1997 HONDA CIVIC Torque spec

Master Cylinder/Brake Booster
Pushrod Glearance Adjustment
NOTEr
. The master cylinder pushrod-to-piston clearancemust be checked and adjustments made, if neces_sary, before installing the master cylinder.. ABS type is shown, conventional brake type is similar.
1. Set the special tool on the master cylinde. body; push
in the center shaft until the top of it contacts the endofthe secondary piston by turning the adjusting nut.
Without disturbing the center shaft's Dosition, installthe specialtool upside down on the booster.Install the master cylinder nuts, and tighten to thespecified torque.
Connect the booster in-line with a vacuum gauge O _
101 kPa (0 - 760 mmHg, 30 in.Hg) to the booster,sengine vacuum supply, and maintain an enginespeed that will deliver 66 kpa (500 mmHg, 20 in.Hg)vacuum.
With a feeler gauge. measure the clearance Detweenthe gauge body and the adjusting nut as shown.
Clearance: 0 - 0.4 mm {0 - 0.02 in)
VACUUM GAUGE(Comm€rcially availeblel0 - 101 kPa{0 - 760 mm Hg, 30 in.Hg)
AOJUSTING NUT
FEELER GAUGE
19-22
10.
NOTE: lf the clearance between the gauge bodyand adjusting nut is 0.4 mm (0.02 in), the pushrod-to-piston clearance is 0 mm. However, if the clear_ance between the gauge body and adjusting nut is0 mm, the pushrod-to-piston clearance is 0.4 mm(0.02 in) or more. Therefore, it must be adjusted andrechecked.
6. lf clearance is incorrect, loosen the star locknut, andturn the adjuster in or out to adjust.
NOTE;
. Adjust the clearance while the specified vacuumis applied to the booster.. Hold the clevis while adjusting.
Tighten the star locknut securely.
Remove the special tool.
0 - 0.4 mm (0 - 0.02 in)
7.
ADJUSTERPUSHRODADJUSTMENT GAUGE07JAG - SD('1(x)
9. Adjust the pushrod length as shown if the boosterrs removed.
STAR LOCKNUT22 N.m{2.2 kg,f.m, 16lbtft)
11610.5 mm{{.571 0.02 in)
PUSHRODLOCKNUT15 N.m 11.5 kgf.m, 11 tbtftl
Install the master cylinder {see page l9-21).

Brake Hoses/Lines
LJ
Inspection/Torque Specifications
t. Inspect the brake hoses for damage, deterioration, leaks, interference, and twisting.
2. Check the brake lines for damage, rusting. and leakage. Also check for bent brake lines.
3. Check for ieaks at hose and line ioints and connections, and retighten if necessary'
4. Check the master cylinder and ABS modulator unit for damage and leakage
CAUTION: Replace tho brake hose clip whenev€r the brake hose is serviced.
ABS MODULATOR UNIT-Io-BRAKE l-lNE19 N.m (1.9 kgf.m, 14lbl.ftl
PROPOBTIONING CONTROL VALVE.io-BRAKE LINEl5 N.m (1.511 tbf.ftl
MASTER CYLINDER-Io-BMKE LINE
15 N.m (1.5 ksrf.m, 11 lbf'ft)
REAR DISG BRAKE:BRAKE HOSE-to4ALlPER
{BANJO BOLT}34 N.m (3.5 kgtm,25 lbf ftlBLEEO SCREW9 N'm (0.9 kgf.m, 6.5 lM.ftlBRAKE LINE-to-WHEEL CYLINDER15 N.m (1.5 kgl.m, 11 lbf.ftlBLEED SCREW7 N.m {0.7 kst m, 5 lbf,ttl
JBRAKE LINE-io-aRAKE HOSE15 N.m {1.511 tbtft)
BRAKE LINE-Io-BRAKE HOSE15 N.m (1.5 kgt.m, 11 lbf'ft)
(BANJO BOLT}3,1 N.m 13.5 kgf.m, 25 lbf.ft)
J
19-39

Air Conditioning
Speciaf Tools ......'.....' 22-2
f f f ustrated f ndex ......................... ".......' 22-3
Wiring/Connector Locations'.........'.... 22'4
Description
Outfine ............ .......22-s
Circuit Diagram
'96 - 98 Models ......"..........".......'.... 22-6
'99 Modef """""""' 22-7
Troubleshooting
Symptom Chart ".'......""................. 22-8
Flowcharts
Condenser Fan .........".................,..'. 22-9
Compressor .....""" 22-12
A/C System .........'.22'17
A/C Thermostat
Test ........'.......' """'22'21
Relays
Test ....."'......... ..""'22-21
A/C Service Tips and Precautions ......22-22
A/C System Torque Specifications '...22-23
A/C System Service
Performance Test ... '."......... ".... ....'..22-24
Pressure Test Chart .................. .... "' 22-26
Recovery ...".........," 22-27
Evaporator
Replacement .....",' 22'24
Overhauf .....-.....""' 22'29
Compressor {SANDEN}
Repf acement ......'.' 22-30
fffustrated fndex ......"..................'.... 22'32
Cf utch Inspection ......... "............ ...... 22-33
Clutch Overhau I ........................ ....... 22-34
Thermal Protector Replacement .... 22-36
Relief Valve Replacement ......'..."". 22-36
Compressor (DENSO)
Repfacement ..""',' 22-37
lf lustrated Index ............................... 22-39
Clutch lnspection ............."'...... "'.... 22-40
Cf utch Overhaul .....................'......... 22-41
Ref ief Valve Replacement'..'......"'.. 22-42
A/C Compressor Belt
Adiustment ............22'43
Condenser
Repfacement .......,,22'44
A/C System Service
Evacuation ...,,,.......22-45
Charging '..........--'..22'46
Leak rest """""""'22-46

A/C System Torque Specifications
O Discharge hose to the compressor (6 x 1.0 mml ............... .. .... ...............' 9.8 N'm {1.0 kgf'm,7.2 lbf'ftl
@ Discharge hose to the condenser {6 x 1.0 mm1................... '... ...... . ......... 9.8 N'm 11.0 kgf'm, 7.2 lbf'ft}
O Condenser pipe to the condenser 16 x 1,0 mm)...............'. . . . ...........'..... 9.8 N'm (1.0 kgl'm, 7.2 lbt'ft)
@ Condensel pipe to the receivel/dryer (5 x 1.0 mml......... ..... . ... . '.......... 9.8 N'm (1.0 kgl'm, 7.2 lbt'ft)
O Receiver pipe A to the leceiver/dryer {6 x 1.0 mm)......... ... .......... .. . . .... 9.8 N'm 11.0 kgf'm. 7.2 lbl'ft)
@ Receiver pipe B to the receiver pipe A 13 N m (1.3 kgf'm, 9.'l lbf'ft)
O Receiver pipe C to the receiver pipe B 13 N m (1.3 kgf'm, 9.4 lbnftl
@ Receiver pipe C to the evaporator {6 x 1.0 mm) ....... 9.8 N'm (1.0 kgf'm, 7.2 lbtftl
O Suction pipe B to the evaporator (6 x 1.0 mml................ . .........'......'....... 9.8 N'm (1.0 kgf m, 7.2 lbf'ftl
e0 Suction pipe A to the suction pipe B ...'. . ...... . ... ...... 31 N'm (3.2 kgt'm, 23 lbf'ftl
O Suction hose to the suction pipe A... ............ . . '......... 31 N'm (3.2 kgl'm, 23 lbf'ft|
@ Suction hose to the compressor (6 x 1.0 mm)................... .. . ... .. ............ 9.8 N'm (1.0 kgf'm' 7.2 lbf'ft|
@@ Compressor to the compressor bracket (8 x 1.25 mm)... ..-........'.'......-.......24 N'm (2 'l kgf'm, 17 lbf ftl
@ Compressor bracket to the cytinder block (10 x 1.25 mml 44 N'm l'1.5 kgf'm, 33 lbf ftl
@ Compressor bracket to the left front engine mounl {12 x 1.25 mm}..... . . . . .. ................. ... ... 59 N'm (6.0 kgf'm, '|i} lbf ftl
22-23

Starting System
Starter Test lcont'dl
Ch€ck tor Wear and Damage
The starter should crank the engine smoothly and
steadily, lf the starter engages. but cranks the engine
erratically, remove it, and inspect the starter drive gear
and torque converter or flywheel ring gear for damage.
. Check the drive gear overrunning clutch for binding
or slipping when the armature is rotated with the
drive gear held,- lf damaged. replace the gears.
Check Cranking Voltsge and Curr€nt Draw
Cranking voltage should be no less than 8.5 volts.
Current draw should be no more than 350 amperes.
lf cranking voltage is too low, or current draw too high,
check for;
. dead or low batterv.
. open circuit in starter armature commutator seg-
ments,
. starter armature dragging.
. shorted armature winding.
o excessive drag in engine.
Check Cranking rpm
Engine speed during cranking should be above 100 rpm,
lf speed is too low, check for:
. loose battery or stanerterminals.
. excessively worn starter brushes,
. open circuit in commutator segments.
o dirty or damaged helical spline or drive gear.
. defective drive gear overrunning clutch.
Check Siarter Disengag€ment
With the shift lever in El or @ position (A/T) or with the
clutch pedal depressed (M/T), turn the ignition switch to
START (lll), and release to ON (ll).
The starter drive gear should disengage from the torque
converter or flywheel ring gear when you release the
Key.
lf the drive gear hangs up on the torque converter or fly-
wheel ring gear, check for:
. solenoid plunger and switch malfunction,
. dirty drive gear assembly or damaged overrunning
clutch.
Starter Solenoid Test
1. Check the hold-in coil for continuitv between the S
terminal and the armature housing (ground). The
coil is OK if there is continuitv,
ARMATUREHOUSING(GROUND)
S TERMINAL
M TERMINAL
B TERMINAL
STARTERCAELE B TERMINALMOUNTING NUTI N.m {0.9 kgf.m,7 tbf.ft)
Check the pull-in coil for continuity between the S
and M terminals. The coil is OK if there is continuity.

1. Inspect the electrodes and ceramic insulator for:
Spark Plug lnspection
Crackedinsulator
2.
[ . t.p,op", grp
| . Oil-fouling
i . Carbon deposits
| . Cracked center
I electrode insulator
Burned or worn electrodes may be causecl by:
. Advanced ignition timing
. Loose spark plug
. Plug heat range too low
. Insufficient cooling
Fouled plugs may be caused bY:
. Retarded ignition timang
. Oil in combustion chamber
. Incorrect spark plug gap
. Plug heat rangetoo high
. Excessive idling/low speed running
. Clogged air cleaner element
. Deteriorated ignition coil or ignition wares
D16Y5, D16Y7, D'16Y8 enginel
. Adjust the gap with a suitable gapping tool, and
replace the plug il the center electrode is round-
ed as shown below.
Electrode Gap:
1.1 mm
{o.{X:l in)ROUNDEDELECTRODE
Standard 1.1r8 ' mm (0.043i800oin)
Worn or detormed
1T
23-111
3. 816A2 engine:
. Do not adjust the gap of a platinum tip plug;
replace the spark plug il the center electrode is
rounded or it the gap is not within the specifica
tro ns.
Electlode Gap:
Standard 1.3181mm (0.051 !3oo" in)
flOUNDED ELECTROOE
',/
@_
:
Platinum tip
NOTE: Use only the spark plugs listed below
4. Apply a small quantity of anti seize compound to
the plug threads, and screw the plugs into the cylin
der head finger-tight. Then torque them to 18 N m
11.8 kgf.m, 13lbnft).
Engine TypesSpark Plugs
D16Y5ZFR4F 11 (NGK)
KJ14CR-111 (DENSOi
D16Y7,
D,I6Y8
ZFRSF-11 (NGK)
KJ16CR-111(DENSO)
81642PFR6L.13 (NGK)
PK2OPR.L13 (DENSO}

It -Alternator Belt Inspection and Adiustment
Deflection Method:
Apply a force of 98 N (10 kgl,22lbll, and measure the
deflection between the alternator and the crankshaft pul-
ley.
Detlection | 8.0 - 10.5 mm (0.31 - 0.41 in)
NOTE: On a brand-new belt {one that has been run for less
than five minutes). the deflection should be 6.0 - 8.5 mm
(0.26 - 0.33 in) when first measured. If the belt is worn or
damaged, replace it.
CRANKSHAFTPULLEY
lf adiustm€nt is necossary:
1. Loosen the lower mounting nut and the upper mount-
ing bolt.
2, Move the alternator to obtain the proper belt tension,
then retighten the upper mounting bolt and the lower
mounting nut to the specified torques.
3. Recheckthe deflection ofthe belt.
24 N.m (2.4 kgl m,
Belt T€nsion Gauge Method:
Following the gauge manufacturer's instructions. attach
the soecial tool to the belt, and measure the tension.
Tension 340 - 490 N (35 - 50 kgf,77 - 110lbf)
NOTE: On a brand-new belt {one that has been run for less
than five minutes), the tension should be 540 -740 N
(55 - 75 kgf, 121 - 165 lbf) when first measured. lf the belt
is worn or damaged, replace it.
PULLEY BELT TENSION GAUGE
07JGG - 0010104
It adiustment is necossary:
1, Loosen the lower mounting nut and the upper mount-
ing bolt.
2. Move the alternator to obtain the proper belt tension.
then retighten the upper mounting bolt and the lower
mounting nut to the specified torques
3. Recheck the tension of the belt
23-125