1996 HONDA CIVIC Set idle

\
I
'98 - 0O D16Y5 ongine with CvT
Adjust the idle speed using a Honda PGM Tester if pos-
sible. lf not, use the following procedure:
NOTE:
. Leave the IAC valve connected.
. Before s€tting the idle speed, check the following
rtems:- The MIL has not been reported on.
- lgnition timing
- Spark Plugs- Air clean€r
- PCV svstem
'1. Connect a tachometer.
2. Stan the engine. Hold the engine at 3,000 rpm w'th
no load (transmission in E or E] position) until the
radiator Jan comes on, then let it idle.
3. Check the idle speed under no-load conditions:
head lights, blower fan, rear defogger, radiator fan,
and air conditioner are not operatlng.
ldlo spaod ehould bo: 700 t 50 rpm
. lf the idle speed is within the specification, the
procedure is comPlete.
. lf the idle sDeed is out of specitication, 9o to step 4'
4. tf the idle speed is 810 1 50 rpm, this means the
EVAP system is purging the canister. To stop the
purging temporarily, raise the engine speed above
l,OO0 rgm with the accelsrator pedal. Slowly release
the pedal. and rscheck the idl€ speed.
. tf the idle speed is within the specificstion, the
Drocedure is comPlete.
. lf the idle sp€ed is out of spocification, go to step 5.
5. Disconnect th€ EVAP purgs control solenoid valve
2P connector.
EVAP PURGECONTROL
6. Remove the cap and turn the idle adiusting screw
1/2-turn clockwise or counterclockwlse
IDLE
7.After turning the idle adjusting screw 1/2-turn, check
the idl€ speed again. lf it is out of spec, turn the idle
adjusting screw 1/2-turn again.
NOTE: Do not turn the idle adjusting screw more
than 1/2-turn without checking the idle speed.
Turn the ignition switch OFF. Reconnect the EVAP
purge control solenoid valve 2P connector' then do
the ECM reset Procedure.
Start the engine. ldle the engine for one minute with
heater fan switch at Hl and air conditioner on, then
check the idle speed.
ldle spaed should be:
810 t 50 rpm (in El or E Posiiion)
lf the idle speed is not within specification, see
Svmptom Chart on Page 11-84.
9.
SOLENOID VALVE
11-223

Intake Air System
Throttle Cable (cont'dl
4. Set the locknut on the cable bracket. Adjust theadjusting nut so that its free play is O mm.
5. Bemove the cable sheath from the throttle bracket,reset the adjusting nut and tighten the locknut.
O16Y5, D16Y8 engino:
ADJUSTING NUT
9.8 N.m{1.0 kgl.m,1.2 tbt.ttl
DtGYT 6ngine:
11-246
816A2 engine:
1. Open the throttle valve fully, then install the throttlecable in the throttle linkage. and install the cablehousing in the cable bracket,
THROTTLE LINK
LOCKNUTADJUSTINGNUT
Start the engine. Hold the engine at 3.000 rpm withno load (in Park or neutral) until the radiator fancomes on, then let it idle.
Hold the throttle link to the throttle lever; thereshould be no clearance.
Hold the cable sheath, removing all slack from thecable.
Turn the adjusting nut untit it is 3 mm {1/8 in.) awayfrom the cable bracket,
LOCKNUT9.8 N.m(1.0 kgt m,7.2 tM.ttl
ADJUSTING NUT
Tighten the locknut. The cable deflection shouldnow be 10 - 12 mm l3/B - 1/2 in.). lf nor. seeInspection/Adjustment.
3 mm 11/8 in.)

Emission Control System
Exhaust Gas Recirculation (EGR) System (D16Y5 engine with GWI (cont'dl
lTl49il T_he scan tool indicates Diagnostic Trouble Code (OTC) P1491: A malfunction in the Exhaust Gas Recirculation- lEgh) svstem.
CvT lM/T see page 1l-2611:
J
EGR VALVELIFT SENSOR#16 HOSE
PUMP/GAUGE,0- 30 in.HsA973X-041-XXXXX
EGRVALVE
The MIL has been reoorted on.DTC P1491 is stoled.
Problem verification:1. Do the ECM/PCM Reset Proce-du re.2. Connect the SCS service con'
3. Start the engine. Hold theengine at 3,000 rpm with noload {in Park or neutral) untilthe radiator fan comes on,4. Drive the vehicle on the roadfor approx. 10 minutes. Try tokeep the engine speed in the1,700 - 2,500 rpm range.
Intermittonl failure, system is OKat this time. Check for Door con-nections or loose wires at, C144{EGR velve} and ECM/PCM.
ls DTC P l49l indicated?
Check fo. vacuum to ihe EGR
1. Disconnect the No. 16 hose fromthe EGR valve.2. Connect a vacuum pump/gauge to the hose.3. Start the engine and let it idle.
ls there any vacuum?
Check tor a malfunction in theEGR control solenoid valve:'1. Disconnect the EGR controlsolenoid valve 2P connector,2. Becheck the No. 16 hose for
Check vacuum hose routing o,the entire EGR svstem. lf hoserouting is OK, replac€ the EGRcontrol solenoidvalv6.
ls there any vacuum?
Substitute a known-good ECM/PCM and recheck. It symptom/indicalion goes away, replacethe original ECM/PCM.
(To page 11 257)
11-256

\JExhaust Gas Recirculation System (D16Y5 engine with M/T)
M/T:
EGR VALVE 6P CONNECTOB (C14'rl
G10lIBLK}
1
a
PNK
IE.EGRI
Wi16 side of male terminals
I
sG2{GRN/BLK}
vcc2{YEL/BLU)
- Th6 MIL ha3 b€on reponed on.- DTC Pl,{tl is 3tored.
Prcblem verification:1. Do the ECM Reset Procedure.
2. Connect the SCS service con_nector.3. Start the engine. Hold the
engine at 3,000 rpm with no
load (transmission in neutral)
untilthe radiator fan comes on.
4. Drive the vehicle on the road
for approx. 10 minutes. Try to
keep the engine speed in the
1,700 - 2,500 rpm range.
lnlermittont tailure, svalem is OK
at thi3 tim6. Check foi Poor con'
nections or looso wiro3 at Cl/K
IEGR valvsl and ECM.
ls DTC P1491 indicated?
Check tor a malfunction in the
EGR valv6:1. Turn the ignition switch OFF.
2. Disconnect the EGR valve 6P
connector.3. Stanthe engine and let it idle
4. Measure voltage between the
EGR valve 6P connector termi'
nals No.4and No.6.
Check the EGR valve:1. Turn the ignition switch OFF2. Turn the ignition switch ON lll).3. Measure voltage between theEGR valve 6P connector termi
nals No.2 and No.3.
ls there battery voltage?
Substitute a known-good ECM
and recheck. It symptom/indica_tion goes away, replace th€ origi-
nal ECM.
ls there approx.5V?
(To page 11-262)

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(From page 11-284)
\(cont'd)
11-285
EVAP PURGE CONTROL SOI.INOID
VALVE 2P CONNECTOR IC114I
Wire side otfemaleterminals
?,
I,l,lil?"",,,u
EL,TWYEL)
Check the EVAP pirrge controlsolenoid valvei1. Disconnect the 2P connector
lrom the EVAP purge control
solenoid valve.
2. Ouickly raise the engine speed
to 3,000 rpm.
ls there vacuum?
InsDect vacuum ho56 routing.ll OK, replace the EVAP Purgecontrol solenoid valve.
Chock for a short in the wire(PCS linel:1. Turn the ignition switch OFF
2. Disconnect ECM/PCM connec'
tor A (32Pi.
3. Check for continuity between
the EVAP PUrge control sole
noid valve 2P connector termi
nal No.2 and body ground.
Check the vacuum when hot:
1. Turn the ignition switch OFF
2. Block the rear wheels and set
the parking brake.3. Jack up the front o{ the vehi-
cle and support it with safety
stands,4. Start the engine. Hold the
engine al 3,000 rpm wlth no
load (in Park or neutral) until
the radiator fan comes on, then
let it idle.5, Check for vacuum at the vac-
uum hose with transmissaonin gear (A/T in B Position,M/T in lst gear) after starting
the engrne.6. Ouickly raise the engine speed
to 3,000 rpm.
Reoair short in the wire botween
the EVAP purg€ cor|t]ol solenoid
valve and the ECM/pcM lA15l.ls there continuity?
Substitute a known-good ECM/
PCM and recheck. lf sYmPtom/indication goes eway. repl.c€ the
original ECM/PCM.
Check the EVAP Purg€ control
solenoid valve:1. Turn the ignition switch OFF
2. Disconnect the 2P connector
from the EVAP Purge control
solenoid valve and warm lt
up to normal operating tem_perature again if necessary
3. Stan the engine.4. At the harness side, measure
voltage between the EVAP
Purge control solenoid valve
2P connector terminal No. 1
and No. 2 with the transmission in gear (A,/T in E Posi-tion, M/T in 1st gear).
In3pect vacuum ho3€ touting.
ll OK, replace EVAP Purge con-
lrol aolenoid vtlv€.
Check lo. an open in the wire
llGl linel:At the harness side, measure volt
age between the EVAP Purge con-
trol solenoid valve 2P connectorterminal No. 1 and body groundRepeir open in tho wire between
EVAP purge conttol solenoid valv€
and the No. 15 ALTERNATOR SP
SENSOR (7.5 A fu3e
IBLK/YELI
lTo page 11 286i(To page 11-286)

Emission Control System
Ch€ck the EVAP purge controlsolenoid valv6:1. Disconnect the 2P connectorfrom the EVAP purge controlsolenoid valve.2. Ouickly raise the engine speedto 3,000 rpm.
Insped vacuum hose routing.lf OK. roplace the EVAP purge
control solonoid valve.
Chock tor r short in the wir€
{PCS line):1. Turn the ignition switch OFF.2. Disconnect ECM/PCM connec-tor A (32P).
3- Check tor continuity betweenthe EVAP purge control sole-noid valve 2P connector termi-nal No. 2 and body ground.
Check the vacuum when hot:1. Turn the ignition switch OFF.2. Block the rear wheels and setthe parking brake.3. Jack up the lront of the vehi-cle and support it with safetystands.4. Start the engine. Hold theengine at 3,000 rpm with noload (in Park or neutrali until
the radiator fan comes on, thenlet it idle.5. Check for vacuum at the vac-uum hose with transmissionin gear (A/T in E position,
lvl/T in 1st gear) after startingthe engine.6. Ouickly raise the engine speedto 3,000 rpm.
Rooair shoft in the wire belwegnthe EVAP pulg6 control solenoidvalvs and tho ECM/PCM {A61.ls there continuity?
Substitute a known-good ECM/PCM and rech6ck. lt 3ymptom/indicrtion 90e3 rway, r6plac6 th€o.iginal ECM/FCM.
Check th€ EVAP purge controlsolenoid valve:1. Turn the;gnition switch OFF.2. Disconnect the 2P connectorfrom the EVAP purge controlsolenoid valve and warm itup to normal operating tem-perature again if necessary.3. Start the engine.4- At the harness side, measurevoltage between the EVAPpurge control solenoid valve2P connector terminal No. 1and No.2 with the transmis-sion in gear {A/T in E posi-tion, M/T in lst geari.
In3pect vacuum hoae routing.lf OK, repl.ce EVAP purge con-trol solonoid valve.ls there battery voltage?
Chock for an open in the wire(lG1 lina):At the harnoss side, measure volt-age beNveen the EVAP purge con-trol solenoid valve 2P connectorterminal No. 1 and body ground.
Repair open in the wire b€lwe€nEVAP purge contrl 3olenoid valv6and lhe No. 15 ALTERNATOR SPSENSOR 17.5 A, fu3e.
ls there battery voltage?
Evaporative Emission (EVAPI Controls (cont'dl
(From page 11-289)
(To page 11-291)
11-290
IJ
EVAP PURGE CONTROL SOLENOIDVALVE 2P CONNECTOR IC114I
PCS
IRED/YEL)
temaletermrnars
of
PCS(RED/YEL)
tGlIBLK/YEL)
{To page 11 291)

Troubleshooting
Reverse Gear Noise Reduction System
Whenever the clutch pedal is depressed to shift into reverse, the mainshaft continues to rotate because of its inertia.
The resulting speed difference between mainshaft and reverse idler gear produces gear noise.
The reverse gear noise reduction system employs a cam plate which was added to the reverse shift holder. When shifting
into reverse, the sth/reverse shjft piece, connected to the shift lever, rotates the cam plate. This causes the sth synchro set
to stop the rotating mainshaft. As there is no speed difference between mainshaft and reverse idler gear, there will be less
gear norse.
NOTE: This system is not a fully-synchronized gear noise reduction system.
Therefore, you may hear gear noise when
O you shift into reverse with the vehicle not yet completely stopped.
@ you shift quickly into reverse during fast idling.
-
Gear noise is oresent when shift-ing into reverce after the engineis started.
Test-drive the vehicle.
ls the gear noise present whenshifting into 5th gear?Beplace the 5th synchro hub and3leeve e3 a set,
Measure the clearance between5th shift fork and 5th synchrosleeve {see page 13'26).
ls the clearance 1.0 mm (0.04
in) or less?
Measure the MBS shift piece pin(see page 13-27).
ls ( 6.8 mm (0.27 in) or more?Replace the MBS shift piece.
ReDlace the reve6e ahift hold.r.
13-4

Torque Value
A - 15 N.m (1.5 kgf.m, 1'1 lbf.ft)
B - 27 N.m (2.8 kgf.m. 20 lbift)
C - 31 N.m {3.2 kgnm, 23 lbift)
\
O BALL BEARING (*T)
ANGULAR
BALL BEARING {*2I
O 5TH SYNCHRO HUB
O 5TH SYNCHRO SLEEVE
€) SYNCHRO SPRING
o SYNCHRO B|NG
@ 5TH GEAR
@ gz xgt x 23.5 mm
NEEDLE BEARING
@ SPACER COLLAR
@34x39x23mm
NEEDLE BEARING
(D 4TH GEAR
O SYNCHRO RING
C) SYNCHRO SPRING
CO 3RD/4TH SYNCHRO SLEEVE
@ 3RD/4TH SYNCHRO HUB
(} 3RD GEAR
@34x39x27.5mmNEEDLE BEARING
G) MAINSHAFT
G) WASHER
@ SPRING WASHER
@ BALL BEARING
Check for wear and
operation.(E 26x42x7 mm OIL SEAL
Replace.
@ 28 mm PLUG BOLT
5,1 N.m {5.5 kgf'm, /t0 lbt'ft)
@ lsT/zND SELECT SPRING
L. 36.26 mm (1./P8 in)
@ SHIFT ARM SHAFT
@ CLUTCH HOUSING
@ INTEELOCK GUIDE BOLT
39 N.m (4.0 kgf.m, 29 lbf.ftl
@ REVERSE SHIFT HOLDER
@ REVERSE IDLER GEAR
@ REVERSE IDLER GEAR SHAFT
@ 5 x 22 mm SPRING PIN
Replace.
@ 3RD/4TH SHIFT PIECE
@ 5TH/REVERSE SHIFT PIECE
@ MBS SHIFT PIECE
@ 1ST/2ND SHIFI FORK
*1:D16Y7 engine*2: D16Y5, D16Y8 engines
@ 3RD//|TH SHIFT FORK
@ 5TH/REVERSE SHIFT FORK
@ 52 mm SNAP RING
@ 65 mm THRUST SHIM (*11
70 mm THRUST SHIM (*21
Selection, page 13-36
@ OIL GUIDE PLATE
@ wASHER Replace.
@ BACK.UP LIGHT SWITCH
25 N.m (2.5 kgf'm, 18 lbf'ft)
@ sET SCREW
22 N.m {2.2 kgf.m, 16 lbl.ft}
@ WASHER Replace.
@D SPRING 1.31.6 mm (1.2,1inl
@ STEEL BALL 15/16 in)
@ BACK-UP LIGHT
SWITCH HARNESS BRACKET
@ TRANSMISSION HANGER
@ 32 MM SEALING BOLT
25 N.m (2.5 kgf.m, 18 lbt'ft)
@ OIL SEAL
Replace.
@ OIL DRAIN PLUG
39 N.m (4.0 kgf.m, 29 lbf.ft)
@ WASHER Replace.
@} OIL FILLER PLUG
44 N.m (4.5 kgf.m, 33 lbf'ftl
@ WASHER Replace.
@) TRANSMISSION HOUSING
€) CLUTCH LINE BRACKET
@ OIL GUTTER PLATE
@ REVERSE LOCK CAM
@ REVEBSE SELECT SPRING
L. 63.4 mm {2.,196 in)
@ REVERSE SELECT RETAINER
@ SHIFT ARM C
@ SHIFT ARM B
@ INTERLoCK
@ COLLAR
@ SHIFT ARM A
@ SPRING WASHER
@ MAGNET
@ sET BALL SPRING BOLT
22 N.m (2.2 kgf.m, 16 lbf.ftl
@ 14 x 20 mm DOWEL PIN
@ 72 mm THRUST SHIM l*11
80 mm THRUST SHIM (*21
Selection, page '13-33
@ DIFFERENTIAL ASSEMBLY
See page 13-30
@ 14 x 25 x 17.5 mm OIL SEAL
Replace.
@ 35 x 56 x 8 mm OIL SEAL
Replace.
@ SHIFT ROD
@ BOOr
@ OIL GUIDE PLATE
@30x47x21 mm
NEEDLE BEARING (* 1}
30x55x21 mm
NEEDLE BEARING {'2)
@ COUNTERSHAFT
@36x41 x 25.5 mm
NEEDLE BEARING
Check for wear and
operatron.
@ lsT GEAR
@ FRICTION DAMPER
@ SYNCHRO RING
@ SYNCHRO SPRTNG
@ lST/2ND SYNCHRO HUB
@ REVERSE GEAR
@ SYNCHRO SPRING
@ SYNCHRO RING
@ FRICTION DAMPER
@ SPACER
@39x4lx27mm
NEEDLE BEARING
@ 2ND GEAR
@ 3RD GEAR
@ 4TH GEAR
@ sTH GEAR
@) BALL BEARING {* 1}
NEEDLE BEARING (*2}
@ BALL BEARING
@) SPRING WASHER
@ LoCKNUT Replace.
108 - 0- 108 N.m
ftt.o* o- 1r.o kst.m,l
179.6- 0- 79.6 rbtft I

13-1 1