Civic Turbo Diesel

0-1_Introduction_How to Use This Manual
Introduction
How to Use This Manual
This supplement contains information for the 2002 HONDA CIVIC Turbo General Info
Diesel. Refer to the following shop manuals for service procedures and data Specifications
not included in this supplement.
Maintenance
Description Code. No. Engine Electrical
HONDA CIVIC MAINTENANCE, REPAIR and
Engine
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
Click on the chapter you want from the opening screen, this is followed by a *Body Electrical
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 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
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0-1_Introduction_How to Use This Manual
All Rights Reserved

HONDA MOTOR CO.,LTD.
Service Publication Office
As sections with *include SRS components;
special precautions are required when servicing.

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 manual is intended Some of the most important general service safety precautions are given
for use by qualified, professional technicians. Attempting service or below. However, we cannot warn you of every conceivable hazard that
repairs without the proper training, tools and equipment could cause injury can arise in performing service and repair procedures. Only you can
to you or others. It could also damage the vehicle or create an unsafe decide whether or not you should perform a given task.
condition. IMPORTANT SAFETY PRECAUTIONS
This manual describes the proper methods and procedures for performing ● Make sure you have a clear understanding of all basic shop safety
service, maintenance and repairs. Some procedures require the use of practices and that you are wearing appropriate clothing and using
specially designed tools and dedicated equipment. Any person who safety equipment. When performing any service task, be especially
intends to use a replacement part, service procedure or a tool that is not careful of the following:
recommended by Honda, must determine the risks to their personal ● Read all of the instructions before you begin and make sure you
safety and the safe operation of the vehicle. have the tools, the replacement or repair parts and the skills required
If you need to replace a part, use genuine Honda parts with the correct to perform the tasks safely and completely.
part number or an equivalent part. We strongly recommend that you do ● Protect your eyes by using proper safety glasses, goggles or face
not use replacement parts of inferior quality. shields any time you hammer, drill, grind, or work around pressurised
FOR YOUR CUSTOMER'S SAFETY air or liquids and springs or other stored-energy components. If there
is any doubt, put on eye protection.
Proper service and maintenance are essential to the customer's safety ● Use other protective wear when necessary, for example gloves or
and the reliability of the vehicle. Any error or oversight while servicing a safety shoes. Handling hot or sharp parts can cause severe burns or
vehicle can result in faulty operation, damage to the vehicle, or injury to cuts. Before you grab something that looks like it can hurt you, stop
others. and put on gloves.
● Protect yourself and others whenever you have the vehicle up in the
WARNING air. Any time you lift the vehicle, either with a hoist or a jack, make
Improper service or repairs can create an sure that it is always securely supported. Use jack stands.
unsafe condition that can cause your ● Make sure the engine is off before you begin any servicing
customer or others to be seriously hurt or procedures, unless the instruction tells you to do otherwise. This will
killed. help eliminate several potential hazards:
Follow the procedures and precautions in ● Carbon monoxide poisoning from engine exhaust. Be sure there is
this manual and other service materials adequate ventilation whenever you run the engine.
carefully. ● Burns from hot parts or coolant. Let the engine and exhaust system
cool before working in those areas.

● Injury from moving parts. If the instruction tells you to run the engine,
FOR YOUR SAFETY
be sure your hands, fingers and clothing are out of the way.
Because this manual is intended for the professional service technician,
Gasoline vapours and hydrogen gases from batteries are explosive.
we do not provide warnings about many basic shop safety practices (e.g.,
●
To reduce the possibility of a fire or explosion, be careful when

Hot parts - wear gloves). If you have not received shop safety training or
working around gasoline or batteries.
do not feel confident about your knowledge of safe servicing practices, we
● Use only a non-flammable solvent, not gasoline to clean parts.
recommend that you do not attempt to perform the procedures described
● Never drain or store gasoline in an open container.
in this manual.
● Keep all cigarettes, sparks and flames away from the battery and all
fuel-related parts.
WARNING
Failure to properly follow instructions and
precautions can cause you to be seriously
hurt or killed.
Follow the procedures and precautions in
this manual carefully.
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 model added O -
● K20A2 engine added
Engine Electrical D17A8, D17A9 engines added O -
D14Z6, D16V1 and D16V3 engines added to O -
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 added to O -
suit 5-door LHD model
Diesel engine added O 5-10
Fuel and Emissions Coupe model added O -
KG, KS, KY models added O -
Diesel engine added O 11
Clutch MD4 manual transmission added O 12
Manual X2M5 6-speed manual transmission added O -
Transmission
MD4 manual transmission added O 13
Automatic Shift schedule added O -
Transmission
5-door LHD model added, equipped with 7- O -
position transmission
Shift schedule and stall speed changed O O -
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 changed O 17
Suspension 3-door TYPE-R model added O -
Front damper changed O 18
Brake 3-door TYPE-R model added O -
Conventional brake components modified O 19
Body Coupe model added O -
3-door TYPE-R model added O -
Diesel model emblem added O 20
Heating, Ventilation System for diesel model added O 21
and Air Conditioning
Body Electrical Coupe model added O -

0-4_Introduction_Outline of Model Changes

3-door TYPE-R model added O -
Diesel model added O 22
Restraints Coupe model added O -

1-1_General Information
General Information
Chassis and Engine Numbers 1-2

Identification Number Locations 1-4
Abbreviations 1-5
1-2_General Information_Chassis and Engine Numbers
General Information 1-2

Chassis and Engine Numbers
1-3_General Information_Chassis and Engine Numbers (cont'd)

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-
1-4_General Information_Identification Number Locations (cont'd)

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
1-5_General Information_Abbreviations

Abbreviations
List of automotive abbreviations which may be used in shop manual. EPR Evaporator Pressure Regulator
ABS Anti-lock Brake System EPS Electrical Power Steering
A/C Air Conditioning, Air Conditioner EVAP Evaporative
ACL Air Cleaner EX Exhaust
A/F Air Fuel Ratio
ALR Automatic Locking Retractor F Front
ALT Alternator FIA Fuel Injection Air
AMP Ampere(s) FL Front Left
ANT Antenna FP Fuel Pump
API American Petroleum Institute FR Front Right
APPROX. Approximately FSR Fail Safe Relay
ASSY Assembly FWD Front Wheel Drive
A/T Automatic Transmission
ATDC After Top Dead Centre GAL Gallon
ATF Automatic Transmission Fluid GND Ground
ATT Attachment GPS Global Positioning System
ATTS Active Torque Transfer System
AUTO Automatic H/B Hatchback
AUX Auxiliary HC Hydrocarbons
HID High Intensity Discharge
BARO Barometric HO2S Heated Oxygen Sensor
BAT Battery
BDC Bottom Dead Centre IAB Intake Air Bypass
BTDC Before Top Dead Centre IAC Idle Air Control
IACV Idle Air Control Valve
CARB Carburettor IAR Intake Air Resonator
CAT Catalytic Converter IAT Intake Air Temperature
or CATA
ICM Ignition Control Module
CHG Charge ID Identification
CKF Crankshaft Speed Fluctuation ID or I.D. Inside Diameter
CKP Crankshaft Position IG or IGN Ignition
CO Carbon Monoxide IMA Idle Mixture Adjustment
COMP Complete Integrated Motor Assisted
CPB Clutch Pressure Back up IMMOBI. Immobiliser
CPC Clutch Pressure Control IN Intake
CPU Central Processing Unit INJ Injection
CVT Continuously Variable Transmission INT Intermittent
CYL Cylinder
CYP Cylinder Position KS Knock Sensor
DI Distributor Ignition L Left

DIFF Differential L/C Lock-up Clutch
DLC Data Link Connector LCD Liquid Crystal Display
DOHC Double Overhead Camshaft LED Light Emitting Diode

1-5_General Information_Abbreviations
DPI Dual Point Injection LEV Low Emission Vehicle

DTC Diagnostic Trouble Code LF Left Front
LH Left Handle
EBD Electronic Brake Distribution LHD Left Handle Drive
ECM Engine Control Module LR Left Rear
ECT Engine Coolant Temperature LSD Limited Slip Differential
EGR Exhaust Gas Recirculation L-4 In-line Four Cylinder (engine)
ELD Electrical Load Detector

1-6_General Information_Abbreviations (cont'd)

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 Electronic Control
Proportioning Control Valve VVIS Variable Volume Intake System
PDU Power Drive Unit V-6 V-type Six Cylinder (engine)
PGM-FI Programmed-fuel Injection
PGM-IG Programmed Ignition W With
PH Pressure High W/O Without
PL Pilot Light or Pressure Low WOT Wide Open Throttle
PMR Pump Motor Relay
P/N Part Number 2WD Two Wheel Drive
PRI Primary 4WD Four Wheel Drive
P/S Power Steering 2WS Two Wheel Steering
PSF Power Steering Fluid 4WS Four Wheel Steering
PSP Power Steering Pressure 4AT 4-speed Automatic Transmission
PSW Pressure Switch 5AT 5-speed Automatic Transmission
5MT 5-speed Manual Transmission
Qty Quantity 6MT 6-speed Manual Transmission
Park
R Right Reverse
REF Reference Neutral
RGB Red, Green, Black
Drive (1st through 4th gear)
RH Right Handle
Drive (1st through 3rd gear)
RHD Right Handle Drive
Second
RL Rear Left

1-6_General Information_Abbreviations (cont'd)
RON Research Octane Number First

RR Rear Right Drive
Second
SAE Society of Automotive Engineers Low
SCS Service Check Signal
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

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
2-2_Standards and Service Limits_Engine Electrical
Standards and Service Limits 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/cm2, 406 psi) 2.5 MPa (25.5 kgf/cm2, 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 in.) 0.11 mm (0.004 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 in.) 5.945 mm (0.2341 in.)
Exhaust 5.954 – 5.972 mm (0.2344 – 0.2351 in.) 5.940 mm (0.2339 in.)
Stem-to-guide clearance Intake 0.023 – 0.056 mm (0.0009 – 0.0022 in.) 0.080 mm (0.0031 in.)
Exhaust 0.028 – 0.061 mm (0.0011 – 0.0024 in.) 0.095 mm (0.0037 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.) –
2-3_Standards and Service Limits_Engine Block

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.) from top of Piston grade: A 78.930 – 78.939 mm (3.1075 – 3.1078 in.) –
piston
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 in.) 26.985 mm (1.0624 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 in.) 51.912 mm (2.0438 in.)
Size mark: 51.928 – 51.938 mm (2.0444 – 2.0448 in.) 51.922 mm (2.0442 in.)
Rod journal diameter 45.930 – 45.945 mm (1.8083 – 1.8089 in.) 45.926 mm (1.8081 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 clearance 0.030 – 0.058 mm (0.0012 – 0.0023 in.) 0.08 mm (0.003 in.)
Rod bearing clearance 0.025 – 0.058 mm (0.0010 – 0.0023 in.) 0.1 mm (0.004 in.)
2-4_Standards and Service Limits_Engine Lubrication

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 in.) 0.15 mm (0.006 in.)
Oil pressure with oil temperature at 80°C (176°F) At idle 127 kPa (1.3 kgf/cm2, 18 psi) –
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 more 0.22 mm (0.009 in.)
Pressure plate Height of diaphragm spring – 1.0 mm (0.039 in.) or less
2-5_Standards and Service Limits_Manual Transmission and Differential

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 input shaft – 0.15 mm (0.0059 in.) or less
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 and shaft – 0.15 mm (0.0059 in.) or less
Synchronisers Clearance between blocker ring and inserts 1st/2nd – 3.9 mm (0.154 in.) or less
3rd/4th, 5th – 3.7 mm (0.146 in.) or less
Clearance between blocker ring and gear 3rd/4th, 5th 1.5 mm (0.059 in.) 0.8 mm (0.031 in.) or more
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 cross pin – 0.2 mm (0.008 in.) or less
Clearance between differential case and side – 0.15 mm (0.0059 in.) or less
gear (A – B)
Diameter in differential case for axle shaft – 30.10 mm (1.1850 in.) or less
Backlash between side gear and pinion gear – 0.3 mm (0.0118 in.) or less
2-6_Standards and Service Limits_Steering

Steering

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 position 5° Max.
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.)
2-7_Standards and Service Limits_Brakes

Brakes

Parking brake lever Distance travelled when pulled with 196 N 3-door 7 – 8 clicks
(20 kgf, 44 lbs) of force
5-door 7 – 8 clicks
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 in.) 21.0 mm (0.83 in.)
Rear 8.9 – 9.1 mm (0.350 – 0.358 in.) 9.0 mm (0.35 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 in.) 1.6 mm (0.06 in.)
9.0 – 10.0 mm (0.35 – 0.39 in.) 1.6 mm (0.06 in.)
Thickness Rear 9.5 – 10.5 mm (0.37 – 0.41 in.) 1.6 mm (0.06 in.)
Brake booster Vehicle with ABS Characteristics at 196 N (20 kgf, 44 lbf) Vacuum N (kgf, lbf) kPa (kgf/cm2, psi)
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.)
2-8_Design Specifications
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
2-9_Design Specifications_(cont'd)
Design Specifications 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 cm2x 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)
2-10_Design Specifications_(cont'd)
Design Specifications 2-
(cont'd)
10
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
file:///C|/Users/Navindra/Desktop/Civic_2001-2005_english_/...da%20Civic%202001-2005(english)/EngCivic/Civ41Html/2-10.htm7/6/2011 8:44:47 PM
5-11_Engine Assembly_Engine Installation (cont'd)
Engine Assembly 5-
Engine Installation (cont'd)
11
6. Lower the hoist. 10. Remove the chain hoist from the engine.
7. Install the upper bracket (A), then tighten the bolt/nut in the numbered 11. Raise the hoist to full height.
sequence shown. 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.
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).
14. Connect the stabiliser links, refer to the '01 Civic Shop Manual on this
CD (see page 18-18).
15. Install the exhaust pipe A/three way catalytic converter (TWC)
assembly (A); use new gaskets (B) and new self locking nuts (C).
8. Install the ground cable (B).

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

18. Install the splash shield.
21. Connect the accelerator pedal sensor connector (A), then install the
harness clamp (B).
19. Lower the hoist.
Engine Assembly 5-
13
22. Install the fuel feed hose (A) and fuel return hose (B). 24. Install the upper radiator hose (A) and lower radiator hose (B)
25. Install the water inlet hose (A), water outlet hose (B), expansion tank
hose (C) and water hose (D).
23. Connect the harness connectors (A) and install the harness clamp
(B).
Engine Assembly 5-
14
26. Install the A/C compressor bracket. 28. Install the intercooler inlet hose (A) and intercooler outlet hose (B)
29. Install the expansion tank hoses (A) and brake booster vacuum hose
(B).
27. Install the A/C compressor and harness clamp (A), then connect the
compressor clutch connector (B).
Engine Assembly 5-
15
30. Install the shift cables using the plastic washers (A), washers (B), 32. Install the battery base (A), then install the harness clamps (B) and
new cotter pins (C) and change wire plate (D). ground cable (C).
31. Install the clutch slave cylinder (A) and clutch line bracket mounting
bolt (B).
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).
Engine Assembly 5-
16
34. Install the battery cables (A) to the under-hood fuse/relay box, then
install the battery cable (B) to the battery positive cable clamp.
35. Clean the battery posts and cable terminals with sandpaper, then
assemble them and apply grease to prevent corrosion.
36. Check that the transmission shifts into gear smoothly.
37. Refill the engine with engine oil (see page 8-5).
38. Refill the transmission with fluid (see page 13-4).
39. Refill the radiator with engine coolant and bleed air from the cooling
system with the heater valve open (see page 10-6).
40. Inspect the idle speed (see page 11-154).
41. Check the wheel alignment, refer to the '01 Civic Shop Manual on this
CD (see page 18-4).
6-1_Engine Mechanical
Engine Mechanical
Cylinder Head
Special Tools 6-2
Component Location Index 6-3
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
Outline of Model Change

The 4EE2 engine has been added.
6-2_Cylinder Head_Special Tools
Cylinder Head 6-2

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
6-3_Cylinder Head_Component Location Index
Cylinder Head 6-3

Component Location Index
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
Inspection, page 6-8
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
6-4_Cylinder Head_Engine Compression Inspection
Cylinder Head 6-4 Valve Clearance Adjustment
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 5-8840-9047-0
1. Start the engine and allow it to run for several minutes to warm it up. NOTE: The valve clearances are checked on a cold engine condition.
2. Stop the engine and remove the connector on the injectors. Inspection
3. Remove all of the glow plugs from the engine.
4. Set a compression gauge to the No. 1 cylinder glow plug hole (5-8840- 1. Remove the drive belt (see page 4-20).
9048-0 Adapter for compression gauge). 2. Disconnect the connectors (A), (B) from top of the injector.
3. Remove the leak off hose (C) from the injectors.

5. Turn the engine over with the starter motor and take the compression 4. Remove the injection pipes (A).
gauge reading. ● Use the vinyl tape (or something similar) to seal the fuel delivery
Measure the compression pressure of all cylinders. 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)
6-6_Cylinder Head_Valve Clearance Adjustment (cont'd)
Cylinder Head 6-6 Timing Belt Inspection
Valve Clearance Adjustment (cont'd)
4. Coat new shim with engine oil and insert tappet with identification mark 1. Remove the drive belt (see page 4-20).
facing downwards. 2. Remove the earth cable bolt and upper bracket (see step 2 on page 6-
5. Remove the special tool. 7).
6. Turn the crankshaft 180° in direction of engine rotation-check and 3. Remove the side engine mount bracket (see step 3 on page 6-7).
adjust valve pair (A) and (B).
4. Remove the harness clamp and upper cover (see step 4 on page 6-7).
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.
7. Turn the crankshaft 180° in direction of engine rotation-check and

adjust valve pair (C) and (D).
8. Turn the crankshaft 180° in direction of engine rotation-check and
adjust valve pair (E) and (F).
9. Valve clearance must be checked again for all adjusted valves.
6-20_Cylinder Head_Camshaft Inspection (cont'd)
Cylinder Head 6-
Camshaft Inspection (cont'd)
20
5. Measure the run-out with a dial indicator. If the measured value 8. Remove the bracket.
exceeds the specified limit, the camshaft must be replaced. 9. Compare the width of the plastigage attached to either the camshaft or
Camshaft run-out (TIR): the bracket against the scale printed on the plastigage container.
Standard: If clearance between cam journal and bracket exceed the limit, the
0.03 mm (0.001 in.) camshaft and/or camshaft carrier assembly must be replaced.
Limit: Clearance between cam journal and bracket:
0.05 mm (0.002 in.) Standard:
0.04 – 0.082 mm (0.002 – 0.003 in.)
Limit:
0.11 mm (0.004 in.)
6. Clean the camshaft journal and bracket.

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)
6-28_Cylinder Head_Camshaft and Camshaft Carrier Installation
Cylinder Head 6-
Camshaft and Camshaft Carrier Installation
28
Exploded View
1. CAMSHAFT OIL SEAL
2. CAMSHAFT (IN)
3. BRACKET ; CAMSHAFT
4. CAMSHAFT (EX)
5. CAMSHAFT CARRIER
6-29_Cylinder Head_Camshaft and Camshaft Carrier Installation (cont'd)
Cylinder Head 6-
(cont'd)
29
Special Tools Required 4. Clean sealing surface and remove the residual sealant.
● Lever camshaft sub gear 5-8840-9049-0 5. Check camshaft and bearing bracket for wear and replace if
● Installer camshaft oil seal 5-8840-9051-0 necessary.
Camshaft carrier installation 6. Apply engine oil to camshaft journals.
7. Install camshafts in camshaft carrier.
1. Install the camshaft carrier with new gasket. 8. When installing the camshafts, it must be ensured that the mark (A) on
2. Tighten bolts with tightening order as in illustration. the exhaust camshaft gear align between both marks (B) on the intake
Torque: camshaft gear and that the marks are about level with the upper edge
22 Nm (2.2 kgf/m, 16 lbf/ft) of the camshaft carrier.
9. Apply a bead of surface liquid gasket to sealing surfaces (A) of 1st

camshaft bearing bracket.
Camshaft Installation
3. Before reassembling the exhaust camshaft, the 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).
6-30_Cylinder Head_Camshaft and Camshaft Carrier Installation (cont'd)
Cylinder Head 6-
(cont'd)
30
Camshaft Bracket Installation
10. Install camshaft bearing brackets 1 - 4 on camshaft carrier - note
identification marks - arrows on bearing brackets point towards engine
front side.
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

12. Install camshaft oil seal using special tool (5-8840-9051-0).
6-31_Cylinder Head_Cylinder Head Cover Installation
Cylinder Head 6-
Cylinder Head Cover Installation
31
1. Clean sealing surfaces and remove liquid gasket residue. 3. Tighten cylinder head cover with tightening order in the illustration.
2. Apply liquid gasket (A) and (B) to sealing surfaces on the camshaft Tightening torque:
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.
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

7-2_Engine Block_Special Tools
Engine Block 7-2

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
7-3_Engine Block_Component Location Index
Engine Block 7-3

1. CRANKSHAFT PULLEY
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
7-4_Engine Block_Flywheel Removal and Installation
Engine Block 7-4 Crankshaft End Play Inspection
Flywheel Removal and Installation
Special Tools Required 1. Set the dial indicator as shown in the illustration and measure the
Stopper 5-8840-7007-0 crankshaft thrust clearance.
1. Lock the flywheel with the special tool and remove the fastening bolts.
2. If the thrust clearance exceeds the specified limit, replace the thrust
bearing as a set.
Crankshaft end play:
Standard (New):
2. Apply Locktite to the top thread of the new fastening bolts. 0.05 – 0.15 mm (0.002 – 0.006 in.)
Service Limit:
0.2 mm (0.008 in.)
3. Install the flywheel and the fastening bolts then lock the flywheel with
the stopper.
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
Engine Block 7-5

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

Crankshaft Main Bearing Replacement (cont'd)
Crankshaft Bearing Grade Selection

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
Grade Diameter Grade Diameter Bearing Grade (Reference)
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. 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. Check to see if the bearing has enough tension, so that a good finger pressure is needed to fit the bearing into position.
Engine Block 7-7

Main Bearing Clearance Inspection (with 3. If the clearance between the measured bearing inside diameter and
micrometer) the crankshaft journal exceeds the specified limit, the bearing and/or
1. Measure the crankshaft journal diameter. the crankshaft must be replaced.
Crankshaft journal and bearing clearance:
1. Use a micrometer to measure the crankshaft journal diameter
Standard (New):
across points (''A – A'') and (''B – B'').
2. Use the micrometer to measure the crankshaft journal diameter at 0.030 – 0.058 mm
the two points (I and II). (0.0012 – 0.0023 in.)
Crankshaft journal diameter: Service limit:
Standard (New): 0.08 mm (0.003 in.)
Crankpin and Bearing Clearance Inspection
Size mark
(with plastigage)
51.918 – 51.928 mm
1. Clean the crankshaft, the connecting rod, the bearing cap and the
(2.0440 – 2.0444 in.) bearings.
Size mark 2. Install the bearing to the connecting rod and the bearing cap.
51.928 – 51.938 mm NOTE: Do not allow the crankshaft to move when installing the bearing
cap.
(2.0444 – 2.0448 in.)
Service limit: 3. Prevent the connecting rod from moving.
4. Attach the Plastigage to the crankpin. Apply engine oil to the
Size mark Plastigage to keep it from falling.
51.912 mm (2.0438 in.) 5. Install the bearing cap and tighten it to the two steps specified torque.
NOTE: Do not allow the connecting rod to move when installing and
Size mark
tightening the bearing cap.
51.922 mm (2.0442 in.)
1st step torque:
25 Nm (2.5 kgf/m, 18 lbf/ft)
2nd step:
100°
6. Remove the bearing cap.
7. Compare the width of the Plastigage attached to either the crankshaft
or the bearing against the scale printed on the Plastigage container.
Crankpin and bearing clearance:
Standard (New):
0.025 – 0.058 mm
(0.0010 – 0.0023 in.)
2. Measure the main bearing inside diameter. Service limit:
0.1 mm (0.004 in.)
Engine Block 7-8 Crankshaft and Piston Removal
Crankpin and Bearing Clearance Inspection NOTE: Measure crankshaft thrust play, before removing crankshaft
(with micrometer) bearing cap.
1. Using a micrometer, measure the crankpin diameter. 1. Remove the crankshaft pulley and the crankshaft timing pulley.
Crankpin diameter: 2. Remove the oil pan upper and lower.
Standard (New): 3. Remove the oil pump.
45.930 – 45.945 mm 4. Remove the oil strainer and the baffle plate.
5. Remove connecting rod bearing cap nut (A) from connecting rod.
(1.8083 – 1.8089 in.)
Service limit:
45.926 mm (1.8081 in.)
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. Measure the crankpin bearing inside diameter.
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)
Engine Block 7-9

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

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.
7-10_Engine Block_Crankshaft Inspection
Engine Block 7-
Crankshaft Inspection
10
NOTE: Tufftriding Inspection
● Inspect the surface of the crankshaft journals and crankpins for NOTE: To increase crankshaft strength, tufftriding (Nitriding Treatment)
excessive wear and damage. has been applied. Because of this, it is not possible to regrind the
● Inspect the oil seal fitting surfaces for excessive wear and damage. crankshaft surfaces.
● Inspect the oil ports for obstructions.
4. Use an organic cleaner to thoroughly clean the crankshaft. There must
Run-out be no traces of oil on the surfaces to be inspected.
1. Set a dial indicator to the centre of the crankshaft journal. 5. Prepare a 5 - 10 % solution of ammonium cuprous chloride (dissolved
in distilled water).
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. 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.
Crankshaft run-out:
Standard (New): 7. Wait for thirty to forty seconds. If there is no discoloration after thirty or
0.05 mm or less (0.002 in.) forty seconds, the crankshaft is usable. If discoloration appears (the
Service limit: surface being tested will become the colour of copper), the crankshaft
0.06 mm (0.002 in.) must be replaced.
8. Steam clean the crankshaft surface immediately after completing the
Crankshaft Journal and Crankpin Uneven Wear
test.
3. Use the micrometer to measure the crankshaft journal and the NOTE: The ammonium cuprous chloride solution is highly corrosive.
crankpin uneven wear. Because of this it is imperative that the surfaces being tested be
Crankshaft journal and crankpin uneven wear: cleaned immediately after completing the test.
Standard (New):
0.05 mm (0.002 in.) or less
Service limit:
0.08 mm (0.003 in.)
7-20_Engine Block_Crankshaft Installation (cont'd)
Engine Block 7- Oil Pan Installation
Crankshaft Installation (cont'd)

20
12. Apply a bead (A) of liquid gasket to sealing surfaces of crankshaft Special Tool Required
seal ring retainer (B). Aligner 5-8840-9054-0
1. Clean the sealing surfaces of the upper oil pan and remove the sealant
residue.
2. Apply a bead of liquid gasket to sealing surfaces on the oil pan upper.
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.
14. Apply engine oil to oil seal lip.
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. 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).
8-7_Engine Lubrication_Oil Pump Overhaul (cont'd)
Engine Lubrication 8-7

Oil Pump Overhaul (cont'd)
Inspection 8. Clearance between outer rotor and cylinder block.

6. Check oil pump shaft (A), rotors (B), (C) and cylinder block (D) for Clearance between outer rotor and cylinder
damage. block:
If excessive wear or damage is discovered, the oil pump assembly New rotors:
must be replaced. 0.24 – 0.36 mm
Clearance the oil pump shaft in cylinder 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
9. Chip clearance between inner and outer rotor.

Chip clearance between inner and outer rotor:
New rotors:
0.13 – 0.15 mm
End Play (0.005 – 0.006 in.)
7. Inspect end play. Run-in rotors:
End play between oil pump retainer and rotors 0.20 mm (0.008 in.) Max
(A + B - C):
New rotors:
0.035 – 0.100 mm
(0.001 – 0.004 in.)
Run-in rotors:
0.150 mm (0.006 in.) Max
8-9_Engine Lubrication_Main Release Valve and Check Valve Inspection and Repair
Engine Lubrication 8-9 Oil Jet Installation Procedure
Main Release Valve and Check Valve Inspection

and Repair
1. Make the necessary adjustment, repairs and parts replacement if Special Tool Required
excessive wear or damage is discovered during inspection. ● Installer oil jet 5-8840-9056-0
Tightening Torque:
1. Apply Locktite 262 or TB1386 to the oil jet fixing area in the cylinder
Main release valve: block.
39 Nm (4.0 kgf/m, 28.9 lbf/ft) 2. Set the oil jet setting tool (A) (5-8840-9056-0) with oil jet (B) and the
Check valve: position pin of the oil jet setting tool into the cylinder block crankshaft
29 Nm (3.0 kgf/m, 21.7 lbf/ft) bearing cap bolt holes.
2. Check valve for easy operation when pushing valve by screwdriver.
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
8-10_Engine Lubrication_Oil Filter Element Replacement
Engine Lubrication 8- Oil pressure Switch Replacement
Oil Filter Element Replacement

10
1. Remove the oil filter housing cover, then separate the oil filter housing 1. Disconnect the mass air flow (MAF) sensor connector (A) and remove
cover and oil filter element. the vacuum hose (B), then remove the intake air duct (C) and air
2. Install the new O-rings (A) and oil filter element (B) to the oil filter cleaner housing (D).
housing cover (C).
2. Disconnect the oil pressure switch harness, then remove the oil
3. Install the oil filter housing cover to the oil filter housing. pressure switch.
3. Apply liquid gasket to the oil pressure switch threads, then install the
oil pressure switch.
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

9-2_Intake Manifold and Exhaust System_Intake Manifold and EGR Valve Removal
Intake Manifold and Exhaust System 9-2

Intake Manifold and EGR Valve Removal
1. Remove the acoustic cover. 9. Remove the bolts (A) and nuts (B) then remove the intake manifold
assembly (C).
2. Remove the air cleaner housing (see step 6 on page 5-2).

3. Remove the intake manifold pipe.
4. Remove the EGR valve.
5. Remove the EGR pipe.
6. Remove the oil filter assembly (see page 8-5).
7. Remove the four injection pipes (see page 11-160).
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
Intake Manifold and Exhaust System 9-3 Intake Manifold and EGR Valve Installation
Intake Manifold and EGR Valve Inspection
1. Connect the vacuum pump and gauge to the actuator of EGR valve 1. Apply liquid gasket to the VSS.
assembly. 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. 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. Install the four injection pipes (see page 11-160).
5. Install the oil filter assembly (see page 8-5).
6. Install the EGR valve assembly with specified torque.
Tightening torque:
24.5 Nm (2.5 kgf/m, 18 lbf/ft)
7. Install the EGR pipe and gasket with specified torque.
Tightening torque:
24.5 Nm (2.5 kgf/m, 18 lbf/ft)
8. Install the intake manifold pipe with specified torque.
Tightening torque:
24.5 Nm (2.5 kgf/m, 18 lbf/ft)
2. Apply 0 kPa to 25 kPa (0.25 kgf/cm2, 1.8 lbf/ft) vacuum and check
9. Install the air cleaner housing (see step 6 on page 5-2).
EGR valve moving condition.
3. If there is abnormal moving conditions on the EGR valve, replace the 10. Install the acoustic cover with specified torque.
EGR valve assembly. Tightening torque:
4. Inspect VSS (Variable Swirl System) for damage or any other 7.4 Nm (0.75 kgf/m, 5.4 lbf/ft)
problems and push the valve with your finger to inspect normal
condition or valve sticking.
5. Inspect the EGR valve for damage or any other problems.
9-4_Intake Manifold and Exhaust System_Turbocharger and Exhaust Manifold Removal

Turbocharger and Exhaust Manifold Removal
1. Remove the splash shield (see step 19 on page 5-5). 4. Remove the A/C compressor bracket.
2. Remove the harness clamp (A) and the intercooler inlet hose (B).
5. Remove the oil return hose (A) and two bolts (B) securing the
alternator, then move the alternator (C).
3. Remove the A/C compressor clutch connector (A), then remove the
harness clamp (B) and A/C compressor mounting bolts (C).
9-5_Intake Manifold and Exhaust System_Turbocharger and Exhaust Manifold Removal (cont'd)

(cont'd)
6. Remove the three bolts securing the oil level gauge pipe, then move 8. Remove the exhaust manifold cover.
the oil level gauge.
9. Remove the two bolts (A) securing the EGR pipe, PCV tube (B) and
remove the air flow tube assembly (C).
7. Remove the turbocharger cover.
10. Remove the acoustic cover (see step 1 on page 9-2).
9-6_Intake Manifold and Exhaust System_Turbocharger and Exhaust Manifold Removal (cont'd)
Intake Manifold and Exhaust System 9-6 Turbocharger and Exhaust Manifold Installation

(cont'd)
11. Remove the exhaust pipe A (A) from the turbocharger. 1. Install the turbocharger exhaust pipe (A) with 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)
12. Remove the oil feed pipe (B) and disconnect the turbocharger return
hose (C) from the turbocharger (D).
13. Remove the exhaust manifold fixing nuts and remove the exhaust
manifold (E).
14. Remove the turbocharger fixing nuts (A) and turbocharger exhaust
pipe fixing nuts (B), then remove the turbocharger assembly (C).
2. Install the exhaust manifold with gasket.
9-7_Intake Manifold and Exhaust System_Turbocharger and Exhaust Manifold Installation (cont'd)

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

5. Install the acoustic cover with specified torque.
Tightening torque:
7.4 Nm (0.75 kgf/m, 5.4 lbf/ft) 9. Install the three bolts securing the oil level gauge pipe with new O-ring
6. Install the two bolts (B) securing the EGR pipe with gasket and install (A).
the PCV tube (B) and the air flow tube assembly (C).
9-8_Intake Manifold and Exhaust System_Turbocharger and Exhaust Manifold Installation (cont'd)

Turbocharger and Exhaust Manifold Installation
(cont'd)
10. Install the oil return hose (A) and the alternator (B). 12. Install the A/C compressor (A) and harness clamp (B).
11. Install the A/C compressor bracket.

13. Install the harness clamp (A) and the intercooler inlet hose (B).
14. Install the splash shield (see step 18 on page 5-12).
9-9_Intake Manifold and Exhaust System_Exhaust Pipe and Muffler Replacement

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.
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
Circuit Diagram 10-16
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

10-2_Cooling System_Component Location Index
Cooling System 10-2

1. RADIATOR FAN SWITCH B

Test, page 10-20
Replacement, page 10-21
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
10-3_Cooling System_Expansion Tank Cap Test
Cooling System 10-3 Expansion Tank Test
Expansion Tank Cap Test
1. Remove the radiator cap (A), wet its seal with engine coolant, then 1. Wait until the engine is cool, then carefully remove the expansion tank
install it on the pressure tester (B) (commercially available). Use a cap and fill the expansion tank with engine coolant to the top of the
small adapter H-901122-09 (C) (commercially available) to install the filler neck.
radiator cap. 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. Apply a pressure of 93 - 123 kPa (0.95 - 1.25 kgf/cm2, 14 - 18 psi).

3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.
3. Apply a pressure of 93 - 123 kPa (0.95 - 1.25 kgf/cm2, 14 - 18 psi).

4. Inspect for engine coolant leaks and drop in pressure.
5. Remove the tester and reinstall the expansion tank cap.
6. Check for engine oil in the and/or coolant in the engine oil.
10-4_Cooling System_Expansion Tank Replacement
Cooling System 10-4 Fan Motor Test
Expansion Tank Replacement
1. Drain the engine coolant (see page 10-6). 1. Disconnect the 2P connectors from the radiator fan motor and
2. Remove the expansion tank hoses, then remove the expansion tank. condenser fan motor.
2. Test the motor by connecting battery power to the B terminal and

ground to the A terminal.
3. If the motor fails to run or does not run smoothly, replace it.
3. Install the expansion tank in the reverse order of removal.

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
Cooling System 10-5

Coolant Check
1. Look at the coolant level in the expansion tank. Make sure it is

between the MAX mark (A) and MIN mark (B).
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
Cooling System 10-6

Coolant Replacement
1. Start the engine. Set the heater temperature control dial to maximum 6. Pour genuine Honda All Season Antifreeze/Coolant Type 2 into the
heat, then turn the ignition switch OFF. Make sure the engine and expansion tank up to the MAX mark.
radiator are cool to the touch. NOTE:
2. Remove the expansion tank cap. ● Always use genuine Honda All Season Antifreeze/Coolant Type 2.
3. Loosen the drain plug (A) and drain the coolant. 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. When the coolant stops draining, tighten the drain plug securely.
5. Remove the expansion tank and drain the inside coolant and reinstall
the expansion tank.
7. Install the expansion tank cap loosely.

8. Start the engine and let it run until it warms up (the radiator fan comes
on at least twice).
9. Turn off the engine. Check the level in the expansion tank and add
genuine Honda All Season Antifreeze/Coolant Type 2 if needed.
10. Put the expansion tank cap on tightly, then run the engine again and
check for leaks.
10-7_Cooling System_Water Glow Plug Test
Cooling System 10-7 Water Glow Plug Replacement
Water Glow Plug Test
1. Remove the water glow plug harness (A) from the water glow plug. 1. Disconnect the mass air flow (MAF) sensor connector (A) and remove
the vacuum hose (B), then remove the intake air duct (C) and air
cleaner housing (D).
2. Measure resistance between the positive terminal (A) and body

ground.
Resistance:
Green colour (200W): 2. Remove the water glow plug harness (A), then remove the water glow
0.91 ohms plug (B).
Silver colour (300W):
0.61 ohms
3. Install the water glow plug in the reverse order of removal.
10-8_Cooling System_Water Pump and Thermostat Inspection
Cooling System 10-8

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

Water Pump and Thermostat Inspection (cont'd)
Water Pump Removal Water Pump Installation

1. Drain coolant-collect coolant. 1. Install the water pump assembly (A) with a new gasket (B) to the
2. Loosen fastening bolts (A) before removing drive-belt (B). cylinder block.
3. Remove drive-belt.
4. Remove the water pump assembly (C) and gasket (D). 2. Tighten fastening bolts (C) to the specified torque.
Tightening Torque:
24 Nm (2.4 kgf/m, 17.4 lbf/ft).
3. Install the water pump pulley (D) to the water pump. Install the drive-
belt (E).
4. Tighten fastening bolts (F) to the specified torque.
Tightening Torque:
9.8 Nm (1.0 kgf/m, 7.2 lbf/ft).
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Cooling System 10-10

Water Pump Inspection Thermostat Inspection

Bearing unit inspection Removal
1. Check the bearing unit for remarkable play in radial direction and for 1. Remove the two bolts to the fixing water outlet pipe then remove the
abnormal noise when turning the shaft. thermostat.
Installation
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. Valve opening temperatures 85 + 2°C
Valve lift:
External Inspection 8.0 mm
2. Check the pump body for cracks.
3. Check the seal unit for leakage.
4. Check the impeller for cracks, corrosion or damage.
Inspection and Repair

4. Make the necessary adjustments, repairs and part replacements if
excessive wear or damage is discovered during inspection.
Operating Test
5. Completely submerge the thermostat in water.
6. Heat the water. Stir the water constantly to avoid direct heat being
applied to the thermostat.
7. Check the thermostat initial opening temperature.
Thermostat initial opening temperature:
85 + 2 °C



8. Check the thermostat full opening temperature.

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


10-12_Cooling System_Radiator Replacement

Radiator Replacement
1. Drain the engine coolant (see page 10-6). 4. Remove the intercooler inlet hose (A) and intercooler outlet hose (B).
2. Disconnect the fan motor connectors (A), hood switch connector (B)
and compressor clutch connector (C), then remove the harness
clamps (D).
5. Remove the upper radiator hose (A), lower radiator hose (B) and water
bypass hoses (C).
3. Remove the condenser brackets (A) and the upper bracket and
cushions (B), then remove the bulkhead (C).

10-12_Cooling System_Radiator Replacement

10-13_Cooling System_Radiator Replacement (cont'd)

Radiator Replacement (cont'd)
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
7. Install the radiator in the reverse order of removal. Make sure the upper and lower cushions are securely.
8. Install the bulkhead in the reverse order of removal. Apply body paint to the bulkhead mounting bolts.
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10-14_Fan Controls_Component Location Index
Fan Controls 10-14

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
10-15_Fan Controls_Symptom Troubleshooting Index
Fan Controls 10-15

Symptom Troubleshooting Index
Symptom Diagnostic procedure Also check for

Radiator fan does not run at all, but condenser fan runs with A/C ON Radiator and condenser fans circuit troubleshooting A (see page 10-
17).
Both radiator fan and condenser fan do not run with A/C ON and Check the No. 14 (10A) fuse in the under-dash fuse/relay box.
when the engine coolant temperature is 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 when the engine Replace the radiator fan control relay.
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 the engine Radiator and condenser fans circuit troubleshooting B (see page 10-
coolant temperature is above 95°C (203°F), but both fans run with 18).
A/C ON
Both radiator and condenser fans do not run when the engine Radiator and condenser fans low speed circuit troubleshooting (see
coolant temperature is above 95°C (203°F), but radiator fan runs page 21-13).
with A/C ON
Both radiator fan and condenser fan run with ignition switch ON (II), Radiator and condenser fans circuit troubleshooting C (see page 10-
with A/C OFF and when the engine temperature is below 95°C (203° 19).
F)
Both radiator fan and condenser fan do not run at high speed with Radiator and condenser fans high speed circuit troubleshooting (see
the A/C ON page 21-17).
Both radiator fan speed and condenser fan speed do not change Radiator and condenser fans high speed circuit troubleshooting (see
from Low to Hi when the engine coolant temperature 100°C (212° page 10-19).
F), but both fan's speed change with A/C ON
Condenser fan speed does not change from Low to Hi with A/C ON Condenser fan high speed circuit troubleshooting (see page 21-17).
and the engine coolant temperature above 100°C (212°F)
11-8_Fuel and Emissions Systems_DTC Troubleshooting Index (cont'd)
Fuel and Emissions Systems 11-8

DTC Troubleshooting Index (cont'd)
DTC Indicate Lamp Detection Item Page

Scan Honda DTC MIL (Check Glow Lamp
tool DTC Engine Lamp)
P1535 - On On Incorrect Main Relay Performance (Switches off (see page 11-124)
too early)
P1536 - On On Incorrect Main Relay Performance (Switches off (see page 11-125)
too late)
P1550 - On On Brake SW Signal Correlation Error (After Restart (see page 11-127)
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 Voltage (see page 11-136)
(APS1, APS2, RP, MAP, MAF sensor)
P1619 - On On Injector driver Circuit Shut Off Error (Error at shut (see page 11-137)
off via zero quantity)
P1620 - On On Injector driver Circuit Shut Off Error (Error at shut (see page 11-138)
off via injector power stage (OFF))
P1621 - On On Shut Off Error (5 V power supply Circuit Low, (see page 11-139)
stabiliser limit exceeded)
P1622 - On On Shut Off Error (5 V power supply Circuit High, (see page 11-140)
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)
11-11_Fuel and Emissions Systems_Symptom Troubleshooting Index (cont'd)
Fuel and Emissions Systems 11-

Symptom Troubleshooting Index (cont'd)
11
Symptom Diagnostic Procedure Also check for
Warming up 1. Intake System. ● Low Compression
(Intake manifold, air cleaner, MAF sensor) ● Contaminated Fuel
2. Fuel filter, Fuel Line, Fuel, Fuel Condition. ● Engine Mechanical
3. Glow System. ● Chassis Parts Error
(Glow Relay, Glow Plug)
4. Exhaust System.
(EGR system, Turbocharger, Vacuum system)
5. Fuel Injection System.
(Injector, Supply Pump, Common Rail)
6. ECM (ECM, Fail Safe Mode)
After warm up 1. Intake System. ● Low Compression
(Intake manifold, air cleaner, MAF sensor) ● Contaminated Fuel
2. Fuel filter, Fuel Line, Fuel, Fuel Condition. ● Engine Mechanical
3. Exhaust System. ● Chassis Parts Error
(Injector, Supply Pump, Common Rail)
5. ECM (ECM, Fail Safe Mode)
11-13_Fuel and Emissions Systems_Symptom Troubleshooting Index (cont'd)

Symptom Troubleshooting Index (cont'd)
13
Symptom Diagnostic Procedure Also check for

Black smoke 1. Intake System. ● Engine Mechanical
(Intake manifold, air cleaner, MAF sensor) ● Engine Oil Quality
2. Exhaust System.
3. BARO Sensor
4. Injection Timing System.
(CKP Sensor, CMP Sensor, Mechanical timing)
(Injector, Common Rail)
6. ECM (ECT Sensor, ECM)
White smoke 1. Intake System. Engine Mechanical
(Intake manifold, air cleaner, MAF sensor)
2. Exhaust System.
3. BARO Sensor
4. Injection Timing System.
(CKP Sensor, CMP Sensor, Mechanical timing)
(Injector, Common Rail)
6. ECM (ECT Sensor, ECM)
11-14_Fuel and Emissions Systems_System Descriptions

System Descriptions
14
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.
11-15_Fuel and Emissions Systems_System Descriptions (cont'd)

System Descriptions (cont'd)
15
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 from the Crank Nearly the same as tachometer
Position (CKP) sensor. indication at idle speed: 850 + 50 rpm
This data is used for determining the time and amount of injected fuel. (min-1)
Engine Coolant The ECT sensor converts coolant temperature into voltage and signals the ECM. With cold engine: Nearly the same as
Temperature (ECT) The sensor is a thermistor whose internal resistance changes with coolant ambient temperature and IAT.
temperature. The ECM uses the voltage signals from the ECT sensor to With engine warmed up: about 80 – 100
determine the amount of injected fuel. °C (176 – 212 °F), 0.8 – 0.5 V.
Vehicle Speed The ECM converts pulse signals from vehicle speed sensor (VSS). Nearly the same as 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 turbocharger with Waste- With engine stopped: Nearly the same as
Pressure (MAP) Gate as well as a turbocharger with variable turbine geometry (VTG- atmospheric pressure.
turbocharger). At idle engine: About 20 – 30 kPa (150 –
For governing an exhaust turbocharger with Waste-Gate the actuator is a 260 mmHg, 6 – 10 in. Hg), 0.7 – 1.1 V.
bypass valve through which the exhaust flow is 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 (MAF). About 8 – 13 g/sec at idle speed
This indicates the amount of air entering the engine.
Throttle Position (TP) Based on the accelerator pedal position, the opening angle of the throttle valve is About 0 – 10 % at idle speed
Sensor (Accelerator Pedal indicated.
Position (APP) Sensor)
Intake Air Temperature The IAT sensor converts intake air temperature into voltage and signals the With cold engine: Same as ambient
(IAT) ECM. When intake air temperature is low, the internal resistance of the sensor temperature and ECT.
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

16
ECM Inputs and Outputs at Connector A (81P)
Wire side of female terminals

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 circuit Battery voltage with the ignition switch ON (II)
About 0 V with the ECM power OFF
5 RED Battery plus Power source for the ECM circuit of Battery voltage with the ignition switch ON (II)
drivers injector About 0 V with the ignition switch OFF
11 RED/BLU Vehicle immobilisation system Detects immobiliser signal Pulses signal with the immobiliser communication ON
12 GRN Coolant temperature output Output coolant temperature to meter Pulses signal with the ignition switch ON (II)
signal
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 lamp Drivers MIL Battery voltage with the MIL turned OFF
(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 turbine Driven variable turbine About 0 V to 12 V pulses signal
18 BRN/GRN Variable swirl control valve Drivers variable swirl control valve Battery voltage with the variable swirl control 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 (compressor) relay Battery voltage with the A/C compressor OFF
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.

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 signal Output engine speed to meter Pulses signal with the engine running
48 Silver BLK ISO-K interface Communicates with scan tool (PGM Pulses signal with the scan tool communicating
tester)
49 BLU/WHT Vehicle speed sensor (VSS) Detects VSS signal Pulses signal with the vehicle running
signal
54 GRY/BLU Redundant brake switch signal Detects redundant brake switch signal Battery voltage with the brake pedal (B/P) 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) sensor Ground for the AP sensor 1 0 V at all times
1, ground
77 YEL/BLU Accelerator pedal (AP) sensor Detects AP sensor 1 signal About 3.1 V with the AP fully open
1, signal About 0.7 V with the AP fully closed
78 RED/YEL Accelerator pedal (AP) sensor Provides AP sensor 1 About 5 V with the ignition switch ON (I)
1, supply About 0 V with the ignition switch OFF
79 BLK/WHT Accelerator pedal sensor 2, Ground for the AP sensor 2 0 V at all times
ground
80 YEL/GRN Accelerator pedal sensor 2, Detects AP sensor 2 signal About 1.5 V with the AP fully open
signal About 0.37 V with the AP fully closed
81 RED/WHT Accelerator pedal sensor 2, Provides AP sensor 2 About 5 V with the ignition switch ON (I)
supply About 0 V with the ignition switch OFF

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

No. Colour
84 WHT Engine coolant temperature Detects ECT sensor signal About 0.1 V – 4.8 V with the ignition switch ON (II)
(ECT) sensor signal (depending on ECT)
85 GRY Engine coolant temperature Ground for the ECT sensor 0 V at all times
(ECT) sensor ground
86 YEL Rail pressure (RP) sensor Detects RP sensor signal About 1 V with the engine running at idle (depending on
signal RP)
88 BLK Mass air flow (MAF) sensor Ground for the MAF sensor 0 V at all times
ground
89 BRN Mass air flow (MAF) sensor Detects MAF sensor signal About 2 V – 3 V with the engine running at idle
signal
90 RED/YEL Rail pressure (RP) sensor Provides RP sensor About 5 V with the ignition switch ON (II)
supply About 0 V with the ignition switch OFF
91 YEL/RED Intake air temperature (IAT) Detects IAT sensor signal About 0.1 V – 4.8 V with the ignition switch ON (II)
sensor signal (depending on IAT)
92 BLK/RED Rail pressure (RP) sensor Ground for the RP sensor 0 V at all times
ground
93 RED/BLU Manifold absolute pressure Provides MAP sensor About 5 V with the ignition switch ON (II)
(MAP) sensor supply
94 YEL/RED Manifold absolute pressure Detects MAP sensor signal About 2 V with the ignition switch ON (II)
(MAP) sensor signal About 2 V with the engine running at idle
95 BLK/YEL Manifold absolute pressure Ground for the MAP sensor 0 V at all times
(MAP) sensor ground
97 WHT/RED Mass air flow (MAF) sensor Provides MAF sensor About 5 V with the ignition switch ON (II)
supply
99 WHT/BLU Crank position (CKP) sensor Detects CKP sensor plus signal Pulses signal with the engine running
plus signal
100 ORN/BLU Crank position (CKP) sensor Detects CKP sensor minus signal Pulses signal with the engine running
minus 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.

19
No. Colour
101 BLK Crank position (CKP) sensor Ground for the CKP sensor 0 V at all times
ground/shield
103 BRN/WHT Camshaft position (CMP) Detects CMP sensor signal Pulses signal with the engine running
sensor signal
104 WHT Camshaft position (CMP) Ground for the CMP sensor 0 V at all times
sensor ground
105 PUR Request input cabin heater Detects cabin heater ON switch signal Battery voltage with the cabin heater OFF
About 0 V with the cabin heater ON
108 RED Fuel metering unit (FMU) ''high Power source for the FMU circuit Battery voltage with the ignition switch ON (II)
side''
109 GRN Fuel metering unit (FMU) ''low Drivers FMU About 7 V with the ignition switch ON (II) and engine OFF
side''
110 GRY Cabin heater relay 1 Drivers cabin heater relay 1 (500 W) Battery voltage with the cabin heater OFF
111 GRY/RED Cabin heater relay 2 Drivers cabin heater relay 2 (200 W) Battery voltage with the cabin heater OFF
114 BLU Injector for cylinder 4 Drivers injector 4 About 0 V with the engine running
117 RED Injector ''high bank'' f. cyl. 1 Power source injector 1 and 4 About 0 V with the ignition switch ON (II) and engine OFF
and 4
118 YEL Injector ''high bank'' f. cyl. 2 Power source injector 2 and 3 About 0 V with the ignition switch ON (II) and engine OFF
and 3
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

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

21
Vacuum Hose Routing


22
Vacuum Hose Routing (cont'd)
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

23
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

24
a. TURBO
b. HOSE; V/PIPE
c. PIPE; VACUUM
d. MUST INSERT TO THE END.


25
a. MUST INSERT TO THE END.
b. PIPE; VACUUM


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.

27
System configuration

28
Construction and Operation of the System
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.

29
Construction and Operation of Supply Pump
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.

30
Barometric Pressure (BARO) Sensor Engine Coolant Temperature (ECT) Sensor
The BARO sensor is inside the ECM. It converts atmospheric pressure The ECT sensor is a temperature dependent resistor (thermistor). The
into a voltage signal that modifies the basic duration of the fuel injection resistor of the thermistor decreases as the engine coolant temperature
discharge. increases.
Crankshaft Position (CKP) Sensor
The CKP sensor detects engine speed and determines ignition timing and
timing for fuel injection of each cylinder.
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. SHIM
2. CKP SENSOR
1. MAF/IAT SENSOR
2. AIR CLEANER CASE
3. AIR DUCT
11-80_Diesel Engine Management System_DTC Troubleshooting (cont'd)
Diesel Engine Management System 11-

DTC Troubleshooting (cont'd)
80
15. Measure voltage between the ECM A connector terminals No. 5 and
No. 2.
Is there battery voltage?

YES – Go to step 16.
NO – Repair open in the wire between the main relay and the ECM. If
a problem is not found, replace the main relay.
16. Go to the Starting/Charging System.
17. Substitute a known-good ECM and recheck. If symptom/indication
goes away, replace the original ECM.
NOTICE
The battery power supply short circuit to 5 V power supply damages the
ECM.

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

82
DTC P0704: Incorrect Clutch SW Signal 7. Check the clutch SW signal circuit for open or short to ground.
1. Check the ''On Board Diagnostic (OBD) System Check''. Was a problem found?
Was the ''OBD System Check'' performed? YES – Repair the signal wire between ECM and the clutch SW.
YES – Go to step 2. NO – Substitute a known-good ECM and recheck. If symptom/
NO – Go to OBD System Check. indication goes away, replace the original ECM.
2. Turn the ignition switch OFF.
3. Disconnect the clutch connector.
4. Turn the ignition switch ON (II).
5. Measure voltage between the clutch SW 2P connector terminals No. 1
and No. 2.

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

YES – Repair open in the ground wire.

83
DTC P1000: Injector Low Side Circuit Over Current
1. Check the ''On Board Diagnostic (OBD) System Check''.
Was the ''OBD System Check'' performed?
NO – Go to OBD System Check.
3. Disconnect the ECM connector.
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.
5. Disconnect all injector connectors.
6. Check the all injector power supply circuit and ground circuit for short.

84
Is a problem found?
YES – Repair short in injector circuit wire.
7. Measure resistance between the injectors connector terminals No. 1
and No. 2.
Is there about 0.2 – 0.3 &ohm; (At room temperature:
about 20°C (68°F))?
NO – Replace applicable injector.
8. Clear all DTCs.
Was a problem complete?
YES – System OK.
NO – Substitute a known-good ECM and recheck. If symptom/
indication goes away, replace the original ECM.

85
DTC P1001: Injector High Side Circuit Over Current
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.
5. Disconnect all injector connectors.
6. Check the all injector power supply circuits and ground circuit for short.

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

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

88
DTC P1003: Injector Performance Malfunction
2. Check the DTC.
Are there other DTCs (beside P1003) being output?
YES – Go to relevant DTC chart.
6. Check for the following conditions:
● Damaged injection pipe.
● Damaged injector.
Is a problem found?
YES – Replace the injector or injection pipe.
7. Perform injector spray condition check.
Is a problem found?
YES – Clean or replace relevant injector.

89
2. Check the DTC.
Is there other DTC P1012 being output?
4. Disconnect the ECM B connector.
Is a problem found?
YES – Repair the injector ground circuit.
Is there 0.2 – 0.3 ohms (At room temperature: about 20°C NO – Go to step 6.
(68°F))? 9. Measure resistance between the injectors connector terminals No. 1
NO – Go to step 6. about 20°C (68°F))?
ECM. NOTICE
ECM.

90
2. Check the DTC.
Is there other DTC P1007 being output?
4. Disconnect the ECM B connector.
Is a problem found?
YES – Repair the injector ground circuit.
Is there 0.2 – 0.3 ohms (At room temperature: about 20°C NO – Go to step 9.
(68°F))? 9. Measure resistance between the injectors connector terminals No. 1
NO – Go to step 6. about 20°C (68°F))?
ECM. NOTICE
ECM.

92
DTC P1086: Rail Pressure (RP) System Performance 6. Check the RP sensor signal voltage.
2. Check the DTC.
Are there any other DTC (beside DTC P1086) being
output?
YES – Go to relevant DTC chart.
4. Measure resistance of RP sensor as below.
● Between terminal 86 and 90.
Is about 1 V indicated?
YES – Intermittent failure, system is OK at this time. Check for poor
connections or loose wires at the RP sensor and at the ECM.
● Damaged supply pump.
● Damaged common rail.
● Damaged fuel metering unit.
● Fuel leaks injection pipes.
● Damaged the RP sensor.
Is a problem found?
YES – Repair as necessary.
Is there 0.9 – 1.3 ohms? (At indoor temperature) NO – Go to step 8.
YES – Go to step 5. 8. Turn the ignition switch OFF.
9. Disconnect the RP sensor 3P connector terminals No. 1 and No. 2
NO – Go to step 8. with a jumper wire.
5. Turn the engine ON at idling. Wire side of female terminals
RP sensor 3P connector
JUMPER WIRE

118
DTC P1239: Boost Pressure Control Circuit High Voltage 9. Check the circuit between EVRV connector No. 2 terminal and ECM A
1. Check the ''On Board Diagnostic (OBD) System Check''. connector terminal No. 17 for short to ground.
● Damaged turboactuator or EVRV.
● EVRV wire harness and connector.
Is a problem found?
YES – Repair as necessary.
4. Disconnect the EVRV connector.
Is a problem found?
6. Measure voltage between the EVRV 2P connector terminals No. 1 and YES – Repair short to ground in the wire between EVRV and the
body ground. ECM.
10. Measure resistance between the EVRV 2P connector terminals No. 1
and No. 2.

Is there B+?
Is there 14.7 – 16.1 ohms (20°C (68°F)) (At room
YES – Go to step 7. temperature)?
NO – Repair open in the wire between EVRV and the main relay. YES – Substitute a known-good ECM and recheck. If symptom/
7. Turn the ignition switch OFF. indication goes away, replace the original ECM.
8. Disconnect the ECM A connector. NO – Replace the EVRV.
NOTICE
ECM.
file:///C|/Users/Navindra/Desktop/Civic_2001-2005_english_/...%20Civic%202001-2005(english)/EngCivic/Civ41Html/11-118.htm7/6/2011 8:48:49 PM

124
DTC P1535: Incorrect Main Relay Performance 12. Disconnect the ECM A connector terminals No. 13 and No. 1 with a
1. Turn the ignition switch OFF. jumper wire.
2. Wait 5 seconds. JUMPER WIRE
Is DTC P1535 indicated?
NO – Intermittent failure, system is OK at this time. Check for poor
connections or loose wires at the main relay and at the ECM.
5. Check the main relay and ignition feed fuses (20A and 7.5A)
Are both fuses OK?
NO – Replace the fuse. 14. Measure voltage between the ECM A connector terminals No. 4 and
6. Measure the battery voltage at the battery. No. 2.
Is the battery voltage greater than 9 V?
NO – Charge the battery.
8. Check the battery voltage with the scan tool.
9. Start the engine and raise the engine speed to 2,000 rpm (min-1).
11. Disconnect the ECM connector A.
NO – Repair open in the wire between the main relay and the ECM, if
15. Replace the main relay.
NOTICE
ECM.

125
DTC P1536: Incorrect Main Relay Performance 12. Disconnect the ECM A connector terminals No. 13 and No. 1 with a
1. Turn the ignition switch OFF. jumper wire.
2. Wait 5 seconds. JUMPER WIRE
Is DTC P1536 indicated?
NO – Intermittent failure, system is OK at this time. Check for poor
connections or loose wires at the main relay and at the ECM.
5. Check the main relay and ignition feed fuses (20A and 7.5A)
Are both fuses OK?
NO – Replace the fuse. 14. Measure voltage between the ECM A connector terminals No. 4 and
6. Measure the battery voltage at the battery. No. 2.
NO – Charge the battery.
8. Check the battery voltage with the scan tool.
9. Start the engine and raise the engine speed to 2,000 rpm (min-1).
11. Disconnect the ECM connector A.
NO – Repair open in the wire between the main relay and the ECM, if

126
15. Replace the main relay.
NOTICE
ECM.

127
DTC P1550: Brake SW Signal Correlation Error (After Restart 10. Connect the DVM to the brake SW connector terminal No. 1 and No.
Memory) 2 with a jumper wire.
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. 11. Turn the ignition switch ON (II).
4. Disconnect the ECM connector A. 12. Connect the DVM to the ECM terminal No. 59 and body ground.
6. Connect the DVM to the ECM terminal No. 59 and body ground.
13. Press the brake pedal.

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

128
16. Disconnect the redundant brake SW connector.
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.
18. Replace the redundant brake SW.
19. Connect the ECM connector A.
Is there DTC P1550 being output?
NO – System is OK.
NOTICE
ECM.

129
DTC P1551: Brake SW Signal Correlation Error 10. Connect the DVM to the brake SW connector terminal No. 1 and No.
1. Check the ''On Board Diagnostic (OBD) System Check''. 2 with a jumper wire.
3. Check the brake lamp (10A) fuse.
Is the brake lamp fuse OK?
YES – Go to step 4. JUMPER WIRE
NO – Replace the fuse. Wire side of female terminals
4. Disconnect the ECM connector A. 11. Turn the ignition switch ON (II).
5. Turn the ignition switch ON (II). 12. Connect the DVM to the ECM terminal No. 59 and body ground.
6. Connect the DVM to the ECM terminal No. 59 and body ground.
13. Press the brake pedal.

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

130
15. Turn the ignition switch OFF. DTC P1610: ECM Communication Error
16. Disconnect the redundant brake SW connector. 1. Check the ''On Board Diagnostic (OBD) System Check''.
17. Check for open or short to ground in the redundant brake SW circuit Was the ''OBD System Check'' performed?
wire.
Is a problem found? YES – Substitute a known-good ECM and recheck. If symptom/
YES – Repair open or short to ground in the redundant brake SW
circuit wire. NO – Go to OBD System Check.
18. Replace the redundant brake SW.
19. Connect the ECM connector A.
Is there DTC P1551 being output?
NO – System is OK.
NOTICE
ECM.

133
DTC P1614: Booster (injector driver) Voltage Too High Was a problem found?
1. Check the ''On Board Diagnostic (OBD) System Check''. YES – Repair the ECM ground circuit.
Was the ''OBD System Check'' performed? NO – Substitute a known-good ECM and recheck. If symptom/
YES – Go to step 2. indication goes away, replace the original ECM.
2. Check the ECM ground circuit.
11-152_Diesel Engine Management System_Injector Spray Condition Check

Injector Spray Condition Check
152
Special tool required 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. Remove all injectors (see page 11-155). ● Correct (A)
2. Set an injector to a nozzle tester (A) and nozzle holder (B). ● Incorrect (Restrictions) (B)
● Incorrect (Dripping) (C)
3. Connect the injector test harness to the injector and battery.
4. Observe the fuel pressure indicated by the fuel pressure gauge with
the fuel pump running.
5. Operate the fuel pump running at about 40,000 kPa (410 kgf/cm2,
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

Accelerator Pedal Position Sensor Replacement
153
1. Fully open the throttle valve, then remove the throttle cable (A) from
the throttle link (B).
2. Remove the accelerator pedal position sensor 6P connector (C).

3. Remove the bolts (D).
4. Install the part in the reverse order of removal.
11-154_Idle Control System_Idle Speed Inspection
Idle Control System 11-

Idle Speed Inspection
154
NOTE: 3. Check the idle speed with no-load conditions: headlights, blower fan,
● Leave the Idle Air Control (IAC) valve connected. rear defogger, radiator fan and air conditioner are not operating.
● Before checking the idle speed, check these items: Idle speed should be:
● The Malfunction Indicator Lamp (MIL) has not been reported on. 850+50 rpm (min-1)
● Ignition timing
4. Idle the engine for 1 minute with heater fan switch on HI and air
● Spark plugs
conditioner on, then check the idle speed.
● Air cleaner
Idle speed should be:
● PCV system
850+50 rpm (min-1)
1. Connect a tachometer (A) to the test tachometer connector (B).
NOTE: If the idle speed is not within specification, see the Symptom
Chart.
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
Fuel Supply System 11-

155
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
11-156_Fuel Supply System_Fuel Line Inspection

Fuel Line Inspection
156
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.
11-157_Fuel Supply System_Fuel System Bleeding

Fuel System Bleeding
157
Air must be bled from the fuel after disassembling the fuel system for 6. When the air bubbles cease to appear, tighten the air bleed bolt to the
system for service and after run out of the fuel. specified torque (9 Nm (0.9 kgf/m, 7 lbf/ft)).
See the following for the procedure. 7. After tightening the air bleed plug, operate the fuel hand primer unit it
becomes hard.
1. Fill the fuel tank with fuel. 8. Stop bleeding when the fuel hand primer becomes hard and crank the
2. Remove the fuel filter air bleed bolt and replace the washer with a new engine.
one. 9. If the engine does not start, operate the hand primer again until it
3. Loosely screw the air bleed bolt (A) into the threaded hole in the fuel becomes hard.
filter until the 2 or 3 threads at the cutout of the threaded part of the NOTE:
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.
4. Remove the fuel hand primer from the hose clip.

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
Fuel Supply System 11- Fuel Filter Replacement

Fuel Filter Water Bleeding
158
1. Place a suitable container under the fuel filter to catch the water. 1. Disconnect the hoses from the fuel filter (A).
2. Loosen the water screw (A) at the underside of the fuel filter until water
drops.
2. Remove the bolts (B) from the fuel filter bracket (C).
3. Remove the fuel filter (A).
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. Tighten the water screw securely.
5. Bleed the fuel system (see page 11-157).
4. Install the part in the reverse order of removal.

5. Bleed the fuel system (see page 11-157).
11-159_Fuel Supply System_Injector Replacement

Injector Replacement
159
Special tool required Injector installation
Injector fixing tool 5-86751-052-0 1. Put the bracket (A) onto the bolt; carrier fixing (B).
Injector removal
1. Remove the cylinder head cover and loosen bolts (A).
2. Insert the injectors (C) into the cylinder head.

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

3. Loosen bolt; bracket fixing (C).
4. Remove bracket (D).
5. Remove retainer; injector (E).
6. Remove injector assembly (F).
4. Put the retainer, injector (A) onto slit on the bracket (B).
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)
11-160_Fuel Supply System_Injector Replacement (cont'd)
Fuel Supply System 11- Fuel Supply Pump and Common Rail Replacement
Injector Replacement (cont'd)

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

Fuel Supply Pump and Common Rail
Replacement (cont'd)
161
6. Remove the common rail fixing bolts (A) and remove the common rail 10. Install the fuel supply pump assembly (A) to the cylinder block.
assembly. Tighten fixing nuts (B) to 20 Nm
(2.0 kgf/m, 14 lbf/ft).
Installation
7. Install the common rail assembly (A) to cylinder block.
11. Install the fuel supply pump drive pulley.

12. Install the fuel supply pipe (A) to common rail.
Tightening torque:
23 Nm (2.3 kgf/m, 17 lbf/ft)
8. Tighten the common rail fixing bolt (B) to 25 Nm (2.5 kgf/m, 18 lbf/ft).
9. Tighten pipe assembly with installation angle (20°).
Tighten torque:
30 Nm (3.1 kgf/m, 22 lbf/ft)
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)
14. Connect the fuel feed hose and the fuel return hose on the fuel
supply pump.
11-178_PCV System_PCV Valve Inspection
PCV System 11-

PCV Valve Inspection
178
1. Check the PCV valve (A), hose (B) and connections for leak or
restrictions.
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.
12-3_Clutch_Component Location Index
Clutch 12-3
NOTE: LHD type is shown, RHD type is similar.

1. RESERVOIR
2. RETAINING CLIP
Replace.
3. RESERVOIR HOSE
4. LOCK PIN
5. CLUTCH SWITCH
Adjustment, page 12-4
6. CLUTCH PEDAL
Adjustment, page 12-4
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
13-9_Manual Transmission_Transmission Removal (cont'd)
Manual Transmission 13-9

Transmission Removal (cont'd)
23. Place the transmission jack under the transmission and remove the 25. Pull the transmission (A) away from the engine until the transmission
transmission rear mount (A). mainshaft clears the clutch pressure plate, then lower transmission on
the transmission jack.
24. Remove the transmission mounting bolts.
26. Remove the extension plate (B) and two dowel pins (C).
27. Remove the release bearing and release lever (see page 12-12).
13-10_Manual Transmission_Transmission Installation
Manual Transmission 13-

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

4. Place the transmission (C) on the transmission jack and raise it to the
engine level.
5. Install the transmission mounting bolts.
13-11_Manual Transmission_Transmission Installation (cont'd)

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

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

14. Install the three upper transmission mounting bolt.
16. Loosen the front engine mount bracket mounting bolt, then tighten
the front engine mount bracket mounting bolt.

13
17. Install the splash shield. 20. Install the cable bracket.
21. Install the cables.
18. Remove the chain hoist.

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

14
22. Install the water pipe bolt (A), then connect the back-up light switch 24. Install the battery tray (A), then connect the ground cable (B).
connector (B).
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
clutch line. 25. Install the air cleaner housing (see step 33 on page 5-15).
26. Install the intake air duct (see step 6 on page 5-2).
27. Install the battery. Connect the positive (+) cable first, then the
negative (-) cable to the battery.
28. Refill the transmission fluid (see page 13-4).
29. Test-drive the vehicle.
30. Check the clutch operation.
31. Check the front wheel alignment, refer to the 2001 Civic Shop Manual
on this CD (see page 18-4).
32. Enter the anti-theft code for the radio, then enter the customer's radio
station presets.
13-15_Manual Transmission_Transmission Disassembly

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

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

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

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

17
Special Tools Required 8. Remove the 1st/2nd detent plug (A), 3rd/4th detent plug (B), 5th detent
● Torx bit (No.45) 5-8840-0047-0 (J-29843-8) plug (C), detent springs and detent balls.
● Puller body 5-8840-0013-0 and 5-8840-0014-0 (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. Remove the rear cover assembly.
2. Remove the control box assembly.
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. Remove the 5th gear nut (A).
9. Remove the insert stopper plate.

10. Remove the 5th synchroniser assembly, 5th shift arm, 5th block ring
and output 5th gear.
11. Remove the 5th gear needle bearing.
12. Remove the input 5th gear.
13. Remove the seven 8 X 1.25 torx screw (A) from the transmission
case bearing retainer (B), using the special tool.
5. Remove the sleeve and hub nut from the output shaft. Discard the
fixing nuts.
6. Return the transmission to the neutral position. Align the shift rail
detent positions.
7. Place 5th synchroniser assembly (A) in neutral. Remove the spring pin
(B) at 5th shift arm (C) and discard the spring pin.
14. Remove the output shaft bearing shim and transmission case bearing
retainer from the output shaft.

18
15. Remove the 5th gear needle bearing collar (A) and 5th gear thrust 20. Remove the reverse detent plug (A), the reverse detent spring and
washer (B), using the special tools. reverse detent ball.
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 the
16. Remove the bearing ring. same time.
17. Remove the 10 X 1.25 reverse idler shaft bolt and washer.
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.
19. Remove the reverse idler gear (A) and reverse idler shaft (B).
Manual Transmission 13- Shift Arms Inspection

19
22. Use a hammer and punch to remove the spring pin (A) from the 1. Inspect the shift arms, shafts and levers for wear, distortion or scoring.
3rd/4th shift arm (B). Discard the spring pin (A). Replace if these conditions are present.
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.)
23. Slide the 3rd/4th gear shift up. Remove the 3rd/4th shift arm (B) and
shaft (C) from the case.
24. Follow the same procedure to remove the 1st/2nd shift arm (D) and
rod (E).
NOTE: The spring pins cannot be reused.
25. Remove the input shaft assembly and output shaft assembly at the
same time.
26. Remove the differential gear assembly.
27. Remove the reverse lever fulcrum bracket (A) together with four bolts
(B). Take out three interlock pins.
28. Remove the fulcrum bracket pin and then remove the pin and reverse
shift lever.
29. Remove the output shaft bearing outer race from transmission case.
30. Remove the speedometer driven gear.
31. Remove the clutch housing.
13-20_Manual Transmission_Input Shaft Disassembly
Manual Transmission 13- Input Shaft Inspection
Input Shaft Disassembly

20
Special Tools Required 1. Measure the run-out of the input shaft and replace with a new one if
● Bearing remover 5-8840-0015-0 (J-22912-01) reading exceeds limit.
Limit: 0.02 mm (0.0008 in.)
1. Remove the input shaft bearing (A) using the special tool with a press.
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. Remove the input shaft.
13-21_Manual Transmission_Input Shaft Reassembly

Input Shaft Reassembly
21
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
13-22_Manual Transmission_Input Shaft Reassembly (cont'd)

Input Shaft Reassembly (cont'd)
22
Special Tools Required 6. Install the 4th gear thrust washer. Note the installation direction.
● Bearing installer 5-8840-0054-0 (J-33374)
NOTE: The insert spring set positions differ for right and left. The ends of
the insert spring should not interfere with the hub.
1. Install the 3rd gear needle bearing, input 3rd gear, 3rd block ring,
3rd/4th synchroniser assembly and 4th gear needle bearing collar on
the input shaft. 7. Install the rear input shaft bearing (A). Using the special tool, press the
NOTE: bearing into place.
● 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. Using the special tool with a press the 3rd/4th synchroniser assembly
(A) and 4th gear needle bearing collar (B).
8. Install the input shaft bearing (A). Using the special tool, press the
bearing into place.
3. Install the 4th block ring.

4. Install the 4th gear needle bearing.
5. Install the input 4th gear.
13-23_Manual Transmission_Output Shaft Disassembly

Output Shaft Disassembly
23
Special Tools Required 3. Remove the 2nd gear needle bearing, 2nd gear needle bearing collar,
● Bearing remover 5-8840-0012-0 (J-22227-A) output 2nd gear, 2nd block ring set, 1st and 2nd synchroniser
● Bearing remover 5-8840-0015-0 (J-22912-01) assembly, 1st block ring set, output 1st gear, 3rd and 4th gear feather
key and 1st gear needle bearing, using a press.
1. Remove the front output shaft bearing (A) using the special tool and a
suitable short bar (B) with a press.
2. Remove the rear output shaft bearing (A) and 3rd and 4th output gear
(B) together using the special tool with a press. 4. Remove the 1st thrust bearing.
5. Remove the output shaft.
13-24_Manual Transmission_Output Shaft Inspection

Output Shaft Inspection
24
1. Measure the run-out of the output shaft. Replace with a new one if
reading exceeds limit.
Limit: 0.02 mm (0.0008 in.)
13-25_Manual Transmission_Output Shaft Reassembly

Output Shaft Reassembly
25
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
13-26_Manual Transmission_Output Shaft Reassembly (cont'd)

Output Shaft Reassembly (cont'd)
26
Special Tools Required 8. Install the 2nd block ring set.
● Second collar installer 5-8840-0009-0 (J-8853-01) 9. Install the output 2nd gear.
● Pilot 5-8840-0050-0 (J-33369) 10. Install the 2nd gear needle bearing.
● Bearing installer 5-8840-0054-0 (J-33374) 11. Install the 3rd and 4th gear feather key.
● Output front bearing installer 5-8840-0605-0 (J-38599) 12. Install the 3rd and 4th output gear (A), rear output shaft bearing (B),
using the special tool with a press.
1. Install the output shaft.
2. Install the 1st thrust bearing.
3. Install the 1st gear needle bearing.
4. Install the output 1st gear.
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.
13. Install the front output shaft bearing (A), using the special tool with a
press.
6. Install the 1st and 2nd synchroniser assembly.
NOTE: the installation direction when assembling the synchroniser
assembly.
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.
13-27_Manual Transmission_Synchro Ring and Gear Inspection

Synchro Ring and Gear Inspection
27
1. The synchroniser hubs and sliding sleeves are selected assemblies 5. Measure the clearance between block rings (A) and synchronising
and should be kept together as originally assembled. cones (B) for 1st and 2nd gears by positioning 1st gear, then 1st and
2. Clean synchroniser components with clean solvent and air dry. 2nd synchroniser assembly, then 2nd gear as shown. Replace the 1st
3. Inspect the components for the following: and 2nd gear synchroniser assembly if the measurement exceeds the
● Teeth for wear, scuffs, nicks, burrs or breaks. specified limit.
● Inserts and insert springs for wear, cracks or distortion. Replace if NOTE: When reassembling synchroniser assemblies, each insert
these conditions are present. spring should support all three inserts and each opening portion of the
● If scuffed, nicked or burred conditions cannot be corrected with a insert spring should face the opposite direction from the other.
soft stone or crocus cloth, replace the components. Standard:
● Measure the clearance between block ring (A) and inserts (B).
1.5 mm (0.059 in.)
Replace components if not within the specified limit.
1st/2nd: Limit:
3.9 mm (0.154 in.) or less 0.8 mm (0.031 in.)
3rd/4th, 5th:
3.7 mm (0.146 in.) or less
4. Measure the clearance between block ring (A) and gear (B). Replace
components if not within the specified limit. 6. Clearance between clutch hub (A) and inserts (B).
NOTE: Replace gear assembly if evidence of engine braking can be Limit:
seen on the dog teeth. 0.25 mm (0.0098 in.)
Standard:
1.5 mm (0.059 in.)
Limit:
0.8 mm (0.031 in.)
13-28_Manual Transmission_Synchro Ring and Gear Inspection (cont'd)

Synchro Ring and Gear Inspection (cont'd)
28
7. Inspect all gear teeth for signs of excessive wear or damage. Check all 10. Measure the play in splines.
gear splines for burrs nicks, or scratches on an oil stone. Replace any 1st/2nd, 3rd/4th:
part having excessive wear or damage. 0.12 mm (0.0047 in.) or less
8. Measure the gear inside diameter. Replace the gear if not within the 5th:
specified limit.
1st/2nd: 0.15 mm (0.0059 in.) or less
40.04 mm (1.7736 in.) or less
3rd/4th, 5th:
41.05 mm (1.6161 in.) or less
11. Inspect all thrust washers for excessive wear, distortion or damage.
Replace any thrust washer with these conditions.
12. Inspect the springs for distortion, cracks, or wear. Replace if these
conditions are present.
13. Measure the spring length. Replace springs if not within the specified
limits.
9. Measure the clearance between reverse idler gear (A) and shaft (B). Limit:
(1) – (2) Except reverse 25.5 mm (1.004 in.)
0.15 mm (0.0059 in.) or less Reverse 59.5 mm (2.343 in.)
13-29_Manual Transmission_Synchro Ring and Gear Inspection (cont'd)
Manual Transmission 13- Input Shaft Bearing and Oil Seal Replacement
Synchro Ring and Gear Inspection (cont'd)

29
14. Inspect the two case halves for cracks, porosity, damaged mating Special Tools Required
surfaces, stripped bolt threads, or distortion. Replace the clutch ● Sliding hammer 5-8840-0019-0 (J-23907)
housing if any of these conditions are present. ● Needle bearing remover 5-8840-2409-0 (J-29369-1)
15. Inspect the condition of all needles, rollers and thrust bearings. Wash ● Oil seal installer 5-8840-0026-0 (J-26540)
bearings thoroughly in cleaning solvent. Apply compressed air to ● Needle bearing installer 5-8840-7000-0
bearings.
NOTE: Do not allow the bearings to spin. Turn them slowly by hand. 1. Remove the needle bearings (A), using the special tools.
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. Remove the input shaft oil seal.

3. Install the input shaft oil seal (A), using the special tool.
13-30_Manual Transmission_Input Shaft Bearing and Oil Seal Replacement (cont'd)
Manual Transmission 13- Output Shaft Bearing Replacement
Input Shaft Bearing and Oil Seal Replacement

(cont'd)
30
4. Install the needle bearing (A) using the special tool with a press. Special Tools Required
NOTE: Do not use a hammer to install the needle bearing. ● Puller bridge 5-8840-0183-0 (J-33367)
● Axle shaft oil seal remover 5-8840-0027-0 (J-26941)
● Bearing outer race installer 5-8840-0006-0 (J-7817)
1. Remove the bearing outer races (A) using the special tools.
2. Install the bearing outer race (A) using the special tool with a hammer.
13-31_Manual Transmission_Output Shaft and Differential Thrust Clearance Adjustment

Output Shaft and Differential Thrust Clearance
Adjustment
31
Special Tools Required 5. Place the transmission case (A) over the clutch housing (B). Tighten
● Shim selector set 5-8840-0053-0 (J-33373)
the bolts (included in the shim selector set) to the specified torque.
Shim adjustment Torque:
17 Nm (1.8 kgf/m, 13 lbf/ft)
Select shims for installation between each bearing outer race and bearing
retainer as follows:
1. Install the input shaft assembly (A), output shaft assembly (B) and
differential assembly (C) to the clutch housing (D).
6. Turn the input shaft and each gear in both directions several times to
seat the gauge.
7. Compress the two gauges. Use the appropriate shims. Measure the
gap between the outer sleeve and the base pad.
8. To permit smooth installation of the differential to the gap, use a shim
2. Place each bearing outer race over each bearing. (A) that is 3 sizes too large. To permit smooth installation of the output
3. Place the special tool onto the bearing outer race. shaft to the gap, use a shim that is 1 size too large.
4. Place the seven spacers included in the shim selector set on every
other mounting bolt hole.
9. When each of the two shims have been selected, remove the
transmission case, seven spacers and two gauges.
13-32_Manual Transmission_Output Shaft and Differential Thrust Clearance Adjustment (cont'd)
Manual Transmission 13- Transmission Reassembly
Output Shaft and Differential Thrust Clearance

Adjustment (cont'd)
32
Available Selective Shim NOTE: Prior to reassembling, clean all the parts in solvent, dry them and
Output shaft bearing shim apply lubricant to any contact surfaces.
1. Apply grease to three interlock pins, and install them to the clutch
Part Number Thickness
housing.
894249-6600 1.16 mm (0.046 in.)
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.) 2. Install reverse lever fulcrum bracket (A) to the clutch housing. Use
3rd/4th shift rod to align bracket to clutch housing. Install the four bolts
Differential side bearing shim (B).
Torque:
Part Number Thickness
19 Nm (1.9 kgf/m, 14 lbf/ft)
894249-5451 1.08 mm (0.043 in.)
894131-1450 1.12 mm (0.044 in.)
894249-5461 1.16 mm (0.046 in.)
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.)
3. Make sure the shaft operates smoothly after installation.
894131-1500 1.52 mm (0.060 in.)

894249-5511 1.56 mm (0.061 in.)
894131-1510 1.60 mm (0.063 in.)
894249-5521 1.64 mm (0.065 in.)
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.)
894131-1560 2.00 mm (0.079 in.)
13-33_Manual Transmission_Transmission Reassembly (cont'd)

Transmission Reassembly (cont'd)
33
4. Install the differential gear assembly. 13. Install the rear output shaft bearing outer race and output shaft
5. Install the output shaft assembly. bearing shims into the transmission case.
6. Install the input shaft assembly. 14. Install the differential side bearing outer race and differential side
7. Install 1st/2nd shift arm (A) to the synchroniser sleeve and insert the bearing shims into the transmission case.
shift rod (B) into the reverse lever fulcrum bracket. Align the hole in the 15. Install the transmission case.
arm with the rod and install a new double spring pin (C). NOTE:
NOTE: Carefully wipe any oil and other foreign material from the mating
Before installing the 3rd/4th shift arm, make sure that the interlock pin surfaces of the clutch housing and transmission case. Apply liquid
is inserted to the 3rd/4th shift rod. 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.
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).
9. Install the reverse shift lever.
10. Before installing the 5th and reverse shift rods, make sure that the
interlock pin is inserted to the 5th shift rod.
NOTE: 16. The heads of the bolts to be tightened at the same time as the
● Install the 5th and reverse shift rods at the same time. The rods
transmission hanger are painted green. Take care to install the bolts to
must be facing the same direction as the detent groove. their proper position.
● Mesh the reverse rod and the reverse shift lever.
Torque:
11. Install reverse idler shaft together with the reverse idler gear into the 38 Nm (3.8 kgf/m, 28 lbf/ft)
clutch housing.
Make sure reverse lever engages the gear collar.
12. Install the reverse detent plug, reverse detent spring and reverse
detent ball.
Torque:
25 Nm (2.5 kgf/m, 18 lbf/ft)

34
17. Install the bearing ring. 23. Install the input 5th gear.
18. Install the bearing retainer. NOTE:
NOTE: ● The insert spring set positions should differ for both sides.
Apply LOCTITE 242 to the 7 Torx screws. Use a No.45 Torx bit to ● The ends of the insert springs should not interfere with the hub.
tighten the screws. ● Before installing, apply oil to the output gear thrust surfaces.
Torque:
26 Nm (2.6 kgf/m, 19 lbf/ft)
19. Install the reverse idler shaft bolt (A).
Torque:
38 Nm (3.8 kgf/m, 28 lbf/ft)
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.
25. Align the shift rod (A) and the shift arm (B). Install a new double
spring pin (C).
20. Install the 5th gear needle bearing collar (A) 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.
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)
27. Install the insert stopper plate.
21. Install the 5th gear needle bearing.

22. Install the output 5th gear.

36
40. Install the speedometer driven gear.
41. Rotating torque measurement.
42. Set the transmission as shown in the illustration.
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
44. If the reading does not fall within the limit, reselect the shims and
retest the torque.
13-38_M/T Differential_Backlash Inspection
M/T Differential 13- Final Driven Gear/Carrier Replacement
Backlash Inspection
38
1. Backlash between side gear (A) and pinion gear (B). 1. Remove the bolts and the ring gear.
Limit: 2. Install the ring gear (A).
0.3 mm (0.0118 in.)
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. Apply oil to the mating surfaces of the ring gear and differential case.
2. If the backlash is beyond the limit, adjust by replacing thrust washers.
13-40_M/T Differential_Carrier Replacement (cont'd)
M/T Differential 13-

Carrier Replacement (cont'd)
40
10. Measure the differential case diameter (Drive shaft). 17. Heat the speedometer drive gear to approximately 90°C (194°F) and
Limit: install the 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.
18. Install the side bearing (A) using the special tools.
11. Install the differential case.

12. Apply oil to the cross pin, differential gears, thrust portion, side gear
shaft portion and side gear spline portion before installation.
13. Install the side gears and thrust washers.
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.
15. Install the cross pin by aligning it with the lock pin hole in the
differential case.
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.
13-42_M/T Differential_Oil Seal and Bearing Outer Race Replacement (cont'd)
M/T Differential 13-

Oil Seal and Bearing Outer Race Replacement
(cont'd)
42
Transaxle case side
1. Remove the differential side bearing outer race and shims (A) from the
transmission case using the special tools.
2. Remove the drive shaft oil seal from the transmission case using the
special tools.
3. Apply oil to the bearing outer race installation.
4. Install the differential side bearing outer race with selected shim (A)
using the special tool with a hammer.
5. Press bearing until seated in its bore.

6. Install the new drive shaft oil seal using the special tool with a
hammer.
21-17_Air Conditioning_Radiator and Condenser Fans High Speed Circuit Troubleshooting
Air Conditioning 21-

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

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

Is there continuity?
YES - Replace the A/C pressure switch.
NO - Repair open in the wire between the A/C pressure switch A and
Is there battery voltage? B.
YES - Go to step 5.
NO - Repair open in the wire between the radiator fan relay, fan
control relay and the A/C diode B.
6. Reinstall the A/C diode B.
21-24_Air Conditioning_A/C Pressure Switch Circuit Troubleshooting (cont'd)

A/C Pressure Switch Circuit Troubleshooting
(cont'd)
24
30. Check for continuity between the No. 2 terminal of the heater fan
switch 7P connector and body ground.
HEATER FAN SWITCH 7P CONNECTOR

YES - Go to step 31.
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.
31. Test the A/C switch.
Is the A/C switch OK?
YES - Replace the heater fan switch.
NO - Replace the push switch.
32. Check for proper A/C system pressure.
Is the pressure within specifications?
NO - Repair the A/C pressure problem.
21-25_Air Conditioning_Compressor Replacement

Compressor Replacement
25
1. If the compressor is marginally operable, run the engine at idle speed 6. Remove the mounting bolts and the compressor.
and let the air conditioning work for a few minutes, then shut the
engine off.
2. Make sure you have the anti-theft code for the radio, then write down
the frequencies for the radio's preset buttons.
3. Disconnect the negative cable from the battery.
4. Discharge the refrigerant.
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.
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.
21-26_Air Conditioning_Compressor Clutch Check

Compressor Clutch Check
26
1. Check the driver clutch for discoloration, peeling or other damage. If 4. Check resistance of the clutch coil. If resistance is not within
there is damage, replace the driver clutch and the pulley assembly specifications, replace the field coil (see page 21-27).
(see page 21-27). Clutch Coil Resistance:
2. Check the pulley assembly bearing play and drag by rotating the pulley 3.4 - 3.8 ohms at 20°C (68°F)
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).
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

Compressor Clutch Overhaul
27
1. Remove the driver bolt while holding the driver clutch with driver clutch 3. If you are replacing the clutch coil, remove the retaining ring (A) with
holder 5-8840-4056-0 (J-37872). retaining ring pliers, then remove the pulley assembly (B). Be careful
not to damage the pulley assembly and compressor assembly.
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 shims as necessary, then 4. Remove the screw from the clutch coil ground terminal (A). Remove
reinstall the driver clutch and recheck its clearance (see page 21-26). the retaining ring (B) with retaining ring pliers, then remove the clutch
coil (C). Be careful not to damage the clutch coil and compressor
assembly.
21-28_Air Conditioning_Compressor Clutch Overhaul (cont'd)
Air Conditioning 21- Compressor Relief Valve Replacement
Compressor Clutch Overhaul (cont'd)

28
5. Reassemble the clutch in the reverse order of disassembly and note 1. Discharge the refrigerant.
these items: 2. Remove the relief valve (A), the O-ring (B), the spring (C) and the
Install the clutch coil with the wire side facing down and align the boss valve (D). Plug the opening to keep foreign matter from entering the
on the clutch coil with the hole in the compressor assembly. system 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. Clean the mating surfaces.

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. Remove the plug and install and tighten the relief valve.
6. Charge the system.
7. Check for system performance (see page 21-30).
21-29_Air Conditioning_Condenser Replacement

Condenser Replacement
29
1. Discharge the refrigerant. 4. Remove the mounting bolts, then remove the condenser by lifting it up.
2. Remove the front bumper. Be careful not to damage the radiator and condenser fins when
3. Remove the bolts, then disconnect the discharge line (A) and the removing the condenser.
condenser line (B) from the condenser. Plug or cap the lines
immediately after disconnecting them to avoid moisture and dust
contamination.
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).
21-30_Air Conditioning_A/C System Tests

A/C System Tests
30
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 conditioner system is
operating within specifications.
● Use only a gauge set for refrigerant HFC-134a (R-134a).
1. CHECK VALVE
● Use a vacuum pump adapter which is equipped with a check valve to
2. LOW-PRESSURE VALVE
prevent the backflow of the vacuum pump oil. 3. HIGH-PRESSURE VALVE
If accidental system discharge occurs, ventilate work area before 4. EVACUATION STOP VALVE
resuming service. 5. VACUUM PUMP
6. HIGH-PRESSURE QUICK JOINT
R-134a service equipment or vehicle air conditioning systems should not 7. LOW-PRESSURE QUICK JOINT
be pressure tested or leak tested with compressed air.
Additional health and safety information may be obtained from the 2. Insert a thermometer in the centre air vent. Determine the relative
refrigerant and lubricant manufacturers. humidity and air temperature.
1. Connect a R-134a gauge set as shown. NOTE: LHD type is shown, RHD type is symmetrical.
THREE VALVE GAUGE:
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.
-1
● Run the engine at 900 (min ).
● No driver or passengers in vehicle.
4. After running the air conditioning for 10 minutes under the above test
conditions, read the delivery temperature from the thermometer in the
centre air vent, the intake temperature near the blower unit behind the
1. CHECK VALVE
2. LOW-PRESSURE VALVE glove box and the high and low system pressure from the A/C gauges.
3. EVACUATION VALVE
4. HIGH-PRESSURE VALVE
5. VACUUM PUMP
6. HIGH-PRESSURE QUICK JOINT
7. LOW-PRESSURE QUICK JOINT

21-30_Air Conditioning_A/C System Tests

21-31_Air Conditioning_A/C System Tests (cont'd)

A/C System Tests (cont'd)
31
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.
21-32_Climate Control_Symptom Troubleshooting Index
Climate Control 21-

Symptom Troubleshooting Index
32
Symptom Diagnostic procedure Also check for
Both fans do not run at low speed with the A/C on Radiator and Condenser Fans Low Speed Circuit ● Blown fuse No. 1 (30A) in the under-hood
when the refrigerant pressure is below 1,520 kPa Troubleshooting (see page 21-13) fuse/relay box and No. 14 (10A) in the under-
(15.5 kgf/cm2, 220 psi). dash fuse/relay box
● Poor ground at No. G301
● Cleanliness and tightness of all connectors
Condenser fan does not run at high speed when the Condenser Fan High Speed Circuit Troubleshooting ● Blown fuse No. 14 (10A) in the under-dash
engine coolant temperature is above 100°C (212°F) (see page 21-16) fuse/relay box
or the refrigerant pressure is above 1,520 kPa (15.5 ● Poor ground at No. G302
kgf/cm2, 220 psi) with the A/C on. ● Cleanliness and tightness of all connectors
Both fans do not run at high speed with the A/C on Radiator and Condenser Fans High Speed Circuit Cleanliness and tightness of all connectors
when the refrigerant pressure is above 1,520 kPa Troubleshooting (see page 21-17)
(15.5 kgf/cm2, 220 psi).
Compressor clutch does not engage. Compressor Clutch Circuit Troubleshooting (see ● Blown fuse No. 6 (20A) in the under-hood
page 21-18) 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 and A/C Pressure Switch Circuit Troubleshooting (see Cleanliness and tightness of all connectors
compressor). page 21-36)
21-33_Climate Control_System Description
Climate Control 21-

System Description
33
Climate Control Unit Inputs and Outputs
CLIMATE CONTROL UNIT CONNECTORS
CONNECTOR A (14P) CONNECTOR B (22P)

CONNECTOR A (O on Circuit Diagram)
Cavity Wire colour Signal
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)

Cavity Wire colour Signal
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
22 RED/WHT ENGINE COOLANT TEMPERATURE (ECT) SENSOR OUTPUT

21-33_Climate Control_System Description

21-34_Climate Control_Circuit Diagram
Climate Control 21-

Circuit Diagram
34
21-35_Climate Control_Circuit Diagram
Climate Control 21-

Circuit Diagram
35
21-36_Climate Control_A/C Pressure Switch Circuit Troubleshooting
Climate Control 21-

A/C Pressure Switch Circuit Troubleshooting
36
1. Disconnect the A/C pressure switch 4P connector. 6. Reconnect the A/C pressure switch 4P connector.
2. Turn the ignition switch ON (II). 7. Disconnect the climate control unit connector A (14P).
3. Measure the voltage between the No. 1 terminal of the A/C pressure 8. Turn the ignition switch ON (II).
switch 4P connector and body ground. 9. Measure the voltage between the No. 4 terminal of climate control unit
A/C PRESSURE SWITCH 4P CONNECTOR connector A (14P) and body ground.
CLIMATE CONTROL UNIT CONNECTOR A (14P)
Wire side of female terminals Wire side of female terminals

Is there battery voltage? Is there battery voltage?
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 pressure switch 4P connector. If
NO - Repair open in the wire between the A/C diode A, the ECM and the connections are good, substitute a known-good climate control unit
the A/C pressure switch. and recheck. If the symptom/indication goes away, replace the original
4. Turn the ignition switch OFF. climate control unit.
5. Check for continuity between the No. 1 and No. 4 terminals of the A/C NO - Repair open in the wire between the climate control unit and the
pressure switch. A/C pressure switch.
A/C PRESSURE SWITCH
10. Check for proper A/C system pressure.
Is the pressure within specifications?
NO - Repair the A/C pressure problem.
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 the glove box, seat belt tensioners in the front
special precautions and tools, and should therefore be done by an authorised Honda dealer.
WARNING
Honda dealer.
17-2_Steering_Special Tools
Steering 17-2
Special Tools

1 07MAA-SL00200 Locknut Wrench, 43 mm 1
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17-3_Steering_Rack Guide Adjustment
Steering 17-3
Rack Guide Adjustment
Special Tools Required 5. Tighten the rack guide screw (A) to 25 Nm (2.5 kgf/m, 18 lbf/ft), then
Locknut wrench, 43 mm 07MAA-SL00200 loosen it.
1. Set the wheels in the straight ahead position.
2. Remove the transmission mount bracket (see step 18 on page 13-18).
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.
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.
7. Hold the rack guide screw stationary with a wrench and tighten the
locknut by hand until it is fully seated.
4. Remove the old sealant from rack guide screw and apply new sealant
8. Install the special tool on the locknut (B) and hold the rack guide screw
to the middle of the threads (C). Loosely install the rack guide screw
(A) stationary with a wrench. Tighten the locknut an additional 30° with
on the steering gearbox.
the special tool.
9. Reinstall the transmission mount bracket.
10. Check for unusual steering effort through the complete turning travel.
11. Check the steering wheel rotation play and the power assist.
17-4_Memo
Memo 17-4
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 the glove box, seat belt tensioners in the front
special precautions and tools, and should therefore be done by an authorised Honda dealer.
WARNING
Honda dealer.
22-2_Relay and Control Unit Locations_Engine Compartment
Relay and Control Unit Locations 22-2

Engine Compartment

1. HORN RELAY
2. A/C COMPRESSOR CLUTCH RELAY
3. CONDENSER FAN RELAY
4. REAR WINDOW DEFOGGER RELAY
5. BLOWER MOTOR RELAY
6. HEADLIGHT RELAY 1
7. HEADLIGHT RELAY 2
8. ELD UNIT
9. UNDER-HOOD FUSE/RELAY BOX
22-3_Relay and Control unit Locations_Engine Compartment (cont'd)
Relay and Control unit Locations 22-3

Engine Compartment (cont'd)

1. ENGINE GLOW RELAY
2. WATER HEATER RELAY 1
3. MULTI-RELAY BOX
4. WATER HEATER RELAY 2
5. RADIATOR FAN RELAY
6. FAN CONTROL RELAY
22-4_Relay and Control Unit Locations_Dashboard
Relay and Control Unit Locations 22-4

Dashboard

1. MAIN RELAY
[Wire colours: YEL/BLK, WHT/BLK, WHT/BLK
and RED/YEL]
22-5_Wire Harness and Ground Locations_Engine Compartment
Wire Harness and Ground Locations 22-5

Engine Compartment

1. ENGINE WIRE HARNESS
22-6_Fuse/Relay Boxes_Connector to Fuse/Relay Box Index
Fuse/Relay Boxes 22-6

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
Headlight relay 2 14 4
Horn relay 1 4
Rear window defogger relay 4 4
T1 16 Battery positive cable (Engine wire harness)

T101 15 Engine wire harness
22-7_Fuse/Relay Boxes_Connector to Fuse/Relay Box Index (cont'd)
Fuse/Relay Boxes 22-7

Connector to Fuse/Relay Box Index (cont'd)
Under-hood Multi-relay Box

Socket Ref Terminal Connects to
Engine glow relay 1 4
Fan control relay 3 4
Radiator fan relay 5 4
Water heater relay 1 2 4
Water heater relay 2 4 4
22-8_Power Distribution_Fuse to Component Index
Power Distribution 22-8

Fuse to Component Index
Under-hood Fuse/Relay Box

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
22-9_Power Distribution_Fuse to component Index (cont'd)
Power Distribution 22-9

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
22-10_Power Distribution_Fuse to Component Index (cont'd)
Power Distribution 22-

Fuse to Component Index (cont'd)
10
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
10 7.5A Fuse/relay box Multiplex control unit
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
22-11_Power Distribution_Fuse to Component index (cont'd)

Fuse to Component index (cont'd)
11
IGP Fuser
Number
- 7.5A LT GRN ECM
*: Not used
22-12_Power Distribution_Circuit Identification

Circuit Identification
12
To go to the pages referenced in the above diagram, click on the following:

22-16 22-17 22-14
22-13_Power Distribution_Circuit Identification (cont'd)

Circuit Identification (cont'd)
13

22-14 22-16

14

22-15 22-16 22-13

15

18

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0-1_Introduction_How to Use This Manual

● Safety Messages – preceded by a safety alert symbol

● Instructions – how to service this vehicle correctly and safely.

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All Rights Reserved

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SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

A Few Words About Safety

cool before working in those areas.

To reduce the possibility of a fire or explosion, be careful when

ITEM DESCRIPTION 2001 2001 2001 2001 2002 REFERENCE

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3-door model added O O -

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Chassis and Engine Numbers 1-2

General Information 1-2

General Information 1-3

Model/Applicable Area Code/VIN/Engine Number/Transmission Number List

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-

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-

General Information 1-4

1. Vehicle Identification Number (VIN)

General Information 1-5

DI Distributor Ignition L Left

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DPI Dual Point Injection LEV Low Emission Vehicle

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General Information 1-6

MAP Manifold Absolute Pressure STD Standard

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RON Research Octane Number First

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Standards and Service Limits

Standards and Service Limits 2-2

Item Measurement Qualification Standard or New Service Limit

Height Reference: 95.0 mm (3.74 in.) –

Exhaust – 1.5 mm (0.06 in.)

Standards and Service Limits 2-3

Item Measurement Qualification Standard or New Service Limit

Standards and Service Limits 2-4

Item Measurement Qualification Standard or New Service Limit

Fuel and Emissions

Pressure plate Height of diaphragm spring – 1.0 mm (0.039 in.) or less

Standards and Service Limits 2-5

Item Measurement Qualification Standard or Service Limit

Output shaft Run out – 0.02 mm (0.0008 in.)

Output shaft 5th gear I.D. – 41.05 mm (1.6161 in.) or less

3rd/4th, 5th – 3.7 mm (0.146 in.) or less

Reverse – 59.5 mm (2.343 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

Standards and Service Limits 2-6