1996 HONDA CIVIC Elect

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Fuel Tank Pro3sure sensor 196 D16Y8 engine (coupe).'97 D15Y7 engine {coupe: KL model, sedan: KL (LX) modeu,'97
D16Y8 engine (coupe: all models, sedan: KL model, '98-all models) '99 - 00 D16Y5 engine with M/Tl:
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PTANK
{LT GRNI
vcc2(YEL/BLU}
Wire side oI female terminals
FUEL TANKPRESSURE SENSOR3P CONNECTOR (C7921
sG2IGRN/8LK)
Foc2l::il":"toolindicatesDiagnosticTroublecode(DTc)P0452:A|owvo|tageprob|emintheFue|TankPressure
The fuel tank pressure sensor converts fuel tank absolute pressure into electrical signals and inputs the EcM/PCM.
OUTPUTVOLTAGEtvt4.5
-? kPa(-50 mmHg,-2 in.Hg)
ECM/PCM CONNECTOR O I16P)
Wire side of female terminals
+7 kPs150 mmHg,2 in.Hg)
PRESSURE
(cont'd)
11-275
- The MIL has been reported on- DTC P0452 is stored.
Check the vacuum lines:
Check the vacuum lines of the
fuel tank pressure sensor for mis-
routing, leakage, breakage and
cloggrng.
Are the vacuum lines OK?
Problem v€ritication:1. Do the ECM/PCM Reset Proce
dure.2. Remove the luel fill caP.
3. Turn the ignition switch ON lll)4. Monitor the FTP Sensor volt_
age with the Honda PGM
Tester, or measure voltage
between bodY ground and
ECM/PCM terminal Dl5.lntermittent tailuro, sYstem i5 OK
dt this timo. Chock for Poot con-
neciion3 or loose wir* at C131
llocatod under right side ot dashl,
C4O1 (located .bove under'da3htuso/ielay box), C574 1C568)*
{located under acc€ss Panell.C792 lfuel tank pressule sen3or)
and EcM/PCM.
ls there approx. 2.5 V?
Check tol an op€n in wite (VCC2
line):1. Turn the ignition switch OFF
2. Reinstallthe fuel fill caP.3. Disconnect the fuel tank Pres'sure sensor 3P connector-4. Turn the ignition switch ON (ll)
5, Measure voltage between the
fuel tank pressure sensor 3P
connector No. l terminal and
No. 2 terminal.
Repair open in the wite betweenthe fuel tank Pr€s3ure a€n3or andth6 EcM/PcM (D1ol.ls there approx. 5 V?
(To page 11'276)

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'99 - 00 models excepi Dl6Y5 engine with M/T:
The scan tool indicates Diagnostic Trouble Code (DTC) P0452: A low voltage problem in the Fuel Tank Pressure
sensor.
The fuel tank pressure sensor converts fuel tank absolute pressure into electrical signals and inputs the ECM/PCM
OUTPUTVOLTAGE(vlt.5
0.5-7 kP.(-g) mmHg,-2 in.Hgl
+7 kP.
150 mmHg,2 in.Hgl
PRESSURE
I
Wire side of lemale terminals
FUEL TANKPRESSURE SENSORSUB.HARNESS6P CONNECTOR (C574 (C568)rl
vcc2(YEL/BLUIsG2{GRN/BLK}
Wire side o{ temale terminals
The MIL has been .eported on.
DTC P0452 is stored
Check the vacuum lines:
Check the vacuum lines of the
fuel tank pressure sensor lor mis-
routing, leakage, breakage and
cloggrng.
Are the vacuum hnes OK?
Problem veritication:1. Do the ECM/PCM Reset Proce-
du re,2. Bemove the fuel fill caP.
3. Turn the ignition switch ON {ll)
4. Monitorthe FTP Sensor voltage
with the Honda PGM Tester' or
measure voltage between body
groLrnd and ECM/PCM connec_
tor terminalA29.
lntermitlent tailure, 3Ystem b OK
at this time. Check for Poor con'
nections or loose wire3 at C131
{located under right side of dash},
C401 {located above under'dash
tuse/relay box), C574 (C568)*
llocdted under access Panel),C792 (tuel rank Prcssure sensorl
and ECM/PCM.
ls there approx.2 5 V?
Check for an open in wire {VCC2
line):1. Turn the ignition switch OFF.
2. Reinstall the ltrel fill caP
3, Remove the access Panel from
the floor.4. Disconnect the fuel tank Pres'sure sensor sub-harness 6P
5. Turn the ignition switch ON (ll).
6. At the access Panel side, mea_
sure voltage between the fuel
tank Pressure sensor sub-nar-
ness 6P connector No 5termi
nal and No. 6 termlnal.
Repair open in tho wire between
th6 fu€l tank Prossuro sen3oa and
the ECM/PCM lc28).ls there approx 5 V?
ECM/PCM CONNECTOR A (32P)
PTANK {LT BLUI
I
ll
(To page '11-278)
(cont'd)

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)
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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

Shift Rod
Removal
NOTE: The steel batlsareall of the same size (5/16 in)'
1. Remove the differential assembly'
2. Remove the 28 mm plug bolt and lst/2nd select
spring.
3. Remove the shift arm C attaching bolt'
4. Remove the shift arm shaft'
NOTE: Be careful notto lose the steel ball'
5. Remove the steel ball, spring, and collar'
SHIFT ARM C
SHIFT ARM B
INTERLOCK
6. Remove shift arms C and B, and the interlock, then
remove the reverse select spring and retainer'
7. Remove the shift arm A attaching bolt, the set ball
spring bolt, set spring, and steel ball'
8. Remove the shift rod' then remove the shift arm A'
9. Remove the reverse lock cam'
10. Remove the magnet.
CAM
REVERSE SELECT RETAINER
REVERSE SELECT SPRING
L. 63.4 mm {2.50 inl
REVERSE LOCK
lIV/
' lJ
\s
SPRING L. 21.4 mm(0.843 in)
SI{IFT ARM A
14x20OOWEL PIN
COLLAR
,*(S* \
6S* srtrr ran,t srarr
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',)r,r"o r..."r "rr,*n

t. 36.26 mm {1.428 in,
28 mm PI-UG BOLT
OIL SEALReplace.
&-"onn"
BALLSPRING EOLT
SPRINGL. 25.6 mm 11.01 inl
DIFFERENTIAL ASSEMBLY
SHIFT ROD

Differential
Check lor cracks.
BALL BEARINGCheck for wear and damage.
DIFFERENTIAL
THRUST SHIMSelective part
SPEEDOMETERDRIVE GEAR
10 x 1.0 mm101 N.m (10.3 ksf.m. 74.5 lbt.ftlLeft-hand threads
ffi
FrNAL DRTvEN o*^r'@c'ec'owea'-Zl
BALL BEARINGCheck for wear and damage.
13-30
Backlash Inspection
'1. Place differential assembly on V-blocks, and installboth driveshafts.
OIAL
Measure backlash of both pinion gears.
Standard {New); 0.05 - 0.15 mm {0.002 - 0.006 in)
lf the backlash is not within the standard, reDlacethe differential carrier.
SI

7. lf the clearance is more than the standard, select a
new thrust shim from the following table
NOTE: It the clearance measured in step 6 is within
the standard. go to step 10.
Standard: 0 - 0.10 mm l0 - 0.00/t inl
72 mm THRUST SHIM: D16Y7 engin€
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Part NumberThickness
41441 - PL3 - A001.0 mm (0.0394 in)
41442-PL3-A00'1 .1 mm {0.0433 in)
41443-PL3-A001.2 mm {0.0472 in)
41444-PL3-A001.3 mm (0.0512 in)
41445-PL3-A001.4 mm (0.0551 in)
41446-PL3-A001.5 mm (0.0591 in)
41447-PL3-A001.6 mm (0.0630 in)
41448-PL3-A001.7 mm (0.0669 in)
4r449-PL3-A001.8 mm (0.0709 in)
41450-PL3-A001.05 mm {0.0413 in)
41451-PL3-A001.15 mm (0.0453 in)
41452-PL3-A001.25 mm (0.0492 in)
41453-PL3-A001.35 mm (0.0532 in)
41454-PL3-A00'1.45 mm (0.057'l in)
41455-PL3-A001.55 mm (0.0610 in)
41456-PL3-A001.65 mm (0.0650 in)
41457-PL3-A001.75 mm (0.0689 in)
80 mm THBUST SHIM: D16Y5. D16Y8 engines
Remove the bolts and transmission housing.
Replace the thrust shim selected in step 7, then
recheck the clearance.
Remove the bolts and transmission housing. Apply
liquid gasket to the surface of the transmission
housing and reassemble
8.
9.
10.
Part NumbelThickness
41441 - PL3 - B001.0 mm (0.0394 in)
41442-PL3-8001.1 mm (0.0433 in)
41443-PL3-8001.2 mm (0.0472 in)
41444-PL3-8001.3 mm (0.0512 inl
41445-PL3-8001.4 mm (0.0551 in)
41446-PL3-8001.5 mm (0.0591In)
41447-PL3-8001.6 mm (0.0630 in)
4r 448 - PL3 - 8001.7 mm (0.0669 in)
4 t449 - PL3 - 8001.8 mm (0.0709 in)
41450-PL3-800'1.05 mm (0.0413 in)
41451 - PL3 - 800'1.15 mm (0.0453 in)
41452-PL3-8001.25 mm (0.0492 in)
41453-PL3-B001.35 mm (0.0532 in)
41454-PL3-B001.45 mm (0.0571 in)
41455-PL3-B001.55 mm (0.0610 in)
41456-PL3-8001.65 mm (0.0650 in)
41457-PL3-8001.75 mm {0.0689 in)

Mainshaft Thrust Shim
Adjustment
Remove the thrust shim and oil
the transmission housing.
1.gu ide plate from
THRUST SHIM
OIL GUIDEPLATE
TBANSMISSIONHOUSING
Install the 3rd/4th synchro hub, spacer collar, 5th
synchro hub, ball bearing, and thrust washer on themainshaft. Install the assembly in the transmission
h ousing.
@ gnol+lx syNcHRo HUB
THRUST WASHER
SPACER COLLAR
4.
Measure the distance @ between the end of thetransmission housing and thrust washer.
NOTE:
. Use a straight edge and vernier caliper.. Measure at three locations and average the read-
Ings.
Measure the distance @ between the surfaces ofthe clutch housing and bearing inner race.
NOTE:
. Use a straight edge and depth gauge.
. Measure at three locations and average the read-
Ings.
sTH SYNCHRO IIUB
BALL EEARING
CLUTCH
L
HOUSINGENO OF
13-36
INNER RACE OF BALL AEARING
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5.Select the proper shim on the basis of the followingcalculations:
NOTE: Use only one thrust shim.
(Basic Formula)(B) + {C). 0.95 = shim thickness
Example of calculation:
Distance @ (2.00 mm) + Distance @= 2.09 mm
subtract the spring washer height (0.95
required thrust shim (1.14 mm)
65 mm THRUST SHIM: D16Y7 engine:
(0.09
mm)
mm)
= tne
r1
Part NumborThickness
23931 - PL3 A100.60 mm (0.0236 in)23932 - PL3 A100.63 mm 10.0284 in)c23933 - PL3 A100.66 mm {0.0260 iniD23934 PL3 - A100.69 mm (0.0272 in)
E23935-PL3-4100.72 mm 10.0283 in)
F23936-PL3-4100.75 mm 10.0295 in)G23937-PL3-A100.78 mm {0.0307 in}
23938 PL3 - A100.81 mm (0.0319 in)I23939 - PL3 At00.84 mm (0.0331 in)J23940-PL3-Ar00.87 mm (0.0343 in)
23941 - PL3 - A100.90 mm (0.0354 in)
L23942 - PL3 A100.93 mm (0.0366 in)
23943-PL3-A100.96 mm (0.0378 in)N23944 PL3 - A100.99 mm 10.0390 in)
o23945-PL3-A101.02 mm {0.0402 in}23946 - PL3 A101.05 mm (0.0413 in)o23947 PL3 - 4101.08 mm (0.0425 in)R23948-PL3-A101.11mm (0.0437 in)s23949 PL3 - A101.14 mm {0.0449 in}T23950-PL3-A101.17 mm (0.0461 in)
U23951 PL3 - A101.20 mm (0.0472 in)
23952-PL3-Ar01.23 mm {0.0484 in)
23953-PL3-A101.26 mm {0.0496 in}X23954 - P13, A101.29 mm (0.0508 in)23955 - PL3 A101.32 mm (0.0520 in)z23956-PL3-Ar01.35 mm {0.0531 in)
23957-PL3-A101.38 mm (0.0543 in)
AB239s8 - PL3 A101.41 mm (0.0555 in)AC23959 PL3 - A101.44 mm (0.0567 in)
AD23960 - PL3 A101.47 mm (0.0579 in)23961 - PL3 4101.50 mm (0.0591 in)23962 PL3 - A101.53 mm (0.0602 in)AG23963-PL3-4101.56 mm (0.0614 in)AH23964 - PL3 A101.59 mm (0.0626 in)AI23965-PL3-A101.62 mm {0.0638 in)
23966 PL3 - A101.65 mm (0.0650 in)AK23967-PL3-A101.68 mm {0.0661 in)
23968 PL3 - A101.71 mm {0.0673 in)23969-PL3-A101.74 mm (0.06a5 iniAN23970- PL3 -A101.77 mm (0.0697 in)AO23971 - PL3 - A101.80 mm 10.0709 in)

70 mm THRUST SHIM: Dl6Y5, Dl6Y8 engin€s
Part NumberThickness
23931 - PL3 - 8000.60 mm 10.0236 in)
23932-PL3-8000.63 mm (0.0284 in)
c23933-PL3-8000.66 mm (0.0260 in)
D23334-PL3-8000.69 mm 10.0272 in)
E23935-PL3-8000.72 mm (0.0283 in)
F23936 - PL3 8000.75 mm (0.0295 in)
23937-PL3-B000.78 mm (0.0307 in)
23938-PL3-8000.81 mm (0.0319 inl
23939-PL3-8000.84 mm (0.0331 in)
23940-PL3-8000.87 mm {0.0343 in)
23941 - PL3 - 8000.90 mm (0.0354 in)
L23942-PL3-8000.93 mm (0.0366 in)
23943-PL3-8000.96 mm (0.0378 in)
N23944-PL3-8000.99 mm i0.0390 in)
o2394s-PL3-8001.02 mm (0.0102 in)
P23946-PL3-8001.05 mm {0.0413 in}
o23947-PL3-8001.08 mm (0.0{25 in)
23948 - PL3 800'1.1'1 mm (0.0437 4n)
23949-PL3-8001.14 mm (0.0449 inl
T23950-PL3-8001.17 mm (0.0461 in)
23951 - PL3 - 8001.20 mm (0.0472 in)
23952-PL3-8001.23 mm (0.0444 in)
239s3-PL3-8001.26 mm {0.0496 in)
X23954-PL3-8001.29 mm (0.0508 in)
2395s-PL3-8001.32 mm (0.0520 in)
z23956-PL3-8001.35 mm (0.0531 in)
23957-PL3-8001.38 mm (0.0543 in)
A823958-PL3-8001.41 mm (0.0555 in)
AC23959-PL3-8001.44 mm {0.0567 in)
AD23960-PL3-8001.47 mm (0.0579 in)
2396't-PL3-8001.50 mm (0.0591 in)
23962-PL3-8001.53 mm (0.0602 in)
AG23963-PL3-8001.56 mm (0.0614 in)
AH23964-PL3-8001.59 mm (0.0626 in)
23965-PL3-8001,62 mm (0.0638 in)
23966-PL3-8001.65 mm (0.0650 in)
AK23967-PL3-8001.68 mm (0.0661 in)
23968-PL3-8001.71 mm (0.0673 in)
23969-PL3-8001.74 mm (0.0685 in)
AN23970-PL3-8001.77 mm (0.0697 in)
AO23971- PL3 8001.80 mm (0.0709 inl
6. Installthe oil guide plate and selected thrust shim in
ths transmission housing
NOTE:
. Clean the thrust washer, spring washel and
thrust shim thoroughly belore installation.
. lnstall the thrust washer, spring washer and
thrust shim proPerlY.
THRUST SHIM
I
OIL GUIDEPLATE
TRANSMISSIONHOUSING
8.
o
10.
7, Install the thrust washer and spring washer in the
mainshaft.
lnstall the mainshaft in the clutch housing
Place the transmission housing over the mainshaft
and onto the clutch housing.
Tighten the clutch and transmission housings with
several 8 mm bolts.
NOTE: lt is not necessary to use sealing agent
between the housings'
8 x 1.25 mm
27 N'm t2.8 kgf.m. 20 lbf'ft)
Tap the mainshaft with a plastic hammer.
Check the thrust clearance in the manner doscribsd
below.
CAUnON: Mc.suromont 3hould bo mlde !t room
tomp9laturs.
a. Slide the mainshaft base and the collar over the
mainshaft.
CLUTCHHOUSING
11.
lz.
MAITISHAFT BASE07GAJ-PG20130COLLAF07GAJ -PG20120
{cont'd}
13-37
THRUST WASHER
SPRING WASI{ER