1988 HONDA CIVIC COUPLE CRX CHASSIS MAINTENANCE & REPAIR SHOP MANUAL – PDF DOWNLOAD
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1988 HONDA CIVIC COUPLE CRX CHASSIS MAINTENANCE & REPAIR SHOP MANUAL – PDF DOWNLOAD
- 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.
TABLE OF CONTENTS:
1988 HONDA CIVIC COUPLE CRX CHASSIS MAINTENANCE & REPAIR SHOP MANUAL – PDF DOWNLOAD
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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