This manual contains service information for the CIVIC COUPE CRX. Separate volumes are published regarding vehicle construction, engine, and transmission; the applicable refe:ence manuals are listed below. ·· This manual is divided into sections. This first page of each section is marked with a black tab that lines up with one of the thumb index tabs on the next page. You can quickly find the first page of each section without looking through a full table of contents. The symbols printed at the top corner of each page can also be used as a quick reference system. Each section includes: 1. A table of contents, or an exploded-view index showing: • Parts disassembly sequence. • Bolt torques and thread sizes: • Page references to descriptions in text. 2. Disassembly/assembly procedures and tools. 3. Inspection. 4. Testing/troubleshooting. 5. Repair. 6. Adjustments.Detailed descriptions of standard workshop procedures. safety principles and service operations are not included. Please note that this manual does contain warnings and cautions against some specific service methods which could cause PERSONAL INJURY, or could damage a vehicle or make it unsafe. Please understand that these warnings cannot cover all conceivable ways in which service, whether or not recommended by Honda Motor. might be done, or of the possible hazardous consequences of each conceivable way, nor could Honda Motor investigate all such ways. Anyone using service procedures or tools. whether or not recommended by Honda Motor. must satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized. 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, stored in 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.
Introduction........................................................... 3
General Information.................................................... 7
Chassis and Engine Numbers......................................... 8
Identification Number Locations.................................... 9
Label Locations.................................................... 10
Lift and Support Points............................................ 11
Towing............................................................. 14
Preparation of Work................................................ 15
Symbol Marks....................................................... 21
Abbreviation....................................................... 21
Special Tools.......................................................... 23
Existing Tools (common with other models).......................... 24
Specifications......................................................... 29
Standards and Service Limits....................................... 30
Design Specifications.............................................. 36
Body Specifications................................................ 39
Maintenance............................................................ 41
Lubrication Points................................................. 42
Maintenance Schedule............................................... 44
Engine................................................................. 45
Engine Tune-up..................................................... 47
Radiator Cap Testing........................................... 48
Coolant Level Inspection....................................... 48
Engine Oil Level Inspection.................................... 49
Engine Oil Replacement......................................... 49
Air Cleaner Element Inspection/Replacement..................... 50
Compression Pressure Inspection................................ 50
Spark Plug Inspection.......................................... 51
Drive Belt Inspection.......................................... 52
Alternator Belt Adjustment..................................... 52
P/S Pump Belt Adjustment....................................... 53
A/C Compressor Belt Adjustment................................. 53
Valve Clearance Adjustment..................................... 54
Idle Speed Inspection/Adjustment............................... 56
Tailpipe Emissions Inspection.................................. 57
Ignition Timing Inspection and Setting......................... 57
Timing Belt........................................................ 59
SOHC........................................................... 61
Illustrated Index.......................................... 62
Inspection................................................. 63
Tension Adjustment......................................... 63
Replacement................................................ 64
Positioning Timing Belt.................................... 66
DOHC........................................................... 67
Illustrated Index.......................................... 68
Inspection................................................. 69
Tension Adjustment......................................... 69
Replacement................................................ 70
Positioning Timing Belt.................................... 72
Cylinder Head Removal/Installation................................. 73
SOHC........................................................... 75
Removal.................................................... 76
Installation............................................... 79
DOHC........................................................... 81
Removal.................................................... 82
Installation............................................... 86
Engine Removal/Installation........................................ 89
Exhaust Pipe and Muffler........................................... 98
Radiator...........................................................100
Illustrated Index..............................................101
Replacement....................................................103
Refilling and Bleeding.........................................104
Cap Testing....................................................105
Radiator Testing...............................................105
Thermostat Replacement.........................................106
Water Pump.....................................................107
Fuel and Emissions.....................................................108
General............................................................108
Special Tools..................................................109
Component Locations............................................110
System Description.............................................114
Vacum Connections..........................................114
Electrical Connections.....................................119
Troubleshooting................................................121
Troubleshooting Guide......................................121
Self-diagnostic Procedure..................................125
How to Read Flowcharts.....................................127
PGM-FI Control System (troubleshooting flowcharts).................128
ECU............................................................128
O2 Sensor......................................................131
MAP Sensor.....................................................133
TDC/Crank Sensor (DOHC)........................................139
TDC/Crank/CYL Sensor (SOHC)....................................143
Coolant Temperature Sensor.....................................149
Throttle Angle Sensor..........................................151
CYL Sensor (DOHC)..............................................153
Intake Air Temperature Sensor..................................155
IMA Sensor (without CATA)......................................157
Atmospheric Pressure Sensor....................................160
Ignition Output Signal.........................................162
Vehicle Speed Sensor...........................................164
CYL Sensor Overhaul................................................165
Idle Control System................................................167
System Troubleshooting Guide...................................167
Troubleshooting Flowcharts.....................................169
EACV.......................................................169
Air Conditioning Signal....................................172
Alternator FR Signal.......................................174
Starter Switch Signal......................................176
Idle Speed Setting.............................................177
Fuel Supply System.................................................178
System Troubleshooting Guide...................................178
Fuel Pressure..................................................179
Fuel Injectors.................................................180
Injector Resistor..............................................184
Pressure Regulator.............................................184
Fuel Filter....................................................185
Fuel Pump......................................................186
Main Relay.....................................................187
Fuel Tank......................................................189
Air Intake System..................................................190
System Troubleshooting Guide...................................190
Throttle Cable.................................................191
Throttle Body..................................................192
Throttle Control System........................................194
Emission Control System............................................197
System Troubleshooting Guide...................................197
Tailpipe Emission..............................................198
Positive Crankcase Ventilation System..........................198
Catalytic Convertor............................................199
Evaporative Emission Controls..................................200
Transaxle..............................................................209
Clutch.............................................................211
Illustrated Index..............................................212
Adjustment.....................................................213
Release Bearing................................................214
Pressure Plate.................................................216
Clutch Disc....................................................217
Flywheel.......................................................218
Flywheel Bearing...............................................218
Flywheel and Clutch............................................219
Manual Transmission................................................221
Maintenance....................................................222
Backup Light Switch............................................222
Gearshift Mechanism............................................223
Transmission...................................................224
Driveshafts........................................................229
Driveshafts....................................................230
Intermediate Shaft.............................................234
Steering...............................................................237
Manual Steering....................................................237
Special Tools..................................................238
Component Location.............................................239
Inspection.....................................................240
Steering Wheel Rotational Play.............................240
Steering Effort Check......................................240
Steering Gearbox Adjustment................................240
Gearbox........................................................241
Removal/Installation.......................................241
Disassembly/Inspection.....................................243
Reassembly.................................................244
Steering Wheel Disassembly/Reassembly..........................246
Steering Column................................................247
Removal....................................................247
Disassembly/Inspection.....................................249
Reassembly.................................................250
Installation...............................................254
Power Steering.....................................................255
Special Tools..................................................255
Component Location.............................................256
Troubleshooting................................................257
General Troubleshooting....................................257
Noise and Vibration........................................260
Fluid Leaks................................................261
Maintenance................................................262
On Car Checks..................................................262
Rack Guide Adjustment......................................262
Fluid Replacement..........................................263
Pump Pressure Check........................................263
Steering Wheel Rotational Play.............................264
Power Assist Check.........................................264
Steering Column................................................265
Removal....................................................265
Disassembly/Inspection.....................................267
Reassembly.................................................268
Installation...............................................270
Steering Lock..................................................273
Lock Replacement...........................................273
Lock Cylinder Replacement..................................273
Steering Pump..................................................274
Illustrated Index..........................................274
Replacement................................................275
Preload Inspection.........................................275
Pulley Replacement.........................................276
Control Valve Inspection and Replacement...................276
Housing Disassembly........................................279
Housing Reassembly.........................................280
Steering Gearbox...............................................282
Illustrated Index..........................................282
Valve Body Unit Overhaul...................................283
Steering Rack Removal......................................289
Steering Gearbox Overhaul..................................292
Steering Gearbox Installation..............................305
Suspension.............................................................309
Special Tools......................................................310
Component Location.................................................311
Wheel Alignment....................................................312
Caster.........................................................312
Camber.........................................................312
Rear Toe Inspection/Adjustment.................................313
Front Toe Inspection/Adjustment................................313
Turning Angle Inspection/Adjustment............................314
Wheel Measurements.................................................315
Bearing End Play...............................................315
Runout.........................................................315
Front Suspension...................................................316
Torque Specifications..........................................316
Illustrated Index..............................................317
Knuckle/Hub....................................................318
Knuckle/Hub Replacement........................................319
Lower Ball Joint Replacement...................................323
Upper Arm Bushing Replacement..................................324
Damper.........................................................325
Removal....................................................325
Disassembly/Inspection.....................................325
Reassembly.................................................327
Installation...............................................327
Rear Suspension....................................................328
Torque Specifications..........................................328
Illustrated Index..............................................329
Upper Arm Bushing Replacement..................................330
Compensator Arm Bushing Replacement............................330
Hub unit Bearing Replacement...................................331
Damper.........................................................331
Removal....................................................331
Disassembly/Inspection.....................................332
Disposal...................................................332
Reassembly.................................................334
Installation...............................................334
Brakes.................................................................335
Special Tools......................................................336
Illustrated Index..................................................337
Pedal Height Adjustment............................................338
Parking Brake Adjustment...........................................338
Front Brake........................................................339
Inspection.....................................................339
Inspection/Replacement.........................................340
Disassembly....................................................341
Reassembly.....................................................342
Runout Inspection..............................................343
Thickness and Parallelism Inspection...........................343
Bleeding...........................................................344
Master Cylinder Booster............................................345
Master Cylinder....................................................346
Brake Booster......................................................349
Rear Disc Brake....................................................361
Brake Hoses/Pipes..................................................370
Parking Brake Disassembly and Reassembly...........................372
Body...................................................................373
Doors..............................................................374
Power Door Mirror..................................................380
Manual Door Mirror.................................................381
Windshield, Rear Window Glass, Lower Hatch Glass, Quarter Glass....382
Windshield.....................................................385
Rear Window....................................................392
Lower Hatch Glass..............................................396
Quarter Glass..................................................400
Sunroof........................................................404
Interior Trim......................................................416
Headliner..........................................................417
Seats..............................................................418
Seat Belts.........................................................421
Rearview Mirror....................................................423
Security Compartment/Rear Shelf....................................424
Console............................................................425
Carpet/Door Sill Moldings..........................................426
Dashboard..........................................................427
Front Bumper.......................................................430
Rear Bumper........................................................431
Hood...............................................................432
Tailgate...........................................................434
Fuel Filler/Tailgate Opener........................................435
Rear Spoiler/Rear Panel and Corner Panel...........................436
Side Panels........................................................437
Frame Repair Chart.................................................438
Heater and Air Conditioner.............................................439
Heater.............................................................441
Illustrated Index..............................................442
Door Position..................................................443
Circuit Diagram................................................446
Troubleshooting................................................448
Blower.........................................................456
Heater Assembly................................................458
Heater Control.................................................460
Heater Control Cables..........................................462
Test...........................................................463
Air Conditioner....................................................465
Illustrated Index..............................................466
Wire Harness Routing...........................................467
Circuit Diagram................................................468
Troubleshooting................................................469
Service Tips...................................................481
Discharge Procedure............................................482
Condenser......................................................482
Evaporator.....................................................484
Compressor.....................................................486
Troubleshooting............................................487
Replacement................................................488
Clutch Inspection..........................................490
Overhaul...................................................492
Thermal Protector Inspection...............................493
Thermal Protector Replacement..............................494
Shaft Seal Replacement.....................................494
System Charging................................................496
Test...........................................................499
Electrical.............................................................503
Special Tool/Troubleshooting.......................................504
Relays and Control Unit Locations..................................506
Door and Floor.....................................................507
Relays and Control Unit Locations..................................508
Ground and Wire Harness Routing....................................510
Fuses..............................................................519
Power Distribution.................................................522
Ground Distribution................................................526
Battery............................................................530
Ignition Switch....................................................532
Starting System....................................................534
Ignition System....................................................547
Charging System....................................................557
Cooling Fan System.................................................567
Gauge Assembly.....................................................571
Fuel Gauge.........................................................580
Coolant Temperature Gauge..........................................582
Integrated Control Unit (without daytime dim/dip)..................583
Integrated Control Unit (with daytime dim/dip).....................587
Seatbelt Reminder System...........................................593
Oil Pressure Warning System........................................593
Brake Warning System...............................................594
Light-on Warning System............................................595
Lighting System....................................................596
Tailight Assembly..................................................605
Dome Light.........................................................606
Dome Switches......................................................607
Trunk Light........................................................607
Latch Switch.......................................................608
Back-up Lights.....................................................608
Bak-up/Rear Fog Lights.............................................609
Brake Lights.......................................................610
Turn Signal/Hazard Flasher System..................................611
Dashlight Brightness Control.......................................615
Stereo Sound System................................................617
Clock..............................................................621
Cigarette Lighter..................................................622
Horns..............................................................625
Power Door Mirrors.................................................626
Rear Window Defogger...............................................630
Sunroof............................................................636
Power Windows......................................................642
Seat Heaters.......................................................649
Wipers/Washers.....................................................654
Wiring Diagrams........................................................665
Fuel-Injected System Connectors....................................669
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