
Is the resistance value 2.5 – 3.2 ohms? (At room

temperature)
JUMPER WIRE symptom/indication goes away, replace the original
ECM.
NOTICE

aaa

11-99
DTC P1092: Rail Pressure (RP) Control Valve Circuit 1. 7. Measure the resistance of fuel metering unit as
Short below.
Check''.
Are there any other DTCs (beside DTC P1092) being
output?
3. 3. Check for the following conditions: Is the resistance value 2.5 – 3.2 ohms (At room
Damaged the fuel metering unit. temperature)?
Is a problem found? YES – Substitute a known-good ECM and recheck. If
YES – Repair as necessary (Replace the fuel supply symptom/indication goes away, replace the original
pump). ECM.
NO – Go to step 4. NO – Replace the supply pump.
4. 4. Turn the ignition switch OFF. NOTICE
6. 6. Check the fuel metering unit circuit for short. The battery power supply short circuit to 5 V power
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Is a problem found?
YES – Repair the fuel metering unit circuit.

11-100
DTC P1095: Fuel Rate Low At Cranking 1. 7. Check the RP sensor signal circuit, +5 V circuit
1. 1. Check the ''On Board Diagnostic (OBD) System for open.
Check''.
output?
Damaged supply pump. Is a problem found?
Damaged fuel metering unit. YES – Repair the RP sensor signal or +5 V circuit.
Fuel leaks injection pipes. NO – Go to step 8.
Damaged the RP sensor. 2. 8. Check the RP sensor signal voltage.
Is a problem found?
JUMPER WIRE ECM.
4. 10. Connect the RP sensor connector.
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file:///C|/...%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/Civ41Html/11-100.htm[8/25/2012 6:35:25 PM]

11-101
1. 11. Measure the resistance of RP sensor as below. 1. 14. Recheck the DTC P1095 troubleshooting.
Between terminal 86 and 90. Was a problem completed?
NOTICE

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Is there about 0.9 – 1.3 Kohms?

2. 12. Turn the engine ON at idling.
Is there 1 V indicated?

11-102
DTC P1100: MAF sensor Supply Voltage High/Low 1. 5. Check the MAF with the scan tool.
1. 1. Check the ''On Board Diagnostic (OBD) System Is about 8 – 13 g/sec indicated (Sea level of 0 m at
Check''. indoor temperature)?
Was the ''OBD System Check'' performed? YES – Intermittent failure, system is OK at this time.
YES – Go to step 2. Check for poor connections or loose wires at the MAF
Are there any other DTCs (beside DTC P0101) being 2. 6. Turn the ignition switch OFF.
output? 3. 7. Disconnect the MAF sensor 5P connector.
NO – Go to step 3. for an open or short to ground.
3. 3. Check for the following conditions: Wire side of female terminals
Damaged MAF sensor (A) MAF/IAT sensor 5P connector
The duct work at the MAF sensor for leaks
PCV system vacuum leaks
Incorrect PCV valve
pipes
Intake manifold vacuum leaks JUMPER WIRE
Is a problem found? Is a problem found?

YES – Repair as necessary. YES – Repair the MAF signal or +5 V circuit.
4. 4. Start the engine and allow it to idle. aaa

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1. 10. Check the MAF sensor B+ circuit for an open or 1. 13. Turn the ignition switch ON (II).
short to ground. 2. 14. Check the MAF with the scan tool.
Wire side of female terminals Is about 225 g/sec (811 kg/h) indicated?
MAF/IAT sensor 5P connector YES – Replace the IAT/MAF sensor.
ECM.
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JUMPER WIRE
Is a problem found?
2. 11. Connect ECM connector.
JUMPER WIRE

11-104
DTC P1101: Incorrect MAF High Range

Check''.
#1 circuit or ground circuit failure).
3. 3. Start the engine at idling and allow it to idle. YES – Repair the MAF signal or +5 V circuit.
Is about 8 – 13 g/sec indicated (Sea level of 0 m at 1. 9. Check the MAF sensor B+ circuit for a short to
room temperature)? ground.
8. 8. Check the MAF sensor signal and +5V circuits JUMPER WIRE
for a short to ground.
JUMPER WIRE
Is a problem found?
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11-105
1. 11. Connect the MAF sensor 5P connector aaa

JUMPER WIRE
ECM.
NOTICE


11-106
DTC P1104: Incorrect MAF Low Range

Check''.
#1 circuit or ground circuit failure).
3. 3. Start the engine at idling and allow it to idle. YES – Repair the MAF signal or +5 V circuit.
Is about 8 – 13 g/sec indicated (Sea level of 0 m at 1. 9. Check the MAF sensor B+ circuit for a short to
room temperature)? ground.
8. 8. Check the MAF sensor signal and +5V circuits
for a open or short to ground. Is a problem found?
Wire side of female terminals YES – Repair the MAF B+ circuit.
MAF/IAT sensor 5P connector NO – Go to step 10.
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JUMPER WIRE

11-107
1. 11. Connect the MAF sensor 5P connector DTC P1107: BARO Sensor Circuit Low Voltage
terminals No. 4 and No. 5 with a jumper wire. 1. 1. Check the ''On Board Diagnostic (OBD) System
Wire side of female terminals Check''.
MAF/IAT sensor 5P connector Was the ''OBD System Check'' performed?
ECM.
JUMPER WIRE aaa
Is about 225g/sec indicated?
ECM.
NOTICE


11-108
DTC P1108: BARO Sensor Circuit High Voltage DTC P1195: Rail Pressure (RP) Sensor Supply Voltage
1. 1. Check the ''On Board Diagnostic (OBD) System High/Low
Check''. 1. 1. Check the ''On Board Diagnostic (OBD) System
Was the ''OBD System Check'' performed? Check''.
YES – Substitute a known-good ECM and recheck. If Was the ''OBD System Check'' performed?
symptom/indication goes away, replace the original YES – Go to step 2.
ECM. NO – Go to OBD System Check.
NO – Go to OBD System Check. 2. 2. Check the DTC.
YES – Go to DTC P1627, P1628 chart (5V reference
3. 3. Check the following conditions:
Damaging the RP sensor.
Is a problem found?
Between terminal 86 and 90.
Is there about 0.9 – 1.3 ohms (At room temperature:

about 20°C (68°F))?
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11-109
1. 7. Turn the engine ON at idling. 1. 10. Check the RP sensor signal circuit for short.
2. 8. Check the RP sensor signal voltage. Turn the ignition switch ON (II).
Is about 1V indicated?
3. 9. Disconnect the RP sensor 3P connector.
Is a problem found?
YES – Repair the RP sensor signal circuit for short.
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11-110
1. 12. Check the RP sensor signal circuit for short. DTC P1224: Accelerator Pedal Position (APP) Sensor 1
Wire side of female terminals Circuit High Voltage
RP sensor 3P connector 1. 1. Check the DTC.
P1224 being output?
JUMPER WIRE NO – Go to step 2.

Damaging APP sensor
Damaging accelerator pedal and wire
Is a problem found?
4. 4. Check the TP (APP) with the scan tool.
Is a problem found? NO – Go to step 6.
YES – Repair the RP sensor ground circuit. 5. 5. Press the accelerator pedal.
NO – Go to step 13. Is about 0 (idle) – 100 % (WOT) indicated?
2. 13. Measure the resistance of RP sensor. YES – Intermittent failure, system is OK at this time.
Is there 0.9 – 1.3 ohms? Check for poor connections or loose wires at the APP
symptom/indication goes away, replace the original NO – Go to step 6.
ECM. 6. 6. Turn the ignition switch OFF.
NO – Replace the RP sensor. 7. 7. Disconnect the APP sensor 6P connector.
NOTICE aaa


11-111
1. 8. Turn the ignition switch ON (II). 1. 11. Check the APP sensor signal circuit for short.
2. 9. Measure voltage between the APP sensor 6P
(For example; Right handle)

Is there about 5 V?
YES – Go to step 11. Is a problem found?
NO – Go to step 10. YES – Repair open in the signal wire between ECM
3. 10. Measure voltage between the ECM connector and the APP sensor 1.
terminals A 76 and 78. NO – Replace the APP sensor 1.
NOTICE

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Is there about 5 V?
APP sensor.
ECM.

11-112
DTC P1229: Accelerator Pedal Position (APP) Sensor 2 1. 9. Measure voltage between the APP sensor 6P
Circuit High Voltage connector terminals No. 4 and No. 6.
P1229 being output?
Damaging APP sensor
An incorrect APP sensor fixing Wire side of female terminals
Damaging accelerator pedal Is there about 5 V?
Is a problem found? YES – Go to step 11.
YES – Repair as necessary. NO – Go to step 10.
NO – Go to step 3. 2. 10. Measure voltage between the ECM connector
3. 3. Turn the ignition switch ON (II). terminals A 79 and 81.
4. 4. Check the APP with the scan tool.
Is about 0 (Idle) – 100 % (WOT) indicated?
6. 6. Turn the ignition switch OFF. Is there about 5 V?
7. 7. Disconnect the APP sensor 6P connector.
8. 8. Turn the ignition switch ON (II). YES – Repair open in the wire between ECM and the
APP sensor.
ECM.
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11-113
1. 11. Check the APP sensor signal circuit for short. aaa
Is a problem found?
YES – Repair open in the signal wire between ECM
and the APP sensor 2.
NO – Replace the APP sensor 2.

11-114
DTC P1235: Manifold Absolute Pressure (MAP) Sensor 1. 9. Check the MAP with the scan tool.
Supply Voltage High/Low Is about 250 kPa (1,877 mmHg, 73 in. Hg) indicated?
1. 1. Check the ''On Board Diagnostic (OBD) System YES – Go to step 10.
Check''. NO – Substitute a known-good ECM and recheck. If
Was the ''OBD System Check'' performed? symptom/indication goes away, replace the original
YES – Go to step 2. ECM.
NO – Go to OBD System Check. 2. 10. Check the MAP sensor signal and supply circuit
2. 2. Check the DTC. for B+ short.
Are there other DTCs P1628, P1627 (beside DTC Is a problem found?
P1235) being output? YES – Repair open in the signal wire or supply wire
YES – Go to step 3. between ECM and the MAP sensor.
NO – Clear DTC P1235 by the scan tool. NO – Substitute a known-good ECM and recheck. If
ECM.
Is about atmospheric pressure indicated? NOTICE
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Is about 20 – 30 kPa (150 – 225 mmHg, 5.9 – 8.9 in.
Hg) indicated?
8. 8. Disconnect the MAP sensor 3P connector.

11-115
DTC P1236: Boost Pressure Control Negative Deviation 1. 7. Measure resistance between the EVRV 2P
1. 1. Check the ''On Board Diagnostic (OBD) System connector terminals No. 1 and No. 2.
Check''.
2. 2. Check the DTC. Is there about 14.7 – 16.1 ohms (20°C (68°F)) (At
Are there any other DTCs (beside DTC P1236) being room temperature)?
output? YES – Go to step 8.
YES – Go to relevant DTC chart. NO – Replace the EVRV.
NO – Go to step 3. 2. 8. Remove the EVRV.
3. 3. Check for the following conditions: 3. 9. Connect the hand vacuum pump (with gauge)
Damaged MAP sensor to the EVRV (A).
and EVRV (Turbo control) for leaks
Is a problem found?
Damaged Turboactuator valve or EVRV
EVRV hose vacuum leaks
5. 5. Visually and physically inspect the turboactuator
4. 10. Apply 34 kPa (257 mmHg, 10 in. Hg) of
pintle, for excessive deposits or any kind of a
vacuum with hand vacuum pump.
restriction.
Were vacuum leaks found?
If a problem is found, clean or replace turboactuator
system components as necessary. YES – Replace the EVRV.
Is a problem found? NO – Substitute a known-good ECM and recheck. If
YES – Repair the turboactuator.
ECM.
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6. 6. Disconnect the EVRV connector.

11-116
DTC P1237: Boost Pressure Control Positive 1. 7. Measure resistance between the EVRV 2P
1. 1. Check the ''On Board Diagnostic (OBD) System connector terminals No. 1 and No. 2.
Check''.
2. 2. Check the DTC. Is there about 14.7 – 16.1 ohms (20°C (68°F)) (At
Are there any other DTCs (beside DTC P1237) being room temperature)?
output? YES – Go to step 8.
YES – Go to relevant DTC chart. NO – Replace the EVRV.
NO – Go to step 3. 2. 8. Remove the EVRV.
3. 3. Check for the following conditions: 3. 9. Connect the hand vacuum pump (with gauge)
Damaged MAP sensor to the EVRV (A).
and EVRV (Turbo control) for leaks
Is a problem found?
Damaged Turboactuator valve or EVRV
5. 5. Visually and physically inspect the turboactuator
4. 10. Apply 34 kPa (257 mmHg, 10 in. Hg) of
pintle, for excessive deposits or any kind of a
restriction.
Were vacuum leaks found?
If a problem is found, clean or replace turboactuator
system components as necessary. YES – Replace the EVRV.
Is a problem found? NO – Substitute a known-good ECM and recheck. If
YES – Repair the turboactuator.
ECM.
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11-117
DTC P1238: Boost Pressure Control Circuit Low 1. 9. Check the circuit between EVRV connector No.
Voltage 2 terminal and ECM A connector terminal No.
1. 1. Check the ''On Board Diagnostic (OBD) System 17 for open.
Damaged turboactuator or EVRV.
EVRV wire harness and connector.
Is a problem found? JUMPER WIRE
6. 6. Measure voltage between the EVRV 2P
Is a problem found?
Wire side of female terminals YES – Repair open in the wire between EVRV and
Is there B+? the ECM.
YES – Go to step 7. NO – Go to step 10.
NO – Repair open in the wire between EVRV and the 2. 10. Measure resistance between the EVRV 2P
main relay. connector terminals No. 1 and No. 2.
8. 8. Disconnect the ECM A connector.
Is there 14.7 – 16.1 ohms (20°C (68°F)) (At room

temperature)?
ECM.
NO – Replace the EVRV.
NOTICE

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11-118
DTC P1239: Boost Pressure Control Circuit High 1. 9. Check the circuit between EVRV connector No.
Voltage 2 terminal and ECM A connector terminal No.
1. 1. Check the ''On Board Diagnostic (OBD) System 17 for short to ground.
Check''.
Damaged turboactuator or EVRV.
Is a problem found?
4. 4. Disconnect the EVRV connector. YES – Repair short to ground in the wire between
5. 5. Turn the ignition switch ON (II). EVRV and the ECM.
6. 6. Measure voltage between the EVRV 2P
connector terminals No. 1 and body ground. NO – Go to step 10.
2. 10. Measure resistance between the EVRV 2P
Wire side of female terminals Is there 14.7 – 16.1 ohms (20°C (68°F)) (At room
Is there B+? temperature)?
YES – Go to step 7. YES – Substitute a known-good ECM and recheck. If
NO – Repair open in the wire between EVRV and the symptom/indication goes away, replace the original
main relay. ECM.
7. 7. Turn the ignition switch OFF. NO – Replace the EVRV.
8. 8. Disconnect the ECM A connector. NOTICE

aaa

11-119
DTC P1248: Accelerator Position Control 1 And 2 1. 9. Measure voltage between the APP sensor 6P
Comparison connector terminals No. 4 and No. 6.
Are there other any DTCs (beside DTC P1228) being
output?
Damaging APP sensor
Damaging accelerator pedal Wire side of female terminals
Is a problem found? Is there about 5 V?
YES – Repair as necessary. YES – Go to step 11.
3. 3. Turn the ignition switch ON (II). 2. 10. Measure voltage between the ECM connector
4. 4. Check the APP with the scan tool. terminals A 76 and 78.
Is about 0 – 5 V indicated?
7. 7. Disconnect the APP sensor 6P connector. Is there about 5 V?
APP sensor.
NO – Replace the ECM.
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11-120
1. 11. Check the APP sensor signal circuit for open. DTC P1331: Crankshaft Position (CKP)-Camshaft
Position (CMP) Correlation Dynamic Implausible
Check''.
Wire side of female terminals YES – Go to step 2.
Is a problem found? NO – Go to OBD System Check.
YES – Repair the signal wire between ECM and the 2. 2. Attempt to start the engine.
APP sensor. Did the engine start and continue to run?
NO – Replace the APP sensor. YES – Intermittent failure, system is OK at this time.
Check for poor connections or loose wires at the CKP
3. 3. Check the engine speed (cranking speed) with
the scan tool.
5. 5. Disconnect the CKP sensor 3P connector.
7. 7. Check the CKP sensor signal circuit for open or
short to ground.
CKP sensor 3P connector
JUMPER WIRE
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11-121

Damage to the CKP sensor (A)
CKP sensor fixing condition.
Is a problem found?
YES – Repair in the signal wire between ECM and
the CKP sensor.
Is a problem found?
1. 8. Connect the CKP sensor 3P connector.
2. 9. Turn the ignition switch ON (II). NO – Go to step 12.
3. 10. Check the CKP sensor ground circuit for open 2. 12. Replace the CKP sensor.
or short to ground. 3. 13. Check the engine speed (cranking speed) with
the scan tool.
ECM.
NO – Repair the CKP signal plate.
aaa
NO – Repair in the ground wire between ECM and
the CKP sensor.

11-122
DTC P1377: Glow Time Control Circuit Open 1. 8. Check connection at the glow relay and replace
1. 1. Check the ''On Board Diagnostic (OBD) System the terminals if necessary.
Was the ''OBD System Check'' performed? YES – Replace the terminal.
NO – Go to OBD System Check. 2. 9. Replace the glow relay.
2. 2. Turn the ignition switch ON (II). 3. 10. Connect the ECM connector A.
Is DTC P1377 indicated? 4. 11. Turn the ignition switch ON (II).
Check for poor connections or loose wires at the glow
ECM.
NO – System is OK.
3. 3. Check the glow relay (60A) fuses.
Are fuses OK? NOTICE
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6. 6. Disconnect the glow relay connector.
7. 7. Check for an open in the glow relay circuit
between the glow relay connector and the ECM
connector A No. 19.

YES – Repair open in the wire between the glow
relay connector and the ECM connector A terminal
No. 19.

11-123
DTC P1378: Glow Time Control Circuit Short 1. 8. Check connection at the glow relay and replace
1. 1. Check the ''On Board Diagnostic (OBD) System the terminals if necessary.
Was the ''OBD System Check'' performed? YES – Replace the terminal.
NO – Go to OBD System Check. 2. 9. Replace the glow relay.
2. 2. Turn the ignition switch ON (II). 3. 10. Connect the ECM connector A.
Is DTC P1378 indicated? 4. 11. Turn the ignition switch ON (II).
Check for poor connections or loose wires at the glow
ECM.
3. 3. Check the glow relay (60A) fuses.
Are fuses OK? NOTICE
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6. 6. Disconnect the glow relay connector.
7. 7. Check for short to ground in the glow relay
circuit between the glow relay connector and
the ECM connector A No. 19.

YES – Repair short to ground in the wire between the
glow relay connector and the ECM connector A
terminal No. 19.

11-124
DTC P1535: Incorrect Main Relay Performance 1. 12. Disconnect the ECM A connector terminals No.
1. 1. Turn the ignition switch OFF. 13 and No. 1 with a jumper wire.
(20A and 7.5A)
Are both fuses OK?
2,000 rpm (min -1 ).
main relay.
4. 15. Replace the main relay.
original ECM.
NOTICE

aaa

11-125
DTC P1536: Incorrect Main Relay Performance 1. 12. Disconnect the ECM A connector terminals No.
1. 1. Turn the ignition switch OFF. 13 and No. 1 with a jumper wire.
(20A and 7.5A)
Are both fuses OK?
2,000 rpm (min -1 ).
main relay.
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11-126
1. 15. Replace the main relay. aaa

original ECM.
NOTICE


11-127
DTC P1550: Brake SW Signal Correlation Error (After 1. 10. Connect the DVM to the brake SW connector
Restart Memory) terminal No. 1 and No. 2 with a jumper wire.
Check''.
3. 3. Check the brake lamp (10A) fuse. JUMPER WIRE
Is the brake lamp fuse OK? Wire side of female terminals
YES – Go to step 4. 2. 11. Turn the ignition switch ON (II).
NO – Replace the fuse. 3. 12. Connect the DVM to the ECM terminal No. 59
and body ground.
6. 6. Connect the DVM to the ECM terminal No. 59
and body ground.
4. 13. Press the brake pedal.

YES – Replace the brake SW.
7. 7. Press the brake pedal. NO – Go to step 14.
Is there battery voltage? 5. 14. Measure voltage between the brake SW
YES – Go to step 15. connector terminals No. 1 and body ground.
9. 9. Disconnect the brake SW connector.

YES – Repair open in the wire between the brake SW
and the ECM.
NO – Repair open in the wire between the brake SW
and the battery.
aaa

11-128

2. 16. Disconnect the redundant brake SW connector.
3. 17. Check for open or short to ground in the
redundant brake SW circuit wire.
Is a problem found?
YES – Repair open or short to ground in the
redundant brake SW circuit wire.
4. 18. Replace the redundant brake SW.
5. 19. Connect the ECM connector A.
Is there DTC P1550 being output?
ECM.
NOTICE


11-129
DTC P1551: Brake SW Signal Correlation Error 1. 10. Connect the DVM to the brake SW connector
1. 1. Check the ''On Board Diagnostic (OBD) System terminal No. 1 and No. 2 with a jumper wire.
Check''.
3. 3. Check the brake lamp (10A) fuse.
Is the brake lamp fuse OK? JUMPER WIRE
YES – Go to step 4. Wire side of female terminals
NO – Replace the fuse. 2. 11. Turn the ignition switch ON (II).
and body ground.
and body ground.
4. 13. Press the brake pedal.

7. 7. Press the brake pedal. YES – Replace the brake SW.
Is there battery voltage? NO – Go to step 14.
YES – Go to step 15. 5. 14. Measure voltage between the brake SW
NO – Go to step 8. connector terminals No. 1 and body ground.
9. 9. Disconnect the brake SW connector.

YES – Repair open in the wire between the brake SW
and the ECM.
NO – Repair open in the wire between the brake SW
and the battery.
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11-130
1. 15. Turn the ignition switch OFF. DTC P1610: ECM Communication Error
2. 16. Disconnect the redundant brake SW connector. 1. 1. Check the ''On Board Diagnostic (OBD) System
3. 17. Check for open or short to ground in the Check''.
redundant brake SW circuit wire. Was the ''OBD System Check'' performed?
Is a problem found?
YES – Repair open or short to ground in the symptom/indication goes away, replace the original
redundant brake SW circuit wire. ECM.
NO – Go to step 18. NO – Go to OBD System Check.
4. 18. Replace the redundant brake SW. aaa
5. 19. Connect the ECM connector A.
Is there DTC P1551 being output?
ECM.
NOTICE


11-131
DTC P1611: ECM Write Error DTC P1612: Gate Array Quantity Stop
1. 1. Check the ''On Board Diagnostic (OBD) System 1. 1. Check the ''On Board Diagnostic (OBD) System
Check''. Check''.
Was the ''OBD System Check'' performed? Was the ''OBD System Check'' performed?
YES – Substitute a known-good ECM and recheck. If YES – Substitute a known-good ECM and recheck. If
symptom/indication goes away, replace the original symptom/indication goes away, replace the original
ECM. ECM.
NO – Go to OBD System Check. NO – Go to OBD System Check.
aaa

11-132
DTC P1613: Gate Array Communication aaa

Check''.
ECM.

11-133
DTC P1614: Booster (injector driver) Voltage Too High Was a problem found?
1. 1. Check the ''On Board Diagnostic (OBD) System YES – Repair the ECM ground circuit.
NO – Go to OBD System Check. aaa
2. 2. Check the ECM ground circuit.

11-134
DTC P1615: Booster (injector driver) Voltage Too Low Was a problem found?
NO – Go to OBD System Check. NOTICE
aaa

11-135
DTC P1616: RAM Performance DTC P1617: ECM Internal Ground Connection Error
1. 1. Check the ''On Board Diagnostic (OBD) System 1. 1. Check the ''On Board Diagnostic (OBD) System
Check''. Check''.
Was the ''OBD System Check'' performed? Was the ''OBD System Check'' performed?
YES – Substitute a known-good ECM and recheck. If YES – Substitute a known-good ECM and recheck. If
symptom/indication goes away, replace the original symptom/indication goes away, replace the original
ECM. ECM.
NO – Go to OBD System Check. NO – Go to OBD System Check.
aaa

11-136
DTC P1618: Reference #1 And #2 Circuit Low/High Was a problem found?

Voltage (APS1, APS2, RP/MAP/MAF Sensor) YES – Repair the ECM ground circuit.
1. 1. Check the ''On Board Diagnostic (OBD) System NO – Substitute a known-good ECM and recheck. If
Check''. symptom/indication goes away, replace the original
Was the ''OBD System Check'' performed? ECM.
YES – Go to step 2. NOTICE
2. 2. Check the ECM ground circuit. The battery power supply short circuit to 5 V power
aaa

11-137
DTC P1619: Shut Off Error (Error at shut off via zero Was a problem found?
quantity) YES – Repair the ECM ground circuit.
aaa

11-138
DTC P1620: Shut Off Error Was a problem found?

aaa

11-139
DTC P1621: Shut Off Error (Reference Circuit Low, Was a problem found?
stabiliser limit exceeded) YES – Repair the ECM ground circuit.
aaa

11-140
DTC P1622: Shut Off Error (Reference Circuit High, Was a problem found?
stabiliser limit exceeded) YES – Repair the ECM ground circuit.
Was the OBD System Check performed? ECM.
aaa

11-141
DTC P1623: Ignition Switch Circuit Low aaa

Check''.
Was the OBD System Check performed?
2. 2. Check the ignition switch circuit (ECM terminal
No. 58).
YES – Repair the ignition switch circuit.
ECM.
NOTICE


11-142
DTC P1625: Reference #1 Circuit Low Voltage (APS1, Was a problem found?
MAF Sensor) YES – Repair the ECM ground circuit.
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11-143
DTC P1626: Reference #1 Circuit High Voltage (APS1, Was a problem found?
MAF Sensor) YES – Repair the ECM ground circuit.
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11-144
DTC P1627: Reference #2 Circuit Low Voltage (APS2, Was a problem found?
MAP Sensor, RP Sensor) YES – Repair the ECM ground circuit.
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11-145
DTC P1628: Reference #2 Circuit High Voltage (APS2, Was a problem found?
MAP Sensor, RP Sensor) YES – Repair the ECM ground circuit.
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11-146_Diesel Engine Management System_OBD System Troubleshooting
11-146
OBD System Troubleshooting
The on board diagnostic check is the starting point for 1. 11. Check the scan tool data communication circuit
any driveability diagnosis. Before using this procedure, (ECM connector terminal No. 48) for an open
perform a careful visual physical check of the ECM and or short to voltage. Also check the DLC ignition
engine grounds for cleanliness and tightness. feed circuit for an open or short to ground and
The on board diagnostic check is an organised approach the DLC ground circuit for an open.
to identifying a problem created by an electronic engine DATA LINK CONNECTOR (DLC)
control system malfunction.
2. 2. Observe the malfunction indicator lamp (MIL).
Is the MIL ON?
NO – Go to No MIL Chart.
4. 4. Install a scan tool.
5. 5. Turn the ignition switch ON (II). Is a problem found?
6. 6. Attempt to display ECM engine data with the YES – Repair for an open or short in the circuit.
scan tool. NO – Substitute a known-good ECM and recheck. If
Does the scan tool display ECM data? symptom/indication goes away, replace the original
NO – Go to step 9. aaa
7. 7. Start the engine at idling.
Does the engine start and continue to run?
NO – Go to Cranks But Will Not Run.
8. 8. Select ''Display DTCs'' with the scan tool.
Are there any DTCs?
YES – Go to applicable DTC chart.
NO – Go to symptom table.

11-147_Diesel Engine Management System_OBD System Troubleshooting (cont'd)
11-147
OBD System Troubleshooting (cont'd)
No Malfunction Indicator Lamp (MIL) 1. 7. Turn the ignition switch OFF.

1. 1. Check the ''On Board Diagnostic (OBD) System 2. 8. Disconnect meter connector.
Check''. 3. 9. Check for an open in the wire between the
Was the OBD System Check performed? ECM A connector terminal No. 15 and meter
connector terminal No. 18.
Is a problem found?
YES – Repair an open in the wire.
The meter fuse
The ignition feed fuse 4. 10. Connect the meter connector terminal No. 8
and body ground with a test light.
Is the fuse OK?
METER CONNECTOR 22P CONNECTOR
4. 4. Disconnect ECM A connector.
5. 5. Connect the ECM A connector terminal No. 15
and body ground with a jumper wire.
Is the test light turn ON?
NO – Repair an open in the instrument cluster ignition
feed circuit.
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Is the MIL turn ON?
ECM.

11-148

2. 13. Check for an open in the valve of MIL.
Is a problem found?
YES – Replace the valve of MIL.
NO – Replace the meter assembly.

11-149
Malfunction Indicator Lamp (MIL) ON Steady 1. 8. Check for the following conditions:
1. 1. Check the ''On Board Diagnostic (OBD) System Damaged meter assembly
Check''. Dirt on the wire in the meter assembly
Was the OBD System Check performed? Is a problem found?
YES – Go to step 2. YES – Repair an open in the wire.
NO – Go to OBD System Check. NO – Replace the meter assembly.
3. 3. Disconnect ECM A connector.
Does the MIL come ON?
ECM.
6. 6. Disconnect meter connector.
7. 7. Check for short to ground in the wire between
the ECM A connector terminal No. 15 and
meter connector terminal No. 18.
Is a problem found?
YES – Repair for short to ground in the wire.

11-150
Engine Cranks But Will Not Run 1. 8. Perform a compression pressure measurement.
1. 1. Check the ''On Board Diagnostic (OBD) System Refer to (compression pressure measurement).
Check''. Standard:
Was the OBD System Check performed? about 2,800 kPa (28.6 kgf/cm2 , 407 psi) at
YES – Go to step 2. 200 rpm (min -1 )
NO – Go to OBD System Check. (When the ECT is about 50°C (122°F))
2. 2. Check the immobiliser control system.
Is there an abnormality in the immobiliser control
system?
YES – Check the immobiliser control system.
If the problem is found, repair as necessary.
Fuel volume.
Engine oil condition.
Damaged or faulty intake air duct.
Faulty air cleaner and filter.
Is a compression pressure standard?
Damaged or faulty fuel pipe.
Damaged or faulty fuses. YES – Go to step 10.
Main relay (20A) fuse NO – Go to step 9.
Ignition 1 (7.5A) fuse 2. 9. Check for the following conditions:
Glow relay (60A) fuse If the problem is found, repair as necessary.
Faulty battery voltage. Refer to engine mechanical.
5. 4. Turn the ignition switch OFF. Faulty or incorrect valve clearances.
6. 5. Install a scan tool. Fuel injector fixing condition or other
7. 6. Turn the ignition switch ON (II). damaged.
8. 7. Check the engine cranking speed with the scan Leaking head gasket.
tool. Turn the engine cranking. Excessive valve deposit.
Is the engine cranking speed about 200 rpm (min -1 )? Is a problem found?
YES – Go to step 8. YES – Repair as necessary.
NO – Go to (Starter motor inspection). NO – Go to step 10.
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11-151
1. 13. Measure the voltage of ECM as below. aaa

Between B terminal No. 86 and body
ground.
Engine cranking.
Is the voltage about 0 V?

If the problem is found, repair as necessary.
Damaged or faulty supply pump.
Damaged or faulty fuel metering unit
Is a problem found?
YES – Repair the supply pump.
ECM. Go to injector inspection.

11-152_Diesel Engine Management System_Injector Spray Condition Check
11-152
Injector Spray Condition Check
Special tool required 1. 6. Check the spray condition.

Injector test harness 5-8840-7010-0 If the spray condition is bad, the injector must
be replaced or reconditioned.
1. 1. Remove all injectors (see page 11-155).
2. 2. Set an injector to a nozzle tester (A) and nozzle Correct (A)
holder (B). Incorrect (Restrictions) (B)
Incorrect (Dripping) (C)
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3. 3. Connect the injector test harness to the injector

and battery.
4. 4. Observe the fuel pressure indicated by the fuel

pressure gauge with the fuel pump running.
5. 5. Operate the fuel pump running at about 40,000
kPa (410 kgf/cm 2 , 5,800 psi) and then
immediately use the injector switch box to
command the fuel pump ON.
WARNING
Test fluid from the nozzle tester will
spray out of the injector under great
pressure.
It can easily puncture a person's skin.
Keep your hands away from the
injector at all times.

11-153_Diesel Engine Management System_Accelerator Pedal Position Sensor Replacement
11-153
Accelerator Pedal Position Sensor Replacement
1. 1. Fully open the throttle valve, then remove the

throttle cable (A) from the throttle link (B).
2. 2. Remove the accelerator pedal position sensor

6P connector (C).
3. 3. Remove the bolts (D).
4. 4. Install the part in the reverse order of removal.
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11-154_Idle Control System_Idle Speed Inspection
11-154
Idle Control System
Idle Speed Inspection
NOTE: 1. 3. Check the idle speed with no-load conditions:

Leave the Idle Air Control (IAC) valve headlights, blower fan, rear defogger, radiator
connected. fan and air conditioner are not operating.
Before checking the idle speed, check these Idle speed should be:
items: 850+50 rpm (min -1 )
The Malfunction Indicator Lamp (MIL) has not
2. 4. Idle the engine for 1 minute with heater fan
been reported on.
switch on HI and air conditioner on, then check
Ignition timing
the idle speed.
Spark plugs
Idle speed should be:
Air cleaner
PCV system 850+50 rpm (min -1 )
2. 1. Connect a tachometer (A) to the test NOTE: If the idle speed is not within specification, see
tachometer connector (B). the Symptom Chart.
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3. 2. Start the engine. Hold the engine at 3,000 rpm

(min -1 ) with no load (in Park or neutral) until
the radiator fan comes on, then let it idle.

11-155_Fuel Supply System_Component Location Index
11-155
Fuel Supply System
1. FUEL SUPPLY PUMP

2. COMMON RAIL
3. FUEL GAUGE SENDING UNIT
Test, page 11-162
4. FUEL TANK
5. FUEL FEED PIPE
6. FUEL FILTER
Water bleeding, page 11-158
7. FUEL HAND PRIMER
8. FUEL RETURN PIPE
9. INJECTOR
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11-156_Fuel Supply System_Fuel Line Inspection
11-156
Fuel Supply System
Fuel Line Inspection
Check the fuel system lines, hoses and fuel filter for damage, leaks and deterioration. Replace any damaged parts.
Check all clamps and retighten if necessary.
: Do not disconnect the hose from the pipe at these joints.
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11-157_Fuel Supply System_Fuel System Bleeding
11-157
Fuel Supply System
Fuel System Bleeding
Air must be bled from the fuel after disassembling the fuel 1. 6. When the air bubbles cease to appear, tighten
system for system for service and after run out of the the air bleed bolt to the specified torque (9 Nm
fuel. (0.9 kgf/m, 7 lbf/ft)).
See the following for the procedure. 2. 7. After tightening the air bleed plug, operate the
fuel hand primer unit it becomes hard.
1. 1. Fill the fuel tank with fuel.
3. 8. Stop bleeding when the fuel hand primer
2. 2. Remove the fuel filter air bleed bolt and replace
becomes hard and crank the engine.
the washer with a new one.
4. 9. If the engine does not start, operate the hand
3. 3. Loosely screw the air bleed bolt (A) into the
primer again until it becomes hard.
threaded hole in the fuel filter until the 2 or 3
NOTE:
threads at the cutout of the threaded part of the
bolt come out. Note that the continuous cranking time of
the engine must be 30 seconds to shorter at
one operation. Cranking the engine for
longer than 30 seconds can cause damage
to the starter and fuel pump.
Do not reuse the copper washer of the air
bleed bolt. Replace it with a new one
whenever it is removed.
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4. 4. Remove the fuel hand primer from the hose

clip.
5. 5. Squeeze the fuel hand primer (A) and operate it
40 to 50 times. Fuel with air bubbles will flow
out.

11-158_Fuel Supply System_Fuel Filter Water Bleeding
11-158
Fuel Supply System Fuel Filter Replacement
Fuel Filter Water Bleeding
1. 1. Place a suitable container under the fuel filter to 1. 1. Disconnect the hoses from the fuel filter (A).
catch the water.
2. 2. Loosen the water screw (A) at the underside of
the fuel filter until water drops.
2. 2. Remove the bolts (B) from the fuel filter bracket

(C).
3. 3. Remove the fuel filter (A).
3. 3. Drain about 85 ml (2.9 fl.oz, 3.0 lmp.oz) to 150

ml (5.1 fl.oz, 5.3 lmp.oz) of water.
4. 4. Tighten the water screw securely.
5. 5. Bleed the fuel system (see page 11-157).
4. 4. Install the part in the reverse order of removal.

5. 5. Bleed the fuel system (see page 11-157).
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11-159_Fuel Supply System_Injector Replacement
11-159
Fuel Supply System
Injector Replacement
Special tool required Injector installation

Injector fixing tool 5-86751-052-0 1. 1. Put the bracket (A) onto the bolt; carrier fixing
Injector removal (B).
1. 1. Remove the cylinder head cover and loosen
bolts (A).
2. 2. Insert the injectors (C) into the cylinder head.

3. 3. Fix the injector angle by the injector fixing tool.
2. 2. Loosen bolts; bracket fixing (B).

3. 3. Loosen bolt; bracket fixing (C).
4. 4. Remove bracket (D).
5. 5. Remove retainer; injector (E).
6. 6. Remove injector assembly (F).
4. 4. Put the retainer, injector (A) onto slit on the

bracket (B).
5. 5. Put the bracket (C), apply engine oil to bolt (D)
and tighten temporary.
Temporary tightening torque:
2 Nm (0.2 kgf/m, 1 lbf/ft)
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11-160_Fuel Supply System_Injector Replacement (cont'd)
Fuel11-160
Supply Pump and Common Rail
Fuel Supply System Replacement
Injector Replacement (cont'd)
1. 6. Apply engine oil to the bolt; bracket fixing (E) Special Tool Required
and tighten temporary. Remove the fuel supply pump pulley 5-8840-7002-0
Removal
2 Nm (0.2 kgf/m, 1 lbf/ft)
1. 1. Disconnect the fuel feed hose and the fuel
2. 7. Tighten nut (F) for bracket (B) in order of the return hose on the fuel supply pump.
middle, then both ends in condition of dry. 2. 2. Remove the fuel supply pipe (A) to common
Tightening torque: rail.
22 Nm (2.2 kgf/m, 16 lbf/ft) (When wet
condition: 11 Nm (1.1 kgf/m, 8.0 lbf/ft))
3. 8. Tighten bolt (E) with tightening torque 22 Nm
(2.2 kgf/m, 16 lbf/ft).
4. 9. Apply engine oil to the bolt (G) and insert in
order of No. 1 then No. 2, 3, 4.
5. 10. Tighten all bolt (G) temporary.
7 Nm (0.7 kgf/m, 5.0 lbf/ft)
6. 11. Fully tighten all bolts (G) with tightening torque
17 Nm (1.7 kgf/m, 12 lbf/ft).
7. 12. Make sure that the tightening torque of bolt (G)
with 17 Nm (1.7 kgf/m, 12 lbf/ft).
3. 3. Remove the injection pipes (B) from common
8. 13. Once loosen the bolt (D) to 60 degrees then
rail to injector.
fully tighten them with tightening torque 27 Nm
4. 4. Remove the fuel supply pump drive pulley by
(2.8 kgf/m, 20 lbf/ft).
remover.
9. 14. Loosen the bolts (G) to 60 degrees then tighten
5. 5. Remove the fuel supply pump fixing nuts (A) for
them with tightening torque 17 Nm (1.7 kgf/m,
removal of the fuel supply pump assembly from
12 lbf/ft).
cylinder block.
10. 15. Make sure that the tightening torque of bolt (D)
is 27 Nm (2.8 kgf/m, 20 lbf/ft) (Do not loosen
the bolt (D) again).
11. 16. Remove the injector fixing tool.
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11-161_Fuel Supply System_Fuel Supply Pump and Common Rail Replacement (cont'd)
11-161
Fuel Supply System
Fuel Supply Pump and Common Rail
Replacement (cont'd)
1. 6. Remove the common rail fixing bolts (A) and 1. 10. Install the fuel supply pump assembly (A) to the
remove the common rail assembly. cylinder block.
Tighten fixing nuts (B) to 20 Nm
(2.0 kgf/m, 14 lbf/ft).
Installation
2. 7. Install the common rail assembly (A) to cylinder
block.
2. 11. Install the fuel supply pump drive pulley.

3. 12. Install the fuel supply pipe (A) to common rail.
Tightening torque:
23 Nm (2.3 kgf/m, 17 lbf/ft)
3. 8. Tighten the common rail fixing bolt (B) to 25

Nm (2.5 kgf/m, 18 lbf/ft).
4. 9. Tighten pipe assembly with installation angle
(20°).
Tighten torque:
30 Nm (3.1 kgf/m, 22 lbf/ft)
4. 13. Install the injection pipes (B) in tightening order,

injector side and common rail side.
Tightening torque:
23 Nm (2.3 kgf/m, 17 lbf/ft)
5. 14. Connect the fuel feed hose and the fuel return
hose on the fuel supply pump.
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11-162_Fuel Supply System_Fuel Gauge Sending Unit Test
11-162
Fuel Supply System
Fuel Gauge Sending Unit Test
Special Tool Required 1. 7. Measure voltage between the fuel pump 5P

Adjustable ring wrench 07WAA-0010100 connector terminals No. 1 and No. 2 with the
ignition switch ON (II). There should be battery
NOTE: For the fuel gauge system circuit diagram, refer to
voltage.
the Gauges Circuit Diagram (see page 22-88).
If the voltage is as specified, go to step 8.
1. 1. Check the No. 10 METER (7.5A) fuse in the If the voltage is not as specified, check for:
under-dash fuse/relay box before testing. an open in the YEL/BLK or BLK wire.
2. 2. Do the gauge drive circuit check (see page 22- poor ground (G501).
30).
FUEL PUMP 5P CONNECTOR
If the fuel gauge needle sweeps from the
minimum to maximum position and then
returns to the minimum position, the gauge
is OK. Go to step 3.
If the fuel gauge needle does not sweep
from the minimum to maximum position and Wire side of female terminals
then back to the minimum position, replace 3. 8. Turn the ignition switch OFF. Remove the No.
the gauge assembly and retest. 9 BACK UP (10A) fuse from the under-hood
3. 3. Turn the ignition switch OFF. fuse/relay box for at least 10 seconds and
4. 4. Remove the rear seat cushion, refer to the reinstall it.
2001 Civic 3-door Shop Manual on this CD 4. 9. Install a 2 ohm resistor between the fuel pump
(see page 20-40). 5P connector terminals No. 1 and No. 2, then
5. 5. Remove the access panel (A) from the floor. turn the ignition switch ON (II).
FUEL PUMP 5P CONNECTOR

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6. 6. Disconnect the fuel pump 5P connector (B).

11-163_Fuel Supply System_Fuel Gauge Sending Unit Test (cont'd)
11-163
Fuel Supply System
Fuel Gauge Sending Unit Test (cont'd)
1. 10. Check that the pointer of the fuel gauge 1. 14. Measure the resistance between the No. 1 and
indicates ''F''. No. 2 terminals with the float at E (EMPTY), 1/2
If the pointer of the fuel gauge does not (HALF FULL) and F (FULL) positions.
indicate ''F'', replace the gauge. If you do not get the following readings, replace
If the gauge is OK, inspect the fuel gauge the fuel gauge sending unit (see page 11-164).
sending unit. Float F ½ LOW E
NOTE: The pointer of the fuel gauge returns to the Position
bottom of the gauge dial when the ignition switch is
Resistance 11 - 68.5 - 114.4 - 130 -
OFF, regardless of the fuel level.
(ohms) 13 74.5 126.6 132
2. 11. Remove the fuel fill cap.
3. 12. Disconnect the quick-connect fittings from the
NOTE: Remove the No. 9 BACK UP (7.5A) fuse
fuel pump.
from the under-hood fuse/relay box for at least 10
4. 13. Using the tool, loosen the fuel tank unit
seconds after completing troubleshooting
locknut (A).
otherwise it may take up to 20 minutes for the
fuel gauge to indicate the correct fuel level.
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11-164_Fuel Supply System_Fuel Gauge Sending Unit Replacement
11-164
Fuel Supply System
Fuel Gauge Sending Unit Replacement
Special Tool Required 1. 7. Remove the locknut (A) and the fuel tank unit.
Adjustable ring wrench 07WAA-0010100
1. 1. Remove the fuel fill cap.
2. 2. Remove the rear seat cushion, refer to the
2001 Civic 3-door Shop Manual on this CD
(see page 20-40).
3. 3. Remove the access panel (A) from the floor.
2. 8. Remove the stopper (B). Release the hook (C)

and remove the strainer case (D), the fuel
4. 4. Disconnect the fuel pump 5P connector (B). gauge sending unit (E) and the case (F).
5. 5. Disconnect the quick-connect fitting (C) from 3. 9. Install the part in the reverse order of removal
the fuel tank unit. with a new base gasket (G) and new O-rings
6. 6. Using the tool, loosen the fuel tank unit locknut (H), then check these items:
(A). When connecting the wire harness, make
sure the connection is secure and the
connector (I) is firmly locked into the place.
When installing the fuel gauge sending unit,
make sure the connection is secure and the
connector is firmly locked into place. Be
careful not to bend or twist it excessively.
When installing the fuel tank unit, align the
marks (J) on the fuel tank (K) and the fuel
tank unit (L).
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11-165_Fuel Supply System_Fuel Tank Replacement
11-165
Fuel Supply System
Fuel Tank Replacement
1. 1. Drain the fuel tank: Remove the fuel gauge sending unit (see page 11-164). Using a hand pump, hose and container
suitable for gasoline, draw the fuel from the fuel tank.
2. 2. Jack up the vehicle and support it with jackstands.
3. 3. Loosen the clamp (A).
4. 4. Disconnect the hoses (B). Slide back the clamps, then twist the hoses as you pull to avoid damaging them.
5. 5. Place a jack, or other support, under the tank (C).
6. 6. Remove the strap bolts and let the strap (D) fall free.
7. 7. Remove the fuel tank. If it sticks to the undercoat on its mount, carefully pry it off the mount.
8. 8. Install the remaining parts in the reverse order of removal.
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11-166_Intake Air System_Component Location Index
11-166
Intake Air System
1. AIR CLEANER ELEMENT

2. THROTTLE CABLE
Adjustment, page 11-171
Removal/Installation, page 11-172
3. VACUUM SWITCHING VALVE
(VSV)
4. VARIABLE SWIRL CONTROL
VALVE (VSCV)
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11-167_Intake Air System_DTC Troubleshooting
11-167
Intake Air System
DTC Troubleshooting
DTC P1112: Variable Swirl Control Valve (VSCV) Circuit 1. 10. Measure voltage between the ECM A connector
Open terminals No. 18 and body ground.
Check''.
Was the OBD System Check performed?
3. 3. Disconnect the VSCV connector.
5. 5. Measure voltage between the VSCV 2P

NO – Repair open in the wire between the VSCV and
the ECM connector terminal No. 7.
3. 12. Connect the VSCV connector.
4. 13. Connect the DVM the ECM connector terminals
Wire side of female terminals No. 18 and body ground.
Is there battery voltage? 5. 14. Turn the ignition switch ON (II).
YES – Go to step 6. Is there B+?
NO – Repair open in the wire between the VSCV and YES – Go to inspection.
the main relay. NO – Substitute a known-good ECM and recheck. If
6. 6. Turn the ignition switch OFF. symptom/indication goes away, replace the original
7. 7. Disconnect the ECM A connector. ECM.
8. 8. Connect the VSCV connector terminals No. 1 NOTICE
and No. 2 with a jumper wire.
9. 9. Turn the ignition switch ON (II). The battery power supply short circuit to 5 V power
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11-168_Intake Air System_DTC Troubleshooting (cont'd)
11-168
Intake Air System
DTC P1113: Variable Swirl Control Valve (VSCV) Circuit 1. 9. Connect the ECM A connector.
Short Are there DTC P1113 being output?
1. 1. Check the ''On Board Diagnostic (OBD) System YES – Substitute a known-good ECM and recheck. If
YES – Go to step 2. NO – System is OK.
3. 3. Disconnect the VSCV connector. The battery power supply short circuit to 5 V power
4. 4. Disconnect the ECM A connector. supply damages the ECM.
terminals No. 18 and body ground.

YES – Repair short in the wire between the VSCV
and the ECM.
8. 8. Replace the VSCV.

11-169_Intake Air System_VSV Inspection
11-169
Intake Air System
VSV Inspection
1. 1. Check the resistance between the VSV aaa

connector terminals using a circuit tester.
Resistance (At room temperature):
30 – 34 (ohms)

11-170_Intake Air System_Air Cleaner Element Replacement
11-170
Intake Air System
Air Cleaner Element Replacement
1. 1. Open the air cleaner housing cover (A). aaa
2. 2. Remove the air cleaner element (B) from the air

cleaner housing (C).
3. 3. Install the parts in the reverse order of removal.

11-171_Intake Air System_Throttle Cable Adjustment
11-171
Intake Air System
Throttle Cable Adjustment
1. 1. Check cable free play at the throttle linkage. aaa

Cable deflection (A) should be 10 - 12 mm (3/8
- 1/2 in.).
2. 2. If deflection (A) is not within spec (10 - 12 mm,

3/8 - 1/2 in.) loosen the locknut (B), turn the
adjusting nut (C) until the deflection (A) is as
specified, then retighten the locknut (B).
3. 3. With the cable properly adjusted, check the
throttle valve to be sure it opens fully when you
push the accelerator pedal to the floor. Also
check the throttle valve to be sure it returns to
the idle position whenever you release the
accelerator pedal.

11-172_Intake Air System_Throttle Cable Removal/Installation
11-172
Intake Air System
Throttle Cable Removal/Installation
1. 1. Fully open the throttle valve, then remove the 1. 4. Install in the reverse order of removal.
throttle cable (A) from the throttle link (B). 2. 5. After installing, start the engine. Hold the
engine at 3,000 rpm (min -1 ) with no load (in
Park or neutral) until the radiator fan comes on,
then let it idle.
3. 6. Hold the cable, removing all slack from the
cable.
4. 7. Set the locknut on the cable bracket (A).
Adjust the adjusting nut (B) so that its free play
is 0 mm.
2. 2. Remove the cable housing (C) from the cable

bracket (D).
3. 3. Remove the throttle cable (A) from the
accelerator pedal (B).
5. 8. Remove the cable from the throttle bracket (A).

Reset the adjusting nut (B) and tighten the
locknut (C).
6. 9. With the cable properly adjusted, check the
throttle valve to be sure it opens fully when you
push the accelerator pedal to the floor. Also
check the throttle valve to be sure it returns to
the idle position whenever you release the
accelerator pedal.
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11-173_EGR System_DTC Troubleshooting
11-173
EGR System
DTC Troubleshooting
DTC P1401: EGR Valve Control Negative Deviation 1. 10. Visually and physically inspect the pintle, valve
(EGR EVRV Fault) passages and adapter for excessive deposits or
1. 1. Check the ''On Board Diagnostic (OBD) System any kind of a restriction.
Check''. If a problem is found, clean or replace EGR system
Was the OBD System Check performed? components as necessary.
YES – Go to step 2. Is a problem found?
NO – Go to OBD System Check. YES – Repair the EGR valve.
2. 2. Check the DTC. NO – Go to step 11.
Are there DTCs P0562 or P1112 being output? 2. 11. Disconnect the EVRV connector.
YES – Go to relevant DTC chart. 3. 12. Measure resistance between the EVRV 2P
Damaging EGR valve or EVRV
pipes Is there about 14.7 – 16.1 ohms (20°C (68°F)) (At
Is a problem found? room temperature)?
YES – Repair as necessary. YES – Go to step 13.
NO – Go to step 4. NO – Replace the EVRV.
4. 4. Start the engine and allow it to idle. 4. 13. Remove the EVRV.
5. 5. Check the MAF with the scan tool. 5. 14. Connect the hand vacuum pump (with gauge)
6. 6. While idling, jab the accelerator pedal about to the EVRV (A).
halfway down and immediately let the engine
return to idle.
Did the MAF value on the scan tool show an
immediate large change?
NO – Replace the MAF sensor.
6. 15. Apply 34 kPa (257 mm Hg, 10 in. Hg) of
Damaged EGR valve or EVRV vacuum with hand vacuum pump.
EVRV hose vacuum leaks Were vacuum leaks found?
Vacuum leaks in EGR valve flange and YES – Replace the EVRV.
pipes
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11-174_EGR System_DTC Troubleshooting (cont'd)
11-174
EGR System
1. 17. Inspect the manifold EGR (A) ports and the aaa
EGR inlet and outlet pipe for blockage caused
by excessive deposits or other damage.
Was the problem found?

YES – Correct the condition as necessary.
2. 18. Connect the hand vacuum pump (with gauge)
to the EGR valve.
3. 19. Apply 26 kPa (200 mm Hg, 7.9 in. Hg) of
Did the EGR valve work properly?
YES – Substitute a known good ECM and recheck. If
ECM.
NO – Replace the EGR valve.

11-175
EGR System
DTC P1403: EGR Valve Control Circuit Open 1. 7. Turn the ignition switch OFF.
1. 1. Check the ''On Board Diagnostic (OBD) System 2. 8. Disconnect the ECM A connector.
Check''. 3. 9. Check the circuit between EVRV connector No.
Was the OBD System Check performed? 2 terminal and ECM A connector terminal No.
16 for open.
Are there DTCs P0562 or P1112 being output?
Damaged EGR valve or EVRV
Is a problem found?
4. 4. Disconnect the EVRV connector. YES – Repair open in the wire between EVRV and
5. 5. Turn the ignition switch ON (II). the ECM.
6. 6. Measure voltage between the EVRV 2P NO – Go to step 10.
connector terminals No. 1 and body ground. 4. 10. Measure resistance between the EVRV 2P

temperature)?
Is there B+?
YES – Go to step 7. symptom/indication goes away, replace the original
NO – Repair open in the wire between EVRV and the ECM.
main relay. NO – Replace the EVRV.
NOTICE

aaa

11-176
EGR System
DTC P1404: EGR Valve Control Circuit Short 1. 7. Turn the ignition switch OFF.
1. 1. Check the ''On Board Diagnostic (OBD) System 2. 8. Disconnect the ECM A connector.
Check''. 3. 9. Check the circuit between EVRV connector No.
Was the OBD System Check Performed? 2 terminal and ECM A connector terminal No.
16 for short to ground.
Are there DTCs P0562 or P1112 being output?
Damaged EGR valve or EVRV
The EVRV wire harness and connector.
Is a problem found?
4. 4. Disconnect the EVRV connector. YES – Repair short to ground in the wire between
5. 5. Turn the ignition switch ON (II). EVRV and the ECM.
6. 6. Measure voltage between the EVRV 2P NO – Go to step 10.
connector terminals No. 1 and body ground. 4. 10. Measure resistance between the EVRV 2P

Wire side of female terminals temperature)?
Is there B+? YES – Substitute a known-good ECM and recheck. If
YES – Go to step 7. symptom/indication goes away, replace the original
NO – Repair open in the wire between EVRV and the ECM.
main relay. NO – Replace the EVRV.
NOTICE

aaa

11-177_Catalytic Converter System_Catalytic Converter Inspection
11-177
Catalytic Converter System
Catalytic Converter Inspection
If excessive exhaust system back-pressure is suspected, aaa

remove the TWC from the vehicle.
Using a flashlight, make a visual check for plugging,
melting or cracking of the catalyst.
Replace the TWC if any of the visible area is damaged or
plugged.

11-178_PCV System_PCV Valve Inspection
11-178
PCV System
PCV Valve Inspection
1. 1. Check the PCV valve (A), hose (B) and aaa

connections for leak or restrictions.

12-0_Transaxle
Transaxle
Clutch 12-1
Manual Transmission 13-1
Driveline/Axle 16-1
aaa

12-1_Clutch
Clutch
Special Tools 12-2

Clutch Pedal and Clutch Switch Adjustment 12-4
Clutch Master Cylinder Replacement 12-5
Clutch Master Cylinder Overhaul 12-7
Slave Cylinder Replacement 12-9
Slave Cylinder Overhaul 12-10
Clutch Replacement 12-11

MD4 Manual Transmission has been added.
aaa

12-2_Clutch_Special Tools
12-2
Clutch
Special Tools

1 5-8840-0573-0 (J-36190) Driver handle 1
2 5-8840-0574-0 (J-37245) Bushing remover 1
3 5-8840-0575-0 (J-37158) Bearing remover 1
4 5-8840-0576-0 (J-37159) Inner bearing installer 1
5 5-8840-0577-0 (J-36037) Outer bushing installer 1
6 5-8840-7001-0 Clutch alignment arbor 1
aaa

12-3_Clutch_Component Location Index
12-3
Clutch
NOTE: LHD type is shown, RHD type is similar.

1. RESERVOIR
2. RETAINING CLIP
Replace.
3. RESERVOIR HOSE
4. LOCK PIN
5. CLUTCH SWITCH
6. CLUTCH PEDAL
7. PEDAL PIN
8. CLUTCH MASTER CYLINDER
Overhaul, page 12-7
9. O-RING
Replace.
10. DRIVEN PLATE
Removal, page 12-11
11. PRESSURE PLATE
Removal, page 12-11
12. RELEASE BEARING
13. CLUTCH HOSE CLIP
14. CLUTCH HOSE
15. CLUTCH HOSE CLIP
16. O-RING
Replace.
17. SLAVE CYLINDER
Overhaul, page 12-10
18. ROLL PIN
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12-4_Clutch_Clutch Pedal and Clutch Switch Adjustment
12-4
Clutch
Clutch Pedal and Clutch Switch Adjustment
NOTE: 1. 3. Tighten locknut (D).

LHD type is shown, RHD type is similar. 2. 4. With the clutch pedal released, turn the clutch
Remove the driver's side floor mat before pedal adjusting bolt (B) in until it contacts the
adjusting the clutch pedal. clutch pedal (C).
The clutch is self-adjusting to compensate for 3. 5. Turn the adjusting bolt (B) in an additional 3/4
wear. to 1 turn.
If there is no clearance between the master 4. 6. Tighten locknut (A).
cylinder piston and push rod, the release 5. 7. Loosen locknut (J) and the clutch switch (K).
bearing will be held against the diaphragm 6. 8. Press the clutch pedal to the floor.
spring, which can result in clutch slippage or 7. 9. Release the clutch pedal 15 - 20 mm (0.59 -
other clutch problems. 0.79 in.) from the fully depressed position and
hold it there. Adjust the position of the clutch
1. 1. Loosen locknut (A) and back off the clutch
switch (K) so that the engine will start with the
pedal adjusting bolt (B) until it no longer
clutch pedal in this position.
touches the clutch pedal (C).
8. 10. Tighten locknut (J).
aaa
2. 2. Loosen locknut (D) and turn the push rod (E) in

or out to get the specified height (F), stroke
(G), free play (H) and disengagement height (I)
at the clutch pedal.
Clutch Pedal Stroke:
140 - 150 mm (5.51 - 5.91 in.)
Clutch Pedal Pedal Free Play:
9 - 15 mm (0.35 - 0.59 in.)
Clutch Pedal Height:
LHD model: 193 mm (7.60 in.)
RHD model: 194 mm (7.64 in.)
Disengagement Height:
LHD model: 115 mm (4.53 in.)
RHD model: 117 mm (4.61 in.)

12-5_Clutch_Clutch Master Cylinder Replacement
12-5
Clutch
Clutch Master Cylinder Replacement
NOTE: Do not spill brake fluid on the vehicle; it may 1. 4. Remove the clutch master cylinder (A) and the
damage the paint; if brake fluid does contact the paint, clutch master cylinder seal (B).
wash it off immediately with water.
1. 1. Remove the brake fluid from the clutch master
cylinder reservoir with a syringe.
2. 2. Remove the clutch line bracket (A), then
disconnect the clutch line (B) from the clip (C).
2. 5. Remove the retaining clip (A). Disconnect the

clutch line (B) and remove the O-ring (C). Plug
the end of the clutch line with a shop towel to
prevent brake fluid from coming out.
3. 3. Pry out the lock pin (A) and pull the pedal pin
(B) out of the yoke. Remove the nuts (C).
3. 6. Disconnect the reservoir hose (D) from the

clutch master cylinder reservoir. Plug the end of
the reservoir hose with a shop towel to prevent
brake fluid from coming out.
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12-6_Clutch_Clutch Master Cylinder Replacement (cont'd)
12-6
Clutch
Clutch Master Cylinder Replacement (cont'd)
1. 7. Install the clutch master cylinder in the reverse aaa

order of removal. Install a new O-ring. Tighten
the master cylinder mounting nuts to 13 Nm
(1.3 kgf/m, 9.4 lbf/ft). Make sure the tabs on the
master cylinder hose clamps are pointed in the
directions shown.
2. 8. To prevent the retaining clip (A) from coming
off, pry open the tip of the retaining clip (B) with
a screwdriver.
3. 9. Bleed the clutch hydraulic system (see step 6

on page 12-9).
NOTE: The reservoir filling is covered in the
bleeding procedure.

12-7_Clutch_Clutch Master Cylinder Overhaul
12-7
Clutch
Clutch Master Cylinder Overhaul
Exploded View
1. Clip catches shall be on arrow
marked side
2. RESERVIOUR HOSE
Inspect for damage, leaks,
interference and twisting
3. CLUTCH LINE CONNECTOR
4. O-RING
Replace.
5. RESERVIOR
6. RETAINING CLIP
Replace.
7. MASTER CYLINDER BODY
Check the cylinder wall for
scoring and wear.
8. (Brake Assembly Lube)
9. PUSH ROD
10. CIRCLIP
11. LOCK PIN
Replace.
12. YOKE
13. PEDAL PIN
14. STOPPER
Check for damage and bending
15. CLUTCH MASTER CYLINDER
SEAL
16. O-RING
Replace.
17. CONNECTOR
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12-8_Clutch_Clutch Master Cylinder Overhaul (cont'd)
12-8
Clutch
Clutch Master Cylinder Overhaul (cont'd)
NOTE: 1. 3. Slide the piston assembly into the clutch master

Refer to the Exploded View, as needed during cylinder.
this procedure.
Do not spill brake fluid on the vehicle; it may
damage the paint; if brake fluid does contact
the paint, wash it off immediately with water.
Clean all parts in brake fluid and air dry; blow
out all passages with compressed air.
Before reassembling, check that all parts are
free of dust and other foreign particles.
Replace parts with new ones whenever
specified to do so.
Make sure no dirt or other foreign matter is
allowed to contaminate the brake fluid.
Do not mix different brands of brake fluid as
they may not be compatible.
Do not reuse the drained fluid. Use only clean
DOT 3 or 4 brake fluid. 2. 4. Install the circlip in the groove of the clutch
master cylinder.
1. 1. Pry the circlip off the clutch master cylinder. aaa
2. 2. Carefully remove the piston by applying air

pressure through the clutch line hole.

12-9_Clutch_Slave Cylinder Replacement
12-9
Clutch
Slave Cylinder Replacement
NOTE: Do not spill brake fluid on the vehicle; it may 1. 5. Apply Urea Grease UM264 (P/N 41211-PY5-
damage the paint; if brake fluid does contact the paint, 305) to the tip of the push rod of the slave
wash it off immediately water. cylinder. Tighten the slave cylinder mounting
1. 1. Remove the mounting bolts (A) and the slave bolts to 22 Nm (2.2 kgf/m, 1.6 lbf/ft).
cylinder (B). 2. 6. Bleed the clutch hydraulic system.
NOTE: Be careful not to damage the slave
cylinder by overtightning the bleeder screw.
Attach a hose to the bleeder screw (A) and
suspended the hose in a container of brake
fluid.
Make sure there is an adequate supply of
fluid at the clutch master cylinder, then
slowly pump the clutch pedal until no more
bubbles appear at the bleeder hose.
Refill the clutch master cylinder with fluid
when done.
Always use only Genuine Honda DOT 3 or
2. 2. Remove the roll pins (C). Disconnect the clutch 4 brake fluid.
line (D),and remove the O-ring (E). Plug the
end of the clutch line with a shop towel to
prevent brake fluid coming out.
3. 3. Install the slave cylinder in the reverse order of
removal. Install the new O-ring (A).
aaa
4. 4. Pull the boot (B) back and apply grease to the

boot and slave cylinder rod (C). Reinstall the
boot.

12-10_Clutch_Slave Cylinder Overhaul
12-10
Clutch
Slave Cylinder Overhaul
NOTE:
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off
immediately with water.
Clean all parts in brake fluid and air dry; blow out all passages with compressed air.
Before reassembling, check that all parts are free of dust and other foreign particles.
Replace parts with new ones whenever specified to do so.
Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
Do not mix different brands of brake fluid as they may not be compatible.
Do not reuse the drained fluid. Use only clean DOT 3 or 4 brake fluid.
1. O-RING
Replace.
2. BLEEDER SCREW CAP
3. BLEEDER SCREW
8 Nm (0.8 kgf/m, 5.8 lbf/ft)
5. PISTON CUP
Replace.
6. SLAVE CYLINDER PISTON
Check for wear and damage.
7. PUSH ROD
8. Urea Grease UM264
(P/N 41211-PY5-305)
10. BOOT
Check that it is fitted securely over
the cylinder body.
11. SLAVE CYLINDER SPRING
Install with small and facing piston.
12. SLAVE CYLINDER BODY
Check the cylinder wall for scoring
and wear
13. CONNECTOR
aaa

12-11_Clutch_Clutch Replacement
12-11
Clutch
Clutch Replacement
Special Tools Required Driven Plate and Pressure Plate Installation

Driver handle 5-8840-0573-0 (J-36190) 1. 1. Install the driven plate assembly (A) using the
Bushing remover 5-8840-0574-0 (J-37245) special tool.
Bearing remover 5-8840-0575-0 (J-37158)
Inner bearing installer 5-8840-0576-0 (J-37159)
Outer bearing installer 5-8840-0577-0 (J-
36037)
Clutch alignment arbor 5-8840-7001-0
Pressure Plate and Drive Plate Removal
1. 1. Measure the height of each diaphragm springs
at 50mm from centre of pressure
plate.Maximum height difference : 1.0 mm
(0.039 in) with pressure plate mounting bolt
torque of 19 N.m(1.9kgf.m, 14ibf.ft). 2. 2. Install the pressure plate assembly.
TORQUE:
19 Nm (1.9 kgf/m, 14 lbf/ft)
3. 3. Tighten the bolts holding the pressure plate

2. 2. Remove the pressure plate assembly. assembly in the order shown in the figure.
3. 3. Remove the driven plate assembly. PRESSURE PLATE MOUNTING BOLT
4. 4. Make the necessary correction or parts TORQUE:
replacement if wear, damage or any other 19 Nm (1.9 kgf/m, 14 lbf/ft)
abnormal conditions are found during
4. 4. Remove the special tools.
inspection.
5. 5. Apply high temperature grease to the input
5. 5. Check the pressure plate for scoring, cracks or
shaft splines in.
warpage.
aaa
6. 6. Check the driven plate for surface deterioration
or contamination with oil.
Slight surface deterioration can be removed
with sand pager.
7. 7. Measure the clutch disc thickness. If the
thickness is less than the service limit, replace
the clutch disc.

12-12_Clutch_Clutch Replacement (cont'd)
12-12
Clutch
Clutch Replacement (cont'd)
Release Bearing Replacement 1. 5. Apply high temperature grease to the sliding

1. 1. Remove the spring (A) from the shift fork (B). surface, shift fork and lever, then install the
release bearing (A).
2. 2. Remove the release bearing (C).

3. 3. Make the necessary correction or parts
replacement if wear, damage, or any other
abnormal condition is found during inspection.
4. 4. Check the release bearing for excessive play,
noise and centre adjustment function. Replace,
if necessary.
NOTE: The release bearing is packed with
grease. Do not wash it in solvent.
2. 6. Install the spring (B).

3. 7. Make sure bearing pads are located on shift
fork ends (pads must be indexed) and both
spring ends are in shift fork holes with the
spring completely seated in bearing groove.
4. 8. Move the release lever right and left to make
sure that it fits properly against the release
bearing and that the release bearing slides
smoothly.
aaa

13-1_Manual Transmission
Manual Transmission
Special Tools 13-2

Transmission Fluid Inspection and Replacement 13-4
Back-Up Light Switch Test 13-4
Transmission Removal 13-5
Transmission Installation 13-10
Transmission Disassembly 13-15
Shift Arms Inspection 13-19
Input Shaft Disassembly 13-20
Input Shaft Inspection 13-20
Input Shaft Reassembly 13-21
Output Shaft Disassembly 13-23
Output Shaft Inspection 13-24
Output Shaft Reassembly 13-25
Synchro Ring and Gear Inspection 13-27
Input Shaft Bearing and Oil Seal Replacement 13-29
Output Shaft Bearing Replacement 13-30
Output Shaft and Differential Thrust Clearance Adjustment 13-31
Transmission Reassembly 13-32
Gearshift Mechanism Replacement 13-37
M/T Differential
Backlash Inspection 13-38
Final Driven Gear/Carrier Replacement 13-38
Carrier Replacement 13-39
Oil Seal and Bearing Outer Race Replacement 13-41

MD4 Manual Transmission has been added.
aaa

13-2_Manual Transmission_Special Tools
13-2
Manual Transmission
Special Tools

1 5-8840-0027-0 (J-26941) Axle shaft oil seal remover 1
2 5-8840-0019-0 (J-23907) Sliding hammer 1
3 5-8840-2747-0 (J-38763) Axle shaft oil seal installer 1
4 5-8840-0007-0 (J-8092) Driver handle 1
5 5-8840-0048-0 (J-33366) Transaxle holding fixture 1
6 5-8840-0047-0 (J-29843-8) Torx bit (No.45) 1
7 5-8840-0013-0 and 5-8840-0014-0 (J-22888) Puller body 1
8 5-8840-0566-0 (J-22888-50) Puller legs 1
9 5-8840-0053-0 (J-33373) Shim selector set 1
10 5-8840-0054-0 (J-33374) Bearing installer 1
11 5-8840-0183-0 (J-33367) Puller bridge 1
12 5-8840-0026-0 (J-26540) Oil seal installer 1
13 5-8840-0006-0 (J-7817) Bearing outer race installer 1
14 5-8840-0012-0 (J-22227-A) Bearing remover 1
15 5-8840-0009-0 (J-8853-01) Second collar installer 1
16 5-8840-0050-0 (J-33369) Pilot 1
17 5-8840-0605-0 (J-38599) Output front bearing installer 1
18 5-8840-0018-0 (J-23598) Pilot 1
19 5-8840-0008-0 (J-8611-01) Bearing outer race installer 1
20 5-8840-0016-0 (J-22919) Differential side bearing installer 1
21 5-8840-0015-0 (J-22912-01) Bearing remover 1
22 5-8840-2409-0 (J-29369-1) Needle bearing remover 1
23 5-8840-7000-0 Needle bearing installer 1
aaa

13-3_Manual Transmission_Special Tools (cont'd)
13-3
Manual Transmission
Special Tools (cont'd)
aaa

13-4_Manual Transmission_Transmission Fluid Inspection and Replacement
13-4 Back-up Light Switch Test

Manual Transmission
Transmission Fluid Inspection and
Replacement
1. 1. Park the vehicle on level ground and turn the 1. 1. Disconnect the back-up light switch (A)
engine OFF. connector.
2. 2. Remove the oil filler plug (A) and O-ring (B),
check the condition of the fluid and make sure
the fluid is at the proper level (C).
3. 3. If the transmission fluid is dirty, remove the

drain plug (D) and drain the fluid. 2. 2. Check for continuity between the back-up light
4. 4. Reinstall the drain plug with a new O-ring and switch connector terminals. There should be
refill the transmission fluid to the proper level. continuity when the shift lever is in reverse.
Oil Capacity 3. 3. If necessary, replace the back-up light switch.
Install the new washer and back-up light switch
2.0 l (2.1 US qt, 1.8 lmp qt)
on the transmission housing.
Always use Genuine Honda Manual Transmission aaa
Fluid (MTF). Using motor oil can cause stiffer shifting
because it does not contain the proper additives.
5. 5. Reinstall the oil filler plug with a new O-ring.

13-5_Manual Transmission_Transmission Removal
13-5
Manual Transmission
Transmission Removal
NOTE: Use fender covers to avoid damaging painted 1. 6. Disconnect the back-up light switch connector
surfaces. (A), then remove the water pipe bolt (B).
1. 1. Write down the frequencies for the radio' s
preset buttons. Disconnect the negative (-)
cable first, then the positive (+) cable from the
battery. Remove the battery.
2. 2. Remove the intake air duct (see step 6 on page
5-2).
3. 3. Remove the air cleaner housing (see step 33
on page 5-15).
4. 4. Disconnect the ground cable (A), then remove
the battery tray (B).
2. 7. Disconnect the cables (A) from the cable

bracket (B). Carefully remove both cables so as
not to bend the cables.
5. 5. Carefully remove the slave cylinder so as not to

bent the clutch line. Do not operate the clutch
pedal once the slave cylinder has been
aaa
removed.

13-6_Manual Transmission_Transmission Removal (cont'd)
13-6
Manual Transmission
Transmission Removal (cont'd)
1. 8. Remove the cable bracket. 1. 10. Attach the chain hoist (A) to the engine bracket
(B).
2. 11. Remove the transmission mount bracket (A)

2. 9. Disconnect the vehicle speed sensor (VSS) and transmission mounting bolt (B).
connector.
aaa

13-7
Manual Transmission
1. 12. Remove the three upper transmission mounting 1. 17. Remove the exhaust pipe A.
bolts.
2. 13. Raise the vehicle and make sure it is securely 2. 18. Remove the three bolts securing the
supported. transmission rear mount.
3. 14. Drain the transmission fluid. Reinstall the drain
bolt using a new O-ring (see page 13-4).
4. 15. Remove the splash shield.
aaa
5. 16. Remove the driveshafts (see page 16-3).

13-8
Manual Transmission
1. 19. Remove the front engine mount bracket 1. 21. Make reference marks (A) front suspension
mounting bolt. subframe (B) and mounting bolts (C), then
remove the front suspension subframe.
2. 20. Support the subframe with a 4 X 4 X 40 in.

piece of wood and a jack.
2. 22. Remove the front engine mount.
aaa

13-9
Manual Transmission
1. 23. Place the transmission jack under the 1. 25. Pull the transmission (A) away from the engine
transmission and remove the transmission rear until the transmission mainshaft clears the
mount (A). clutch pressure plate, then lower transmission
on the transmission jack.
2. 24. Remove the transmission mounting bolts.
2. 26. Remove the extension plate (B) and two dowel

pins (C).
3. 27. Remove the release bearing and release lever
(see page 12-12).
aaa

13-10_Manual Transmission_Transmission Installation
13-10
Manual Transmission
Transmission Installation
1. 1. Install the release lever and release bearing 1. 6. Install the transmission rear mount (B).
(see page 12-12).
2. 2. Check the two dowel pins (A) are installed in
the clutch housing.
2. 7. Install the front engine mount.
3. 3. Install the extension plate (B).

4. 4. Place the transmission (C) on the transmission
jack and raise it to the engine level.
5. 5. Install the transmission mounting bolts.
aaa

13-11_Manual Transmission_Transmission Installation (cont'd)
13-11
Manual Transmission
Transmission Installation (cont'd)
1. 8. Support subframe with a 4 X 4 X 40 in. piece of 1. 10. Loosely tighten the front engine mount bracket
wood and a jack. mounting bolt.
2. 9. Install the front suspension subframe (A) in its 2. 11. Install the three mounting bolts for the
original position by aligning the marks (B) you transmission rear mount.
made in the removal procedure.
aaa

13-12
Manual Transmission
1. 12. Install the exhaust pipe A. 1. 15. Install the transmission mount bracket (A) and
transmission mounting bolt (B).
2. 13. Install the driveshafts (see page 16-19).

3. 14. Install the three upper transmission mounting
bolt.
2. 16. Loosen the front engine mount bracket

mounting bolt, then tighten the front engine
mount bracket mounting bolt.
aaa

13-13
Manual Transmission
1. 17. Install the splash shield. 1. 20. Install the cable bracket.
2. 21. Install the cables.
2. 18. Remove the chain hoist.

3. 19. Connect the vehicle speed sensor (VSS)
connector.
aaa

13-14
Manual Transmission
1. 22. Install the water pipe bolt (A), then connect the 1. 24. Install the battery tray (A), then connect the
back-up light switch connector (B). ground cable (B).
2. 23. Apply Urea Grease UM264 (P/N 41211-PY5-

305) to the end of the slave cylinder rod. Install
the slave cylinder. Take care not to bend the
2. 25. Install the air cleaner housing (see step 33 on
clutch line.
page 5-15).
3. 26. Install the intake air duct (see step 6 on page
5-2).
4. 27. Install the battery. Connect the positive (+)
cable first, then the negative (-) cable to the
battery.
5. 28. Refill the transmission fluid (see page 13-4).
6. 29. Test-drive the vehicle.
7. 30. Check the clutch operation.
8. 31. Check the front wheel alignment, refer to the
2001 Civic Shop Manual on this CD (see page
18-4).
9. 32. Enter the anti-theft code for the radio, then
enter the customer's radio station presets.
aaa

13-15_Manual Transmission_Transmission Disassembly
13-15
Manual Transmission
Transmission Disassembly
Exploded View-Clutch Housing
1 INPUT SHAFT ASSEMBLY 10 CABLE CLIP BRACKET 23 SLAVE CYLINDER BRACKET

2 OUTPUT SHAFT ASSEMBLY 11 SPEEDOMETER 24 8 x 1.25 mm FLANGE BOLT
3 REVERSE DETENT PLUG, REVERSE 12 DRIVEN GEAR 25 Nm (2.5 kgf/m, 18 lbf/ft)
DETENT SPRING AND REVERSE 6 x 1.0 mm RETAINER 25 REVERSE LEVER FULCRUM BRACKET
DETENT BALL 13 BOLT 26 8 x 1.25 mm FULCRUM BRACKET BOLT
4 25 Nm (2.5 kgf/m, 18 lbf/ft) 14 6 Nm (0.6 kgf/m, 52 19 Nm (1.9 kgf/m, 14 lbf/ft)
5 TRANSMISSION CASE DOWEL PIN 15 lbf/ft) 27 BEARING RING
6 INTERLOCK PIN 16 SPEED SENSOR 28 REVERSE IDLER GEAR, REVERSE IDLER
7 TRANSMISSION CABLE LOWER 17 RETAINER SHAFT AND REVERSE IDLER SHAFT
BRACKET CLUTCH HOUSING 29 STRAIGHT PIN
8 8 x 1.25 mm FLANGE BOLT 18 TRANSMISSION CASE 30 WASHER
9 25 Nm (2.5 kgf/m, 18 lbf/ft) MAGNET 10 x 1.25 mm REVERSE IDLER SHAFT
TRANSMISSION CASE UPPER 19 REVERSE SHIFT LEVER 31 BOLT
BRACKET DIFFERENTIAL GEAR 32 38 Nm (3.8 kgf/m, 28 lbf/ft)
8 x 1.25 mm FLANGE BOLT 20 ASSEMBLY STRAIGHT KNOCK PIN
25 Nm (2.5 kgf/m, 18 lbf/ft) 21 FRT OUTPUT SHAFT INPUT SHAFT OIL SEAL
22 OIL NOZZLE
1ST/2ND, 3RD/4TH
SHIFT ROD AND ARM
ASSEMBLY
5TH SHIFT ARM
SHIFT ARM SPRING
PIN
5TH/REVERSE SHIFT
ROD AND BLOCK
ASSEMBLY
aaa

13-16_Manual Transmission_Transmission Disassembly (cont'd)
13-16
Manual Transmission
Transmission Disassembly (cont'd)
Exploded View-Transmission Housing
1 TRANSMISSION REAR 14 OUTPUT 5TH GEAR 24 10 x 1.5 mm FLANGE BOLT

2 COVER 15 5TH GEAR NEEDLE BEARING 38 Nm (3.8 kgf/m, 28 lbf/ft)
8 x 1.25 mm FLANGE 16 5TH GEAR NEEDLE BEARING COLLAR 10 x 1.5 mm BOLT
BOLT 17 5TH BLOCK RING 38 Nm (3.8 kgf/m, 28 lbf/ft)
19 Nm (1.9 kgf/m,14 18 8 x 1.25 mm FLANGE BOLT 25 DRAIN PLUG AND FILLER
3 lbf/ft) 19 Nm (1.9 kgf/m, 14 lbf/ft) PLUG
10 x 1.5 mm FLANGE 19 WASHER 26 39 Nm (4.0 kgf/m, 29 lbf/ft)
4 BOLT 20 BACK-UP LIGHT SWITCH 27 PLUG O-RING
5 42 Nm (4.3 kgf/m, 31 39 Nm (4.0 kgf/m, 29 lbf/ft) 28 DRIVE SHAFT OIL SEAL
6 lbf/ft) 21 CONTROL BOX ASSEMBLY 6 x 1.0 mm TRANSMISSION
7 INPUT SHAFT REAR 22 REAR OUTPUT SHAFT BEARING OUTER RACE CASE OIL GUTTER BOLT
8 COVER GUTTER AND OUTPUT SHAFT BEARING SHIM 29 6 Nm (0.6 kgf/m, 52 lbf/ft)
REAR COVER WASHER 23 DIFFERENTIAL SIDE BEARING OUTER RACE 30 TRANSMISSION CASE OIL
9 6 x 1.0 mm OIL AND DIFFERENTIAL SIDE BEARING SHIM 31 GUTTER
10 GUTTER BOLT TRANSMISSION CASE
11 SLEEVE AND HUB NUT DETENT PLUGS, DETENT
INSERT STOPPER 32 SPRING AND DETENT BALLS
12 PLATE 25 Nm (2.5 kgf/m, 18 lbf/ft)
13 5TH SYNCHRONISER TRANSMISSION HANGER
ASSEMBLY
5TH GEAR UNIT
INPUT 5TH GEAR
TRANSMISSION CASE
BEARING RETAINER
5TH GEAR THRUST
WASHER
8 x 1.25 mm TORX
SCREW
26 Nm (2.7 kgf/m, 20
lbf/ft)
aaa

13-17
Manual Transmission
Special Tools Required 1. 8. Remove the 1st/2nd detent plug (A), 3rd/4th
Torx bit (No.45) 5-8840-0047-0 (J-29843-8) detent plug (B), 5th detent plug (C), detent
Puller body 5-8840-0013-0 and 5-8840-0014-0 springs and detent balls.
(J-22888)
Puller legs 5-8840-0566-0 (J-22888-50)
NOTE: Place the clutch housing on two pieces of wood
thick enough to keep the input shaft from hitting the
workbench.
1. 1. Remove the rear cover assembly.
2. 2. Remove the control box assembly.
3. 3. Use a screwdriver to shift the transmission
through each speed (1st gear to 4th gear). Use
the 5th shift arm to shift into 5th gear (double
engagement).
4. 4. Remove the 5th gear nut (A).
2. 9. Remove the insert stopper plate.

3. 10. Remove the 5th synchroniser assembly, 5th
shift arm, 5th block ring and output 5th gear.
4. 11. Remove the 5th gear needle bearing.
5. 12. Remove the input 5th gear.
6. 13. Remove the seven 8 X 1.25 torx screw (A) from
the transmission case bearing retainer (B),
using the special tool.
5. 5. Remove the sleeve and hub nut from the output

shaft. Discard the fixing nuts.
6. 6. Return the transmission to the neutral position.
Align the shift rail detent positions.
7. 7. Place 5th synchroniser assembly (A) in neutral.
Remove the spring pin (B) at 5th shift arm (C)
and discard the spring pin.
7. 14. Remove the output shaft bearing shim and

transmission case bearing retainer from the
output shaft.
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13-18
Manual Transmission
1. 15. Remove the 5th gear needle bearing collar (A) 1. 20. Remove the reverse detent plug (A), the
and 5th gear thrust washer (B), using the reverse detent spring and reverse detent ball.
special tools.
2. 21. Lift the 5th shift rod (A). With the detent aligned
facing the same way, remove 5th (A) and
reverse (B) shift rods and blocks assembly at
2. 16. Remove the bearing ring. the same time.
3. 17. Remove the 10 X 1.25 reverse idler shaft bolt
and washer.
4. 18. Remove the two (10 X 1.5 mm) flange bolts
and 12 (10 X 1.5 mm) bolts and separate the
transmission case from clutch housing.
5. 19. Remove the reverse idler gear (A) and reverse
idler shaft (B).
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Shift13-19
Arms Inspection
Manual Transmission
1. 22. Use a hammer and punch to remove the spring 1. 1. Inspect the shift arms, shafts and levers for
pin (A) from the 3rd/4th shift arm (B). Discard wear, distortion or scoring. Replace if these
the spring pin (A). conditions are present.
2. 2. Measure shift arm thickness and replace if
thinner than the specified limits.
Limit : Except. Reverse
7.5 mm (0.295 in.)
Limit : Reverse
7.4 mm (0.291 in.)
2. 23. Slide the 3rd/4th gear shift up. Remove the

3rd/4th shift arm (B) and shaft (C) from the
case.
3. 24. Follow the same procedure to remove the
1st/2nd shift arm (D) and rod (E).
NOTE: The spring pins cannot be reused. aaa
4. 25. Remove the input shaft assembly and output
shaft assembly at the same time.
5. 26. Remove the differential gear assembly.
6. 27. Remove the reverse lever fulcrum bracket (A)
together with four bolts (B). Take out three
interlock pins.
7. 28. Remove the fulcrum bracket pin and then

remove the pin and reverse shift lever.
8. 29. Remove the output shaft bearing outer race
from transmission case.
9. 30. Remove the speedometer driven gear.
10. 31. Remove the clutch housing.

13-20_Manual Transmission_Input Shaft Disassembly
Input13-20
Shaft Inspection
Manual Transmission
Input Shaft Disassembly
Special Tools Required 1. 1. Measure the run-out of the input shaft and
Bearing remover 5-8840-0015-0 (J-22912-01) replace with a new one if reading exceeds limit.
Limit: 0.02 mm (0.0008 in.)
1. 1. Remove the input shaft bearing (A) using the
special tool with a press.
aaa
2. 2. Remove the input 3rd gear, 3rd gear needle

bearing, 3rd block ring, 3rd/4th synchroniser
assembly, 4th block ring, input 4th gear, 4th
gear needle bearing, 4th gear needle bearing
collar, 4th gear thrust washer and rear input
shaft bearing.
NOTE: Remove all of above parts together
using the special tool and a press.
3. 3. Remove the input shaft.

13-21_Manual Transmission_Input Shaft Reassembly
13-21
Manual Transmission
Input Shaft Reassembly
Exploded View
NOTE: Before assembling, apply oil to the thrust surface of all gear and washers.
1. Input shaft bearing

2. Rear input shaft
3. 4th gear thrust washer
4. Input 4th gear
5. 4th gear needle bearing
6. 4th block ring
7. 3rd/4th synchroniser assembly, 4th gear needle bearing collar
8. 3rd block ring
9. Input 3rd gear
10. 3rd gear needle bearing
11. Input shaft
12. Front input shaft collar
13. Stopper bearing plate
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13-22_Manual Transmission_Input Shaft Reassembly (cont'd)
13-22
Manual Transmission
Input Shaft Reassembly (cont'd)
Special Tools Required 1. 6. Install the 4th gear thrust washer. Note the
Bearing installer 5-8840-0054-0 (J-33374) installation direction.
NOTE: The insert spring set positions differ for right and
left. The ends of the insert spring should not interfere with
the hub.
1. 1. Install the 3rd gear needle bearing, input 3rd

gear, 3rd block ring, 3rd/4th synchroniser
assembly and 4th gear needle bearing collar on 2. 7. Install the rear input shaft bearing (A). Using
the input shaft. the special tool, press the bearing into place.
NOTE:
Be careful not to twist the inserts in the
block ring opening portions when pressing.
Note the installation direction when
assembling the synchroniser assembly.
2. 2. Using the special tool with a press the 3rd/4th
synchroniser assembly (A) and 4th gear needle
bearing collar (B).
3. 8. Install the input shaft bearing (A). Using the

special tool, press the bearing into place.
3. 3. Install the 4th block ring.

4. 4. Install the 4th gear needle bearing.
5. 5. Install the input 4th gear.
aaa

13-23_Manual Transmission_Output Shaft Disassembly
13-23
Manual Transmission
Output Shaft Disassembly
Special Tools Required 1. 3. Remove the 2nd gear needle bearing, 2nd gear
Bearing remover 5-8840-0012-0 (J-22227-A) needle bearing collar, output 2nd gear, 2nd
Bearing remover 5-8840-0015-0 (J-22912-01) block ring set, 1st and 2nd synchroniser
assembly, 1st block ring set, output 1st gear,
1. 1. Remove the front output shaft bearing (A) using
3rd and 4th gear feather key and 1st gear
the special tool and a suitable short bar (B) with
needle bearing, using a press.
a press.
2. 2. Remove the rear output shaft bearing (A) and

3rd and 4th output gear (B) together using the
special tool with a press. 2. 4. Remove the 1st thrust bearing.
3. 5. Remove the output shaft.
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13-24_Manual Transmission_Output Shaft Inspection
13-24
Manual Transmission
Output Shaft Inspection
1. 1. Measure the run-out of the output shaft. aaa

Replace with a new one if reading exceeds
limit.
Limit: 0.02 mm (0.0008 in.)

13-25_Manual Transmission_Output Shaft Reassembly
13-25
Manual Transmission
Output Shaft Reassembly
Exploded View
NOTE: Before assembling, apply oil to the thrust surface of all gears, bearing interior and race surfaces.
1. Front output shaft bearing

2. Rear output shaft bearing, 3rd and 4th output gear
3. 3rd and 4th gear feather key
4. 2nd gear needle bearing
5. Output 2nd gear
6. 2nd block ring set
7. 2nd gear needle bearing collar, 1st and 2nd synchroniser assembly, output 1st gear
8. 1st and 2nd synchroniser assembly
9. 1st block ring set
10. Output 1st gear
11. 1st block needle bearing
12. 1st thrust bearing
13. Output shaft
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13-26_Manual Transmission_Output Shaft Reassembly (cont'd)
13-26
Manual Transmission
Output Shaft Reassembly (cont'd)
Special Tools Required 1. 8. Install the 2nd block ring set.

Second collar installer 5-8840-0009-0 (J-8853- 2. 9. Install the output 2nd gear.
01) 3. 10. Install the 2nd gear needle bearing.
Pilot 5-8840-0050-0 (J-33369) 4. 11. Install the 3rd and 4th gear feather key.
Bearing installer 5-8840-0054-0 (J-33374) 5. 12. Install the 3rd and 4th output gear (A), rear
Output front bearing installer 5-8840-0605-0 (J- output shaft bearing (B), using the special tool
38599) with a press.
1. 1. Install the output shaft.
2. 2. Install the 1st thrust bearing.
3. 3. Install the 1st gear needle bearing.
4. 4. Install the output 1st gear.
5. 5. Install the 1st block ring set.
NOTE: The insert spring set positions differ for
right and left. The ends of the insert spring
must not interfere with the hub.
6. 13. Install the front output shaft bearing (A), using

the special tool with a press.
6. 6. Install the 1st and 2nd synchroniser assembly.

NOTE: the installation direction when
assembling the synchroniser assembly.
7. 7. Install the 2nd gear needle bearing collar (A),
using the special tools with a press.
NOTE: Be careful not to twist the inserts in the
block ring.
aaa

13-27_Manual Transmission_Synchro Ring and Gear Inspection
13-27
Manual Transmission
Synchro Ring and Gear Inspection
1. 1. The synchroniser hubs and sliding sleeves are 1. 5. Measure the clearance between block rings (A)
selected assemblies and should be kept and synchronising cones (B) for 1st and 2nd
together as originally assembled. gears by positioning 1st gear, then 1st and 2nd
2. 2. Clean synchroniser components with clean synchroniser assembly, then 2nd gear as
solvent and air dry. shown. Replace the 1st and 2nd gear
3. 3. Inspect the components for the following: synchroniser assembly if the measurement
Teeth for wear, scuffs, nicks, burrs or exceeds the specified limit.
breaks. NOTE: When reassembling synchroniser
Inserts and insert springs for wear, cracks or assemblies, each insert spring should support
distortion. Replace if these conditions are all three inserts and each opening portion of
present. the insert spring should face the opposite
If scuffed, nicked or burred conditions direction from the other.
cannot be corrected with a soft stone or Standard:
crocus cloth, replace the components.
1.5 mm (0.059 in.)
Measure the clearance between block ring
(A) and inserts (B). Replace components if Limit:
not within the specified limit. 0.8 mm (0.031 in.)
1st/2nd:
3.9 mm (0.154 in.) or less
3rd/4th, 5th:
3.7 mm (0.146 in.) or less
2. 6. Clearance between clutch hub (A) and inserts

4. 4. Measure the clearance between block ring (A) (B).
and gear (B). Replace components if not within Limit:
the specified limit. 0.25 mm (0.0098 in.)
NOTE: Replace gear assembly if evidence of
engine braking can be seen on the dog teeth.
Standard:
1.5 mm (0.059 in.)
Limit:
0.8 mm (0.031 in.)
aaa

13-28_Manual Transmission_Synchro Ring and Gear Inspection (cont'd)
13-28
Manual Transmission
Synchro Ring and Gear Inspection (cont'd)
1. 7. Inspect all gear teeth for signs of excessive 1. 10. Measure the play in splines.
wear or damage. Check all gear splines for 1st/2nd, 3rd/4th:
burrs nicks, or scratches on an oil stone. 0.12 mm (0.0047 in.) or less
Replace any part having excessive wear or 5th:
damage.
0.15 mm (0.0059 in.) or less
2. 8. Measure the gear inside diameter. Replace the
gear if not within the specified limit.
1st/2nd:
40.04 mm (1.7736 in.) or less
3rd/4th, 5th:
41.05 mm (1.6161 in.) or less
2. 11. Inspect all thrust washers for excessive wear,

distortion or damage. Replace any thrust
washer with these conditions.
3. 12. Inspect the springs for distortion, cracks, or
wear. Replace if these conditions are present.
4. 13. Measure the spring length. Replace springs if
not within the specified limits.
Limit:
3. 9. Measure the clearance between reverse idler
Except reverse 25.5 mm (1.004 in.)
gear (A) and shaft (B).
(1) – (2) Reverse 59.5 mm (2.343 in.)
0.15 mm (0.0059 in.) or less
aaa

13-29_Manual Transmission_Synchro Ring and Gear Inspection (cont'd)
Input13-29
Shaft Bearing and Oil Seal
Manual Transmission Replacement
Synchro Ring and Gear Inspection (cont'd)
1. 14. Inspect the two case halves for cracks, Special Tools Required
porosity, damaged mating surfaces, stripped Sliding hammer 5-8840-0019-0 (J-23907)
bolt threads, or distortion. Replace the clutch Needle bearing remover 5-8840-2409-0 (J-
housing if any of these conditions are present. 29369-1)
2. 15. Inspect the condition of all needles, rollers and Oil seal installer 5-8840-0026-0 (J-26540)
thrust bearings. Wash bearings thoroughly in Needle bearing installer 5-8840-7000-0
cleaning solvent. Apply compressed air to
1. 1. Remove the needle bearings (A), using the
bearings.
special tools.
NOTE: Do not allow the bearings to spin. Turn
them slowly by hand. Spinning bearings may
damage the rollers.
Lubricate bearings with a light oil and check them for
roughness by slowly turning the race by hand.
2. 2. Remove the input shaft oil seal.

3. 3. Install the input shaft oil seal (A), using the
special tool.
aaa

13-30_Manual Transmission_Input Shaft Bearing and Oil Seal Replacement (cont'd)
13-30
Output Shaft Bearing Replacement
Manual Transmission
Input Shaft Bearing and Oil Seal Replacement
(cont'd)
1. 4. Install the needle bearing (A) using the special Special Tools Required
tool with a press. Puller bridge 5-8840-0183-0 (J-33367)
NOTE: Do not use a hammer to install the Axle shaft oil seal remover 5-8840-0027-0 (J-
needle bearing. 26941)
Bearing outer race installer 5-8840-0006-0 (J-
7817)
1. 1. Remove the bearing outer races (A) using the
special tools.
2. 2. Install the bearing outer race (A) using the

special tool with a hammer.
aaa

13-31_Manual Transmission_Output Shaft and Differential Thrust Clearance Adjustment
13-31
Manual Transmission
Output Shaft and Differential Thrust Clearance
Adjustment
Special Tools Required 1. 5. Place the transmission case (A) over the clutch
Shim selector set 5-8840-0053-0 (J-33373) housing (B). Tighten the bolts (included in the
Shim adjustment shim selector set) to the specified torque.
Torque:
Select shims for installation between each bearing outer
race and bearing retainer as follows: 17 Nm (1.8 kgf/m, 13 lbf/ft)
1. 1. Install the input shaft assembly (A), output shaft
assembly (B) and differential assembly (C) to
the clutch housing (D).
2. 6. Turn the input shaft and each gear in both

directions several times to seat the gauge.
3. 7. Compress the two gauges. Use the appropriate
shims. Measure the gap between the outer
sleeve and the base pad.
2. 2. Place each bearing outer race over each 4. 8. To permit smooth installation of the differential
bearing. to the gap, use a shim (A) that is 3 sizes too
3. 3. Place the special tool onto the bearing outer large. To permit smooth installation of the
race. output shaft to the gap, use a shim that is 1
4. 4. Place the seven spacers included in the shim size too large.
selector set on every other mounting bolt hole.
5. 9. When each of the two shims have been

selected, remove the transmission case, seven
spacers and two gauges.
aaa

13-32_Manual Transmission_Output Shaft and Differential Thrust Clearance Adjustment (cont'd)
13-32
Transmission Reassembly
Manual Transmission
Output Shaft and Differential Thrust Clearance
Adjustment (cont'd)
Available Selective Shim NOTE: Prior to reassembling, clean all the parts in
Output shaft bearing shim solvent, dry them and apply lubricant to any contact
surfaces.
Part Number Thickness
1. 1. Apply grease to three interlock pins, and install
894249-6600 1.16 mm (0.046 in.)
them to the clutch housing.
894249-6590 1.24 mm (0.049 in.)
894249-6580 1.32 mm (0.052 in.)
894249-6570 1.40 mm (0.055 in.)
894249-6560 1.48 mm (0.058 in.)
894249-6550 1.56 mm (0.061 in.)
894249-6540 1.64 mm (0.065 in.)
894249-6530 1.72 mm (0.068 in.)
894249-6520 1.80 mm (0.071 in.)
894249-6510 1.88 mm (0.074 in.)
894249-6500 1.96 mm (0.077 in.)
894249-6490 2.04 mm (0.080 in.)
894249-6480 2.12 mm (0.084 in.)
894249-6470 2.20 mm (0.087 in.)
894249-6460 2.28 mm (0.090 in.)
894249-6450 2.36 mm (0.093 in.)
894249-6440 2.44 mm (0.096 in.)
Differential side bearing shim 2. 2. Install reverse lever fulcrum bracket (A) to the
clutch housing. Use 3rd/4th shift rod to align
Part Number Thickness bracket to clutch housing. Install the four bolts
894249-5451 1.08 mm (0.043 in.) (B).
894131-1450 1.12 mm (0.044 in.) Torque:
894249-5461 1.16 mm (0.046 in.) 19 Nm (1.9 kgf/m, 14 lbf/ft)
894131-1460 1.20 mm (0.047 in.)
894249-5471 1.24 mm (0.049 in.)
894131-1470 1.28 mm (0.050 in.)
894249-5481 1.32 mm (0.052 in.)
894131-1480 1.36 mm (0.054 in.)
894249-5491 1.40 mm (0.055 in.)
894131-1490 1.44 mm (0.057 in.)
894249-5501 1.48 mm (0.058 in.)
894131-1500 1.52 mm (0.060 in.)
894249-5511 1.56 mm (0.061 in.)
3. 3. Make sure the shaft operates smoothly after
894131-1510 1.60 mm (0.063 in.)
installation.
894249-5521 1.64 mm (0.065 in.) aaa
894131-1520 1.68 mm (0.066 in.)
894249-5531 1.72 mm (0.068 in.)
894131-1530 1.76 mm (0.069 in.)
894249-5541 1.80 mm (0.071 in.)
894131-1540 1.84 mm (0.072 in.)
894249-5551 1.88 mm (0.074 in.)
894131-1550 1.92 mm (0.076 in.)
894249-5561 1.96 mm (0.077 in.)

13-32_Manual Transmission_Output Shaft and Differential Thrust Clearance Adjustment (cont'd)
894131-1560 2.00 mm (0.079 in.)

13-33_Manual Transmission_Transmission Reassembly (cont'd)
13-33
Manual Transmission
Transmission Reassembly (cont'd)
1. 4. Install the differential gear assembly. 1. 13. Install the rear output shaft bearing outer race
2. 5. Install the output shaft assembly. and output shaft bearing shims into the
3. 6. Install the input shaft assembly. transmission case.
4. 7. Install 1st/2nd shift arm (A) to the synchroniser 2. 14. Install the differential side bearing outer race
sleeve and insert the shift rod (B) into the and differential side bearing shims into the
reverse lever fulcrum bracket. Align the hole in transmission case.
the arm with the rod and install a new double 3. 15. Install the transmission case.
spring pin (C). NOTE:
NOTE: Carefully wipe any oil and other foreign material from
Before installing the 3rd/4th shift arm, make sure that the mating surfaces of the clutch housing and
the interlock pin is inserted to the 3rd/4th shift rod. transmission case. Apply liquid gasket (LOCTITE No.
518 or equivalent) to the mating surface of clutch
housing. Then tighten fourteen bolts in diagonal
sequence to the specified torque.
NOTE:
If 5 minutes have passed after applying liquid gasket,
reapply it and assemble the housings. Allow it to cure
at least 20 minutes after assembly before filling the
transmission with oil.
5. 8. Install the 3rd/4th shift arm (D) to the sleeve.

Install the shift rod (E) to the collar of the
reverse lever fulcrum bracket. Align the rod and
arm holes. Install a new roll pin (F).
6. 9. Install the reverse shift lever.
7. 10. Before installing the 5th and reverse shift rods,
make sure that the interlock pin is inserted to
the 5th shift rod.
NOTE: 4. 16. The heads of the bolts to be tightened at the
Install the 5th and reverse shift rods at the same time as the transmission hanger are
same time. The rods must be facing the painted green. Take care to install the bolts to
same direction as the detent groove. their proper position.
Mesh the reverse rod and the reverse shift Torque:
lever. 38 Nm (3.8 kgf/m, 28 lbf/ft)
8. 11. Install reverse idler shaft together with the
reverse idler gear into the clutch housing.
Make sure reverse lever engages the gear
collar.
9. 12. Install the reverse detent plug, reverse detent
spring and reverse detent ball.
Torque:
25 Nm (2.5 kgf/m, 18 lbf/ft)
aaa

13-34
Manual Transmission
1. 17. Install the bearing ring. 1. 23. Install the input 5th gear.
2. 18. Install the bearing retainer. NOTE:
NOTE: The insert spring set positions should differ
Apply LOCTITE 242 to the 7 Torx screws. Use a for both sides.
No.45 Torx bit to tighten the screws. The ends of the insert springs should not
Torque: interfere with the hub.
Before installing, apply oil to the output gear
26 Nm (2.6 kgf/m, 19 lbf/ft)
thrust surfaces.
3. 19. Install the reverse idler shaft bolt (A).
Torque:
38 Nm (3.8 kgf/m, 28 lbf/ft)
2. 24. Install the 5th gear needle bearing collar, 5th

block ring and 5th synchroniser assembly with
shift fork in its groove and back plate to the
output shaft.
3. 25. Align the shift rod (A) and the shift arm (B).
4. 20. Install the 5th gear needle bearing collar (A) Install a new double spring pin (C).
and 5th gear thrust washer (B) together using
the special tool with a hammer.
NOTE: Before installing, apply oil to the thrust
surfaces and collar.
4. 26. Install the 1st/2nd detent plug, 3rd/4th detent

plug, 5th detent plug, detent springs and detent
balls.
Torque:
25 Nm (2.5 kgf/m, 18 lbf/ft)
5. 21. Install the 5th gear needle bearing. 5. 27. Install the insert stopper plate.
6. 22. Install the output 5th gear. aaa

13-35
Manual Transmission
1. 28. Install the 5th gear nut and sleeve and hub nut. 1. 37. Tighten all the bolts to the specified torque.
Use a screwdriver to shift the transmission Bolt Size A:
through each speed (1st gear to 4th gear). Use M10 X 1.5 X 60
the 5th gear shift arm to shift into 5th gear Bolt Size B:
(double engagement).
M10 X 1.5 X 45
Clean the bolt threaded portions.
Bolt Size C:
2. 29. Apply an even coat of LOCTITE 262 to the
grooves of the new nuts, the installation M8 X 1.25 X 60
grooves of the input shaft and the installation Torque:
grooves of the output shaft. Bolt Size A, B:
3. 30. Tighten the nuts to the specified torque. 42 Nm (4.3 kgf/m, 31 lbf/ft)
Carefully wipe away any LOCTITE that oozes
Bolt Size C:
from the area between the nuts and shafts.
19 Nm (1.9 kgf/m, 14 lbf/ft)
4. 31. Caulk each of the tightened nuts in 2 places.
Caulking width must not exceed 24 mm. Do not
allow cracks to appear in the caulking.
Torque:
127 Nm (13 kgf/m, 94 lbf/ft)
5. 32. Return the transmission to the neutral position.
Align the shift rail detent positions.
6. 33. Install the transmission rear cover to the
transmission case.
Make sure transmission shifts properly before
installing transmission rear cover.
7. 34. Apply liquid gasket (ThreeBond TB1215 or the 2. 38. Apply liquid gasket (LOCTITE 242 or
equivalent) to the installation surfaces of the equivalent) to the installation surfaces of the
transmission rear cover. control box assembly.
NOTE: If 5 minutes have passed after applying NOTE: If 5 minutes have passed after applying
liquid gasket, reapply it and assemble the liquid gasket, reapply it and assemble the
housings. Allow it to cure at least 20 minutes housings. Allow it to cure at least 20 minutes
after assembly before filling the transmission after assembly before filling the transmission
with oil. with oil.
3. 39. Apply LOCTITE 242 to the bolt threads.
Torque:
19 Nm (1.9 kgf/m, 14 lbf/ft)
8. 35. Temporarily tighten the specified bolts (refer to

the illustration).
9. 36. Apply liquid gasket (ThreeBond TB1215 or the
equivalent) to the threads of the bolts marked
with an arrow in the illustration.
aaa

13-36
Manual Transmission
1. 40. Install the speedometer driven gear. aaa

2. 41. Rotating torque measurement.
3. 42. Set the transmission as shown in the
illustration.
4. 43. Shift the transmission into neutral and measure
the input shaft rotating torque.
Rotating torque:
0.4 Nm (4 kgf/m, 3.5 lbf/ft) or less
5. 44. If the reading does not fall within the limit,
reselect the shims and retest the torque.

13-37_Manual Transmission_Gearshift Mechanism Replacement
13-37
Manual Transmission
Gearshift Mechanism Replacement
1. SHIFT LEVER KNOB

8 Nm (0.8 kgf/m, 5.8 lbf/ft)
2. SHIFT LEVER HOUSING
3. CLAMP
4. (SILICONE GREASE)
5. (1) Rotate the shift cable towards
the opening.
6. (2) Remove the shift cable from the
shift lever bracket.
7. SHIFT CABLE
8. COTTER PIN
Replace.
9. SHIFT CABLE CLIP
Replace.
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13-38_M/T Differential_Backlash Inspection
Final13-38
Driven Gear/Carrier Replacement
M/T Differential
Backlash Inspection
1. 1. Backlash between side gear (A) and pinion 1. 1. Remove the bolts and the ring gear.
gear (B). 2. 2. Install the ring gear (A).
Limit:
0.3 mm (0.0118 in.)
3. 3. Apply LOCTITE 271 to the bolt threads and

tighten the bolts (B) in sequence shown.
Torque:
113 Nm (11.5 kgf/m, 83 lbf/ft)
NOTE: When installing bolts, clean the bolt threads.
Do not apply oil to the threaded portions.
4. 4. Apply oil to the mating surfaces of the ring gear
and differential case.
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2. 2. If the backlash is beyond the limit, adjust by

replacing thrust washers.

13-39_M/T Differential_Carrier Replacement
13-39
M/T Differential
Carrier Replacement
Special Tools Required 1. 4. Remove the cross pin.

Puller body 5-8840-0013-0 and 5-8840-0014-0 2. 5. Remove the pinion gears and thrust washers.
(J-22888) 3. 6. Remove the side gears and thrust washers.
Puller legs 5-8840-0566-0 (J-22888-50) 4. 7. Remove the differential case.
Pilot 5-8840-0018-0 (J-23598) 5. 8. Measure the clearance between pinion gear (A)
Differential side bearing installer 5-8840-0016-0 and cross pin (B).
(J-22919) Limit:
Driver handle 5-8840-0007-0 (J-8092) 0.2 mm (0.008 in.)
1. 1. Remove the side bearing (A) using the special
tools.
6. 9. Measure the clearance between differential

case (A) and side gear (B).
(1) - (2)
2. 2. Cut the tabs of the speedometer drive gear and 0.15 mm (0.0059 in.) or less
remove the speedometer drive gear (B).
3. 3. Remove the lock pin (A).
NOTE:
Break staking on the lock pin using 5 mm (0.197 in.)
diameter drill. Then drive the cross pin out and
remove all the parts.
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13-40_M/T Differential_Carrier Replacement (cont'd)
13-40
M/T Differential
Carrier Replacement (cont'd)
1. 10. Measure the differential case diameter (Drive 1. 17. Heat the speedometer drive gear to
shaft). approximately 90°C (194°F) and install the
Limit: speedometer drive gear.
30.10 mm (1.1850 in.) NOTE:
If the speedometer drive gear is removed,
install a new one.
When heating the speedometer drive gear,
never use hot water. Use an oil heater or
hair dryer.
2. 18. Install the side bearing (A) using the special
tools.
2. 11. Install the differential case.
3. 12. Apply oil to the cross pin, differential gears,
thrust portion, side gear shaft portion and side
gear spline portion before installation.
4. 13. Install the side gears and thrust washers.
5. 14. Install the 2 side gears to the differential case
together with the thrust washers. Next, position
two thrust washers and pinion gears opposite
each other. Install them in their positions by
turning the side gear.
6. 15. Install the cross pin by aligning it with the lock aaa
pin hole in the differential case.
7. 16. Install the lock pin (A) using pin punch. Stake
portion (B) of lock pin hole in the differential
case with a punch to prevent removal of lock
pin.
NOTE:
Drive the lock pin deep enough so that it bottoms
against the differential case.

13-41_M/T Differential_Oil Seal and Bearing Outer Race Replacement
13-41
M/T Differential
Oil Seal and Bearing Outer Race Replacement
Special Tools Required 1. 4. Install the new drive shaft oil seal (A) using the
Axle shaft oil seal remover 5-8840-0027-0 (J- special tool with a hammer.
26941)
Sliding hammer 5-8840-0019-0 (J-23907)
Bearing outer race installer 5-8840-0008-0 (J-
8611-01)
Driver handle 5-8840-0007-0 (J-8092)
Axle shaft oil seal installer 5-8840-2747-0 (J-
38763)
Puller bridge 5-8840-0183-0 (J-33367)
Clutch housing side
1. 1. Remove the differential side bearing outer race
(A) using the special tools.
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2. 2. Remove the drive shaft oil seal.

3. 3. Install the differential side bearing outer race (A)
using the special tools.

13-42_M/T Differential_Oil Seal and Bearing Outer Race Replacement (cont'd)
13-42
M/T Differential
Oil Seal and Bearing Outer Race Replacement
(cont'd)
Transaxle case side aaa

1. 1. Remove the differential side bearing outer race
and shims (A) from the transmission case using
the special tools.
2. 2. Remove the drive shaft oil seal from the

transmission case using the special tools.
3. 3. Apply oil to the bearing outer race installation.
4. 4. Install the differential side bearing outer race
with selected shim (A) using the special tool
with a hammer.
5. 5. Press bearing until seated in its bore.

6. 6. Install the new drive shaft oil seal using the
special tool with a hammer.

16-1_Driveline/Axle
Driveline/Axle
Driveline/Axle
Special Tools 16-2
Driveshaft Inspection 16-3
Driveshafts Removal 16-3
Driveshafts Disassembly 16-5
Dynamic Damper Replacement 16-9
Driveshafts Reassembly 16-11
Driveshafts Installation 16-19
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16-2_Driveline/Axle_Special Tools
16-2
Driveline/Axle
Special Tools

1 07MAC-SL00200 Ball Joint Remover, 28 mm 1
2 07XAC-0010100 Threaded Adapter, 22 x 1.5 mm 1
3 07936-5790001 Sliding Hammer Set 1
4 07946-MB00000 Inner Handle, 30 mm 1
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16-3_Driveline/Axle_Driveshaft Inspection
Driveshafts
16-3 Removal
Driveline/Axle
Driveshaft Inspection
1. 1. Check the inboard boot (A) and the outboard Special Tool Required
boot (B) on the driveshaft (C) for cracks, Ball joint remover, 28 mm 07MAC-SL00200
damage, leaking grease and loose boot bands
1. 1. Loosen the wheel nuts slightly.
(D). If any damage is found, replace the boot
2. 2. Raise the front of the vehicle and support it
and boot bands.
with safety stands in the proper locations (see
page 1-15).
3. 3. Remove the wheel nuts and front wheels.
2. 2. Turn the driveshaft by hand and make sure the

splines (E) and joint are not excessively loose.
3. 3. Make sure the driveshaft is not twisted or
cracked; if it is, replace it.
4. 4. Lift up the locking tab (A) on the spindle nut

(B), then remove the nut.
5. 5. If the driveshafts are removed, drain the MTF
(see page 13-4).
6. 6. Hold the stabiliser ball joint pin (A) with a hex
wrench (B) and remove the flange nut (C).
Separate the front stabiliser link (D) from the
lower arm.
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16-4_Driveline/Axle_Driveshafts Removal (cont'd)
16-4
Driveline/Axle
Driveshafts Removal (cont'd)
1. 7. Remove the cotter pin (A) from the lower arm 1. 10. Pry the inboard joint (A) with a prybar and
ball joint castle nut (B) and remove the nut. remove the driveshaft from the differential case
or bearing support as an assembly. Do not pull
on the driveshaft (B), because the inboard joint
may come apart. Draw the driveshaft straight
out to avoid damaging the differential oil seal.
LEFT DRIVESHAFT
2. 8. Separate the ball joint from the lower arm (C)

with the special tool,refer to the '01 Civic Shop
Manual, P/N 62S5A00 on this CD (see page
18-9).
3. 9. Pull the knuckle outward and remove the
driveshaft outboard joint from the front wheel
hub using a plastic hammer. RIGHT DRIVESHAFT
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16-5_Driveline/Axle_Driveshafts Disassembly
16-5
Driveline/Axle
Driveshafts Disassembly
Special Tools Required Low Profile Type

Threaded adapter, 22 x 1.5 mm 07XAC-
0010100
Slide hammer 07936-5790001
Boot band pincers, commercially available
Inboard Joint Side:
1. 1. Remove the set ring (A) from the inboard joint.
Ear Clamp Type
2. 2. Remove the boot bands. Be careful not to

damage the boot.
If the boot band is a double loop type (A), lift
up the band band (B) and push it into the
clip (C).
If the boot band is a low profile type (D), lift
up the two tabs (E) with a screwdriver and aaa
pinch the boot band using the commercially
available boot band pincer (F).
It the boot band is an ear clamp type (G), lift
up the three tabs (H) with a screwdriver.
Double Loop Type

16-6_Driveline/Axle_Driveshafts Disassembly (cont'd)
16-6
Driveline/Axle
Driveshafts Disassembly (cont'd)
1. 3. Make a mark (A) on each roller (B) and inboard 1. 4. Remove the circlip (A).
joint (C) to identify the locations of rollers and
grooves in the inboard joint. Then remove the
inboard joint on the shop towel (D). Be careful
not to drop the rollers when separating them
from the inboard joint.
2. 5. Mark the spider (B) and driveshaft (C) to

identify the position of the spider on the shaft.
3. 6. Remove the spider and rollers using a
commercially available bearing remover (D).
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16-7
Driveline/Axle
1. 7. Wrap the splines on the driveshaft with vinyl Outboard Joint Side:
tape (A) to prevent damage to the boot (B). 1. 1. Remove the boot bands. Be careful not to
damage the boot and dynamic damper.
If the boot band is an ear clamp type (A), lift
up the three tabs (B) with a screwdriver.
Ear Clamp Type
2. 8. Remove the inboard boot. Be careful not to

damage the boot.
3. 9. Remove the vinyl tape.
2. 2. Slide the outboard boot (A) to the inboard joint

side. Take care not to damage the boot.
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16-8
Driveline/Axle
1. 3. Wipe off the grease to expose the driveshaft 1. 8. Remove the stop ring from the driveshaft.
and the outboard joint inner race.
2. 4. Make a mark (A) on the driveshaft (B) at the
same position of the outboard joint end (C).
2. 9. Wrap the splines on the driveshaft with vinyl

tape to prevent damage to the boot.
3. 5. Carefully clamp the driveshaft in a vice.
3. 10. Remove the outboard boot. Be careful not to

damage the boot.
4. 6. Remove the outboard joint (A) using the special 4. 11. Remove the vinyl tape.
tools. aaa
5. 7. Remove the driveshaft from the vice.

16-9_Driveline/Axle_Dynamic Damper Replacement
16-9
Driveline/Axle
Dynamic Damper Replacement
Special Tools Required 1. 6. Wrap the spline with vinyl tape (A) to prevent
Boot band pincers, Kent-Moore J-35910 or damage to the dynamic damper (B).
equivalent commercially available
1. 1. Remove the inboard joint (see page 16-5).
2. 2. Remove the dynamic damper band. Be careful
not to damage the dynamic damper.
It the dynamic damper band is an ear clamp
type (A), lift up tab (B) with a screwdriver.
2. 7. Install the dynamic damper onto the driveshaft,

then remove the vinyl tape. Be careful not to
damage the dynamic damper.
3. 8. Position the dynamic damper as shown below.
Left driveshaft:
261.5 - 265.5 mm (10.30 - 10.45 in.)
3. 3. Wrap the splines on the driveshaft with vinyl
tape (A) to prevent damage to the dynamic Right driveshaft:
damper (B). 478 - 482 mm (18.82 - 18.98 in.)
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4. 4. Remove the dynamic damper. Be careful not to

damage the dynamic damper.
5. 5. Remove the vinyl tape.

16-10_Driveline/Axle_Dynamic Damper Replacement (cont'd)
16-10
Driveline/Axle
Dynamic Damper Replacement (cont'd)
1. 9. Close the ear portion (A) of the band with aaa

commercially available boot band pincers (B).
2. 10. Check the clearance between the closed ear

portion of the band. If the clearance is not
within the standard, close the ear portion of the
band further.
3. 11. Install the inboard joint (see page 16-11).

16-11_Driveline/Axle_Driveshafts Reassembly
16-11
Driveline/Axle
Driveshafts Reassembly
Exploded View
1. SET RING
Replace.
2. INBOARD JOINT
3. CIRCLIP
4. SPIDER AND ROLLERS
5. DOUBLE LOOP BAND
Replace.
(Replacement parts only)
6. INBOARD BOOT
Pack cavity with grease
7. EAR CLAMP BAND
Replace.
8. LOW PROFILE BAND
Replace.
9. Pack cavity with grease
10. EAR CLAMP BAND
Replace.
11. DRIVESHAFT
12. STOP RING
Replace.
13. EAR CLAMP BANDS
Replace.
14. OUTBOARD JOINT
15. Pack cavity with grease
16. OUTBOARD BOOT
17. DYNAMIC DAMPER
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16-12_Driveline/Axle_Driveshafts Reassembly (cont'd)
16-12
Driveline/Axle
Driveshafts Reassembly (cont'd)
Special Tools Required 1. 3. Install the spider and rollers (A) onto the
Boot band tool, KD-3191 or equivalent driveshaft by aligning the marks (B), install it
commercially available using special tool.
Boot band pincers, Kent-Moore J-35910 or
equivalent commercially available
Boot band pincers, commercially available
NOTE: Refer to the Exploded View as needed during this
procedure.
Inboard Joint Side
1. 1. Wrap the splines with vinyl tape (A) to prevent
damage to the inboard boot (B).
Ear Clamp Type
2. 4. Fit the circlip (C) into the driveshaft groove.

Always rotate the circlip in its groove to make
sure it is fully seated.
3. 5. Pack the inboard joint with the joint grease
included in the new driveshaft set.
Grease quantity
Inboard joint:
115 - 135 g (4.1 - 4.8 oz)
Double Loop Type
2. 2. Install the inboard boot onto the driveshaft, then

remove the vinyl tape. Be careful not to
damage the inboard boot. aaa
NOTE:
When replacing the inboard boot and band,
install the ear clamp band.
When replacing the band only, install the
double loop band.

16-13
Driveline/Axle
1. 6. Fit the inboard joint onto the driveshaft and 1. 8. Set the new low profile band (A) onto the boot
note these items: (B) and dynamic damper, then hook the tab (C)
Reinstall the inboard joint onto the driveshaft of the band.
by aligning the marks (A) on the inboard NOTE: When replacing the inboard boot and
joint and the rollers. band, install the low profile band.
Hold the driveshaft so the inboard joint
points up to prevent it from falling off.
2. 7. Adjust the length of the driveshafts to the figure

below, then adjust the boots to halfway 2. 9. Close the hook portion of the band, with
between full compression and full extension. commercially available boot band pincers (A),
Make sure the ends of the boots seat in the then hook the tabs (B) of the band.
grooves of the driveshaft and joint.
Left driveshaft:
495.2 - 500.2 mm (19.50 - 19.69 in.)
Right driveshaft:
790.2 - 795.2 mm (31.11 - 31.31 in.)
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16-14
Driveline/Axle
1. 10. Fit the boot ends onto the driveshaft and the 1. 13. Thread the free end of the band through the
inboard joint, then install the band (A) onto the nose section of the commercially available boot
boot (B). band tool KD-3191 or equivalent (A) and into
NOTE: When replacing the band only, install the slot on the winding mandrel (B).
the double loop band.
2. 11. Pull up the slack in the band by hand.

3. 12. Mark a position (A) on the band 10 - 14 mm
(0.4 - 0.6 in.) from the clip (B).
2. 14. Place a wrench on the winding mandrel of the
boot band tool and tighten the band until the
marked spot (C) on the band meets the edge of
the clip.
3. 15. Lift up the boot band tool to bend the free end
of the band 90 degrees to the clip. Centre-
punch the clip, then fold over the remaining tail
onto the clip.
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16-15
Driveline/Axle
1. 16. Unwind the boot band tool and cut off the 1. 18. Close the ear portion (A) of the band with a
excess free end of the band to leave a 5 - 10 commercially available boot band pincers Kent-
mm (0.2 - 0.4 in.) tail protruding from the clip. Moore J-35910 or equivalent (B).
2. 17. Bend the band end (A) by tapping it down with

a hammer.
NOTE:
2. 19. Check the clearance between the closed ear
Make sure the band and clip do not interfere portion of the band. If the clearance is not
with anything and the band does not move. within the standard, close the ear portion of the
Remove any grease remaining on the band further.
surrounding surfaces
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16-16
Driveline/Axle
1. 20. Install the new set ring. Outboard Joint Side:

1. 1. Wrap the splines with vinyl tape (A) to prevent
damage to the outboard boot.
2. 2. Install the new ear clamp bands (B) and

outboard boot, then remove the vinyl tape. Be
careful not to damage the outboard boot.
3. 3. Install the new stop ring into the driveshaft
groove (A).
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16-17
Driveline/Axle
1. 4. Insert the driveshaft (A) into the outboard joint 1. 6. Check the alignment of the paint mark (A) with
(B) until the stop ring (C) is close to the joint. the outboard joint end (B).
2. 7. Pack the outboard joint (A) with the joint grease

included in the new joint boot set.
Grease quantity
2. 5. To completely seat the outboard joint, pick up Outboard joint:
the driveshaft and joint and drop them from 90 - 110g (3.2 - 3.9 oz)
about 10 cm (4 in.) onto a hard surface. Do not
use a hammer as excessive force may damage
the driveshaft.
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16-18
Driveline/Axle
1. 8. Fit the boot (A) ends onto the driveshaft (B) 1. 10. Check the clearance between the closed ear
and outboard joint (C). portion of the bands. If the clearance is not
within the standard, close the ear portion of the
bands further.
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2. 9. Close the ear portion (A) of the band with

commercially available boot band pincers Kent-
Moore J-35910 or equivalent (B).

16-19_Driveline/Axle_Driveshafts Installation
16-19
Driveline/Axle
Driveshafts Installation
1. 1. Install a new set ring onto the set ring groove of 1. 3. Install the outboard joint (A) into the front hub
the driveshaft. (B).
2. 2. Clean the areas where the driveshaft contacts

the differential thoroughly with solvent or
carburettor cleaner and dry with compressed 2. 4. Install the knuckle (A) onto the lower arm (B).
air. Insert the inboard end (A) of the driveshaft Be careful not to damage the ball joint boot (C).
into the differential (B) until the set ring (C) Wipe off the grease before tightening the nut at
locks in the groove (D). the ball joint. Torque the new castle nut (D) to
the lower torque specification, then tighten it
only far enough to align the slot with the pin
hole. Do not align the nut by loosening.
3. 5. Install the new lock pin (E) into the pin hole.
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16-20_Driveline/Axle_Driveshafts Installation (cont'd)
16-20
Driveline/Axle
Driveshafts Installation (cont'd)
1. 6. Connect the front stabiliser link (A) to the lower 1. 9. Refill the transmission with recommended MTF
arm. Hold the stabiliser link ball joint pin (C) (see page 13-4).
with a hex wrench (D) and tighten the new 2. 10. Check the front wheel alignment and adjust it if
flange nut (E). necessary (see page 18-4).
2. 7. Install a new spindle nut (A), then tighten the

nut. After tightening, use a drift to stake the
spindle nut shoulder (B) against the driveshaft.
3. 8. Clean the mating surfaces of the brake disc

and the front wheel, then install the front wheel
with the wheel nuts.
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17-1_Steering
Steering
Steering
Special Tools 17-2
Rack Guide Adjustment 17-3
Electrical Power Steering (EPS)

Special Tools 17-6
Motor Removal/Installation 17-7
Steering Gearbox Removal 17-9
Steering Gearbox Overhaul 17-13
Steering Gearbox Installation 17-21
NOTE: Refer to the '01 CIVIC Shop Manual, P/N 62S5A00, on this CD for the items not shown in this section.
The rack guide adjustment procedure has been changed.

The EPS motor removal/installation procedure has been changed.
The steering gearbox removal/installation procedure has been changed.
The steering gearbox overhaul procedure has been changed.
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17-2_Steering_Special Tools
17-2
Steering
Special Tools

1 07MAA-SL00200 Locknut Wrench, 43 mm 1
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17-3_Steering_Rack Guide Adjustment
17-3
Steering
Rack Guide Adjustment
Special Tools Required 1. 5. Tighten the rack guide screw (A) to 25 Nm (2.5
Locknut wrench, 43 mm 07MAA-SL00200 kgf/m, 18 lbf/ft), then loosen it.
1. 1. Set the wheels in the straight ahead position.
2. 2. Remove the transmission mount bracket (see
step 18 on page 13-18).
3. 3. Loosen the rack guide screw locknut (A) with
the special tool, then remove the rack guide
screw (B).
NOTE: LHD type is shown, RHD type is
symmetrical.
2. 6. Retighten the rack guide screw to 6 Nm (0.6

kgf/;m, 4 lbf/ft), then back it off to specified
angle.
Specified Return Angle:
5° Max.
3. 7. Hold the rack guide screw stationary with a
wrench and tighten the locknut by hand until it
is fully seated.
4. 4. Remove the old sealant from rack guide screw 4. 8. Install the special tool on the locknut (B) and
and apply new sealant to the middle of the hold the rack guide screw (A) stationary with a
threads (C). Loosely install the rack guide screw wrench. Tighten the locknut an additional 30°
on the steering gearbox. with the special tool.
5. 9. Reinstall the transmission mount bracket.
6. 10. Check for unusual steering effort through the
complete turning travel.
7. 11. Check the steering wheel rotation play and the
power assist.
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17-4_Memo
17-4
Memo
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17-5_Memo
17-5
Memo
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17-6_EPS Components_Special Tools
17-6
EPS Components
Special Tools

1 07MAC-SL00200 Ball Joint Remover, 28 mm 1
2 07ZAA-S5A0100 Locknut Wrench 1
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17-7_EPS Components_Motor Removal/Installation
17-7
EPS Components
Motor Removal/Installation
Removal 1. 5. Remove the connector stay (A) on the gearbox

1. 1. Disconnect the negative cable from the battery. housing and disconnect the motor 2P connector
2. 2. Remove the air cleaner (A). (B).
2. 6. Remove the motor (A) from the gearbox

housing.
3. 3. Remove the air cleaner mounting bracket (A)

from the bulkhead.
3. 7. Remove the O-ring (B) and discard it.

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4. 4. Remove the evaporative emission (EVAP)
canister (B) from its bracket and move it aside.

17-8_EPS Components_Motor Removal/Installation (cont'd)
17-8
EPS Components
Motor Removal/Installation (cont'd)
Installation 1. 11. Install the motor on the gearbox by engaging

1. 8. Clean the mating surface of the motor (A) and the motor shaft and worm shaft. Note the motor
gearbox. installation position (direction of motor wires
(D)). Before tightening the bolts, turn the motor
2 or 3 times right and left about 45 degrees
and check for close contact at the mating
surface of the motor. Loosely tighten the bolts.
Then, holding the motor head firmly, tighten the
bolts alternately to tighten the motor securely.
CAUTION
There must be no foreign material and O-ring
trapped in the mating surfaces and there
must be no loose contact (lift) at the
surfaces.
2. 12. Install the removed parts in the reverse order of

removal and note these item:
Make sure the motor 2P connector and EPS
wire harness 6P connector properly
2. 9. Apply a thin coat of silicone grease to the new connected.
O-ring (B) and carefully fit it on the motor. Make sure the motor and EPS wires are not
3. 10. Apply grease (Nippon Grease WR-S or caught or pinched by any parts.
equivalent grease) into the motor shaft (C).
3. 13. After installation, start the engine and let it idle.
Turn the steering wheel from lock-to-lock
several times. Check that the EPS indicator
does not come on.
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17-9_EPS Components_Steering Gearbox Removal
17-9
EPS Components
Steering Gearbox Removal
Special Tools Required 1. 7. Disconnect the EPS wire harness 6P connector

Ball joint remover, 28 mm 07MAC-SL00200 (A) and remove the wire harness stay (B).
Note these items during removal: Be sure to remove the
steering wheel before disconnecting the steering joint.
Damage to the cable reel can occur.
1. 1. Remove the motor on the steering gearbox
(see page 17-7).
2. 2. Raise the front of the vehicle and make sure it
is securely supported.
3. 3. Remove the front wheels.
4. 4. Remove the driver's airbag and the steering
wheel.
5. 5. Remove the driver's dashboard lower covers.
6. 6. Remove the steering joint bolts, disconnect the 2. 8. From under the steering gearbox, remove the
steering joint by moving the steering joint (A) ground cable terminal (A).
towards the column.
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17-10_EPS Components_Steering Gearbox Removal (cont'd)
17-10
EPS Components
Steering Gearbox Removal (cont'd)
1. 9. Remove the cotter pin (A) from the tie-rod ball 1. 13. Remove the steering gearbox attaching nut and
joint nut (B) and loosen the nut. washer from right side (RHD: left) of the
gearbox.
2. 10. Separate the tie-rod ball joint and damper

steering arm using the special tool. 2. 14. Remove the steering gearbox attaching bolts
3. 11. Grasp the passenger's side tie-rod and pull the and washers from left side (RHD: right) of the
rack all the way to the passenger's side (RHD: gearbox.
left direction, LHD: right direction), then remove
the driver's side tie-rod end.
4. 12. Remove the engine wire harness stay (A) from
the right side (RHD: left) of the bulkhead.
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17-11
EPS Components
1. 15. Pull on the steering gearbox to free it from the 1. 19. Remove the evaporative emission (EVAP)
mounting stud (A) on the gearbox mounting canister by disconnecting the hoses and
bracket. remove the canister bracket (A).
2. 16. Remove the gearbox mounting bracket (B).
3. 17. Lower the steering gearbox and rotate it so the 2. 20. Remove the coolant expansion tank (B) from
pinion shaft points upward. the bulkhead and move it aside. Do not
4. 18. Remove the pinion shaft grommet (A) from the disconnect the hoses.
top of the torque sensor. 3. 21. Open the cable clamp (A) and disconnect the
heater valve cable (B). Remove the heater
valve (C) from the bulkhead and free it.
4. 22. Release the coolant hose (D) from the hose

holders.
aaa

17-12
EPS Components
1. 23. Carefully move the steering gearbox to the aaa

wheel well opening on the passenger's side.
Raise the driver's side (pinion side) of the
steering gearbox and remove it.
file:///C|/...3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/Civ41Html/17-12.Htm[8/25/2012 6:36:17 PM]

17-13_EPS Components_Steering Gearbox Overhaul
17-13
EPS Components
Steering Gearbox Overhaul
Exploded View
1. MOTOR CONNECTOR
2. MOTOR
3. O-RINGS
Replace.
4. PINION SHAFT GROMMET
5. TORQUE SENSOR
6. GEARBOX HOUSING
7. SPRING
8. RACK GUIDE SCREW
9. LOCKNUT
10. RACK HOUSING
11. STOP RING
Replace.
12. LOCK SCREW
162 Nm (16.5 kgf/m, 119 lbf/ft)
Replace.
13. SLIDER GUIDE
14. BOOT BAND
Replace.
15. TIE-ROD END
16. TIE-ROD
54 Nm (5.5 kgf/m, 40 lbf/ft)
17. LOCK WASHER
Replace.
18. BRACKET
19. O-RINGS
Replace.
20. STOP PLATE
Replace.
21. BOOT
22. BOOT BAND
Replace.
23. DISC WASHER
24. RACK GUIDE
aaa

17-14_EPS Components_Steering Gearbox Overhaul (cont'd)
17-14
EPS Components
Steering Gearbox Overhaul (cont'd)
Special Tools Required 1. 4. Remove the stop plate (A), the 12 mm flange
Locknut wrench 07ZAA-S5A0100 bolts (B), O-rings (C), bracket (D) from the
Pincers, Oetiker 1098 or equivalent, steering gearbox.
commercially available.
NOTE:
Refer to the Exploded View as needed during
this procedure.
Do not allow dust, dirt, or other foreign
materials to enter the gearbox.
RHD type is shown, LHD type is symmetrical.
Removal
1. 1. Remove the steering gearbox (see page 17-9).
Disassembly
2. 2. Unbend the lock washer (A).
2. 5. Loosen the locknut (A), then remove the rack

guide screw (B), spring (C), disc washer (D)
and rack guide (E) from the steering gearbox.
3. 3. Hold the bracket (A) with one wrench and

unscrew both rack ends (B) with another
wrench. Remove the lock washers.
aaa

17-15
EPS Components
1. 6. Remove the two boot bands (A) from boot (B). 1. 8. Set the special tool (A) on the lock screw (B)
Compress the boot by hand and apply vinyl securely, then loosen and remove the lock
tape (C) so the boot stays collapsed and pulled screw from inner of the gearbox housing.
back.
2. 9. Remove the special tool.

3. 10. Pull on the rack housing (A) to remove it from
2. 7. Attach the yoke (A) of a universal puller to the
the gearbox housing. Remove the boot (B) and
steering gearbox mount with bolts. Securely
slider guide (C) from the cylinder.
clamp the yoke in a vice as shown. Do not
clamp the gearbox housing in the vice.
aaa

17-16
EPS Components
1. 11. Check the slider guide for damage and cracks. 1. 15. Apply grease to the indicated part (shaded part)
Using vernier calipers to measure the thickness of the outer surface of the rack housing. Do not
of the slider guide. If the thickness is less than apply to the dents and grooves.
service limit, replace the slider guide.
2. 12. Remove and discard the stop ring (A) on the

cylinder by expanding it using a snap ring aaa
pliers. Remove and discard the lock screw (B).
3. 13. Install the new lock screw on the rack housing.

4. 14. Install the new stop ring in the groove (C) on
the cylinder by expanding it using a pair of snap
ring pliers. Be careful not to scratch or damage
the housing surface with the stop ring edges.

17-17
EPS Components
1. 16. Set the new boot bands (A) on the band 1. 19. Push the rack housing (A) into the gearbox
installation grooves of the boot (B) by aligning housing (B) so the notch (C) is aligned with the
the tabs (C) with the holes (D) of the band. Do pin (D) on bottom of the gearbox housing
not close the ear of the boot band in this step. inside.
2. 20. Tighten the lock screw (A) by hand first, then

2. 17. Compress the boot by hand and apply vinyl install the special tool (B) on the lock screw.
tape (E) to the bellows so the boots stay Lightly tighten the lock screw. Do not tighten
collapsed and pulled back. the lock screw to specified torque yet.
Pass the boot over the rack housing so the
smaller diameter end of the boot faces the
gearbox housing.
3. 18. Attach the yoke (A) of a universal puller to the
gearbox housing mounts (B) with bolts, then
securely clamp the yoke in a vice as shown. Do
not clamp the gearbox housing in a vice.

aaa

17-18
EPS Components
1. 22. Grease the sliding surface and circumference of 1. 25. Center the steering rack within its stroke and
the rack guide (A) and install it onto the align the slider guide (A) with the holes (B) in
gearbox housing. Wipe the grease off the boot (C). Fit the slider guide to boot by
threaded section of the housing. pressing around the edges of the holes
securely.
2. 23. Install the disc washer (B) with its convex side
facing the rack guide. Install the spring (C). 2. 26. Before installing the bracket (D), clean the
Apply sealant to the middle of the threads on mating surface of the 12 mm flange bolts (E)
the rack guide screw (D), then install and and bracket. Coat the new O-rings (F) with
tighten it to 25 Nm (2.5 kgf/m, 18 lbf/ft). Loosely grease and install them on the 12 mm flange
install the locknut (E). bolts.
3. 24. Apply multipurpose grease to the sliding surface 3. 27. Loosely install the bracket on the steering rack
of the slider guide (A). Keep grease off of the by tightening the 12 mm flange bolts to 25 Nm
rack-to-slider guide matching surfaces and the (2.5 kgf/m, 18 lbf/ft).
boot-to-slider guide matching surfaces. 4. 28. Hold the gearbox housing using a yoke, then
Slide the steering rack all the way to left and install the special tool on the lock screw (A).
place the slider guide on the steering rack by Retighten the lock screw to specified torque
aligning the bolt holes (B). values.

aaa

17-19
EPS Components
1. 30. Retighten the 12 mm flange bolts (A) to 1. 34. Close the ear portion (A) of the bands (B) with
specified torque values. commercially available pincers, Oetiker 1098 or
equivalent (C).
2. 31. After tightening the 12 mm flange bolts, install a

new stop plate (B) over one of bolt the heads.
Be sure the tabs (C) on the stop plate are
aligned with the flat surfaces of the bolt head.
3. 32. Clean off any grease or contamination from the 2. 35. Install the new lock washer (A) with its radiused
boot installation grooves around on the side facing (B) to the tie-rod (C) and screw the
housing. tie-rod on the bracket (D). Repeat this step for
4. 33. Expand boot (A) by removing the vinyl tape and the other side of the tie-rod. Hold the bracket
fit to the boot ends (B) in the installation with one wrench and tighten the tie-rods to the
grooves on the cylinder housing. specified torque with another wrench.
aaa

17-20
EPS Components
1. 36. Bend the lock washer against the flat spots on aaa
the bracket with a large pair of pliers.

17-21_EPS Components_Steering Gearbox Installation
17-21
EPS Components
Steering Gearbox Installation
NOTE: RHD type is shown, LHD type is symmetrical. 1. 3. Install the heater valve (A) on the bulkhead.
1. 1. Before installing the gearbox, slide the rack all Through the heater valve cable (B) into the
the way to the passenger's side (RHD: left canister bracket and connect the heater valve
direction, LHD: right direction). cable end to the heater valve arm (C). Close
2. 2. Pass the passenger's side of the steering the cable clamp.
gearbox together with the tie-rods through the
wheel well opening on the passenger's side.
Continue moving the steering gearbox toward
the passenger's side until the driver's side rack
end clears the master cylinder. Lower the
driver's side (pinion side) of the steering
gearbox and back it toward the driver's side
until the steering gearbox is in position.
2. 4. Hold the coolant hose (D) on the hose holders.

3. 5. Install the coolant expansion tank (A) and
canister bracket (B).
aaa

17-22_EPS Components_Steering Gearbox Installation (cont'd)
17-22
EPS Components
Steering Gearbox Installation (cont'd)
1. 6. Install the pinion shaft grommet (A). 1. 8. Slip the left side of the steering gearbox over
the mounting stud on the gearbox mounting
bracket.
2. 9. Install the washer (A) and the gearbox attaching
nut (B) and lightly tighten.
2. 7. Install the gearbox mounting bracket (A) on the

frame.
3. 10. Insert the pinion shaft up through the bulkhead

and install the washers (A) and gearbox
attaching bolts (B) and tighten to the specified
torque. Then tighten the right side of the
gearbox attaching nut to the specified torque
value.
aaa

17-23
EPS Components
1. 11. Install the engine wire harness stay (A) on the 1. 13. Install the EPS wire harness stay (A) on the
bulkhead and fit the engine wire harness on the gearbox housing and connect the 6P connector
stay. (B).
2. 12. Under the steering gearbox, install the ground

cable terminal (A) on the gearbox housing.
2. 14. Centre the steering rack within its stroke and

install the left (RHD: right) tie-rod end (A).
3. 15. Wipe off any grease contamination from the ball

joint tapered section and threads. Then
reconnect the tie-rod end (A) to the damper
steering arms. Install the ball joint nut (B) and
tighten it.
4. 16. Install the new cotter pin (C) and bend it as
shown (D) or (E).
aaa

17-24
EPS Components
1. 17. Install the motor on the steering gearbox (see aaa

page 17-7).
2. 18. Install the steering joint (A) and reconnect the
steering shaft (B) and pinion shaft (C). Make
sure the steering joint is connected as follows:
Insert the upper end of the steering joint
onto the steering shaft (line up the bolt hole
(D) with the flat portion (E) on the shaft).
Slip the lower end of the steering joint onto
the pinion shaft (line up the bolt hole (F)
with the groove (G) around the shaft) and
loosely install the lower joint bolt. Be sure
that the lower joint bolt is securely in the
groove in the pinion shaft.
Pull on the steering joint to make sure that
the steering joint is fully seated. Then install
the upper joint bolt and tighten it.
3. 19. Install the driver's dashboard lower covers.

4. 20. Centre the cable reel by first rotating it
clockwise until it stops. Then rotate it
counterclockwise (about 2 and a half turns) until
the arrow mark on the label points straight up.
Reinstall the steering wheel.
5. 21. Install the front wheels.
6. 22. After installation, perform the following checks.
Perform the front toe inspection.
Check the steering wheel spoke angle.
Adjust by turning the right and left tie-rods
equally, if necessary.

18-1_Suspension
Suspension
Front Suspension
Damper/Spring Replacement 18-2
NOTE: Refer to the '01 CIVIC Shop Manual, P/N 62S5A00,on this CD for the items not shown in this section.
The front damper has been changed; related information was entered.
aaa

18-2_Front Suspension_Damper/Spring Replacement
18-2
Damper/Spring Replacement
Exploded View
1. DAMPER MOUTING BASE
Check for deformation.
2. SLF-LOCKING NUT
12 x 1.25 mm
44 Nm (4.5 kgf/m, 33 lbf/ft)
Replace.
3. UPPER SPRING SEAT
4. BUMP STOP
Check for weakness and damage.
5. DAMPER UNIT
Check for oil leaks, gas leaks and
smooth operation.
6. DAMPER SPRING
Check for free length.
7. UPPER SPRING MOUTING
CUSHION
Check for deterioration and damage.
8. DAMPER MOUTING BEARING
Check for smooth operation.
aaa

18-3_Front Suspension_Damper/Spring Replacement
18-3
Damper/Spring Replacement
Disassembly/Inspection 1. 3. Reassemble all the parts, except for the upper

1. 1. Compress the damper spring with the spring seat, mounting cushion and spring.
commercially available strut compressor (A) 2. 4. Compress the damper assembly by hand and
according to the manufacturer's instructions, check for smooth operation through a full
then remove the self-locking nut (B) while stroke, both compression and extension. The
holding the damper shaft (C) with a hex wrench damper should extend smoothly and constantly
(D). Do not compress the spring more than when compression is released. If it does not,
necessary to remove the nut. the gas is leaking and the damper should be
replaced.
2. 2. Release the pressure from the strut spring

compressor, then disassemble the damper as
shown in the Exploded View.
3. 5. Check for oil leaks, abnormal noises and

binding during these tests.
aaa

18-4_Front Suspension_Damper/Spring Replacement (cont'd)
18-4
Damper/Spring Replacement (cont'd)
Reassembly 1. 7. Check that the cutout (A) in the side of the

NOTE: Refer to the Exploded View as needed. upper spring seat (B) is in position shown. If
the cutout is out of position, repeat to the step
1. 1. Install the upper spring mounting cushion (A) on
1 and reassemble the spring and upper spring
the upper spring seat (B) by aligning the log
seat accordingly.
portion (C) on cushion with cutout (D) in the
Left side:
seat.
2. 2. Install the spring (E) in the groove of the Right side:

cushion securely fitted.
3. 3. Install the damper mounting bearing and
damper mounting base on the upper spring
seat.
4. 4. Install the upper spring seat and the spring on
a commercially available strut spring
compressor (A) and compress the spring lightly.
2. 8. Hold the bottom of the damper with your hand

and compress the spring. Do not compress the
spring excessively.
aaa
5. 5. Insert the damper unit (B) up through the

compressed spring.
6. 6. Align the bottom of the spring (C) and the
stepped part (D) of the lower spring seat.

18-5_Front Suspension_Damper/Spring Replacement (cont'd)
18-5
Damper/Spring Replacement (cont'd)
1. 9. Install the 12 mm nut (A) on the damper shaft aaa

(B). Hold the damper shaft with a hex wrench
(C) and tighten the 12 mm nut to the specified
torque.
2. 10. Remove the damper assembly from the strut

spring compressor.

19-1_Brakes
Brakes
Conventional Brake Components

Brake System Indicator Circuit Diagram 19-2
Vacuum Switch Test 19-3
Vacuum Switch Replacement 19-5
Front Brake Pads Inspection and Replacement 19-6
Front Brake Caliper Overhaul 19-8
Master Cylinder Removal/Installation 19-9
Brake Booster Replacement 19-11
NOTE: Refer to the '01 CIVIC Shop Manual, P/N 62S5A00 on this CD, for the items not shown in this section.
The vacuum switch has been added; related information was entered.
The front brake caliper has been changed; related information was entered.
The master cylinder removal/installation procedure has been changed.
The brake booster replacement procedure has been changed.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If body maintenance required)

will require special precautions and tools and should therefore be done by an authorised Honda dealer.
WARNING
To avoid rendering the SRS inoperative, which could lead to personal injury or
death in the event of a severe frontal collision, all SRS service work must be
performed by an authorised Honda dealer.
Improper service procedures, including incorrect removal and installation of
the SRS, could lead to personal injury caused by unintentional deployment of
the airbags.
Do not bump the SRS unit. Otherwise, the system may fail in a collision, or
airbags may deploy when the ignition switch is ON (II).
SRS electrical wiring connectors are identified by yellow colour coding.
Related components are located in the steering column, front console,
dashboard, dashboard lower panel and in the dashboard above the glove box.
Do not use electrical test equipment on these circuits.
aaa

19-2_Conventional Brake Components_Brake System Indicator Circuit Diagram
19-2
Brake System Indicator Circuit Diagram
aaa

19-3_Conventional Brake Components_Vacuum Switch Test
19-3
Vacuum Switch Test
For proper inspection of vacuum switch, do these checks. 1. 1. Make sure the ignition switch is OFF, then
Brake booster leak test: disconnect the 12P connector (green colour)
Press the brake pedal with the engine running, from the under-dash fuse/relay box and
then stop the engine. If the pedal height does vacuum switch 1P connector.
not vary while pressed for 30 seconds, the 2. 2. Check for continuity between the 12P
vacuum booster is OK. If the pedal rises, the connector terminal No. 1 and body ground.
booster is faulty. UNDER-DASH FUSE/RELAY BOX 12P
CONNECTOR
With the engine stopped, press the brake pedal
several times using normal pressure. When the
pedal is first pressed, it should be low. On
consecutive applications, the pedal height
should gradually rise. If the pedal position does
not vary, check the booster check valve.
Check the brake booster check valve, vacuum
hoses and connections for leaks or restrictions.
Verify brake fluid level switch and parking brake
switch operation. If necessary, do these tests.
YES - Repair short to body ground in the GRN/RED
wire between the vacuum switch and MPCS (built into
the under-dash fuse/relay box).
NO - Go to step 3.
aaa

19-4_Conventional Brake Components_Vacuum Switch Test (cont'd)
19-4
Vacuum Switch Test (cont'd)
1. 3. Check for continuity between the 12P connector 1. 7. Connect the vacuum switch 1P connector to
terminal No. 1 and vacuum switch 1P connector the vacuum switch.
terminal No. 1. 2. 8. Start the engine and wait at least 10 seconds.
UNDER-DASH FUSE/RELAY BOX 12P 3. 9. Stop the engine and switch the ignition switch
CONNECTOR OFF.
4. 10. Return the ignition switch ON (II) and watch the
brake system indicator.
Does the brake system indicator come on?
YES – If the brake system indicator stays on, check
for a loose vacuum switch connector. If necessary,
replace the new vacuum switch and recheck (see
page 19-5).
NO – If the brake system indicator comes on and
goes off, it is OK. Press the brake pedal seven to
eight times to deplete the brake booster. If the
vacuum switch is in good condition the brake system
indicator should come on.
Terminal side of male terminals aaa
YES - Go to step 4.
NO - Repair open in the GRN/RED wire between the
vacuum switch and MPCS.
2. 4. Connect the 12P connector to the under-dash
fuse/relay box.
3. 5. Release the parking brake lever fully.
4. 6. Turn the ignition switch ON (II) and watch the
brake system indicator.
Does the brake system indicator come on?
YES - If the brake system indicator stays on, perform
the MPSC troubleshooting (see page 22-36).
NO – If the brake system indicator comes on and
goes off, it is OK. Go to step 7.

19-5_Conventional Brake Components_Vacuum Switch Replacement
19-5
Vacuum Switch Replacement
1. 1. Disconnect the vacuum hose (A) and 1P 1. 5. Install the new vacuum switch on the bracket
connector (B) from the vacuum switch (C). and tighten it to specified torque.
2. 6. Install the vacuum switch in the reverse order
of removal and note these items:
Make sure the vacuum hose and wire
harness connector properly connected.
Release the parking brake lever fully and
start the engine. Then stop the engine and
turn the ignition switch ON (II). Check that
the brake system indicator goes off.
aaa
2. 2. Remove the vacuum switch bracket (D).

3. 3. Securely clamp the joint (A) of the bracket in a
vice. Remove the vacuum switch (B) from the
bracket.
4. 4. Remove the old sealant from the threads in the

joint. Apply new sealant to the threads of the
switch on the shaded area (C) shown. Keep
sealant off the fitting area (D).

19-6_Conventional Brake Components_Front Brake Pads Inspection and Replacement
19-6
Front Brake Pads Inspection and Replacement
Replacement
CAUTION
1. 1. Remove the brake hose mounting bolt (A).
Frequent inhalation of brake pad dust,
regardless of material composition, could
be hazardous to your health.
Avoid breathing dust particles.
Never use an air hose or brush to
clean brake assemblies. Use an
appropriate vacuum cleaner.
Inspection
1. 1. Raise the front of the vehicle and make sure it
is securely supported. Remove the front
wheels. 2. 2. Remove the bolt (B) and pivot the caliper (C)
2. 2. Check the thickness of the inner pad (A) and up out of the way. Check the hose and pin
outer pad (B). Do not include the thickness of boots for damage and the deterioration.
the backing plate. 3. 3. Remove the piston shim (A), pad shims (B) and
Brake pad thickness: pads (C).
Standard:
10.5 - 11.5 mm (0.41 - 0.45 in.)
Service limit:
1.6 mm (0.06 in.)
aaa
3. 3. If the brake pad thickness is less than the

service limit, replace all the pads as a set.

19-7_Conventional Brake Components_Front Brake Pads Inspection and Replacement (cont'd)
19-7
(cont'd)
1. 4. Remove the pad retainers (A). 1. 9. Push in the piston (A) so the caliper will fit over
the pads. Make sure the piston boot is in
position to prevent damaging it when pivoting
the caliper down.
2. 5. Clean the caliper thoroughly; remove any rust

and check for grooves and cracks.
3. 6. Check the brake disc for damage and cracks.
4. 7. Install the pad retainers. 2. 10. Pivot the caliper down into position. Being
5. 8. Install the piston shim (A), brake pads (B) and careful not to damage the pin boots, install the
pad shims (C) correctly. Install the pads with bolt (B) and tighten it to the specified torque.
the wear indicators (D) on the inside. 3. 11. Install the brake hose bracket onto the
If you are reusing the pads, always reinstall the dampers.
brake pads in their original positions to prevent 4. 12. Press the brake pedal several times to make
a momentary loss of braking efficiency. sure the brake works, then test-drive.
NOTE: Engagement of the brake may require a
greater pedal stroke immediately after the
brake pads have been replaced as a set.
Several applications of the brake pedal will
restore the normal pedal stroke.
5. 13. After installation, check for leaks at hose and
line joints or connections and retighten if
necessary.
aaa

19-8
(cont'd)
CAUTION
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous
to your health.
Avoid breathing dust particles.
Never use an air hose or brush to clean brake assemblies. Use an appropriate vacuum
cleaner.
Remove, disassemble, inspect, reassemble and install the caliper and note these items:
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately
with water.
To prevent dripping, cover disconnected hose joints with rags or shop towels.
Clean all parts in brake fluid and air dry; blow out all passages with compressed air.
Before reassembling, check that all parts are free of dust and other foreign particles.
Replace parts with new ones as specified in the illustration.
Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency.
Do not reuse drained brake fluid.
Use only clean Genuine Honda DOT 3 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the
system.
Do not mix different brands of brake fluid as they may not be compatible.
Coat the piston, piston seal groove and caliper bore with clean brake fluid.
Make sure no grease or oil gets on the brake discs or pads.
Replace all rubber parts with new ones whenever disassembled.
After installing the caliper, check the brake hose and line for leaks, interference and twisting.
: KLUBER SYNTHESO GLKO
1. CALIPER PIN
2. PIN BOOT
Replace.
3. BANJO BOLT
34 Nm (3.5 kgf/m, 25 lbf/ft)
4. SEALING WASHERS
Replace.
5. BRAKE HOSE
6. CALIPER BOLTS
27 Nm (2.8 kgf/m, 20 lbf/ft)
7. BLEED SCREW
9.8 Nm (1.0 kgf/m, 7.2
lbf/ft)
8. CALIPER BODY
9. PISTON SHIM
10. PISTON BOOT
Replace.
11. PISTON
12. PISTON SEAL
Replace.
13. BRAKE PADS
14. OUTER PAD SHIM
15. WEAR INDICATOR
Install inner pad with its
wear indicator downward.
16. INNER PAD SHIM
17. PAD RETAINERS
18. CALIPER BRACKET
19. 12 x 1.25 mm
108 Nm (11.0 kgf/m, 80
lbf/ft)

20. PIN BOOTS

Replace.
21. CALIPER PIN
aaa

19-9_Conventional Brake Components_Master Cylinder Removal/Installation
19-9
Master Cylinder Removal/Installation
NOTE: Do not spill brake fluid on the vehicle; it may 1. 5. Remove the brake fluid level sensor connector
damage the paint; if brake fluid does contact the paint, (A).
wash it off immediately with water.
1. 1. Remove the air cleaner (A).
2. 2. Remove the sub fuse box (A) and clutch

reservoir (B) from the master cylinder mounting
2. 6. Disconnect the brake lines (B) from the master
base and move these aside. Do not disconnect
cylinder (C). To prevent spills, cover the hose
the clutch line from the reservoir.
joints with rags or shop towels.
3. 7. Remove the master cylinder mounting nuts (D)
and washers.
4. 8. Remove the master cylinder from the brake
booster (E). Be careful not to bend or damage
the brake lines when removing the master
cylinder.
5. 9. Remove the rod seal (F) from the brake
booster.
aaa
3. 3. Remove the reservoir mounting bolt (C) from

the mounting base.
4. 4. Remove the reservoir cap and brake fluid from
the reservoir tank.

19-10_Conventional Brake Components_Master Cylinder Removal/Installation (cont'd)
19-10
Master Cylinder Removal/Installation (cont'd)
1. 10. Install the master cylinder in the reverse order aaa

of removal and note these items:
Replace all the rubber parts with new ones
whenever the master cylinder is removed.
Check the pushrod clearance before installing
the master cylinder and adjust it if necessary.
Use a new rod seal on reassembly.
Coat the inner bore lip (A) and outer
circumference (B) of the new rod seal with the
recommended seal grease in the master
cylinder set.
Install the rod seal onto the master cylinder with
its grooved side (C) toward the master cylinder.
Check the brake pedal height and free play
after installing the master cylinder and adjust it
if necessary.

19-11_Conventional Brake Components_Brake Booster Replacement
19-11
Brake Booster Replacement
1. 1. Remove the master cylinder (see page 19-9). 1. 4. Remove the clip (A) and the joint pin (B) and
2. 2. Remove the air cleaner mounting base (A). disconnect the yoke from the brake pedal.
2. 5. Remove the brake booster mounting flange

nuts (C).
3. 6. Remove the brake booster (A) from the engine
3. 3. Disconnect the vacuum hose (B) from the brake compartment.
booster.
4. 7. Install the brake booster in the reverse order of

removal and note these items:
Adjust the pushrod clearance before installing
the brake booster.
Use a new clip whenever installing.
After installing the brake booster and master
cylinder, fill the reservoir with new brake fluid,
bleed the brake system and adjust the brake
pedal height and free play.
aaa

20-1_Body
Body
Exterior Trim
Emblem Replacement 20-2
NOTE: Refer to the '01 CIVIC Shop Manual, P/N 62S5A00 and '01 CIVIC Shop Manual Supplement, P/N 62S5A21, P/N 62S5A22,
on this CD for the items not shown in this section.
Outline of 5-door/3-door Model Changes
The diesel engine model has been added.
The CTDi emblem has been added.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If HVAC maintenance is required)

the glove box, seat belt tensioners in the front seat belt retractors, seat belt buckle tensioners in the front seat belt buckles and
side airbags in the front seat-backs. Information necessary to safely service the SRS is included in the '01 Civic Shop Manual, P/N
62S5A00 on this CD. Items marked with an asterisk (*) on the contents page include, or are located near SRS components.
Servicing, disassembling or replacing these items will require special precautions and tools and should therefore be done by an
To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal
collision, all SRS service work must be performed by an authorised Honda dealer.
Improper service procedures, including incorrect removal and installation of the SRS, could lead to personal injury caused
by unintentional deployment of the airbags and/or side airbags.
Do not bump the SRS unit. Otherwise, the system may fail in a collision, or airbags may deploy when the ignition switch
is ON (II).
SRS electrical wiring connectors are identified by yellow colour coding. Related components are located in the steering
column, front console, dashboard, dashboard lower panel, in the dashboard above the glove box in the front seats and
around the floor. Do not use electrical test equipment on these circuits.
aaa

20-2_Exterior Trim_Emblem Replacement
20-2
Exterior Trim
Emblem Replacement
NOTE:
When removing the emblem, take care not to scratch the body.
5-door: For the front and rear ''H''emblems, refer to the '01 Civic Shop Manual, P/N 62S5A00 on this CD (see page 20-
257).
3-door: For the front and rear ''H''emblems, refer to the '01 Civic Shop Manual Supplement, P/N 62S5A22 on this CD
(see page 20-43).
1. 1. Clean the body surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water from getting on
the surface.
2. 2. Apply the emblem, where shown.
5-door:
1. FRONT "H" EMBLEM
2. CIVIC EMBLEM
3. CTDi EMBLEM
4. REAR "H" EMBLEM
Unit: mm (in.)
[A] : Measure along the tailgate surface.
aaa

20-3_Exterior Trim_Emblem Replacement (cont'd)
20-3
Exterior Trim
Emblem Replacement (cont'd)
3-door
1. FRONT "H" EMBLEM
2. CIVIC EMBLEM
3. CTDi EMBLEM
4. REAR "H" EMBLEM
Unit: mm (in.)
[A] : Measure along the tailgate surface.
aaa

21-1_HVAC (Heating, Ventilation, and Air Conditioning)
HVAC (Heating, Ventilation, and Air

Conditioning)
Heating
System Description 21-2
Air Conditioning
A/C Service Tips and Precautions 21-7
A/C Refrigerant Oil Replacement 21-7
Radiator and Condenser Fans Low Speed Circuit Troubleshooting 21-13
Condenser Fan High Speed Circuit Troubleshooting 21-16
Radiator and Condenser Fans High Speed Circuit Troubleshooting 21-17
Compressor Clutch Circuit Troubleshooting 21-18
A/C Pressure Switch Circuit Troubleshooting 21-20
Compressor Replacement 21-25
Compressor Clutch Check 21-26
Compressor Clutch Overhaul 21-27
Compressor Relief Valve Replacement 21-28
Condenser Replacement 21-29
A/C System Tests 21-30
Climate Control
A/C Pressure Switch Circuit Troubleshooting 21-36
NOTE: Refer to the 2001 Civic Shop Manual P/N 62S5A00, on this CD for items not shown in this section.
The Turbo Diesel model has been added; related information is included.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If HVAC maintenance is required)

the glove box, seat belt tensioners in the front seat belt retractors, seat belt buckle tensioners in the front seat belt buckles, and
side airbags in the front seat-backs. Information necessary to safely service the SRS is included in the '01 Civic Shop Manual on
this CD, P/N 62S5A00. Items marked with an asterisk (*) on the contents page include or are located near SRS components.
Servicing, disassembling or replacing these items will require special precautions and tools, and should be done only by an
To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal
collision, all SRS service work must be performed by an authorised Honda dealer.
Improper service procedures, including incorrect removal and installation of the SRS, could lead to personal injury caused
by unintentional deployment of the airbags and/or side airbags.
Do not bump the SRS unit. Otherwise, the system may fail in a collision, or airbags may deploy when the ignition switch
is ON (II).
SRS electrical wiring connectors are identified by yellow colour coding. Related components are located in the steering

21-1_HVAC (Heating, Ventilation, and Air Conditioning)
column, front console, dashboard, dashboard lower panel, in the dashboard above the glove box, in the front seats, and
around the floor. Do not use electrical test equipment on these circuits.
aaa

21-2_Heating_System Description
21-2
Heating
System Description
Heater Control Panel Inputs and Outputs (KE Model)

HEATER CONTROL PANEL CONNECTORS
CONNECTOR A (14P) CONNECTOR B (22P)

CONNECTOR A (O on Circuit Diagram)
Cavity Wire colour Signal
1 GRY AIR MIX POTENTIAL +5V OUTPUT
2 LT GRN SENSOR COMMON GROUND INPUT
3 PNK/BLU AIR MIX HOT OUTPUT
4 BLU/ORN A/C PRESSURE SWITCH INPUT
5 GRN/YEL RECIRCULATE INPUT
6 GRN/WHT FRESH INPUT
7 BLU/YEL POWER TRANSISTOR OUTPUT
8 BLU/RED BLOWER FEEDBACK INPUT
9 GRN AIR MIX COOL OUTPUT
10 YEL/RED MODE DEF OUTPUT
11 YEL/BLU MODE VENT OUTPUT
12 YEL/BLK REAR WINDOW DEFOGGER RELAY INPUT
13 BLK GROUND OUTPUT
14 BLK/YEL IG2 (Power) INPUT
CONNECTOR B (¨ on Circuit Diagram)

1 - - -
2 - - -
3 BLK/RED REAR WINDOW DEFOGGER SWITCH LED INPUT
4 LT GRN A/C SWITCH LED INPUT
5 LT GRN/BLK RECIRCULATION CONTROL SWITCH LED INPUT
6 PNK/BLK AIR MIX POTENTIAL OUTPUT
7 BRN EVAPORATOR TEMPERATURE SENSOR OUTPUT
8 - - -
9 - - -
10 - - -
11 RED UNDER-DASH FUSE/RELAY BOX OUTPUT
12 RED/BLK TAILLIGHTS RELAY INPUT
13 PUR ECM INPUT
14 BLU REAR WINDOW DEFOGGER SWITCH INPUT
15 LT GRN/RED A/C SWITCH INPUT
16 YEL/RED RECIRCULATION CONTROL SWITCH INPUT
17 YEL/GRN MODE 4 OUTPUT
18 WHT/BLU MODE 3 OUTPUT
19 RED/BLU MODE 2 OUTPUT
20 RED/YEL MODE 1 OUTPUT
21 BRN/WHT IGN (Power) OUTPUT

21-2_Heating_System Description
22 - - -
aaa

21-3_Heating_Circuit Diagram
21-3
Heating
Circuit Diagram
KE Model
aaa

21-4_Heating_Circuit Diagram (cont'd)
21-4
Heating
Circuit Diagram (cont'd)
Except KE Model
aaa

21-5_Air Conditioning_Component Location Index
21-5
Air Conditioning
NOTE: LHD type is shown, RHD type is similar

1. SERVICE VALVE
(LOW-PRESSURE SIDE)
2. EVAPORATOR CORE
(Built into the heater unit)
3. SERVICE VALVE
(HIGH-PRESSURE SIDE)
4. RECEIVER/DRYER
5. CONDENSER
6. COMPRESSOR
Clutch Check, page 21-26
Clutch Overhaul, page 21-
27
Relief Valve Replacement,
page 21-28
aaa

21-6_Air Conditioning_Component Location Index (cont'd)
21-6
Air Conditioning
NOTE: LHD type is shown, RHD type is similar

1. A/C DIODE C
(Located in the right side of dash)
2. A/C DIODE A
(Located in the middle under the
dash)
3. RADIATOR FAN RELAY,
FAN CONTROL RELAY,
A/C DIODE B
(Located in the multi-relay box)
4. BLOWER MOTOR RELAY,
CONDENSER FAN RELAY
COMPRESSOR CLUTCH RELAY
(Located in the under-hood
fuse/relay box)
5. A/C PRESSURE SWITCH
6. RADIATOR FAN
7. CONDENSER FAN
aaa

21-7_Air Conditioning_A/C Service Tips and Precautions
A/C Refrigerant
21-7 Oil Replacement
Air Conditioning
A/C Service Tips and Precautions
Recommended PAG oil: DELPHI DH-PS:

WARNING
Add the recommended refrigerant oil in the amount listed
Compressed air mixed with R-134a
if you replace any of the following parts.
forms a combustible vapour.
The vapour can burn or explode To avoid contamination, do not return the oil to
causing serious injury. the container once dispensed and never mix it
Never use compressed air to with other refrigerant oils.
pressure test R-134a service Immediately after using the oil, reinstall the cap
equipment or vehicle air on the container and seal it to avoid moisture
conditioning systems. absorption.
Do not spill the refrigerant oil on the vehicle; it
CAUTION may damage the paint; if it gets on the paint,
Air conditioning refrigerant or wash it off immediately.
lubricant vapour can irritate your Condenser
eyes, nose, or throat. 25 ml (5/6 fl/oz, 0.9 lmp/oz)
Be careful when connecting service
Evaporator
equipment.
Do not breathe refrigerant or 45 ml (1 1/2 fl/oz, 1.6 lmp/oz)
vapour. Line or hose
10 ml (1/3 fl/oz, 0.4 lmp/oz)
The air conditioning system uses HFC-134a (R-134a)
Receiver/Dryer
refrigerant and polyalkyleneglycol (PAG) refrigerant oil,
which are not compatible with CFC-12 (R-12) refrigerant 10 ml (1/3 fl/oz, 0.4 lmp/oz)
and mineral oil. Do not use R-12 refrigerant or mineral oil Leakage repair
in this system and do not attempt to use R-12 servicing 25 ml (5/6 fl/oz, 0.9 lmp/oz)
equipment; damage to the air conditioning system or your
Compressor
servicing equipment will result.
For compressor replacement, subtract the volume of
Separate the manifold gauge sets (pressure gauges,
oil drained from the removed compressor from 150 ml
hoses, joints) for refrigerants R-12 and R-134a. Do not
(5 fl/oz, 5.3 lmp/oz) and drain the calculated volume of
confuse them.
oil from the new compressor: 150 ml (5 fl/oz, 5.3
If accidental system discharge occurs, ventilate work area lmp/oz) - Volume of removed compressor = Volume to
before resuming service. drain from new compressor.
R-134a service equipment or vehicle air conditioning NOTE: Even if no oil is drained from the removed
systems should not be pressure tested or leak tested with compressor, do not drain more than 50 ml (1 2/3 fl/oz,
compressed air. 1.8 lmp/oz) from the new compressor.
Additional health and safety information may be obtained
from the refrigerant and lubricant manufacturers.
Always disconnect the negative cable from the
battery whenever replacing air conditioning
parts.
Keep moisture and dirt out of the system. When
disconnecting any lines, plug or cap the fittings
immediately; do not remove the caps or plugs
aaa
until just before you reconnect each line.
Before connecting any hose or line, apply a few
drops of refrigerant oil to the O-ring.
When tightening or loosening a fitting, use a
second wrench to support the matching fitting.
When discharging the system, do not let
refrigerant escape too fast; it will draw the
compressor oil out of the system.

21-8_Air Conditioning_A/C Refrigerant Oil Replacement (cont'd)
21-8
Air Conditioning
A/C Refrigerant Oil Replacement (cont'd)
1. Discharge hose to the compressor (6 x 1.0 mm) : 9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
2. Discharge hose to the condenser (6 x 1.0 mm) : 9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
3. Condenser line to the condenser (6 x 1.0 mm) : 9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
4. Condenser line to the receiver/dryer (6 x 1.0 mm) : 9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
5. Receiver line A to the receiver/dryer (6 x 1.0 mm) : 9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
6. Receiver line A to the receiver line B : 13 Nm (1.3 kgf/m, 9.4 lbf/ft)
7. Receiver line B and the suction line to the evaporator (6 x 1.0 mm) : 9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
8. Suction line to the suction hose : 31 Nm (3.2 kgf/m, 23 lbf/ft)
9. Suction hose to the compressor (6 x 1.0 mm) : 9.8 Nm (1.0 kgf/m, 7.2 lbf/ft)
10. Compressor to the compressor bracket (8 x .25 mm) : 25 Nm (2.5 kgf/m, 18 lbf/ft)
11. Compressor bracket to the engine block (10 x 1.5 mm) : 43 Nm (4.4 kgf/m, 32 lbf/ft)
aaa

21-9_Air Conditioning_Symptom Troubleshooting Index
21-9
Air Conditioning

Both fans do not run at low speed with Radiator and Condenser Fans Low Blown fuse No. 1 (30A) in the
the A/C on when the refrigerant Speed Circuit Troubleshooting (see page under-hood fuse/relay box and
pressure is below 1,520 kPa (15.5 21-13) No. 14 (10A) in the under-dash
kgf/cm 2 , 220 psi). fuse/relay box
Poor ground at No. G301
Cleanliness and tightness of all
connectors
Condenser fan does not run at high Condenser Fan High Speed Circuit Blown fuse No. 14 (10A) in the
speed when the engine coolant Troubleshooting (see page 21-16) under-dash fuse/relay box
temperature is above 100°C (212°F) or Poor ground at No. G301
the refrigerant pressure is above 1,520 Cleanliness and tightness of all
kPa (15.5 kgf/cm 2 , 220 psi) with the connectors
A/C on.
Both fans do not run at high speed with Radiator and Condenser Fans High Cleanliness and tightness of all connectors
the A/C on when the refrigerant Speed Circuit Troubleshooting (see page
pressure is above 1,520 kPa (15.5 21-17)
kgf/cm 2 , 220 psi).
Compressor clutch does not engage. Compressor Clutch Circuit Blown fuse No. 6 (20A) in the
Troubleshooting (see page 21-18) under-hood fuse/relay box, and
No. 14 (10A) in the under-dash
fuse/relay box
connectors
A/C System does not come on (both A/C Pressure Switch Circuit Blown fuse No. 14 (10A) in the
fans and compressor). Troubleshooting (see page 21-20) under-dash fuse/relay box
(except KE model)
connectors
aaa

21-10_Air Conditioning_System Description
21-10
Air Conditioning
System Description
The air conditioning system removes heat from the passenger compartment by circulating refrigerant through the system as shown
below.
1. A/C PRESSURE SWITCH
(Triple function)
When the refrigerant is
below 196kPa (2.0 kgf/cm 2 ,
28 psi) or above 3,140 kPa
(32 kgf/cm 2 , 455 psi), the
A/C pressure switch opens
the circuit to the A/C switch
and stops the air
conditioning to protect the
compressor.
When the refrigerant is
above 1,520 kPa (15.5
kgf/cm 2 , 220 psi), the A/C
pressure switch switches the
radiator and condenser fans
to high speed.
2. EXPANSION VALVE
(Meters the required amount
of refrigerant into the
evaporator)
3. BLOWER FAN
4. EVAPORATOR
(Absorption of heat)
5. EVAPORATOR
TEMPERATURE SENSOR
6. RELIEF VALVE
(Relieves pressure at the
compressor when the
pressure is too high)
7. COMPRESSOR
(Suction and compression)
8. HIGH PRESSURE VAPOUR
9. HIGH PRESSURE LIQUID
10. LOW PRESSURE LIQUID
11. LOW PRESSURE VAPOUR
12. CONDENSER
(Radiation of heat)
13. RECEIVER/DRYER
(Traps debris, and removes
moisture)
This vehicle uses HFC-134a (R-134a) refrigerant which does not contain chlorofluorocarbons. Pay attention to the following service
items:
Do not mix refrigerants CFC-12 (R-12) and HFC-134a (R-134a). They are not compatible.
Use only the recommended polyalkyleneglycol (PAG) refrigerant oil (DELPHI DH-PS) designed for the R-134a
compressor. Intermixing the recommended (PAG) refrigerant oil with any other refrigerant oil will result in compressor
failure.
All A/C system parts (compressor, discharge line, suction line, evaporator, condenser, receiver/dryer, expansion valve, O-
rings for joints) have to be proper for refrigerant R-134a. Do not confuse with R-12 parts.
Use a halogen gas leak detector designed for refrigerant R-134a.
Use a vacuum pump adapter which is equipped with a check valve to prevent the backflow of the vacuum pump oil.
Separate the manifold gauge sets (pressure gauges, hoses, joints) for refrigerants R-12 and R-134a. Do not confuse
them.
aaa

21-11_Air Conditioning_Circuit Diagram
21-11
Air Conditioning
Circuit Diagram
KE Model
aaa

21-12_Air Conditioning_Circuit Diagram (cont'd)
21-12
Air Conditioning
Except KE Model
aaa

21-13_Air Conditioning_Radiator and Condenser Fans Low Speed Circuit Troubleshooting
21-13
Air Conditioning
Radiator and Condenser Fans Low Speed
Circuit Troubleshooting
1. 1. Check the No. 1 (30 A) fuse in the under-hood 1. 4. Connect the No. 1 and No. 2 terminals of the
fuse/relay box and the No. 14 (10 A) fuse in the condenser fan relay 4P socket with a jumper
under-dash fuse/relay box. wire.
Are the fuses OK?
YES - Go to step 2.
NO - Replace the fuse(s) and recheck.
2. 2. Remove the condenser fan relay from the
under-hood fuse/relay box and test it.
Is the relay OK?
YES - Go to step 3. Does the condenser fan run?
NO - Replace the condenser fan relay. YES - Go to step 5.
3. 3. Measure the voltage between the No. 2 NO - Go to step 14.
terminal of the condenser fan relay 4P socket
2. 5. Disconnect the jumper wire.
and body ground.
CONDENSER FAN RELAY 4P SOCKET
4. 7. Measure the voltage between the No.3 terminal
of the condenser fan relay 4P socket and body
ground.
CONDENSER FAN RELAY 4P SOCKET

YES - Go to step 4.
NO - Replace the under-hood fuse/relay box.
YES - Go to step 8.
NO - Repair open in the wire between the No.14 fuse
in the under-dash fuse/relay box and the condenser
fan relay.
aaa

21-14_Air Conditioning_Radiator and Condenser Fans Low Speed Circuit Troubleshooting (cont'd)
21-14
Air Conditioning
1. 9. Reinstall the condenser fan relay. 1. 14. Disconnect the jumper wire.
2. 10. Remove the A/C diode A from the under middle 2. 15. Reinstall the condenser fan relay.
of dash. 3. 16. Disconnect the condenser fan 2P connector.
3. 11. Check for current flow in both directions 4. 17. Turn the ignition switch ON (II), then turn the
between the No. 1 and No. 2 terminals of the A/C and fan switches ON.
A/C diode A. 5. 18. Measure the voltage between the No. 2
A/C DIODE A terminal of the condenser fan 2P connector and
body ground.
CONDENSER FAN 2P CONNECTOR

Is there current flow in only one direction?
YES - Go to step 19.
NO - Repair open in the wire between the condenser
NO - Replace the A/C diode A. fan relay and the condenser fan.
4. 12. Turn the ignition switch ON (II). 6. 19. Turn the A/C and fan switches OFF, then turn
5. 13. Measure the voltage between the No. 2 the ignition switch OFF.
terminal of the A/C diode A 2P connector and 7. 20. Reconnect the condenser fan 2P connector.
body ground. 8. 21. Connect the No.1 terminal of the condenser fan
A/C DIODE A 2P CONNECTOR 2P connector to body ground with a jumper
wire.
CONDENSER FAN 2P CONNECTOR

YES - Repair open in the wire between the A/C diode
A and the A/C pressure switch. aaa
fan relay and the A/C diode A.

21-15_Air Conditioning_Radiator and Condenser Fans Low Speed Circuit Troubleshooting (cont'd)
21-15
Air Conditioning
1. 22. Turn the ignition switch ON (II), then turn the 1. 30. Check for continuity between the No. 2 terminal
A/C and fan switches ON. of the fan control relay 5P socket and the No. 2
Does the condenser fan run? terminal of the radiator fan 2P connector.
YES - Go to step 23. FAN CONTROL RELAY 5P SOCKET
NO - Replace the condenser fan motor.
2. 23. Turn the A/C and fan switches OFF, then turn
the ignition switch OFF.
4. 25. Remove the fan control relay from the multi-
fuse/relay box and test it.
Is the relay OK?
NO - Replace the fan control relay.
5. 26. Turn the ignition switch ON (II), then turn the
A/C and fan switches ON. RADIATOR FAN 2P CONNECTOR
6. 27. Measure the voltage between the No. 5 Wire side of female terminals
terminal of the fan control relay 5P socket and
body ground.
FAN CONTROL RELAY 5P SOCKET YES - Go to step 31.
NO - Repair open in the wire between the fan control
relay and the radiator fan.
2. 31. Check for continuity between the No. 1 terminal
of the radiator fan 2P connector and body
ground.
RADIATOR FAN 2P CONNECTOR

fan and the fan control relay.
7. 28. Turn the A/C and fan switches OFF, then turn Wire side of female terminals
the ignition switch OFF.
8. 29. Disconnect the radiator fan 2P connector.
YES - Replace the radiator fan motor.
NO - Check for an open in the wire between the
radiator fan and body ground. If the wire is OK, check
for poor ground at G301.
aaa

21-16_Air Conditioning_Condenser Fan High Speed Circuit Troubleshooting
21-16
Air Conditioning
Condenser Fan High Speed Circuit
Troubleshooting
1. 1. Check the No. 14 (10 A) fuse in the under-dash 1. 6. Check for continuity between the No. 4 terminal
fuse/relay box. of the fan control relay 5P socket and body
Is the fuse OK? ground.
YES - Go to step 2. FAN CONTROL RELAY 5P SOCKET
NO - Replace the fuse and recheck.
2. 2. Remove the fan control relay from the multi-
fuse/relay box and test it.
Is the relay OK?
YES - Go to step 3.
NO - Replace the fan control relay.
4. 4. Measure the voltage between the No. 3
terminal of the fan control relay 5P socket and
body ground.
FAN CONTROL RELAY 5P SOCKET Is there continuity?
YES - Repair open in the wire between the fan
control relay and the A/C diode B.
NO - Check for an open in the wire between the fan
control relay and body ground. If the wire is OK,
check for poor ground at G301.
aaa

YES - Go to step 5.
NO - Repair open in the wire between the No. 14 fuse
in the under-dash fuse/relay box and the fan control
relay.

21-17_Air Conditioning_Radiator and Condenser Fans High Speed Circuit Troubleshooting
21-17
Air Conditioning
Circuit Troubleshooting
1. 1. Remove the A/C diode B from the multi-relay 1. 7. Disconnect the A/C pressure switch 4P
box. connector.
2. 2. Check for current flow in both directions 2. 8. Turn the ignition switch ON (II).
between the No. 1 and No. 2 terminals of the 3. 9. Measure the voltage between the No. 3
A/C diode B. terminal of the A/C pressure switch 4P
A/C DIODE B connector and body ground.
A/C PRESSURE SWITCH 4P CONNECTOR

Is there current flow in only one direction? NO - Repair open in the wire between the A/C diode
YES - Go to step 3. B and the A/C pressure switch.
NO - Replace the A/C diode B. 4. 10. Turn the ignition switch OFF.
3. 3. Turn the ignition switch ON (II). 5. 11. Check for continuity between the No. 1 and No.
4. 4. Measure the voltage between the No. 2 2 terminals of the A/C pressure switch 4P
terminal of the A/C diode B 3P socket and body connector.
ground. A/C PRESSURE SWITCH 4P CONNECTOR
A/C DIODE B 3P SOCKET

YES - Replace the A/C pressure switch.
NO - Repair open in the wire between the A/C
Is there battery voltage? pressure switch A and B.
YES - Go to step 5. aaa
NO - Repair open in the wire between the radiator fan
relay, fan control relay and the A/C diode B.
6. 6. Reinstall the A/C diode B.

21-18_Air Conditioning_Compressor Clutch Circuit Troubleshooting
21-18
Air Conditioning
Compressor Clutch Circuit Troubleshooting
1. 1. Check the No. 4 (10 A) fuse in the under-hood 1. 5. Connect the No. 1 and No. 2 terminals of the
fuse/relay box and the No. 14 (10 A) fuse in the compressor clutch relay 4P socket with a
under-dash fuse/relay box. jumper wire.
Are the fuses OK? COMPRESSOR CLUTCH RELAY 4P SOCKET
YES - Go to step 2.
NO - Replace the fuse(s) and recheck.
2. 2. Check the engine coolant temperature.
Is the coolant temperature above normal?
YES - Troubleshoot and repair cause of high engine
coolant temperature.
NO - Go to step 3.
3. 3. Remove the compressor clutch relay from the
under-hood fuse/relay box and test it. Is the
relay OK?
Does the compressor clutch click?
YES - Go to step 4.
YES - Go to step 6.
NO - Replace the compressor clutch relay.
NO - Go to step 15.
of the compressor clutch relay 4P socket and 2. 6. Disconnect the jumper wire.
body ground. 3. 7. Turn the ignition switch ON (II).
COMPRESSOR CLUTCH RELAY 4P SOCKET 4. 8. Measure the voltage between the No. 3
terminal of the compressor clutch relay 4P
socket and body ground.
COMPRESSOR CLUTCH RELAY 4P SOCKET

YES - Go to step 5.
NO - Replace the under-hood fuse/relay box.
YES - Go to step 9.
NO - Repair open in the wire between the PGM-FI
main relay and the compressor clutch relay.
aaa

21-19_Air Conditioning_Compressor Clutch Circuit Troubleshooting (cont'd)
21-19
Air Conditioning
(cont'd)
1. 9. Turn the ignition switch OFF. 1. 14. Measure the voltage between the No. 60
2. 10. Reinstall the compressor clutch relay. terminal of the ECM connector A (81P) and
3. 11. Make sure the A/C switch is OFF. body ground with the PCM connectors
4. 12. Turn the ignition switch ON (II). connected.
5. 13. Measure the voltage between the No. 20 ECM CONNECTOR A (81P)
terminal of the ECM connector A (81P) and
body ground with the PCM connectors
connected.
ECM CONNECTOR A (81P)

YES - Repair open in the wire between the ECM and
the A/C pressure switch.
Wire side of female terminals NO - Check for loose wires or poor connections at the
Is there battery voltage? ECM connector A (81P). If the connections are good,
YES - Go to step 14. substitute a known-good PCM and recheck. If the
NO - Repair open in the wire between the compressor
ECM.
clutch relay and the ECM.
3. 16. Disconnect the compressor clutch 1P
connector.
aaa

21-20_Air Conditioning_Compressor Clutch Circuit Troubleshooting (cont'd)
21-20
A/C Pressure Switch Circuit
Air Conditioning Troubleshooting
(cont'd)
1. 17. Check for continuity between the No. 1 terminal KE Model

of the compressor clutch relay 4P socket and 1. 1. Disconnect the A/C pressure switch 4P
the No. 1 terminal of the compressor clutch 1P connector.
connector. 2. 2. Turn the ignition switch ON (II).
COMPRESSOR CLUTCH RELAY 4P SOCKET 3. 3. Measure the voltage between the No. 1
terminal of the A/C pressure switch 4P
connector and body ground.
COMPRESSOR CLUTCH 1P CONNECTOR

YES - Check the compressor clutch clearance and the Wire side of female terminals
compressor clutch coil (see page 21-26). Is there battery voltage?
NO - Repair open in the wire between the compressor YES - Go to step 4.
clutch relay and the compressor clutch.
NO - Repair open in the wire between the A/C diode
A, the ECM and the A/C pressure switch.
5. 5. Check for continuity between the No. 1 and No.
4 terminals of the A/C pressure switch.
A/C PRESSURE SWITCH
YES - Go to step 6.
NO - Go to step 10.
aaa

21-21_Air Conditioning_A/C Pressure Switch Circuit Troubleshooting (cont'd)
21-21
Air Conditioning
A/C Pressure Switch Circuit Troubleshooting
(cont'd)
1. 6. Reconnect the A/C pressure switch 4P Except KE Model

connector. 1. 1. Check the No.14 (10 A) fuse in the under-dash
2. 7. Disconnect the heater control panel connector fuse/relay box.
A (14P). Is the fuse OK?
YES - Go to step 2.
terminal of heater control panel connector A NO - Replace the fuse and recheck.
(14P) and body ground. 2. 2. Disconnect the A/C pressure switch 4P
HEATER CONTROL PANEL CONNECTOR A (14P) connector.
terminal of the A/C pressure switch 4P
connector and body ground.

YES - Check for loose wires or poor connections at
heater control panel connector A (14P) and at the A/C
pressure switch 4P connector. If the connections are
good, substitute a known-good heater control panel
and recheck. If the symptom/indication goes away, Wire side of female terminals
replace the original heater control panel. Is there battery voltage?
NO - Repair open in the wire between the heater YES - Go to step 5.
control panel and the A/C pressure switch.
5. 10. Check for proper A/C system pressure. A, the ECM and the A/C pressure switch.
Is the pressure within specifications?
aaa
NO - Repair the A/C pressure problem.

21-22
Air Conditioning
(cont'd)
1. 5. Turn the ignition switch OFF. 1. 11. Measure the voltage between the No. 1
2. 6. Check for continuity between the No. 1 and No. terminal of the A/C thermostat 3P connector
4 terminals of the A/C pressure switch. and body ground.
A/C PRESSURE SWITCH A/C THERMOSTAT 3P CONNECTOR
YES - Go to step 7.
NO - Go to step 32.
3. 7. Reconnect the A/C pressure switch 4P
NO - Repair open in the wire between the A/C
connector.
pressure switch and the A/C thermostat.
4. 8. Disconnect the A/C thermostat 3P connector.
5. 9. Turn the ignition switch ON (II). 2. 12. Turn the ignition switch OFF.
6. 10. Measure the voltage between the No. 3 3. 13. Reconnect the A/C thermostat 3P connector.
terminal of the A/C thermostat 3P connector 4. 14. Make sure the A/C switch is OFF.
and body ground. 5. 15. Turn the ignition switch ON (II).
A/C THERMOSTAT 3P CONNECTOR 6. 16. Measure the voltage between the No. 2
terminal of the A/C thermostat 3P connector
and body ground with the A/C thermostat 3P
connector connected.
A/C THERMOSTAT 3P CONNECTOR

NO - Repair open in the wire between the No. 14 fuse Wire side of female terminals
in the under-dash fuse/relay box and the A/C Is there battery voltage?
thermostat.
NO - Replace the A/C thermostat.
aaa

21-23
Air Conditioning
(cont'd)
1. 17. Turn the ignition switch OFF. 1. 24. Disconnect the push switch 10P connector.
2. 18. Remove the A/C diode C from the right side of 2. 25. Turn the ignition switch ON (II).
dash. 3. 26. Measure the voltage between the No. 3
3. 19. Check for current flow in both directions terminal of the push switch 10P connector and
between the No.1 and No.2 terminals of the body ground.
A/C diode C. PUSH SWITCH 10P CONNECTOR
A/C DIODE C

C and the push switch.
5. 28. Disconnect the heater fan switch 7P connector.
6. 29. Check for continuity between the No. 4 terminal
of the push switch 10P connector and the No.
Is there current flow in only one direction?
3 terminal of the heater fan switch 7P
YES - Go to step 20. connector.
NO - Replace the A/C diode C. PUSH SWITCH 10P CONNECTOR
4. 20. Turn the ignition switch ON (II). Wire side of female terminals
of the A/C diode C 2P connector and body
ground.
A/C DIODE 2P SOCKET
HEATER FAN SWITCH 7P CONNECTOR

NO - Repair open in the wire between the push
YES - Go to step 22. switch and the heater fan switch.
NO - Repair open in the wire between the A/C aaa
thermostat and the A/C diode C.
7. 23. Reinstall the A/C diode C.

21-24
Air Conditioning
(cont'd)
1. 30. Check for continuity between the No. 2 terminal aaa

of the heater fan switch 7P connector and body
ground.
HEATER FAN SWITCH 7P CONNECTOR

NO - Check for an open in the wire between the
heater fan switch and body ground. If the wire is OK,
check for poor ground at G501.
2. 31. Test the A/C switch.
Is the A/C switch OK?
YES - Replace the heater fan switch.
NO - Replace the push switch.
3. 32. Check for proper A/C system pressure.

21-25_Air Conditioning_Compressor Replacement
21-25
Air Conditioning
Compressor Replacement
1. 1. If the compressor is marginally operable, run 1. 6. Remove the mounting bolts and the
the engine at idle speed and let the air compressor.
conditioning work for a few minutes, then shut
the engine off.
2. 2. Make sure you have the anti-theft code for the
radio, then write down the frequencies for the
radio's preset buttons.
3. 3. Disconnect the negative cable from the battery.
4. 4. Discharge the refrigerant.
5. 5. Remove the bolts, then disconnect the suction
line (A) and the discharge line (B) from the
compressor. Plug or cap the lines immediately
after disconnecting them to avoid moisture and
dust contamination.
2. 7. Install the compressor in the reverse order of

removal and note these items:
If you are installing a new compressor, you
must calculate the amount of refrigerant oil to
be removed from it (see page 21-7).
Replace the O-rings with new ones at each
fitting and apply a thin coat of refrigerant oil
before installing them. Be sure to use the
right O-rings for HFC-134a (R-134a) to
avoid leakage.
Use refrigerant oil (DELPHI DH-PS) for
HFC-134a DELPHI compressor only.
To avoid contamination, do not return the oil
to the container once dispensed and never
mix it with other refrigerant oils.
Immediately after using the oil, reinstall the
cap on the container and seal it to avoid
moisture absorption.
Do not spill the refrigerant oil on the vehicle;
it may damage the paint; if the refrigerant oil
contacts the paint, wash it off immediately.
Charge the system.
Check for system performance (see page
21-30).
Enter the anti-theft code for the radio, then
enter the customer's radio station presets.
aaa

21-26_Air Conditioning_Compressor Clutch Check
21-26
Air Conditioning
Compressor Clutch Check
1. 1. Check the driver clutch for discoloration, peeling 1. 4. Check resistance of the clutch coil. If resistance
or other damage. If there is damage, replace is not within specifications, replace the field coil
the driver clutch and the pulley assembly (see (see page 21-27).
page 21-27). Clutch Coil Resistance:
2. 2. Check the pulley assembly bearing play and 3.4 - 3.8 ohms at 20°C (68°F)
drag by rotating the pulley assembly by hand.
Replace the driver clutch and the pulley
assembly with a new one if it is noisy or has
excessive play/drag (see page 21-27).
aaa
3. 3. Measure the clearance between the pulley

assembly (A) and the driver clutch (B) all the
way around. If the clearance is not within
specified limits, remove the driver clutch (see
page 21-27) and add or remove driver shims as
needed to increase or decrease clearance.
Clearance:
0.30 - 0.60 mm (0.012 - 0.024 in.)
NOTE: The driver shims are available in three
thickness: 0.2 mm, 0.3 mm and 0.4 mm.

21-27_Air Conditioning_Compressor Clutch Overhaul
21-27
Air Conditioning
Compressor Clutch Overhaul
1. 1. Remove the driver bolt while holding the driver 1. 3. If you are replacing the clutch coil, remove the
clutch with driver clutch holder 5-8840-4056-0 retaining ring (A) with retaining ring pliers, then
(J-37872). remove the pulley assembly (B). Be careful not
to damage the pulley assembly and compressor
assembly.
2. 2. Remove the driver clutch (A) and driver shim(s)

(B), taking care not to lose the driver shim(s). If
the clutch needs adjustment, increase or
decrease the number and thickness of driver 2. 4. Remove the screw from the clutch coil ground
shims as necessary, then reinstall the driver terminal (A). Remove the retaining ring (B) with
clutch and recheck its clearance (see page 21- retaining ring pliers, then remove the clutch coil
26). (C). Be careful not to damage the clutch coil
and compressor assembly.
aaa

21-28_Air Conditioning_Compressor Clutch Overhaul (cont'd)
Compressor
21-28 Relief Valve Replacement
Air Conditioning
Compressor Clutch Overhaul (cont'd)
1. 5. Reassemble the clutch in the reverse order of 1. 1. Discharge the refrigerant.

disassembly and note these items: 2. 2. Remove the relief valve (A), the O-ring (B), the
Install the clutch coil with the wire side facing spring (C) and the valve (D). Plug the opening
down and align the boss on the clutch coil with to keep foreign matter from entering the system
the hole in the compressor assembly. and the compressor oil from running out.
Clean the pulley assembly and compressor
assembly sliding surfaces with contact
cleaner or other non-petroleum solvent.
Install new retaining rings, note the
installation direction and make sure they are
fully seated in the groove.
Make sure that the pulley assembly turns
smoothly after it is reassembled.
Route and clamp the wires properly or they
can be damaged by the pulley assembly.
3. 3. Clean the mating surfaces.

4. 4. Replace the O-ring with a new one at the relief
valve and apply a thin coat of refrigerant oil
before installing it.
5. 5. Remove the plug and install and tighten the
relief valve.
6. 6. Charge the system.
7. 7. Check for system performance (see page 21-
30).
aaa

21-29_Air Conditioning_Condenser Replacement
21-29
Air Conditioning
Condenser Replacement
1. 1. Discharge the refrigerant. 1. 4. Remove the mounting bolts, then remove the
2. 2. Remove the front bumper. condenser by lifting it up. Be careful not to
3. 3. Remove the bolts, then disconnect the damage the radiator and condenser fins when
discharge line (A) and the condenser line (B) removing the condenser.
from the condenser. Plug or cap the lines
immediately after disconnecting them to avoid
moisture and dust contamination.
2. 5. Install the condenser in the reverse order of

removal and note these items.
If you are installing a new condenser, add
refrigerant oil (DELPHI DH-PS) (see page 21-
7).
Replace the O-rings with new ones at each
fitting and apply a thin coat of refrigerant oil
before installing them. Be sure to use the
right O-rings for HFC-134a (R-134a) to
avoid leakage.
Immediately after using the oil, reinstall the
cap on the container and seal it to avoid
moisture absorption.
Do not spill the refrigerant oil on the vehicle;
it may damage the paint; if the refrigerant oil
contacts the paint, wash it off immediately.
Be careful not to damage the radiator and
condenser fins when installing the
condenser.
Charge the system.
Check for system performance (see page
21-30).
aaa

21-30_Air Conditioning_A/C System Tests
21-30
Air Conditioning
A/C System Tests
Performance Test TWO VALVE GAUGE:
CAUTION
Air conditioning refrigerant or
lubricant vapour can irritate your
eyes, nose, or throat.
Be careful when connecting service
equipment.
Do not breathe refrigerant or
vapour.
WARNING
Compressed air mixed with R-134a
forms a combustible vapour.
The vapour can burn or explode
causing serious injury.
Never use compressed air to
pressure test R-134a service
equipment or vehicle air
conditioning systems.
The performance test will help determine if the air 1. 1. CHECK VALVE
conditioner system is operating within specifications. 2. LOW-PRESSURE VALVE
3. HIGH-PRESSURE VALVE
Use only a gauge set for refrigerant HFC-134a 4. EVACUATION STOP VALVE
(R-134a). 5. VACUUM PUMP
Use a vacuum pump adapter which is equipped 6. HIGH-PRESSURE QUICK JOINT
with a check valve to prevent the backflow of 7. LOW-PRESSURE QUICK JOINT
the vacuum pump oil.
2. 2. Insert a thermometer in the centre air vent.
If accidental system discharge occurs, ventilate work area
Determine the relative humidity and air
before resuming service.
temperature.
R-134a service equipment or vehicle air conditioning NOTE: LHD type is shown, RHD type is
systems should not be pressure tested or leak tested with symmetrical.
compressed air.
Additional health and safety information may be obtained
from the refrigerant and lubricant manufacturers.
1. 1. Connect a R-134a gauge set as shown.
THREE VALVE GAUGE:
3. 3. Test conditions:
Avoid direct sunlight.
Open the hood.
Open the front doors.
Set the temperature control dial on MAX
COOL, the mode control dial on VENT and
the recirculation control switch on
RECIRCULATE.
Turn the A/C switch on and the fan switch
on MAX.
Run the engine at 900 (min -1 ).
No driver or passengers in vehicle.

21-30_Air Conditioning_A/C System Tests
4. 4. After running the air conditioning for 10 minutes

under the above test conditions, read the
delivery temperature from the thermometer in
2. 1. CHECK VALVE the centre air vent, the intake temperature near
2. LOW-PRESSURE VALVE the blower unit behind the glove box and the
3. EVACUATION VALVE high and low system pressure from the A/C
4. HIGH-PRESSURE VALVE
gauges.
5. VACUUM PUMP
6. HIGH-PRESSURE QUICK JOINT aaa
7. LOW-PRESSURE QUICK JOINT

21-31_Air Conditioning_A/C System Tests (cont'd)
21-31
Air Conditioning
A/C System Tests (cont'd)
1. 5. To complete the charts:

Mark the delivery temperature along the vertical line.
Mark the intake temperature (ambient air temperature) along the bottom line.
Draw a line straight up from the air temperature to the humidity.
Mark a point 10 % above and 10 % below the humidity level.
From each point, draw a horizontal line across the delivery temperature.
The delivery temperature should fall between the two lines.
Complete the low-side pressure test and high-side pressure test in the same way.
Any measurements outside the line may indicate the need for further inspection.
aaa

21-32_Climate Control_Symptom Troubleshooting Index
21-32
Climate Control

Both fans do not run at low speed with Radiator and Condenser Fans Low Blown fuse No. 1 (30A) in
the A/C on when the refrigerant pressure Speed Circuit Troubleshooting (see page the under-hood fuse/relay
is below 1,520 kPa (15.5 kgf/cm 2 , 220 21-13) box and No. 14 (10A) in the
psi). under-dash fuse/relay box
Poor ground at No. G301
Cleanliness and tightness of
all connectors
Condenser fan does not run at high Condenser Fan High Speed Circuit Blown fuse No. 14 (10A) in
speed when the engine coolant Troubleshooting (see page 21-16) the under-dash fuse/relay
temperature is above 100°C (212°F) or box
the refrigerant pressure is above 1,520 Poor ground at No. G302
kPa (15.5 kgf/cm 2 , 220 psi) with the A/C Cleanliness and tightness of
on. all connectors
Both fans do not run at high speed with Radiator and Condenser Fans High Cleanliness and tightness of all connectors
the A/C on when the refrigerant pressure Speed Circuit Troubleshooting (see page
is above 1,520 kPa (15.5 kgf/cm 2 , 220 21-17)
psi).
Compressor clutch does not engage. Compressor Clutch Circuit Blown fuse No. 6 (20A) in
Troubleshooting (see page 21-18) the under-hood fuse/relay
box, and No. 14 (10A) in the
under-dash fuse/relay box
Cleanliness and tightness of
all connectors
A/C System does not come on (both fans A/C Pressure Switch Circuit Cleanliness and tightness of all connectors
and compressor). Troubleshooting (see page 21-36)
aaa

21-33_Climate Control_System Description
21-33
Climate Control
System Description
Climate Control Unit Inputs and Outputs

CLIMATE CONTROL UNIT CONNECTORS
CONNECTOR A (14P) CONNECTOR B (22P)

CONNECTOR A (O on Circuit Diagram)
1 GRY AIR MIX POTENTIAL +5 V OUTPUT
2 LT GRN SENSOR COMMON GROUND INPUT
3 PNK/BLU AIR MIX HOT OUTPUT
4 BLU/ORN A/C PRESSURE SWITCH INPUT
5 GRN/YEL RECIRCULATE INPUT
6 GRN/WHT FRESH INPUT
7 BLU/YEL POWER TRANSISTOR OUTPUT
8 BLU/RED BLOWER FEEDBACK INPUT
9 GRN AIR MIX COOL OUTPUT
10 YEL/RED MODE DEF OUTPUT
11 YEL/BLU MODE VENT OUTPUT
12 YEL/BLK REAR WINDOW DEFOGGER RELAY INPUT
13 BLK GROUND OUTPUT
14 BLK/YEL IG2 (Power) INPUT
CONNECTOR B (¨ on Circuit Diagram)

1 - - -
2 - - -
3 BLK/RED REAR WINDOW DEFOGGER SWITCH LED INPUT
4 LT GRN A/C SWITCH LED INPUT
5 LT GRN/BLK RECIRCULATION CONTROL SWITCH LED INPUT
6 PNK/BLK AIR MIX POTENTIAL OUTPUT
7 BRN EVAPORATOR TEMPERATURE SENSOR OUTPUT
8 PNK OUTSIDE AIR TEMPERATURE SENSOR OUTPUT
9 LT BLU IN-CAR TEMPERATURE SENSOR OUTPUT
10 ORN SUNLIGHT SENSOR OUTPUT
11 RED UNDER-DASH FUSE/RELAY BOX OUTPUT
12 RED/BLK TAILLIGHTS RELAY INPUT
13 PUR EUM INPUT
14 BLU REAR WINDOW DEFOGGER SWITCH INPUT
15 LT GRN/RED A/C SWITCH INPUT
16 YEL/RED RECIRCULATION CONTROL SWITCH INPUT
17 YEL/GRN MODE 4 OUTPUT
18 WHT/BLU MODE 3 OUTPUT
19 RED/BLU MODE 2 OUTPUT
20 RED/YEL MODE 1 OUTPUT
21 BRN/WHT IGN (Power) OUTPUT

21-33_Climate Control_System Description
22 RED/WHT ENGINE COOLANT TEMPERATURE (ECT) SENSOR OUTPUT
aaa

21-34_Climate Control_Circuit Diagram
21-34
Climate Control
Circuit Diagram
aaa

21-35_Climate Control_Circuit Diagram
21-35
Climate Control
Circuit Diagram
aaa

21-36_Climate Control_A/C Pressure Switch Circuit Troubleshooting
21-36
Climate Control
1. 1. Disconnect the A/C pressure switch 4P 1. 6. Reconnect the A/C pressure switch 4P
connector. connector.
2. 2. Turn the ignition switch ON (II). 2. 7. Disconnect the climate control unit connector A
3. 3. Measure the voltage between the No. 1 (14P).
terminal of the A/C pressure switch 4P 3. 8. Turn the ignition switch ON (II).
connector and body ground. 4. 9. Measure the voltage between the No. 4
A/C PRESSURE SWITCH 4P CONNECTOR terminal of climate control unit connector A
(14P) and body ground.
CLIMATE CONTROL UNIT CONNECTOR A (14P)

YES - Go to step 4.
YES - Check for loose wires or poor connections at
climate control unit connector A (14P) and at the A/C
A, the ECM and the A/C pressure switch.
pressure switch 4P connector. If the connections are
4. 4. Turn the ignition switch OFF. good, substitute a known-good climate control unit and
5. 5. Check for continuity between the No. 1 and No. recheck. If the symptom/indication goes away, replace
4 terminals of the A/C pressure switch. the original climate control unit.
A/C PRESSURE SWITCH
NO - Repair open in the wire between the climate
control unit and the A/C pressure switch.
5. 10. Check for proper A/C system pressure.
aaa
YES - Go to step 6.
NO - Go to step 10.

22-1_Body Electrical
Body Electrical
Relay and Control Unit Location

Engine Compartment 22-2
Dashboard 22-4
Wire Harnesses and Ground Location

Fuse/Relay Boxes Connector to Fuse/Relay Box Index 22-6
Power Distribution
Fuse to Components Index 22-8
Ground Distribution
Circuit Identification 22-19
Gauges
Immobiliser System
Troubleshooting 22-36
Immobiliser Control Unit-Receiver Replacement 22-37

Diesel engine model has been added; related information is included.
The information which differs from the '01 CIVIC Shop Manual on this CD has been included.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If electrical maintenance required)

This model has an SRS which includes a drivers airbag in the steering wheel hub, a passenger's airbag in the dashboard above
will require special precautions and tools, and should therefore be done by an authorised Honda dealer.
WARNING
aaa

22-2_Relay and Control Unit Locations_Engine Compartment
22-2
Relay and Control Unit Locations
Engine Compartment

1. HORN RELAY
2. A/C COMPRESSOR CLUTCH
RELAY
4. REAR WINDOW DEFOGGER
RELAY
5. BLOWER MOTOR RELAY
6. HEADLIGHT RELAY 1
8. ELD UNIT
aaa

22-3_Relay and Control unit Locations_Engine Compartment (cont'd)
22-3
Relay and Control unit Locations
Engine Compartment (cont'd)

1. ENGINE GLOW RELAY
2. WATER HEATER RELAY 1
3. MULTI-RELAY BOX
aaa

22-4_Relay and Control Unit Locations_Dashboard
22-4
Dashboard

1. MAIN RELAY
[Wire colours: YEL/BLK, WHT/BLK,
WHT/BLK and RED/YEL]
aaa

22-5_Wire Harness and Ground Locations_Engine Compartment
22-5
Wire Harness and Ground Locations
Engine Compartment

1. ENGINE WIRE HARNESS
aaa

22-6_Fuse/Relay Boxes_Connector to Fuse/Relay Box Index
22-6
Fuse/Relay Boxes
Connector to Fuse/Relay Box Index
Under-hood Fuse/Relay Box

Socket Ref Terminal Connects to
A 10 2 Engine compartment wire harness
A/C compressor clutch relay 2 4
B 11 12 Engine compartment wire harness
Blower motor relay 5 4
C 7 7 Engine compartment wire harness
Condenser fan relay 3 4
D 8 14 Engine compartment wire harness
E 9 5 Engine compartment wire harness
F 13 - Not used
G 12 - Not used
Headlight relay 1 6 4
Horn relay 1 4
Rear window defogger relay 4 4
T1 16 Battery positive cable (Engine wire harness)
T101 15 Engine wire harness
aaa

22-7_Fuse/Relay Boxes_Connector to Fuse/Relay Box Index (cont'd)
22-7
Fuse/Relay Boxes
Connector to Fuse/Relay Box Index (cont'd)
Under-hood Multi-relay Box

Engine glow relay 1 4
Fan control relay 3 4
Radiator fan relay 5 4
Water heater relay 1 2 4
aaa

22-8_Power Distribution_Fuse to Component Index
22-8
Power Distribution
Fuse to Component Index

Fuse Amps Wire Colour Component(s) or Circuit(s) Protected
Number
1 30A BLU/YEL Condenser fan motor
2 15A WHT/GRN Dash lights, Front parking lights, Multiplex control unit, License plate lights,
Taillights, Taillight relay
3 7.5A WHT/BLU Ceiling light, Spotlights, Cargo light
4 10A BLU/BLK A/C compressor clutch
5 15A WHT/BLK Hazard warning light, Security control unit, Turn signal/hazard relay
6 20A WHT/BLK Main relay, ECM, Engine glow relay, Water heater relay 1, Water heater relay 2
7 15A WHT/GRN ABS modulator-control unit, Brake lights, Multiplex control unit, Security horn relay,
ECM, Horn
8 20A WHT/GRN ABS modulator-control unit
9 10A WHT/RED Audio unit, Data link connector, Gauge assembly, Multiplex control unit, Immobiliser
receiver unit, Keyless receiver unit, Security control unit
10 40A WHT/RED ABS modulator-control unit
11 30A BLK/YEL Rear window defogger, Noise condenser
12 40A BLU/WHT Blower motor
13 40A WHT/BLK Power window motors, Sunroof motor
14 40A WHT/RED No. 3, 5, 15 and 16 fuses (in the under-dash fuse/relay box)
15 15A RED/YEL High beam indicator light, Left headlight
16 20A WHT Multiplex control unit
17 15A RED Right headlight
18 60A WHT/BLU EPS control unit
19 100A - Battery, Power distribution
20 50A WHT Ignition switch (BAT)
: Spare fuse
aaa

22-9_Power Distribution_Fuse to component Index (cont'd)
22-9
Power Distribution
Fuse to component Index (cont'd)
Under-hood Sub Fuse Box

Number
1 - - Not used
2 70A WHT/BLK Water heater 1
3 60A WHT Glow plugs
4 30A WHT/BLU Water heater 2
5 30A RED Radiator fan motor
6 - - Not used
aaa

22-10_Power Distribution_Fuse to Component Index (cont'd)
22-10
Power Distribution
Fuse to Component Index (cont'd)
Under-dash Fuse/Relay Box

Number
1 - - Not used
2 - - Not used
3 - - Not used
4 - - Not used
5 7.5A Fuse/relay box Multiplex control unit
socket
6 7.5A YEL/GRN Headlight adjuster switch, Headlight adjuster unit, Power window master switch,
Sunroof open relay, Sunroof close relay, Power window relay
7 20A GRN Sunroof motor
8 7.5A Fuse/relay box Optional connector V, Multiplex control unit
socket
YEL/RED Audio unit
9 10A GRN Rear wiper motor, Rear washer motor
socket
YEL Back-up lights, EPS control unit, Gauge assembly, Keyless receiver unit, Security
control unit, Immobiliser control unit
11 7.5A BLK/ORN ABS modulator-control unit
12 - - Not used
13 10A PNK SRS unit
14 10A Fuse/relay box Optional connector V
socket
BLK/YEL Fan control relay, Blower motor relay, Condenser fan relay, Climate control unit
(with auto A/C), Heater control panel (without auto A/C), Power mirror actuator,
Power mirror defogger, Radiator fan relay, Rear window defogger relay,
Recirculation control motor, Seat heater main relay
15 30A RED/YEL Headlight washer control unit
16 20A RED/BLK Driver's seat heater, Passenger's seat heater
17 15A BLK/YEL Inertia switch, SRS unit
18 15A YEL/GRN Cigarette lighter
19 7.5A YEL/BLK Turn signal/hazard relay
20 30A Fuse/relay box Multiplex control unit
socket
GRN/BLK Windshield wiper motor, Windshield washer motor
21 - - Not used
22 20A GRN/BLK Front passenger's power window motor
23 20A GRN/WHT Driver's power window motor
24 20A YEL/RED Left rear power window motor
25 20A YEL/BLU Right rear power window motor
aaa

22-11_Power Distribution_Fuse to Component index (cont'd)
22-11
Power Distribution
Fuse to Component index (cont'd)
IGP Fuser
Number
- 7.5A LT GRN ECM
*: Not used
aaa

22-12_Power Distribution_Circuit Identification
22-12
Power Distribution
Circuit Identification
To go to the pages referenced in the above diagram, click on the following:

22-16 22-17 22-14
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22-13_Power Distribution_Circuit Identification (cont'd)
22-13
Power Distribution
Circuit Identification (cont'd)

22-14 22-16
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22-14
Power Distribution

22-15 22-16 22-13
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22-15
Power Distribution
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22-16
Power Distribution
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22-17
Power Distribution
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22-18
Power Distribution
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22-19_Ground Distribution_Circuit Identification
22-19
Ground Distribution
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22-20
Ground Distribution
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22-21_Ground Distribution_Circuit Identification (cont'd)
22-21
Ground Distribution
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22-22
Ground Distribution
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22-23
Ground Distribution
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22-24
Ground Distribution
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22-25
Ground Distribution
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22-26
Ground Distribution
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22-27
Ground Distribution
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22-28
Ground Distribution
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22-29_Gauges_Component Location Index
22-29
Gauges
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22-30_Gauges_Circuit Diagram
22-30
Gauges
Circuit Diagram
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22-31_Gauges_Circuit Diagram (cont'd)
22-31
Gauges
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22-32
Gauges
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22-33
Gauges
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22-34
Gauges
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22-35_Immobiliser System_Circuit Diagram
22-35
Immobiliser System
Circuit Diagram
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22-36_Immobiliser System_Troubleshooting
22-36
Immobiliser System
Troubleshooting
Before troubleshooting the Immobiliser system, 1. 5. Disconnect the 7P connector from the
troubleshoot any ECM with Diagnostic Trouble Codes immobiliser control unit-receiver.
(DTCs) (see section 11) and make sure the ECM has no
malfunction.
Note these items before troubleshooting:
Due to the action of the immobiliser system, the
engine takes slightly more time to start than on
a vehicle without an Immobiliser system.
When the system is normal and the proper key
is inserted, the indicator light comes on for 2
seconds, then it will go off.
If the indicator starts to blink after 2 seconds, or
if the engine does not start, repeat the starting
procedure. 2. 6. Check for voltage between the immobiliser
If the engine still does not start, continue with control unit-receiver 7P connector No. 7
this procedure. terminal and body ground.
1. 1. Turn the ignition switch ON (II) with proper key.
2. 2. Check to see if the Immobiliser indicator light YES – Go to step 7.
comes on. NO – Repair open in the WHT/RED wire.
Does the indicator light blink? 3. 7. Check for voltage between the immobiliser
YES – Go to step 3. control unit-receiver 7P connector No. 6
NO – Check for these problems: terminal and body ground.
Blown No. 9 (10A) fuse in the under-hood
fuse/relay box. YES – Go to step 8.
An open in the wire between the gauge NO – Check for these problems:
assembly and the immobiliser control unit- Blown No. 10 (7.5A) fuse in the under-dash
receiver. fuse/relay box.
A faulty immobiliser indicator light. An open in the YEL wire.
An open in the wire between the gauge
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assembly and the under-hood fuse/relay
box.
3. 3. Remove the dashboard lower cover.
4. 4. Remove the steering column lower covers (see
section 17).

22-37_Immobiliser System_Troubleshooting (cont'd)
Immobiliser
22-37 Control Unit-Receiver
Immobiliser System Replacement
Troubleshooting (cont'd)
1. 8. Check for continuity between the immobiliser 1. 1. Remove the dashboard lower cover.
control unit-receiver 7P connector No. 1 2. 2. Remove the steering column covers (see
terminal and body ground. section 17).
Is there continuity? 3. 3. Disconnect the connectors (A) from the
YES – Go to step 9. immobiliser control unit-receiver (B).
NO – Repair open in the BLK wire.
2. 9. Check for voltage between the immobiliser
control-unit receiver 7P connector No. 4
terminal and body ground with the parking
brake lever pulled, then released.
Is there 1 V or less, then 5 V or more?
NO – Check for these problems:
Faulty parking brake switch or a poor body 4. 4. Remove the two screws and the immobiliser
ground of the parking brake switch. control unit-receiver from the ignition key
Repair open in the GRN/ORN wire. cylinder (C).
5. 5. Install the immobiliser control unit-receiver in
3. 10. Check for continuity between the immobiliser
the reverse order of removal.
control unit-receiver 7P connector No. 2
6. 6. After replacement, check the immobiliser
terminal and ECM terminal 11.
system.
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NO – Repair open in the RED/BLU wire.
4. 11. Check for continuity between the immobiliser
control unit-receiver 7P connector No. 2
terminal and the multiplex control unit (under-
dash fuse/relay box connector terminal C3).
YES – Replace the immobiliser control unit-receiver.
After replacing the immobiliser control unit-receiver,
rewrite the unit with a Honda PGM-Tester.
NO – Repair open in the RED/BLU wire. If the
harness is OK, check to see if there is any Diagnostic
Trouble Code (DTC) for the multiplex control unit. If it
is, troubleshoot the multiplex control unit (see section
11), then recheck.

22-1_Body Electrical
Body Electrical
Relay and Control Unit Location

Dashboard 22-4
Wire Harnesses and Ground Location

Fuse/Relay Boxes Connector to Fuse/Relay Box Index 22-6
Power Distribution
Fuse to Components Index 22-8
Ground Distribution
Circuit Identification 22-19
Gauges
Immobiliser System
Troubleshooting 22-36
Immobiliser Control Unit-Receiver Replacement 22-37

Diesel engine model has been added; related information is included.
The information which differs from the '01 CIVIC Shop Manual on this CD has been included.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If electrical maintenance required)

This model has an SRS which includes a drivers airbag in the steering wheel hub, a passenger's airbag in the dashboard above
will require special precautions and tools, and should therefore be done by an authorised Honda dealer.
WARNING
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22-2_Relay and Control Unit Locations_Engine Compartment
22-2
Engine Compartment

1. HORN RELAY
2. A/C COMPRESSOR CLUTCH
RELAY
4. REAR WINDOW DEFOGGER
RELAY
5. BLOWER MOTOR RELAY
8. ELD UNIT
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22-3_Relay and Control unit Locations_Engine Compartment (cont'd)
22-3
Relay and Control unit Locations
Engine Compartment (cont'd)

1. ENGINE GLOW RELAY
3. MULTI-RELAY BOX
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22-4_Relay and Control Unit Locations_Dashboard
22-4
Dashboard

1. MAIN RELAY
[Wire colours: YEL/BLK, WHT/BLK,
WHT/BLK and RED/YEL]
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22-5_Wire Harness and Ground Locations_Engine Compartment
22-5
Wire Harness and Ground Locations
Engine Compartment

1. ENGINE WIRE HARNESS
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22-6_Fuse/Relay Boxes_Connector to Fuse/Relay Box Index
22-6
Fuse/Relay Boxes
Connector to Fuse/Relay Box Index

A 10 2 Engine compartment wire harness
A/C compressor clutch relay 2 4
B 11 12 Engine compartment wire harness
Blower motor relay 5 4
C 7 7 Engine compartment wire harness
Condenser fan relay 3 4
D 8 14 Engine compartment wire harness
E 9 5 Engine compartment wire harness
F 13 - Not used
G 12 - Not used
Horn relay 1 4
Rear window defogger relay 4 4
T1 16 Battery positive cable (Engine wire harness)
T101 15 Engine wire harness
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22-7_Fuse/Relay Boxes_Connector to Fuse/Relay Box Index (cont'd)
22-7
Fuse/Relay Boxes
Connector to Fuse/Relay Box Index (cont'd)
Under-hood Multi-relay Box

Engine glow relay 1 4
Fan control relay 3 4
Radiator fan relay 5 4
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22-8_Power Distribution_Fuse to Component Index
22-8
Power Distribution
Fuse to Component Index

Number
1 30A BLU/YEL Condenser fan motor
2 15A WHT/GRN Dash lights, Front parking lights, Multiplex control unit, License plate lights,
Taillights, Taillight relay
3 7.5A WHT/BLU Ceiling light, Spotlights, Cargo light
4 10A BLU/BLK A/C compressor clutch
5 15A WHT/BLK Hazard warning light, Security control unit, Turn signal/hazard relay
6 20A WHT/BLK Main relay, ECM, Engine glow relay, Water heater relay 1, Water heater relay 2
7 15A WHT/GRN ABS modulator-control unit, Brake lights, Multiplex control unit, Security horn relay,
ECM, Horn
8 20A WHT/GRN ABS modulator-control unit
9 10A WHT/RED Audio unit, Data link connector, Gauge assembly, Multiplex control unit, Immobiliser
receiver unit, Keyless receiver unit, Security control unit
10 40A WHT/RED ABS modulator-control unit
11 30A BLK/YEL Rear window defogger, Noise condenser
12 40A BLU/WHT Blower motor
13 40A WHT/BLK Power window motors, Sunroof motor
14 40A WHT/RED No. 3, 5, 15 and 16 fuses (in the under-dash fuse/relay box)
15 15A RED/YEL High beam indicator light, Left headlight
16 20A WHT Multiplex control unit
17 15A RED Right headlight
18 60A WHT/BLU EPS control unit
19 100A - Battery, Power distribution
20 50A WHT Ignition switch (BAT)
: Spare fuse
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22-9_Power Distribution_Fuse to component Index (cont'd)
22-9
Power Distribution
Fuse to component Index (cont'd)
Under-hood Sub Fuse Box

Number
1 - - Not used
2 70A WHT/BLK Water heater 1
3 60A WHT Glow plugs
4 30A WHT/BLU Water heater 2
5 30A RED Radiator fan motor
6 - - Not used
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22-10_Power Distribution_Fuse to Component Index (cont'd)
22-10
Power Distribution
Fuse to Component Index (cont'd)
Under-dash Fuse/Relay Box

Number
1 - - Not used
2 - - Not used
3 - - Not used
4 - - Not used
socket
6 7.5A YEL/GRN Headlight adjuster switch, Headlight adjuster unit, Power window master switch,
Sunroof open relay, Sunroof close relay, Power window relay
7 20A GRN Sunroof motor
8 7.5A Fuse/relay box Optional connector V, Multiplex control unit
socket
YEL/RED Audio unit
9 10A GRN Rear wiper motor, Rear washer motor
socket
YEL Back-up lights, EPS control unit, Gauge assembly, Keyless receiver unit, Security
control unit, Immobiliser control unit
11 7.5A BLK/ORN ABS modulator-control unit
12 - - Not used
13 10A PNK SRS unit
14 10A Fuse/relay box Optional connector V
socket
BLK/YEL Fan control relay, Blower motor relay, Condenser fan relay, Climate control unit
(with auto A/C), Heater control panel (without auto A/C), Power mirror actuator,
Power mirror defogger, Radiator fan relay, Rear window defogger relay,
Recirculation control motor, Seat heater main relay
15 30A RED/YEL Headlight washer control unit
16 20A RED/BLK Driver's seat heater, Passenger's seat heater
17 15A BLK/YEL Inertia switch, SRS unit
18 15A YEL/GRN Cigarette lighter
19 7.5A YEL/BLK Turn signal/hazard relay
20 30A Fuse/relay box Multiplex control unit
socket
GRN/BLK Windshield wiper motor, Windshield washer motor
21 - - Not used
22 20A GRN/BLK Front passenger's power window motor
23 20A GRN/WHT Driver's power window motor
24 20A YEL/RED Left rear power window motor
25 20A YEL/BLU Right rear power window motor
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22-11_Power Distribution_Fuse to Component index (cont'd)
22-11
Power Distribution
Fuse to Component index (cont'd)
IGP Fuser
Number
- 7.5A LT GRN ECM
*: Not used
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22-12_Power Distribution_Circuit Identification
22-12
Power Distribution

22-16 22-17 22-14
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22-13
Power Distribution

22-14 22-16
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22-14
Power Distribution

22-15 22-16 22-13
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22-15
Power Distribution
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22-16
Power Distribution
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22-17
Power Distribution
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22-18
Power Distribution
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22-19
Ground Distribution
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22-20
Ground Distribution
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SERVICE

This supplement contains information for the 2002 General Info

Instructions – how to service this vehicle

notice. No part of this publication may be reproduced, or

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SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

A Few Words About Safety

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from the battery and all fuel-related parts.

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ITEM DESCRIPTION 2001 2001 2001 2001 2002 REFERENCE

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3-door TYPE-R model added O -

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Chassis and Engine Numbers 1-2

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Model/Applicable Area Code/VIN/Engine Number/Transmission Number List

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1. Vehicle Identification Number (VIN)

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ECM Engine Control Module LSD Limited Slip Differential

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MAP Manifold Absolute Pressure STD Standard

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O/D Over Drive

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Standards and Service Limits

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Item Measurement Qualification Standard or New Service Limit

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Item Measurement Qualification Standard or New Service Limit

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Item Measurement Qualification Standard or New Service Limit

Fuel and Emissions

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Item Measurement Qualification Standard or Service Limit

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Item Measurement Qualification Standard or New Service

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Item Measurement Qualification Standard or New Service Limit

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Item Measurement Qualification Specification

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Item Measurement Qualification Specification

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Item Measurement Qualification Specification

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*1: With Roof Antenna

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Lubricants and Fluids 3-2

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2 Transmission Genuine Honda Manual Transmission Fluid (MTF) *1

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NOTES SECTION and PAGE

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NOTES SECTION and PAGE

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